Engine: Service and Repair

NOTE: Engine replacement procedures are for engine only without transmission attached. Remove or disconnect parts of secondary air injection system that will interfere with removal or installation of engine.

REMOVAL
1. Drain engine cooling system and crankcase.
2. Disconnect battery ground cable, then remove air cleaner outlet tube as follows:
a. Disconnect wire harness from intake air temperature sensor, then crankcase ventilation tube from air cleaner outlet tube.
b. Loosen air cleaner tube clamps on outlet tube, then disconnect outlet tube from throttle body.
c. Disconnect outlet tube from mass airflow sensor, then remove tube.
3. Disconnect upper radiator hose from water outlet connection and lower radiator hose at water pump.
4. Remove radiator electric motor, fan blade and fan shroud as an assembly.
5. Remove radiator and drive belt.
6. Remove generator/secondary air injection pump and generator bracket as an assembly and position aside.
7. Disconnect engine control sensor wiring from oil pressure sender, then low oil level sensor located on lefthand side of oil pan.
8. Relieve fuel pressure, then disconnect fuel supply and return lines.
9. Disconnect accelerator cable from throttle body.
10. On models equipped with speed control, disconnect speed control linkage.
11. On models equipped with air conditioning, isolate and remove A/C compressor.
12. Disconnect power steering pump bracket from cylinder block. Position pump aside and in position to prevent fluid from draining out.
13. Disconnect brake booster vacuum line from intake manifold.
14. Disconnect heater water hose from intake manifold heater inlet tube, then engine control sensor wiring from water temperature indicator sender unit.
15. Remove flywheel housing to engine upper bolts.
16. Disconnect fuel charging wiring at two 10-pin connectors.
17. Raise and support front of vehicle, then disconnect starter cable from starter motor and remove starter motor.
18. Disconnect dual converter and pipe from exhaust manifolds, then front engine support insulators from front subframe.
19. Disconnect downstream secondary air injection tubing and check valve from righthand exhaust manifold stud.
20. Lower vehicle and support transmission.
21. Attach engine lifting sling and hoist to engine lifting eyes on exhaust manifolds.
22. Raise engine slightly, then carefully pull from transmission. Carefully lift engine out of engine compartment, then install engine on work stand.

CAUTION: Avoid bending or damaging engine rear plate or other components.

INSTALLATION
1. Attach engine lifting sling and engine lifting eyes to exhaust manifold, then hoist engine from work stand.
2. Lower engine carefully into engine compartment. Ensure exhaust manifolds are properly aligned with dual converter and pipe.
3. Start manual transmission input shaft pilot into crankshaft.
4. Install flywheel housing upper bolts. Ensure dowels in cylinder block engage housing.
5. Install front engine support insulators to front subframe attaching fasteners.
6. Raise and support front of vehicle, then connect dual converter and pipe to exhaust manifolds.
7. Install starter motor and starter wiring.
8. Install remaining housing bolts.
9. Remove support from transmission and lower vehicle.
10. Connect fuel charging wiring at two 10-pin connectors.
11. Connect engine control sensor wiring to water temperature indicator sender unit, then heater water hoses to intake manifold heater inlet tube.
12. Connect engine control sensor wiring to low oil level sensor.
13. Connect accelerator cable and throttle valve control actuating cable.
14. Connect speed control actuator.
15. Connect fuel supply and return line.
16. Connect engine control sensor wiring to oil pressure sender.
17. Install generator/air pump bracket and generator bracket as an assembly, then bolts.
18. Connect engine control sensor wiring.
19. Install A/C compressor.
20. Install drive belt, then power steering pump bracket and bracket bolts.
21. Connect brake booster vacuum line.
22. Install radiator, then connect upper and lower radiator hoses.
23. Install radiator electric motor, fan blade and fan shroud as an assembly.
24. Fill cooling system, then fill crankcase with proper grade and quantity of oil.
25. Install air cleaner outlet tube.
26. Operate engine at fast idle and check all gaskets and hose connections for leaks.
27. Install and adjust hood as necessary.