Engine: Service and Repair

1. On manual transmission models, remove gear shift lever. On automatic transmission models, move selector to P position.
2. Disconnect battery ground cable, windshield washer hose at T-fitting, then remove hood.
3. Remove splash pan under engine and expansion tank cap. Disconnect lower hose at radiator and drain coolant. Disconnect lower hose from cold start device and turn end down to drain remaining coolant from engine.
4. On automatic transmission models, disconnect oil cooler lines. On all models, remove lower radiator hose, disconnect upper radiator hose at engine and disconnect expansion tank hose at radiator. Remove radiator.
5. Disconnect harness connector from firewall, heater control valve hoses, vacuum pump hose, and accelerator cable.
6. Disconnect fuel supply line at fuel filter and fuel return line at injection pump. Plug all connections to prevent dirt from entering fuel system. Absolute cleanliness is extremely important. All connections must be cleaned thoroughly before disconnecting.
7. Remove glow plug relay screws and hang relay and harness on engine. Remove and suspend power steering pump.
8. Remove cooling fan, pulley and drive belts. Remove air cleaner cover and disconnect alternator wire harness at voltage regulator.
9. Disconnect exhaust pipes from manifolds and drain engine oil.
10. On manual transmission models, disconnect clutch cable and return spring. On automatic transmission models, disconnect shift lever from transmission.
11. Disconnect speedometer cable, driveshaft, and gear lever. Loosen Allen head lock screw, push out pin and push shift lever up into vehicle.
12. Support transmission with suitable jack and remove transmission crossmember. Disconnect engine mounts and support engine using lifting hooks 5185 and 5186 or equivalent and lifting beam 2810 or equivalent.
13. Raise engine enough to unload mounts and remove left engine mount assembly. Remove jack from under transmission and lift out engine.
14. Reverse procedure to install.