Disassembly and Assembly

REMOVAL

1. Disconnect battery
2. Remove hood and support from front support.
3. Remove air cleaner assembly (Refer to Emission Control System).
4. Drain cooling system. Refer to Cooling System for procedure.
5. Remove upper radiator hose and the heater supply hose to the engine. Disconnect the heater return hose from the control valve.






6. Remove front crossmember.
7. Remove accessory drive belt. Refer to Accessory Drive Cooling System.
8. Remove power steering pump mounting bolts and set pump aside.
9. Disconnect engine electrical connector and ground cable to frame.
10. Remove lower radiator hose.
11. Remove windshield wipers and cowl panel.
12. Disconnect battery feed connector and brake booster hose.
13. Disconnect vacuum lines, evaporative emission harness, fuel lines and accelerator cable.
14. Disconnect the cast exhaust extension from exhaust manifolds.
15. Attach engine lifting hoist.









16. Disconnect Engine and Transmission Mounts.
17. Remove gear shifter lever.
18. Hoist vehicle. Remove drive shaft and disconnect torque bar from transmission. Refer to Transmission Removal for procedure.
19. Remove transmission rear support bracket. Refer to Transmission Removal for procedure.
20. Remove engine and transmission as assembly.




INSTALLATION

1. Attach hoist and lower engine and transmission into engine compartment.







2. Align engine mounts and install all mounting nuts. Tighten nuts to torque specified.
3. Support transmission with floor jack until rear support is installed, tighten bolts to torque specified.
4. Remove engine hoist.
5. Install transmission inspection cover.
6. Connect exhaust assembly to exhaust manifold, and heated oxygen sensors. Tighten side exhaust to 33 Nm (25 ft. lbs.).
7. Install power steering pump. For belt installation see Accessory Belt Drive in Cooling System.
8. Lower vehicle and connect all vacuum lines.
9. Connect all electrical connections including ground strap.
10. Connect fuel lines and accelerator cable.
11. Install radiator hoses and connect heater hoses. Fill cooling system.
12. Fill engine crankcase with proper oil to correct level.
13. Install hood support bracket and hood.
14. Connect battery.
15. Start engine and run until operating temperature is reached.