AMC Coupes/Sedans/Wagons 1975-1988 Repair Information

Engine

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REMOVAL & INSTALLATION 4-121 Engine



It is recommended by the manufacturer that the engine be removed from the car separately, and the transmission remain in the car.

  1. Mark the hinge locations and remove the hood.
  2.  
  3. Drain the coolant and remove the air cleaner and TAC hose.
  4.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Detach the negative cable at the alternator bracket and battery.
  2.  
  3. Remove the fuel and vacuum lines from the engine. Plug the fuel line.
  4.  
  5. Disconnect the necessary wiring, the throttle cable, and automatic transmission valve linkage.
  6.  
  7. If your car has air conditioning, the system must be bled, the hoses disconnected, and the condenser moved. See General Information and Maintenance .
  8.  
  9. Raise the car, disconnect and remove the starter motor and exhaust pipe support bracket. Unbolt the exhaust pipe from the manifold.
  10.  
  11. Remove the torque convertor nuts and fluid cooler lines, if the car has automatic transmission.
  12.  
  13. Disconnect the wiring at the backup lamp switch and from the alternator.
  14.  
  15. Remove the lower radiator hose and heater hose from the radiator.
  16.  
  17. Remove all the bell housing bolts, except the top center bolt.
  18.  
  19. Lower the car and remove the top radiator hose and the cold air induction manifold at the radiator.
  20.  
  21. Remove the radiator screws, move the radiator one inch to the left, rotate, and lift the radiator and shroud assembly out of the car. With air conditioning, first remove the condenser attaching bolts and more the condenser away from the radiator.
  22.  
  23. Remove any other heater hoses and wiring that are still attached to the car.
  24.  
  25. With power steering, disconnect the hoses from the steering gear. Remove the transmission filler tube support screws with automatic transmission.
  26.  
  27. Remove the engine support cushion nuts on both sides of the engine and attach a lifting device.
  28.  
  29. With the engine partially raised, support the transmission and remove the center bolt from the transmission bell housing. Carefully remove the engine from the car.
  30.  

To install:

When mating the engine to the transmission bell housing, install three bolts for a more secure mounting until the engine is bolted into place.

  1. With the engine partially raised, support the transmission and install the center bolt in the transmission bell housing. Carefully install the engine in the car.
  2.  
  3. Install the engine support cushion nuts on both sides of the engine and remove the lifting device.
  4.  
  5. With power steering, connect the hoses to the steering gear. Install the transmission filler tube support screws with automatic transmission.
  6.  
  7. Install the heater hoses and any wiring that was disconnected from the car.
  8.  
  9. Install the radiator and the condenser.
  10.  
  11. Lower the car and install the top radiator hose and the cold air induction manifold at the radiator.
  12.  
  13. Install all remaining bell housing bolts.
  14.  
  15. Install the lower radiator hose.
  16.  
  17. Connect the wiring at the backup lamp switch and alternator.
  18.  
  19. Install the torque convertor nuts and fluid cooler lines, if the car has automatic transmission.
  20.  
  21. Raise the car, install the starter motor and exhaust pipe support bracket. Connect the exhaust pipe at the manifold.
  22.  
  23. If your car has air conditioning, evacuate, charge and leak test the system. See General Information and Maintenance .
  24.  
  25. Connect any remaining wiring, the throttle cable, and automatic transmission valve linkage.
  26.  
  27. Connect the fuel and vacuum lines at the engine.
  28.  
  29. Attach the negative cable at the alternator bracket and battery.
  30.  
  31. Fill the cooling system and install the air cleaner and TAC hose.
  32.  
  33. Install the hood.
  34.  

4-150 Engine

  1. Disconnect the battery ground cable.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Remove the hood.
  6.  
  7. Drain the coolant.
  8.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the lower radiator hose.
  2.  
  3. Remove the upper radiator hose.
  4.  
  5. Disconnect the coolant recovery hose.
  6.  
  7. Remove the fan shroud.
  8.  
  9. Disconnect the automatic transmission coolant lines.
  10.  
  11. Have the refrigerant discharged by a certified technician.
  12.  


CAUTION
Please refer to General Information and Maintenance before discharging the compressor or disconnecting air conditioning lines. Damage to the air conditioning system or personal injury could result. Consult your local laws concerning refrigerant discharge and recycling. In many areas it may be illegal for anyone but a certified technician to service the A/C system. Always use an approved recovery station when discharging the air conditioning.

  1. Disconnect and remove the condenser. Cap all openings at once!
  2.  
  3. Remove the radiator.
  4.  
  5. Remove the fan and install a 5 / 16 in. X 1 / 2 in. (7.9375mm X 12.7mm) capscrew through the pulley and into the water pump flange to maintain the pulley-to-pump alignment.
  6.  
  7. Disconnect the heater hoses.
  8.  
  9. Disconnect the throttle linkage.
  10.  
  11. Disconnect the cruise control linkage.
  12.  
  13. Disconnect the oil pressure sending unit wire.
  14.  
  15. Disconnect the temperature sending unit wire.
  16.  
  17. Disconnect and tag all vacuum hoses connected to the engine.
  18.  
  19. Remove the air conditioning compressor.
  20.  
  21. Remove the power steering hoses at the gear.
  22.  
  23. Drain the power steering reservoir.
  24.  
  25. Remove the power brake vacuum check valve from the booster.
  26.  
  27. Raise and support the front end on jackstands.
  28.  
  29. Disconnect and tag the starter wires.
  30.  
  31. Remove the starter.
  32.  
  33. Disconnect the exhaust pipe at the manifold.
  34.  
  35. Remove the flywheel housing access cover.
  36.  
  37. On vehicles equipped with automatic transmission, matchmark the converter and flywheel and remove the attaching bolts.
  38.  
  39. Remove the upper flywheel housing-to-engine bolts and loosen the lower ones.
  40.  
  41. Remove the engine mount cushion-to-engine compartment bolts.
  42.  
  43. Attach a shop crane to the lifting eyes on the engine.
  44.  
  45. Raise the engine off the front supports.
  46.  
  47. Place a floor jack under the flywheel housing.
  48.  
  49. Remove the remaining flywheel housing bolts.
  50.  
  51. Lift the engine out of the vehicle.
  52.  
  53. Mount the engine on a work stand or cradle. Never let it rest on the oil pan.
  54.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

To install:
  1. Lower the engine into place in the vehicle.
  2.  
  3. Lubricate the manual transmission input shaft with chassis lube before insertion into clutch splines.
  4.  
  5. Install the flywheel housing bolts. Torque the top flywheel housing-to-engine bolts to 27 ft.lb. and the bottom ones to 43 ft.lb.
  6.  
  7. Install the engine mount cushion-to-engine compartment bolts. Torque the front bracket support bolts to 33 ft.lb.
  8.  
  9. Remove the shop crane.
  10.  
  11. On vehicles equipped with automatic transmission, install the converter attaching bolts.
  12.  
  13. Install the flywheel housing access cover.
  14.  
  15. Connect the exhaust pipe at the manifold.
  16.  
  17. Install the starter.
  18.  
  19. Connect the wires.
  20.  
  21. Raise and support the front end on jackstands.
  22.  
  23. Install the power brake vacuum check valve on the booster.
  24.  
  25. Fill the power steering reservoir.
  26.  
  27. Connect the power steering hoses at the gear.
  28.  
  29. Install the air conditioning compressor.
  30.  
  31. Connect all vacuum hoses.
  32.  
  33. Connect all wires.
  34.  
  35. Connect the throttle linkage.
  36.  
  37. Connect the cruise control linkage.
  38.  
  39. Connect the heater hoses.
  40.  
  41. Install the fan.
  42.  
  43. Install the radiator.
  44.  
  45. Install the condenser.
  46.  
  47. Have the system charged by a certified technician.
  48.  
  49. Install the fan shroud.
  50.  
  51. Connect the automatic transmission coolant lines.
  52.  
  53. Install the upper radiator hose.
  54.  
  55. Connect the coolant recovery hose.
  56.  
  57. Install the lower radiator hose.
  58.  
  59. Fill the cooling system.
  60.  
  61. Install the hood.
  62.  
  63. Install the air cleaner.
  64.  
  65. Connect the battery ground cable.
  66.  

4-151 Engine


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Disconnect the battery.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Jack up the vehicle and support it on jackstands.
  6.  
  7. Disconnect the exhaust pipe from the manifold.
  8.  
  9. Disconnect the oxygen sensor.
  10.  
  11. Disconnect the wires from the starter.
  12.  
  13. Unbolt the starter and remove it from the vehicle.
  14.  
  15. Disconnect the wires from the distributor and oil pressure sending unit.
  16.  
  17. Remove the engine mount nuts.
  18.  
  19. On vehicles with manual transmission, remove the clutch slave cylinder and flywheel inspection plate.
  20.  
  21. Remove the clutch or converter housing-to-engine bolts.
  22.  
  23. On vehicle with automatic transmission, disconnect the converter from the drive plate.
  24.  
  25. Lower the vehicle.
  26.  
  27. Support the transmission with a jack.
  28.  
  29. Tag all hoses at the carburetor and remove them.
  30.  
  31. Disconnect the mixture control solenoid wire from the carburetor, (not all vehicles have these).
  32.  
  33. Disconnect the wires from the alternator.
  34.  
  35. Disconnect the throttle cable from the bracket and the carburetor.
  36.  
  37. Disconnect the choke and solenoid wires at the carburetor.
  38.  
  39. Disconnect the temperature sender wire.
  40.  
  41. Drain the radiator at the drain cock, then remove the lower hose.
  42.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the upper radiator hose and the heater hoses.
  2.  
  3. Remove the fan shroud, and radiator.
  4.  
  5. Remove the power steering hoses at the pump.
  6.  
  7. Attach a shop crane to the engine and lift it out of the vehicle.
  8.  

The manual transmission may have to be raised slightly to allow a smooth separation.

To install:
  1. Lower the engine into the vehicle.
  2.  
  3. On vehicle with automatic transmission, connect the converter to the drive plate.
  4.  
  5. Install the clutch or converter housing-to-engine bolts. Torque the bolts to 35 ft. lbs.
  6.  
  7. On vehicles with manual transmission, Install the clutch slave cylinder and flywheel inspection plate. Torque the slave cylinder bolts to 18 ft. lbs.
  8.  
  9. Install the engine mount nuts. Torque them to 34 ft. lbs.
  10.  
  11. Connect the wires to the distributor and oil pressure sending unit.
  12.  
  13. Install the starter. Torque the mounting bolts to 27 ft. lbs.; the bracket nut to 40 inch lbs.
  14.  
  15. Connect the wires to the starter.
  16.  
  17. Connect the oxygen sensor.
  18.  
  19. Connect the exhaust pipe at the manifold. Torque the nuts to 35 ft. lbs.
  20.  
  21. Install the power steering hoses at the pump.
  22.  
  23. Install the fan shroud, and radiator.
  24.  
  25. Install the upper radiator hose and the heater hoses.
  26.  
  27. Connect the temperature sender wire.
  28.  
  29. Connect the choke and solenoid wires at the carburetor.
  30.  
  31. Connect the throttle cable at the bracket and the carburetor.
  32.  
  33. Connect the wires to the alternator.
  34.  
  35. Connect the mixture control solenoid wire at the carburetor (not all vehicles have these).
  36.  
  37. Install all hoses at the carburetor.
  38.  
  39. Lower the vehicle.
  40.  
  41. Install the air cleaner.
  42.  
  43. Connect the battery.
  44.  
  45. Fill the cooling system.
  46.  

6 and 8 Cylinder Engines See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: A lifting device may be fabricated to support the engine weight when removing the mounts

The engine is removed without the transmission on all models except the Pacer.


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Mark the hood hinge locations, disconnect the underhood light, if equipped, and remove the hood.
  2.  
  3. Drain the coolant and engine oil. Remove the filter on the Pacer.
  4.  


CAUTION
When draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Disconnect and remove the battery and air cleaner. On Pacers, first run the wipers to the center of the windshield.
  2.  
  3. Disconnect and tag the alternator, ignition coil distributor temperature and oil sender wiring. On Pacers, also disconnect the brake warning switch wiring.
  4.  
  5. If equipped with TCS, remove the switch bracket and vacuum solenoid wire harness.
  6.  
  7. Disconnect and plug the hose from the fuel pump. On Pacers, also disconnect the automatic transmission fluid cooler line.
  8.  
  9. Disconnect the engine ground strap at the block and the starter cable at the starter. Remove the right front engine support cushion-to-bracket bolt.
  10.  
  11. If your car has air conditioning, the system must be bled, the hoses disconnected, and the system removed. Have this service performed by a certified technician.
  12.  


CAUTION
Please refer to General Information and Maintenance before discharging the compressor or disconnecting air conditioning lines. Damage to the air conditioning system or personal injury could result. Consult your local laws concerning refrigerant discharge and recycling. In many areas it may be illegal for anyone but a certified technician to service the A/C system. Always use an approved recovery station when discharging the air conditioning.

  1. Disconnect the return hose from the fuel filter. TAC hose from the manifold, carburetor vent hose, heater or A/C vacuum hose and/or power brake hose at intake manifold, and power brake vacuum check valve from booster, if equipped.
  2.  
  3. Disconnect the throttle cable and throttle valve rod, if equipped.
  4.  
  5. Disconnect the radiator and heater hoses from the engine, automatic transmission cooler lines from the radiator, radiator shroud, fan, and spacer, and remove the radiator.
  6.  
  7. Install a 5 / 16 in. X 1 / 2 in. bolt through the fan pulley into the water pump flange to maintain alignment (all but Pacer).
  8.  
  9. With power steering, disconnect the hoses, drain the reservoir, and cap the fittings. With power brakes, remove the vacuum check valve from the booster.
  10.  
  11. On Pacers only, remove the carburetor and plug the fitting, remove the valve cover(s) and remove the vibration damper.
  12.  
  13. With automatic transmission, remove the filler tube.
  14.  
  15. Jack and support the front of the car. Remove the starter.
  16.  
  17. With automatic transmission on all except the Pacer, remove the converter cover, converter bolts (rotate the crankshaft for access), and the exhaust pipe/transmission linkage support.
  18.  

With manual transmission on all but the Pacer, remove the clutch cover, bellcrank inner support bolts and springs, the bellcrank, outer bellcrank-to-strut retainer, and disconnect the back-up lamp wire harness at the firewall for access later.

On Pacers disconnect the transmission and clutch linkage, speedometer cable at the transmission remove the driveshaft (plug the transmission), and support the transmission with a jack. Remove the rear crossmember.

  1. Attach the lifting device and support the engine. Remove the engine mount bolts.
  2.  
  3. Disconnect the exhaust pipe from the manifold.
  4.  
  5. On all but the Pacer, remove the upper converter or clutch housing bolts and loosen the lower bolts. Raise the car and move the jackstands to the jack pad area. Remove the A/C idler pulley and bracket, if equipped. Lift the engine off the front supports, support the transmission, remove the lower transmission cover attaching bolts, and lift the engine out of the car.
  6.  

On Pacers, lift the engine slightly and remove the front support cushions. Remove the transmission support, raise the front of the car so that the bottom of the bumper is three feet from the floor, and partially remove the engine/transmission assembly until the rear of the cylinder head clears the cowl Lower the car and remove the engine.

To install:
  1. On installation with manual transmission, insert the transmission shaft into the clutch spline and align the clutch housing to the engine. Install and tighten the lower housing bolts.
  2.  

With automatic transmission, align the converter housing to the engine and loosely install the bottom housing bolts. Then install the next higher bolts and tighten all four bolts.

With both transmissions, next, lower the engine onto the mounts, and install the mounting bolts.

On Pacers raise the car with a jack as in Step 20. Lower the engine/transmission assembly into the compartment. Raise the transmission into position with a jack and install the rear crossmember.

  1. On all but the Pacer, install the upper converter or clutch housing bolts and loosen the lower bolts. Raise the car and move the jackstands to the jack pad area. Install the A/C idler pulley and bracket, if equipped. Lift the engine off the front supports, support the transmission, install the lower transmission cover attaching bolts, and lift the engine out of the car.
  2.  

On Pacers, lift the engine slightly and install the front support cushions. Install the transmission support, raise the front of the car so that the bottom of the bumper is three feet from the floor, and partially install the engine/transmission assembly until the rear of the cylinder head clears the cowl Lower the car and install the engine.

  1. Connect the exhaust pipe from the manifold.
  2.  
  3. Install the engine mount bolts.
  4.  
  5. With automatic transmission on all except the Pacer, install the converter cover, converter bolts (rotate the crankshaft for access), and the exhaust pipe/transmission linkage support.
  6.  

With manual transmission on all but the Pacer, install the clutch cover, bellcrank inner support bolts and springs, the bellcrank, outer bellcrank-to-strut retainer, and connect the back-up lamp wire harness at the firewall.

On Pacers connect the transmission and clutch linkage, speedometer cable at the transmission and install the driveshaft. Install the rear crossmember.

  1. Install the starter.
  2.  
  3. With automatic transmission, install the filler tube.
  4.  
  5. On Pacers only, install the carburetor, valve cover(s) and vibration damper.
  6.  
  7. With power steering, connect the hoses. With power brakes, install the vacuum check valve on the booster.
  8.  
  9. Install the fan, spacer, and radiator. Connect the radiator and heater hoses, automatic transmission cooler lines and install the radiator shroud.
  10.  
  11. Connect the throttle cable and throttle valve rod, if equipped.
  12.  
  13. Connect the return hose to the fuel filter. Connect the TAC hose to the manifold, carburetor vent hose, heater or A/C vacuum hose and/or power brake hose at intake manifold, and power brake vacuum check valve to booster, if equipped.
  14.  
  15. Have the system evacuated, charged and leak tested by a certified technician.
  16.  
  17. Connect the engine ground strap at the block and the starter cable at the starter. Install the right front engine support cushion-to-bracket bolt.
  18.  
  19. Connect the hose at the fuel pump. On Pacers, also connect the automatic transmission fluid cooler line.
  20.  
  21. If equipped with TCS, install the switch bracket and vacuum solenoid wire harness.
  22.  
  23. Connect the alternator, ignition coil distributor temperature and oil sender wiring. On Pacers, also connect the brake warning switch wiring.
  24.  
  25. Install and connect the battery and install the air cleaner.
  26.  
  27. Fill the cooling system and engine oil.
  28.  
  29. Install the hood. Connect the underhood light, if equipped.
  30.  

 
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