Chrysler Full-Size Trucks 1967-1988 Repair Guide

Engine

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REMOVAL & INSTALLATION



See Figures 1 through 13

It is always advisable to purchase new tune-up parts, filters, and fluids before you start this project. If you are going to all the trouble to replace an engine, you should make sure it is tuned-up and has fresh fluids.

Carbureted Engines
2-WHEEL DRIVE
  1. Scribe matchmarks on the hood hinges and remove the hood from the truck, this makes it easier to work.
  2.  
  3. Disconnect and remove the battery.
  4.  
  5. Drain the coolant from the radiator and engine block.
  6.  
  7. Disconnect both radiator hoses, then remove with radiator and support brace as a unit. Set the fan shroud aside.
  8.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted to 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. Drain the engine oil. On V8s, remove the oil filter.
  2.  


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. Remove the air cleaner.
  2.  
  3. Remove the starter.
  4.  
  5. On some models, it may be helpful to remove the front bumper, grille, support brace and radiator. This will allow more access to the front of the engine, as well as requiring less lifting of the engine out of the vehicle. Although this procedure is not totally necessary, many individuals find it a time saver.
  6.  
  7. Discharge the air-conditioning if so equipped, and remove the condenser.
  8.  
  9. Remove the power steering and air pumps with the hoses attached, make sure you plug the lines.
  10.  
  11. Disconnect the throttle linkage, heater and vacuum hoses and all electrical connections to the ignition, alternator, and all other electrical connections. Make sure you mark any wiring that you are unsure of where it may belong on replacement.
  12.  
  13. Remove the alternator, fan, pulley and drive belts.
  14.  
  15. Remove the heater blower motor.
  16.  
  17. Remove and plug the inlet line to the fuel pump.
  18.  
  19. Remove the oil dipstick tube. On V8s, remove the intake manifold and left exhaust manifold. If equipped with air conditioning, remove the right side valve cover.
  20.  
  21. To provide clearance on some models, the oil pan and transmission must be removed.
  22.  
  23. Raise the engine slightly in preparation for removal. Support it with an engine lifting fixture. This tool can be fabricated from galvanized pipe fittings obtained locally. Use only galvanized parts with an inside diameter of 1 1 / 2 in. (38mm) or larger. Be sure they are firmly threaded together to assure maximum strength.
  24.  
  25. Raise the vehicle and support it on jackstands. Remove the starter and distributor.
  26.  



Click image to see an enlarged view

Fig. Fig. 1: Front engine mounts on 1967-83 2WD 6-225

  1. Remove the driveshaft and engine rear support. Remove the rear support by removing the rear mount through bolt and the U-shaped bracket from the crossmember. Remove the insulator from the bottom face of the transmission housing.
  2.  
  3. If equipped with an automatic transmission, remove the transmission intact with the filler tube and the torque converter separated from the drive plate.
  4.  
  5. Raise the rear of the engine approximately 2 in. (50mm), then remove the clutch or drive plate and the flywheel.
  6.  
  7. On some models equipped with V8 engines, the oil pan should be removed to provide added clearance. In order to gain the necessary clearance for pan removal, position the cut-out in the crankshaft flange at 3 o'clock. Remove the oil pan screws and lower the oil pan far enough to reach inside and turn the oil pump pick-up tube slightly to the right to clear the pan. Remove the oil pan.
  8.  
  9. Lower the vehicle.
  10.  
  11. Using a suitable hoist attached to the engine with the shortest hook-up possible, take up all tension and support the engine. If you are using a hoist without removing the bumper and other portions of the front of the vehicle, lift the engine up and out of the engine compartment. Make sure you have cleared the front support as well as the fenders before backing up and lowering the engine to the floor. If you have removed the radiator and the front of the vehicle, raise the engine enough to clear any frame members, then back out the hoist from the engine compartment. The advantage with this method is that the engine does not have to be raised nearly as high as the previous method, which is safer for most individuals.
  12.  
  13. Remove the engine front mounts and insulator.
  14.  



Click image to see an enlarged view

Fig. Fig. 2: Front engine mounts on 1967-83 4WD 6-225



Click image to see an enlarged view

Fig. Fig. 3: Rear engine mounts 1967-87 2WD and 4WD 6-225, 8-318/360/400/440

  1. Carefully remove the engine from the vehicle.
  2.  

To install:
  1. Carefully lower the engine into the vehicle.
  2.  
  3. Install the engine front mounts and insulator.
  4.  
  5. Raise the vehicle, if necessary.
  6.  
  7. Install the oil pan, if removed earlier.
  8.  
  9. Install the clutch or drive plate and the flywheel.
  10.  
  11. If equipped with an automatic transmission, install the transmission intact with the filler tube and the torque converter separated from the drive plate.
  12.  
  13. Install the insulator on the bottom face of the transmission housing. Install the driveshaft and engine rear support. Install the rear support by installing the rear mount through-bolt and the U-shaped bracket from the cross-member.
  14.  



Click image to see an enlarged view

Fig. Fig. 4: Front engine mounts 1984-87 4WD 6-225



Click image to see an enlarged view

Fig. Fig. 5: Front engine mounts 1984-87 2WD 6-225

  1. Install the starter and distributor.
  2.  
  3. Install the oil dipstick tube. On V8s, install the intake manifold and left exhaust manifold. If equipped with air conditioning, install the right side valve cover.
  4.  
  5. Install the inlet line at the fuel pump.
  6.  
  7. Install the heater blower motor.
  8.  
  9. Install the alternator, fan, pulley and drive belt.
  10.  
  11. Connect the throttle linkage, heater and vacuum hoses, then engage all the electrical connections tagged during the removal procedure.
  12.  
  13. Install the compressor, if equipped.
  14.  
  15. Evacuate and charge the air conditioning system. See General Information & Maintenance .
  16.  
  17. Install the power steering and air pumps.
  18.  
  19. Install the radiator and support brace as a unit. Connect both radiator hoses.
  20.  
  21. Install the air conditioning condenser.
  22.  
  23. Install the front bumper, grille, and support brace, if removed earlier.
  24.  
  25. Install the air cleaner.
  26.  
  27. Fill the crankcase with new oil. Install a new oil filter.
  28.  
  29. Fill the cooling system with fresh coolant.
  30.  
  31. Connect the battery.
  32.  
  33. Warm the engine and adjust, check for any leaks.
  34.  



Click image to see an enlarged view

Fig. Fig. 6: Front engine mount 1967-83 2WD 8-318/360



Click image to see an enlarged view

Fig. Fig. 7: Front engine mounts 1984-87 4WD 8-318/360



Click image to see an enlarged view

Fig. Fig. 8: Front engine mount 8-383

  1. Install the hood and line it up.
  2.  
  3. Road test the truck.
  4.  

Check all fluid levels, if the engine was rebuilt, and perform all tune-up adjustments.

If the engine was rebuilt or,it has a new, camshaft, or new lifters were installed, add 1 quart of engine oil supplement to aid break-in. This should be left in the engine for at least 500 miles.

4-WHEEL DRIVE-EXCEPT WM-300
  1. Drain the coolant from the radiator and cylinder block.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted to 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. Disconnect the battery ground cable. Remove the battery.
  2.  
  3. Scribe the outline on the hood hinges and remove the hood.
  4.  
  5. If equipped with air conditioning, remove the compressor with lines attached and lay it aside.
  6.  


CAUTION
Do not disconnect any refrigerant lines!

  1. Engage the electrical connections at the alternator, ignition coil, temperature and oil pressure sending units, starter-to-solenoid and engine/body ground.
  2.  
  3. Remove the air cleaner and carburetor. Install an engine lifting fixture.
  4.  
  5. Remove the distributor cap and rotor.
  6.  
  7. Disconnect and plug the fuel pump line.
  8.  
  9. Disconnect the radiator and heater hoses. Disconnect and plug the oil cooler lines.
  10.  
  11. Remove the fan, spacer, fluid drive, and radiator. Do not store the fan drive unit with the shaft pointing downward. Fluid will leak out.
  12.  



Click image to see an enlarged view

Fig. Fig. 9: Front engine mount 8-400/440



Click image to see an enlarged view

Fig. Fig. 10: Rear engine mount 8-383

  1. Raise the truck and support the rear of the engine.
  2.  
  3. Disconnect the exhaust pipes at the manifolds.
  4.  
  5. Remove the starter on V8 models.
  6.  
  7. Remove the automatic transmission dust cover and attach a C-clamp to the front bottom of the torque converter housing to prevent the converter from falling out. Remove the drive plate bolts from the torque converter. On manual transmission models, remove the rear crossmember, transmission, transfer case and adapter. You can leave the transfer case in place on six-cylinder models.
  8.  
  9. Support the transmission and remove the transmission attaching bolts.
  10.  
  11. Lower the truck and attach a hoist to the engine.
  12.  
  13. Remove the bolts, nuts and washers from the front motor mounts.
  14.  
  15. Carefully remove the engine.
  16.  

To install:
  1. Carefully lower the engine into the truck.
  2.  
  3. Install the front motor mounts and secure using the bolts, nuts and washers.
  4.  
  5. Lower the truck and remove the hoist.
  6.  
  7. Install the transmission attaching bolts.
  8.  
  9. Install the drive plate bolts in the torque converter. On manual transmission models, install the rear crossmember, transmission, transfer case and adapter. Install the automatic transmission dust cover.
  10.  
  11. Install the starter on V8 models.
  12.  
  13. Connect the exhaust pipes at the manifolds.
  14.  
  15. Install the fan, spacer, fluid drive, and radiator.
  16.  
  17. Connect the radiator and heater hoses. Connect the oil cooler lines.
  18.  
  19. Connect the fuel pump line.
  20.  
  21. Install the distributor cap and rotor.
  22.  
  23. Install the carburetor and air cleaner.
  24.  
  25. Engage the electrical connections at the alternator, ignition coil, temperature and oil pressure sending units, starter-to-solenoid and engine/body ground.
  26.  
  27. If equipped with air conditioning, install the compressor.
  28.  
  29. Install the hood.
  30.  
  31. Connect the battery ground cable. Install the battery on V8 models.
  32.  
  33. Fill the cooling system.
  34.  
  35. Fill the crankcase.
  36.  
  37. Adjust the transmission linkage, carburetor and ignition timing.
  38.  

4-WHEEL DRIVE-WM-300
  1. Drain the cooling system.
  2.  


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 battery.
  2.  
  3. Disconnect the fuel line at the pump.
  4.  
  5. Disconnect the headlight wiring.
  6.  



Click image to see an enlarged view

Fig. Fig. 11: Rear engine mount V6



Click image to see an enlarged view

Fig. Fig. 12: Rear engine mount 1988 4WD 8-318/360

  1. Remove the upper and lower radiator hoses.
  2.  
  3. Remove the front sheet metal and radiator as a unit.
  4.  
  5. Remove the floor mat and remove the floor pan cover.
  6.  
  7. Remove the transmission and transfer case. See Drive Train .
  8.  
  9. Disconnect the clutch yoke by removing the cotter key and pin.
  10.  
  11. Disconnect the exhaust pipe at the manifold.
  12.  
  13. Disconnect the throttle and choke control cables.
  14.  
  15. Disconnect the temperature sending unit wire.
  16.  
  17. Disconnect the oil pressure tube.
  18.  
  19. Disconnect the starter wires, ignition wires and the alternator wiring.
  20.  
  21. Disconnect the brake booster hose.
  22.  
  23. Remove the air cleaner.
  24.  
  25. Remove the crankcase ventilation hoses.
  26.  
  27. Remove the carburetor.
  28.  
  29. Remove the ignition coil.
  30.  
  31. Attach a lifting bracket and shop crane and take up the weight of the engine.
  32.  
  33. Remove the front and rear engine mount bolts and lift the engine from the truck.
  34.  

To install:
  1. Lower the engine into the truck.
  2.  
  3. Install the front and rear engine mount bolts. Torque the bolts to 25 ft. lbs. (34 Nm).
  4.  
  5. Remove the shop crane.
  6.  
  7. Install the ignition coil.
  8.  
  9. Install the carburetor.
  10.  
  11. Install the crankcase ventilation hoses and the air cleaner.
  12.  
  13. Connect the brake booster hose.
  14.  
  15. Connect the alternator wiring, ignition and the starter wires.
  16.  
  17. Connect the oil pressure tube.
  18.  
  19. Connect the temperature sending unit wire.
  20.  
  21. Connect the throttle and choke control cables.
  22.  
  23. Connect the exhaust pipe at the manifold. Torque the bolts to 35 ft. lbs. (47 Nm).
  24.  
  25. Connect the clutch yoke.
  26.  
  27. Install the transmission and transfer case. See Drive Train .
  28.  
  29. Install the floor mat and install the floor pan cover.
  30.  
  31. Install the front sheet metal and radiator as a unit.
  32.  
  33. Install the upper and lower radiator hoses.
  34.  
  35. Connect the headlight wiring.
  36.  
  37. Connect the fuel line at the pump.
  38.  
  39. Install the battery.
  40.  
  41. Fill the cooling system.
  42.  



Click image to see an enlarged view

Fig. Fig. 13: Rear engine mount 1988 2WD 8-318/360

Diesel Engines

See Figure 14

  1. Scribe matchmarks on the hood hinges and remove the hood, this makes the job much easier.
  2.  
  3. Disconnect the battery cables and remove the battery.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Drain the cooling system.
  8.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted to 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 upper and lower radiator hoses.
  2.  
  3. Remove the coolant reserve tank.
  4.  
  5. Raise the truck and safely support on jackstands. Disconnect and remove the transmission oil cooler lines from the radiator. Remove the lower radiator and fan shroud mounting screws.
  6.  
  7. Lower the truck, then remove the upper radiator and fan shroud mounting screws. Remove the radiator and fan shroud.
  8.  
  9. Disconnect the heater hoses from the engine and push them aside.
  10.  
  11. Disconnect the speedometer cable housing from the engine.
  12.  
  13. Disengage the electrical connections at the alternator, temperature sending unit, starter relay-to-solenoid wires, the oil gauge sending unit and the injection pump control motor.
  14.  
  15. Make sure you mark any wiring that you are unsure of where it may belong on reassembly. Set the wiring harnesses aside.
  16.  
  17. Remove and plug the fuel line at the transfer pump inlet. Disconnect and cap the return line at the injector lines bleed-back connection.
  18.  
  19. Disconnect and remove the injection pump linkage. Disconnect and remove the accelerator and throttle cable linkage.
  20.  
  21. Disconnect the starter motor wire from the solenoid. Remove the starter motor.
  22.  
  23. Remove the battery ground cable from the engine block.
  24.  
  25. Disconnect and plug the power steering hoses at the power steering gear.
  26.  
  27. Raise the truck and disconnect the exhaust pipe from the exhaust manifold.
  28.  
  29. Drain the engine oil and remove the dipstick tube from the oil pan. Remove the transmission cooler line and road draft tube bracket from the oil pan.
  30.  


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. Remove the oil pan bolts. Unfasten the transmission inspection plate. Use a new gasket upon installation.
  2.  



Click image to see an enlarged view

Fig. Fig. 14: Engine mounts diesel engines

  1. Remove the four flex plate-to-torque converter cover bolts.
  2.  
  3. Remove the exhaust pipe bracket and the lower housing bolts.
  4.  
  5. Remove any other brackets that can interfere with removal.
  6.  
  7. Support the transmission with a floor jack.
  8.  
  9. Remove the cylinder head (valve) cover and the gasket.
  10.  
  11. Attach a boom hoist to the engine, wrapping the chain as tight and close as possible.
  12.  
  13. Remove the four bolts and six nuts from the engine mounts.
  14.  
  15. Remove the two upper bell housing bolts.
  16.  
  17. Roll the boom hoist back, removing the engine from the truck.
  18.  

To install:
  1. Lower the engine into the truck.
  2.  
  3. Install the two upper bell housing bolts.
  4.  
  5. Install the four bolts and six nuts from the engine mounts.
  6.  
  7. If the engine is positioned securely, remove the boom hoist from the engine.
  8.  
  9. Install the cylinder head (valve) cover and the gasket.
  10.  
  11. Remove the floor jack.
  12.  
  13. Install any brackets that were removed.
  14.  
  15. Install the exhaust pipe bracket and the lower housing bolts.
  16.  
  17. Install the four flex plate-to-torque converter cover bolts.
  18.  
  19. Install the transmission inspection plate. Install the oil pan. Use a new gasket on installation.
  20.  
  21. Install the dipstick tube in the oil pan. Install the transmission cooler line and road draft tube bracket to the oil pan.
  22.  
  23. Connect the exhaust pipe to the exhaust manifold.
  24.  
  25. Connect the power steering hoses at the power steering gear.
  26.  
  27. Install the battery ground cable at the engine block.
  28.  
  29. Install the starter motor.
  30.  
  31. Install and connect the injection pump linkage. Connect the accelerator and throttle cable linkage.
  32.  
  33. Connect the fuel line at the transfer pump inlet. Connect the return line at the injector lines bleed-back connection.
  34.  
  35. Engage the electrical connections at the alternator, temperature sending unit, starter relay-to-solenoid wires, the oil gauge sending unit and the injection pump control motor.
  36.  
  37. Connect the speedometer cable housing to the engine.
  38.  
  39. Connect the heater hoses at the engine.
  40.  
  41. Install the radiator and fan shroud. Install the upper radiator and fan shroud mounting screws.
  42.  
  43. Connect the transmission oil cooler lines to the radiator. Install the lower radiator and fan shroud mounting screws.
  44.  
  45. Install the coolant reserve tank.
  46.  
  47. Install the upper and lower radiator hoses.
  48.  
  49. Fill the cooling system.
  50.  
  51. Install the air cleaner.
  52.  
  53. Install the battery and connect the battery cables.
  54.  
  55. Warm the engine. Check for any leaks.
  56.  
  57. Install the hood and line it up.
  58.  
  59. Road test the truck.
  60.  

Fuel Injected Engines

The mounting of the engine for a manual transmission is different from an automatic transmission. The procedure will varies slightly depending on which you may have.

  1. Scribe the hood hinges and remove the hood.
  2.  
  3. Drain the cooling system, and engine oil, remove the battery and air cleaner.
  4.  
  5. Disconnect and remove the radiator hoses, fan shroud and radiator, along with heater hoses.
  6.  
  7. If equipped, discharge the air conditioning system.
  8.  
  9. Tag all vacuum lines and remove them. Tag the wiring to the distributor cap, remove as an assembly.
  10.  
  11. Disconnect throttle body linkage and remove the throttle body. Disconnect starter and oil pressure wires. Mark and remove any other wiring harnesses that may need to be removed and lay aside.
  12.  
  13. Remove all air conditioning and power steering hoses (if equipped).
  14.  
  15. Remove the starter, alternator, charcoal canister and horns.
  16.  
  17. Remove the exhaust pipe at the manifold.
  18.  
  19. On automatics, remove the bell housing bolts and inspection plate. Attach a C-clamp on the bottom front of converter housing to prevent the converter from coming out. Mark the converter and drive plate, then remove the drive plate bolts. Support the transmission in place for ease of replacement. Disconnect the engine from the torque converter drive plate.
  20.  
  21. Install an engine lifting device, attach a chain hoist to the device eye-bolts.
  22.  
  23. Remove the engine front mounting bolts. Remove the engine from the engine compartment and insert on an engine repair stand.
  24.  
  25. Inspect, and replace if needed the engine mounts.
  26.  

To install:
  1. Install the good engine with the lifting device, inserting into engine compartment.
  2.  
  3. On automatics, install the torque converter drive plate bolts along with the front engine mounts. Replace the bell housing bolts and disconnect the C-clamp. Insert the inspection plate.
  4.  
  5. Reassemble the engine mounting, remove the engine lifting device.
  6.  
  7. Install the throttle body and lines.
  8.  
  9. Replace the vacuum lines distributor cap and wiring, they were previously tagged so installation should be quite easy.
  10.  
  11. Reinstall the exhaust pie to manifold.
  12.  
  13. Connect the throttle body linkage and wiring to the engine.
  14.  
  15. Install the radiator, radiator hoses and heater hoses.
  16.  
  17. Replace the fan shroud. Fill the cooling system with a fresh antifreeze, water mixture.
  18.  
  19. Install the throttle body air cleaner. Connect all vacuum hoses, power steering hoses, if equipped.
  20.  
  21. Install the air conditioning equipment and charge the system.
  22.  
  23. Double check all hoses, wiring, lines and any other components to make sure they are fastened and secure.
  24.  
  25. Install fresh oil in the engine.
  26.  
  27. Start the engine and top off the cooling system. Check the level of the engine oil. Adjust the engine.
  28.  
  29. Install the hood and line up.
  30.  
  31. Road test the vehicle.
  32.  

 
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