Chrysler Full-Size Vans 1967-1988 Repair Guide

Engine

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REMOVAL & INSTALLATION



See Figures 1, 2, 3 and 4

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Fig. Fig. 1: Common engine mounting for inline 6-cylinder engines



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Fig. Fig. 2: Common engine mounting for V6 and V8 engines



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Fig. Fig. 3: Common engine rear mount, or transmission mount, for all vehicles



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Fig. Fig. 4: When removing nuts, bolts and other parts, place them in a tray or other container

1967-69 Inline 6-Cylinder Engines

  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. Disconnect the battery.
  2.  
  3. Disconnect the upper and lower radiator hoses.
  4.  
  5. Disconnect the heater hoses.
  6.  
  7. Disconnect the:

    throttle linkage
     
    alternator wiring
     
    distributor wiring
     
    starter wiring
     
    engine-to-body ground strap
     
    temperature sending unit
     
    oil pressure sending unit
     

  8.  
  9. Remove the alternator.
  10.  
  11. Raise and support the van on jackstands.
  12.  
  13. Drain the engine oil.
  14.  


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. Drain the transmission. On automatic transmissions, also drain the torque converter.
  2.  
  3. Disconnect the shift linkage at the transmission.
  4.  
  5. Disconnect the anti-rattle block from the sill.
  6.  
  7. Disconnect the speedometer cable at the transmission.
  8.  
  9. Remove the clutch torque shaft, transmission shift control rod, parking lock cable, neutral start switch wiring and oil cooler lines.
  10.  
  11. Disconnect the exhaust pipe at the manifold.
  12.  
  13. Matchmark and remove the driveshaft.
  14.  
  15. Disconnect the fuel line at the pump.
  16.  
  17. Support the engine and transmission as an assembly, with a floor jack and safety chain.
  18.  
  19. Remove the engine cover.
  20.  
  21. Open the side doors and hook an engine crane to the engine.
  22.  
  23. Remove the engine rear support bolt and the front engine mount loer stud nuts.
  24.  
  25. Remove the right engine support bracket from the body sill.
  26.  
  27. Lower the transmission and engine assembly, separate them and place the engine on a work stand.
  28.  

To install:
  1. Join the transmission and engine and raise into the van.
  2.  
  3. Install the right engine support bracket. Torque the bolts to 65 ft. lbs.
  4.  
  5. Install the engine rear support bolt and the front engine mount lower stud nuts. Torque the bolt to 35 ft. lbs.; the nuts to 45 ft. lbs.
  6.  
  7. Remove the engine crane.
  8.  
  9. Install the engine cover.
  10.  
  11. Connect the fuel line at the pump.
  12.  
  13. Install the driveshaft.
  14.  
  15. Connect the exhaust pipe at the manifold.
  16.  
  17. Install the clutch torque shaft, transmission shift control rod, parking lock cable, neutral start switch wiring and oil cooler lines.
  18.  
  19. Connect the speedometer cable at the transmission.
  20.  
  21. Connect the anti-rattle block at the sill.
  22.  
  23. Connect the shift linkage at the transmission.
  24.  
  25. Fill the transmission.
  26.  
  27. Fill the crankcase.
  28.  
  29. Install the alternator.
  30.  
  31. Connect the:

    throttle linkage
     
    alternator wiring
     
    distributor wiring
     
    starter wiring
     
    engine-to-body ground strap
     
    temperature sending unit
     
    oil pressure sending unit
     

  32.  
  33. Connect the heater hoses.
  34.  
  35. Connect the upper and lower radiator hoses.
  36.  
  37. Connect the battery.
  38.  
  39. Fill the cooling system.
  40.  

1967-69 318 Engine

  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. Disconnect the battery.
  2.  
  3. Disconnect the upper and lower radiator hoses.
  4.  
  5. Disconnect the heater hoses.
  6.  
  7. Disconnect the:

    throttle linkage
     
    alternator wiring
     
    starter wiring
     
    engine-to-body ground strap
     
    temperature sending unit
     
    oil pressure sending unit
     

  8.  
  9. Remove the right inner valve cover nuts and remove the distributor cap and rotor.
  10.  
  11. Remove the alternator.
  12.  
  13. Raise and support the van on jackstands.
  14.  
  15. Drain the engine oil.
  16.  


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. Drain the transmission. On automatic transmissions, also drain the torque converter.
  2.  
  3. Disconnect the shift linkage at the transmission.
  4.  
  5. Disconnect the anti-rattle block from the sill.
  6.  
  7. Disconnect the speedometer cable at the transmission.
  8.  
  9. Remove the clutch torque shaft, transmission shift control rod, parking lock cable, neutral start switch wiring and oil cooler lines.
  10.  
  11. Disconnect the exhaust pipe at the manifold.
  12.  
  13. Matchmark and remove the driveshaft.
  14.  
  15. Disconnect the fuel line at the pump.
  16.  
  17. Support the engine and transmission as an assembly, with a floor jack and safety chain.
  18.  
  19. Remove the engine cover.
  20.  
  21. Open the side doors and hook an engine crane to the engine.
  22.  
  23. Remove the engine rear support bolt and the front engine mount loer stud nuts.
  24.  
  25. Remove the right engine support bracket from the body sill.
  26.  
  27. Lower the transmission and engine assembly, separate them and place the engine on a work stand.
  28.  

To install:
  1. Join the transmission and engine and raise into the van.
  2.  
  3. Install the right engine support bracket. Torque the bolts to 65 ft. lbs.
  4.  
  5. Install the engine rear support bolt and the front engine mount lower stud nuts. Torque the bolt to 35 ft. lbs.; the nuts to 45 ft. lbs.
  6.  
  7. Remove the engine crane.
  8.  
  9. Install the engine cover.
  10.  
  11. Connect the fuel line at the pump.
  12.  
  13. Install the driveshaft.
  14.  
  15. Connect the exhaust pipe at the manifold.
  16.  
  17. Install the clutch torque shaft, transmission shift control rod, parking lock cable, neutral start switch wiring and oil cooler lines.
  18.  
  19. Connect the speedometer cable at the transmission.
  20.  
  21. Connect the anti-rattle block at the sill.
  22.  
  23. Connect the shift linkage at the transmission.
  24.  
  25. Fill the transmission.
  26.  
  27. Fill the crankcase.
  28.  
  29. Install the alternator.
  30.  
  31. Install the distributor cap and rotor and the valve cover nuts.
  32.  
  33. Connect the:

    throttle linkage
     
    alternator wiring
     
    distributor wiring
     
    starter wiring
     
    engine-to-body ground strap
     
    temperature sending unit
     
    oil pressure sending unit
     

  34.  
  35. Connect the heater hoses.
  36.  
  37. Connect the upper and lower radiator hoses.
  38.  
  39. Connect the battery.
  40.  
  41. Fill the cooling system.
  42.  

1970-72 Inline 6-Cylinder Engines

  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. Disconnect the battery.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Remove the starter.
  8.  
  9. If so equipped, discharge the air conditioning system. See General Information And Maintenance .
  10.  
  11. Disconnect the refrigerant lines at the condenser. Cap all openings at once.
  12.  
  13. Remove the front bumper.
  14.  
  15. Remove the grille and support brace.
  16.  
  17. Disconnect the upper radiator hose.
  18.  
  19. Disconnect the lower radiator hose.
  20.  
  21. Remove the radiator and condenser as an assembly.
  22.  
  23. Remove the air conditioning compressor.
  24.  
  25. Remove the power steering pump from its bracket and position it out of the way, WITHOUT DISCONNECTING THE HOSES!
  26.  
  27. Disconnect the heater hoses.
  28.  
  29. Tag and disconnect all vacuum lines at the engine.
  30.  
  31. Disconnect the:

    coil
     
    alternator
     
    temperature sending unit
     
    oil pressure sending unit
     
    engine-to-body ground strap
     

  32.  
  33. Disconnect the throttle linkage and remove the operating lever from the accelerator bellcrank.
  34.  
  35. Remove the alternator.
  36.  
  37. Remove the fan, pulley and drive belts.
  38.  
  39. Disconnect the fuel line at the pump.
  40.  
  41. Remove the oil dipstick and tube.
  42.  
  43. Remove the intake manifold with the carburetor attached.
  44.  
  45. Remove the exhaust manifolds.
  46.  
  47. Raise and support the van on jackstands.
  48.  
  49. Remove the entire exhaust system.
  50.  
  51. Matchmark and remove the driveshaft.
  52.  
  53. Disconnect the shift rods.
  54.  
  55. Remove the clutch torque shaft, or the shifter torque shaft and oil cooler lines.
  56.  
  57. Disconnect the speedometer cable at the transmission.
  58.  
  59. Disconnect any electrical connections at the transmission.
  60.  
  61. Remove the inspection plate or converter cover plate from the bellhousing.
  62.  
  63. Support the transmission on a transmission jack.
  64.  
  65. Remove the rear engine support.
  66.  
  67. Position a 3 / 4 " thick piece of wood between the oil pan and crossmember.
  68.  
  69. Remove the transmission-to-bellhousing bolts, or the converter housing-to-engine bolts.
  70.  
  71. Roll the transmission back until it is clear of the engine or clutch, then lower it and move it away.
  72.  
  73. Lower the van to the ground.
  74.  
  75. Install an engine lifting fixture to the number 3, 4, and 5 lower exhaust manifold studs.
  76.  
  77. Attach a shop crane to the lifting fixture. Take up the weight of the engine.
  78.  
  79. Remove the front engine mounts.
  80.  
  81. Raise the engine and maneuver it through the front of the van. It may be necessary to raise the van slightly to keep the crane arm horizontal.
  82.  

To install:
  1. Lower the engine into the van.
  2.  
  3. Install the front engine mounts. Don't tighten them yet!
  4.  
  5. Position a 3 / 4 " thick piece of wood between the oil pan and crossmember.
  6.  
  7. Remove the shop crane.
  8.  
  9. Install the transmission.
  10.  
  11. Install the transmission-to-bellhousing bolts, or the converter housing-to-engine bolts.
  12.  
  13. Install the rear engine support.
  14.  
  15. Remove the holding fixture.
  16.  
  17. Install the inspection plate or converter cover plate.
  18.  
  19. Connect the electrical connections at the transmission.
  20.  
  21. Connect the speedometer cable at the transmission.
  22.  
  23. Install the clutch torque shaft, or the shifter torque shaft and oil cooler lines.
  24.  
  25. Connect the shift rods.
  26.  
  27. Matchmark and install the driveshaft.
  28.  
  29. Install the exhaust system.
  30.  
  31. Install the exhaust manifolds.
  32.  
  33. Install the intake manifold with the carburetor attached.
  34.  
  35. Install the oil dipstick and tube.
  36.  
  37. Connect the fuel line at the pump.
  38.  
  39. Tighten the front engine mounts. Tighten the nuts to 45 ft. lbs.
  40.  
  41. Install the fan, pulley and drive belts.
  42.  
  43. Install the alternator.
  44.  
  45. Connect the throttle linkage and install the operating lever on the accelerator bellcrank.
  46.  
  47. Connect the:

    coil
     
    alternator
     
    temperature sending unit
     
    oil pressure sending unit
     
    engine-to-body ground strap
     

  48.  
  49. Connect all vacuum lines at the engine.
  50.  
  51. Connect the heater hoses.
  52.  
  53. Install the power steering pump.
  54.  
  55. Install the air conditioning compressor.
  56.  
  57. Install the radiator and condenser as an assembly.
  58.  
  59. Connect the lower radiator hose.
  60.  
  61. Connect the upper radiator hose.
  62.  
  63. Install the grille and support brace.
  64.  
  65. Install the front bumper.
  66.  
  67. Connect the refrigerant lines at the condenser.
  68.  
  69. Evacuate, charge and leak test the air conditioning system. See General Information And Maintenance .
  70.  
  71. Install the starter.
  72.  
  73. Install the air cleaner.
  74.  
  75. Install the engine cover.
  76.  
  77. Connect the battery.
  78.  
  79. Fill the cooling system.
  80.  

1970-72 V8 Engines

  1. Drain the cooling system.
  2.  
  3. Disconnect the battery.
  4.  


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. Disconnect the battery.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Remove the starter.
  8.  
  9. If so equipped, discharge the air conditioning system. See General Information And Maintenance .
  10.  
  11. Disconnect the regrigerant lines at the condenser. Cap all openings at once.
  12.  
  13. Remove the front bumper.
  14.  
  15. Remove the grille and support brace.
  16.  
  17. Remove the fan shroud.
  18.  
  19. Disconnect the upper radiator hose.
  20.  
  21. Disconnect the lower radiator hose.
  22.  
  23. Remove the radiator and condenser as an assembly.
  24.  
  25. Remove the air conditioning compressor.
  26.  
  27. Remove the heater blower motor.
  28.  
  29. Remove the power steering pump with its bracket and position it out of the way, WITHOUT DISCONNECTING THE HOSES!
  30.  
  31. Disconnect the heater hoses.
  32.  
  33. Tag and disconnect all vacuum lines at the engine.
  34.  
  35. Disconnect the:

    coil
     
    alternator
     
    temperature sending unit
     
    oil pressure sending unit
     
    engine-to-body ground strap
     

  36.  
  37. Disconnect the throttle linkage and remove the operating lever from the accelerator bellcrank.
  38.  
  39. Remove the alternator.
  40.  
  41. Remove the fan, pulley and drive belts.
  42.  
  43. Disconnect the fuel line at the pump.
  44.  
  45. Remove the oil dipstick and tube.
  46.  
  47. Remove the intake manifold with the carburetor attached.
  48.  
  49. Remove the exhaust manifolds.
  50.  
  51. Raise and support the van on jackstands.
  52.  
  53. Remove the entire exhaust system.
  54.  
  55. Matchmark and remove the driveshaft.
  56.  
  57. Disconnect the shift rods.
  58.  
  59. Remove the clutch torque shaft, or the shifter torque shaft and oil cooler lines.
  60.  
  61. Disconnect the speedometer cable at the transmission.
  62.  
  63. Disconnect any electrical connections at the transmission.
  64.  
  65. Remove the inspection plate or converter cover plate from the bellhousing.
  66.  
  67. Support the transmission on a transmission jack.
  68.  
  69. Remove the rear engine support throughbolt.
  70.  
  71. Install an engine lifting fixture to the heads.
  72.  
  73. Attach a shop crane and take up the weight of the engine.
  74.  
  75. Remove the front engine mount insulator top stud nuts and washers.
  76.  
  77. Remove the transmission-to-bellhousing bolts, or the converter housing-to-engine bolts.
  78.  
  79. Roll the transmission back until it is clear of the engine or clutch, then lower it and move it away.
  80.  
  81. Lower the van to the ground.
  82.  
  83. Raise the engine and maneuver it through the front of the van. It may be necessary to raise the van slightly to keep the crane arm horizontal.
  84.  

To install:
  1. Lower the engine into the front of the van.
  2.  
  3. Install the transmission.
  4.  
  5. Install the transmission-to-bellhousing bolts, or the converter housing-to-engine bolts.
  6.  
  7. Install the front engine mount insulator top stud nuts and washers. Torque them to 65 ft. lbs.
  8.  
  9. Install the rear engine support throughbolt. Torque to 65 ft. lbs.
  10.  
  11. Remove the shop crane.
  12.  
  13. Install the inspection plate or converter cover plate on the bellhousing.
  14.  
  15. Connect any electrical connections at the transmission.
  16.  
  17. Connect the speedometer cable at the transmission.
  18.  
  19. Install the clutch torque shaft, or the shifter torque shaft and oil cooler lines.
  20.  
  21. Connect the shift rods.
  22.  
  23. Matchmark and install the driveshaft.
  24.  
  25. Install the exhaust system.
  26.  
  27. Install the exhaust manifolds.
  28.  
  29. Install the intake manifold with the carburetor attached.
  30.  
  31. Install the oil dipstick and tube.
  32.  
  33. Connect the fuel line at the pump.
  34.  
  35. Install the fan, pulley and drive belts.
  36.  
  37. Install the alternator.
  38.  
  39. Connect the throttle linkage and Install the operating lever on the accelerator bellcrank.
  40.  
  41. Connect the:

    coil
     
    alternator
     
    temperature sending unit
     
    oil pressure sending unit
     
    engine-to-body ground strap
     

  42.  
  43. Connect all vacuum lines at the engine.
  44.  
  45. Connect the heater hoses.
  46.  
  47. Install the power steering pump.
  48.  
  49. Install the heater blower motor.
  50.  
  51. Install the air conditioning compressor.
  52.  
  53. Install the radiator and condenser as an assembly.
  54.  
  55. Connect the lower radiator hose.
  56.  
  57. Connect the upper radiator hose.
  58.  
  59. Install the fan shroud.
  60.  
  61. Install the grille and support brace.
  62.  
  63. Install the front bumper.
  64.  
  65. Connect the refrigerant lines at the condenser.
  66.  
  67. Evacuate, charge and leak test the air conditioning system. See General Information And Maintenance .
  68.  
  69. Install the starter.
  70.  
  71. Install the air cleaner.
  72.  
  73. Install the engine cover.
  74.  
  75. Connect the battery.
  76.  
  77. Fill the cooling system.
  78.  

1973-79 Inline 6-Cylinder Engines

  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. Disconnect the battery.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Drain the engine oil.
  8.  


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 starter.
  2.  
  3. Remove the distributor.
  4.  
  5. If so equipped, discharge the air conditioning system. See General Information And Maintenance .
  6.  
  7. Disconnect the refrigerant lines at the condenser. Cap all openings at once.
  8.  
  9. Remove the front bumper.
  10.  
  11. Remove the grille and support brace.
  12.  
  13. Disconnect the upper radiator hose.
  14.  
  15. Disconnect the lower radiator hose.
  16.  
  17. Remove the radiator and condenser as an assembly.
  18.  
  19. Remove the air conditioning compressor.
  20.  
  21. Remove the power steering pump from its bracket and position it out of the way, WITHOUT DISCONNECTING THE HOSES!
  22.  
  23. Disconnect the heater hoses.
  24.  
  25. Remove the heater blower motor.
  26.  
  27. Tag and disconnect all vacuum lines at the engine.
  28.  
  29. Disconnect the:

    coil
     
    alternator
     
    temperature sending unit
     
    oil pressure sending unit
     
    engine-to-body ground strap
     

  30.  
  31. Disconnect the throttle linkage and remove the operating lever from the accelerator bellcrank.
  32.  
  33. Remove the alternator.
  34.  
  35. Remove the fan, pulley and drive belts.
  36.  
  37. Disconnect the fuel line at the pump.
  38.  
  39. Remove the oil dipstick and tube.
  40.  
  41. Remove the intake manifold with the carburetor attached.
  42.  
  43. Remove the exhaust manifolds.
  44.  
  45. Raise the engine slightly and support it in this position with a holding fixture fabricated from 1 1 / 2 " ID galvanized pipe straddling the engine compartment opening, or with a shop crane through the side doors.
  46.  
  47. Raise and support the van on jackstands.
  48.  
  49. Remove the engine oil pan.
  50.  
  51. Remove the entire exhaust system.
  52.  
  53. Matchmark and remove the driveshaft.
  54.  
  55. Disconnect the shift rods.
  56.  
  57. Remove the clutch torque shaft, or the shifter torque shaft and oil cooler lines.
  58.  
  59. Disconnect the speedometer cable at the transmission.
  60.  
  61. Disconnect any electrical connections at the transmission.
  62.  
  63. Remove the inspection plate or converter cover plate from the bellhousing.
  64.  
  65. Support the transmission on a transmission jack.
  66.  
  67. Remove the rear engine support.
  68.  
  69. Remove the transmission-to-bellhousing bolts, or the converter housing-to-engine bolts.
  70.  
  71. Roll the transmission back until it is clear of the engine or clutch, then lower it and move it away.
  72.  
  73. On vans with manual transmission, remove the clutch and flywheel.
  74.  
  75. On vans with automatic transmission, remove the flex plate.
  76.  
  77. Lower the van to the ground.
  78.  
  79. Install an engine lifting fixture to the number 3, 4, and 5 lower exhaust manifold studs.
  80.  
  81. Attach a shop crane to the lifting fixture. Take up the weight of the engine.
  82.  
  83. Remove the front engine mounts.
  84.  
  85. Raise the engine and maneuver it through the front of the van. It may be necessary to raise the van slightly to keep the crane arm horizontal.
  86.  

To install:
  1. Lower the engine into the van.
  2.  
  3. Installt he front engine mounts. Torque the bolts to 50 ft. lbs.
  4.  
  5. Remove the shop crane.
  6.  
  7. Remove the engine lifting fixture.
  8.  
  9. Raise and support the front end on jackstands.
  10.  
  11. On vans with automatic transmission, install the flex plate. Torque the bolts to 55 ft. lbs.
  12.  
  13. On vans with manual transmission, install the clutch and flywheel. Torque the flywheel bolts to 55 ft. lbs.
  14.  
  15. Roll the transmission into position.
  16.  
  17. On vans with manual transmission, install the transmission-to-bellhousing bolts. Torque the 3 / 8 -16 bolts to 30 ft. lbs.; the -14 bolts to 50 ft. lbs.
  18.  
  19. On vans with automatic transmission, install the converter housing-to-engine bolts. Torque the 3 / 8 -16 bolts to 30 ft. lbs.; the -14 bolts to 50 ft. lbs.
  20.  
  21. Install the rear engine support. Torque the bolts to 50 ft. lbs.
  22.  
  23. On vans with manual transmission, install the inspection plate.
  24.  
  25. On vans with automatic transmission, install the converter cover plate.
  26.  
  27. Connect any electrical connections at the transmission.
  28.  
  29. Connect the speedometer cable at the transmission.
  30.  
  31. Install the clutch torque shaft, or the shifter torque shaft and oil cooler lines.
  32.  
  33. Connect the shift rods.
  34.  
  35. Install the driveshaft.
  36.  
  37. Install the exhaust system.
  38.  
  39. Install the engine oil pan. Torque the bolts to 15 ft. lbs.
  40.  
  41. Lower the van.
  42.  
  43. Remove the holding fixture.
  44.  
  45. Install the exhaust manifolds.
  46.  
  47. Install the intake manifold with the carburetor attached.
  48.  
  49. Install the oil dipstick and tube.
  50.  
  51. Connect the fuel line at the pump.
  52.  
  53. Install the fan, pulley and drive belts. Torque the fan bolts to 15 ft. lbs.
  54.  
  55. Install the alternator.
  56.  
  57. Connect the throttle linkage and install the operating lever on the accelerator bellcrank.
  58.  
  59. Connect the coil.
  60.  
  61. Connect the alternator.
  62.  
  63. Connect the temperature sending unit.
  64.  
  65. Connect the oil pressure sending unit.
  66.  
  67. Connect the engine-to-body ground strap.
  68.  
  69. Connect all vacuum lines at the engine.
  70.  
  71. Install the heater blower motor.
  72.  
  73. Connect the heater hoses.
  74.  
  75. Install the power steering pump on its bracket.
  76.  
  77. Install the air conditioning compressor.
  78.  
  79. Install the radiator and condenser as an assembly.
  80.  
  81. Connect the lower radiator hose.
  82.  
  83. Connect the upper radiator hose.
  84.  
  85. Install the grille and support brace.
  86.  
  87. Install the front bumper.
  88.  
  89. Connect the refrigerant lines at the condenser.
  90.  
  91. Evacuate, charge and leak test the air conditioning system.
  92.  
  93. Install the distributor.
  94.  
  95. Install the crankcase.
  96.  
  97. Fill the crankcase.
  98.  
  99. Install the air cleaner.
  100.  
  101. Installt engine cover.
  102.  

100. Connect the battery.

101. Fill the cooling system.

1978-79 Diesel Engine

  1. Disconnect the battery cables and remove the battery.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Scribe matchmarks on the hood hinges and remove the hood.
  6.  
  7. Drain the cooling system.
  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 upper and lower radiator hoses.
  2.  
  3. Remove the coolant reserve tank.
  4.  
  5. If so equipped, discharge the air conditioning system. See General Information And Maintenance .
  6.  
  7. Disconnect the refrigerant lines at the condenser. Cap all openings at once.
  8.  
  9. Remove the front bumper.
  10.  
  11. Remove the grille and support brace.
  12.  
  13. Remove the air conditioning compressor.
  14.  
  15. 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.
  16.  
  17. Lower the truck and remove the upper radiator and fan shroud mounting screws and remove the radiator, condenser and fan shroud.
  18.  
  19. Remove the heater blower motor.
  20.  
  21. Disconnect the heater hoses from the engine and push them aside.
  22.  
  23. Disconnect the speedometer cable housing from the engine.
  24.  
  25. Disconnect 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. Set the wiring harness aside.
  26.  
  27. Disconnect the plug and fuel line at the transfer pump inlet. Disconnect and cap return line at the injector lines bleed-back connection.
  28.  
  29. Disconnect and remove the injection pump linkage. Disconnect and remove the accelerator and throttle cable linkage.
  30.  
  31. Disconnect the starter motor wire from the solenoid. Remove the starter motor.
  32.  
  33. Remove the battery ground cable from the engine block.
  34.  
  35. Disconnect and plug the power steering hoses at the power steering gear.
  36.  
  37. Raise the truck and disconnect the exhaust pipe from the exhaust manifold.
  38.  
  39. 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.
  40.  


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 from the oil pan.
  2.  
  3. Remove the transmission inspection plate. Remove the oil pan to gain clearance if necessary. Use a new gasket on installation.
  4.  
  5. Remove the four flex plate-to-torque converter bolts.
  6.  
  7. Remvoe the exhaust pipe bracket and the lower housing bolts.
  8.  
  9. Remove any other brackets that can interfere with removal.
  10.  
  11. Support the transmission with a floor jack.
  12.  
  13. Remove the cylinder head (valve) cover and the gasket.
  14.  
  15. Attach a boom hoist to the engine, wrapping the chain as tight and close as possible.
  16.  
  17. Remove the four bolts and six nuts from the engine mounts.
  18.  
  19. Remove the two upper bell housing bolts.
  20.  
  21. Roll the boom hoist back, removing the engine from the van.
  22.  

To install:
  1. Lower the engine into the van.
  2.  
  3. Install the two upper bell housing bolts.
  4.  
  5. Install the bolts and nuts in the engine mounts.
  6.  
  7. Remove the shop crane.
  8.  
  9. Install the cylinder head (valve) cover.
  10.  
  11. Remove the floor jack.
  12.  
  13. Install any brackets which were removed.
  14.  
  15. Install the exhaust pipe bracket and the lower housing bolts.
  16.  
  17. Install the flex plate-to-torque converter bolts.
  18.  
  19. Install the transmission inspection plate.
  20.  
  21. Install the oil pan.
  22.  
  23. Install the dipstick tube.
  24.  
  25. Install the transmission cooler line and road draft tube bracket.
  26.  
  27. Connect the exhaust pipe at the exhaust manifold.
  28.  
  29. Connect the power steering hoses at the power steering gear.
  30.  
  31. Install the battery ground cable.
  32.  
  33. Install the starter motor.
  34.  
  35. Connect the starter motor wire at the solenoid.
  36.  
  37. Install the injection pump linkage.
  38.  
  39. Install the accelerator and throttle cable linkage.
  40.  
  41. Connect the fuel line at the transfer pump inlet.
  42.  
  43. Connect the return line at the injector lines bleed-back connection.
  44.  
  45. Connect 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.
  46.  
  47. Connect the speedometer cable housing.
  48.  
  49. Connect the heater hoses.
  50.  
  51. Install the heater blower motor.
  52.  
  53. Install the radiator, condenser and fan shroud.
  54.  
  55. Connect the transmission oil cooler lines at the radiator.
  56.  
  57. Install the air conditioning compressor.
  58.  
  59. Install the grille and support brace.
  60.  
  61. Install the front bumper.
  62.  
  63. Connect the refrigerant lines at the condenser.
  64.  
  65. Evacuate, charge and leak test the air conditioning system.
  66.  
  67. Install the coolant reserve tank.
  68.  
  69. Install the upper and lower radiator hoses.
  70.  
  71. Fill the crankcase.
  72.  
  73. Fill the cooling system.
  74.  
  75. Install the air cleaner.
  76.  
  77. Install the hood.
  78.  
  79. Install the battery.
  80.  

1973-79 V8 Engines

  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. Disconnect the battery.
  2.  
  3. Drain the engine oil.
  4.  


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 filter.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Remove the starter.
  8.  
  9. If so equipped, discharge the air conditioning system. See General Information And Maintenance .
  10.  
  11. Disconnect the refrigerant lines at the condenser. Cap all openings at once.
  12.  
  13. Remove the front bumper.
  14.  
  15. Remove the grille and support brace.
  16.  
  17. Remove the fan shroud.
  18.  
  19. Disconnect the upper radiator hose.
  20.  
  21. Disconnect the lower radiator hose.
  22.  
  23. Remove the radiator and condenser as an assembly.
  24.  
  25. Remove the air conditioning compressor.
  26.  
  27. Remove the heater blower motor.
  28.  
  29. Remove the power steering pump from its bracket and position it out of the way, WITHOUT DISCONNECTING THE HOSES!
  30.  
  31. Disconnect the heater hoses.
  32.  
  33. Tag and disconnect all vacuum lines at the engine.
  34.  
  35. Disconnect the coil.
  36.  
  37. Disconnect the alternator and air pump.
  38.  
  39. Disconnect the temperature sending unit.
  40.  
  41. Disconnect the oil pressure sending unit.
  42.  
  43. Disconnect the engine-to-body ground strap.
  44.  
  45. Disconnect the throttle linkage and remove the operating lever from the accelerator bellcrank.
  46.  
  47. Remove the alternator.
  48.  
  49. Remove the fan, pulley and drive belts.
  50.  
  51. Disconnect the fuel line at the pump.
  52.  
  53. Remove the oil dipstick and tube.
  54.  
  55. Remove the heater blower motor.
  56.  
  57. Remove the intake manifold with the carburetor attached.
  58.  
  59. On the 8-318 and 8-360, remove the left exhaust manifold.
  60.  
  61. On the 8-318 and 8-360 with air conditioning, remove the right valve cover.
  62.  
  63. Raise the engine slightly and support it in this position with a holding fixture fabricated from 1 1 / 2 " ID galvanized pipe straddling the engine compartment opening, or with a shop crane through the side doors.
  64.  
  65. Raise and support the van on jackstands.
  66.  
  67. Remove the entire exhaust system.
  68.  
  69. Matchmark and remove the driveshaft.
  70.  
  71. Disconnect the shift rods.
  72.  
  73. Remove the clutch torque shaft, or the shifter torque shaft and oil cooler lines.
  74.  
  75. Disconnect the speedometer cable at the transmission.
  76.  
  77. Disconnect any electrical connections at the transmission.
  78.  
  79. Remove the inspection plate or converter cover plate from the bellhousing.
  80.  
  81. Support the transmission on a transmission jack.
  82.  
  83. Remove the rear engine support.
  84.  
  85. Install an engine lifting fixture to the heads.
  86.  
  87. Attach a shop crane and take up the weight of the engine.
  88.  
  89. Remove the front engine mount insulator top stud nuts and washers.
  90.  
  91. Remove the transmission-to-bellhousing bolts, or the converter housing-to engine bolts.
  92.  
  93. Roll the transmission back until it is clear of the engine or clutch, then lower it and move it away.
  94.  
  95. On vans with manual transmission, remove the clutch.
  96.  
  97. Remove the flywheel or flex plate.
  98.  
  99. Raise the rear of the engine about 2".
  100.  
  101. On the 8-318 and 8-360, turn the crankshaft until the cutout portion of the crankshaft flange is at the 3 o'clock position.
  102.  
  103. On the 8-318 and 8-360, remove the oil pan bolts, lower the pan just enough to reach the oil pick-up tube and turn the tube and strainer slightly to the right side to clear the pan. Remove the pan.
  104.  
  105. Lower the van to the ground.
  106.  
  107. Raise the engine and maneuver it through the front of the van. It may be necessary to raise the van slightly to keep the crane arm horizontal.
  108.  

To install:
  1. Lower the engine into the van.
  2.  
  3. Raise and support the front end on jackstands.
  4.  
  5. Install the oil pan. Torque the bolts to 15 ft. lbs.
  6.  
  7. Install the flywheel or flex plate. Torque the bolts to 55 ft. lbs.
  8.  
  9. On vans with manual transmission, install the clutch.
  10.  
  11. Position the transmission.
  12.  
  13. Install the transmission-to-bellhousing bolts, or the converter housing-to-engine bolts. Torque the 3 / 8 -16 bolts to 30 ft. lbs.; the -14 bolts to 50 ft. lbs.
  14.  
  15. Install the front engine mount insulator top stud nuts and washers. Torque the nuts to 75 ft. lbs.
  16.  
  17. Remove the shop crane.
  18.  
  19. Remove the engine lifting fixture.
  20.  
  21. Install the rear engine support. Torque the bolts to 50 ft. lbs.
  22.  
  23. Remove the transmission jack.
  24.  
  25. Install the inspection plate or converter cover plate on the bellhousing.
  26.  
  27. Connect any electrical connections at the transmission.
  28.  
  29. Connect the speedometer cable at the transmission.
  30.  
  31. Install the clutch torque shaft, or the shifter torque shaft and oil cooler lines.
  32.  
  33. Connect the shift rods.
  34.  
  35. Matchmark and install the driveshaft.
  36.  
  37. Install the exhaust system.
  38.  
  39. Lower the van.
  40.  
  41. Remove the holding fixture.
  42.  
  43. If equipped with air conditioning, install the right valve cover.
  44.  
  45. Install the left exhaust manifold.
  46.  
  47. Install the intake manifold with the carburetor attached.
  48.  
  49. Install the heater blower motor.
  50.  
  51. Install the oil dipstick and tube.
  52.  
  53. Connect the fuel line at the pump.
  54.  
  55. Install the fan, pulley and drive belts.
  56.  
  57. Install the alternator.
  58.  
  59. Connect the throttle linkage and install the operating lever from the accelerator bellcrank.
  60.  
  61. Connect the engine-to-body ground strap.
  62.  
  63. Connect the oil pressure sending unit.
  64.  
  65. Connect the temperature sending unit.
  66.  
  67. Connect the alternator.
  68.  
  69. Connect the coil.
  70.  
  71. Connect all vacuum lines at the engine.
  72.  
  73. Connect the heater hoses.
  74.  
  75. Install the power steering pump.
  76.  
  77. Install the heater blower motor.
  78.  
  79. Install the air conditioning compressor.
  80.  
  81. Install the radiator and condenser as an assembly.
  82.  
  83. Connect the lower radiator hose.
  84.  

100.Connect the upper radiator hose.

101.Install the fan shroud.

102.Install the grille and support brace.

103.Install the front bumper.

104.Connect the refrigerant lines at the condenser.

105.Evacuate, charge and leak test the system.

106.Install the starter.

107.Install the air cleaner.

108.Install the engine cover.

109.Install the oil filter.

110.Fill the crankcase.

111.Connect the battery.

112.Fill the cooling system.

1980-87 Inline 6-Cylinder Engine

  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. Disconnect the battery.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Drain the engine oil.
  8.  


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 engine-to-transmission strut.
  2.  
  3. Remove the engine oil pan.
  4.  
  5. Remove the entire exhaust system.
  6.  
  7. Remove the inspection cover on vans with automatic transmission, and remove the torque converter-to-flex plate bolts.
  8.  
  9. Remove the lower bellhousing bolts.
  10.  
  11. Remove the starter.
  12.  
  13. Remove the lower right engine mount insulator nut.
  14.  
  15. Remove the distributor.
  16.  
  17. If so equipped, discharge the air conditioning system. See General Information And Maintenance .
  18.  
  19. Disconnect the refrigerant lines at the condenser. Cap all openings at once.
  20.  
  21. Remove the front bumper.
  22.  
  23. Remove the coolant overflow bottle.
  24.  
  25. Remove the windshield washer reservoir.
  26.  
  27. Remove the grille and support brace.
  28.  
  29. Disconnect the upper radiator hose.
  30.  
  31. Disconnect the lower radiator hose.
  32.  
  33. Remove the radiator and condenser as an assembly.
  34.  
  35. Remove the air conditioning compressor.
  36.  
  37. Remove the power steering pump from its bracket and position it out of the way, WITHOUT DISCONNECTING THE HOSES!
  38.  
  39. Disconnect the heater hoses.
  40.  
  41. Remove the heater blower motor.
  42.  
  43. Tag and disconnect all vacuum lines at the engine.
  44.  
  45. Disconnect the:

    coil
     
    alternator
     
    temperature sending unit
     
    oil pressure sending unit
     
    engine-to-body ground strap.
     

  46.  
  47. Disconnect the throttle linkage and remove the operating lever from the accelerator bellcrank.
  48.  
  49. Remove the alternator.
  50.  
  51. Remove the fan, pulley and drive belts.
  52.  
  53. Disconnect the fuel line at the pump.
  54.  
  55. Remove the oil dipstick and tube.
  56.  
  57. Remove the intake manifold with the carburetor attached.
  58.  
  59. Remove the exhaust manifolds.
  60.  
  61. Raise and support the van on jackstands.
  62.  
  63. Matchmark and remove the driveshaft.
  64.  
  65. Disconnect the shift rods.
  66.  
  67. Remove the clutch torque shaft, or the shifter torque shaft and oil cooler lines.
  68.  
  69. Disconnect the speedometer cable at the transmission.
  70.  
  71. Disconnect any electrical connections at the transmission.
  72.  
  73. Support the transmission on a transmission jack.
  74.  
  75. Attach a shop crane to the lifting fixture. Take up the weight of the engine.
  76.  
  77. Remove the upper left engine mount insulator nut.
  78.  
  79. Remove the rear engine support.
  80.  
  81. Remove the remaining transmission-to-bellhousing bolts, or the converter housing-to-engine bolts.
  82.  
  83. Roll the transmission back until it is clear of the engine or clutch, then lower it and move it away.
  84.  
  85. On vans with manual transmission, remove the clutch and flywheel.
  86.  
  87. On vans with automatic transmission, remove the flex plate.
  88.  
  89. Lower the van to the ground.
  90.  
  91. Install an engine lifting fixture to the number 3, 4, and 5 lower exhaust manifold studs.
  92.  
  93. Raise the engine and maneuver it through the front of the van. It may be necessary to raise the van slightly to keep the crane arm horizontal.
  94.  

To install:
  1. Lower the engine into the van.
  2.  
  3. On vans with manual transmission, install the flex plate.
  4.  
  5. On vans with manual transmission, install the clutch and flywheel.
  6.  
  7. Roll the transmission into position.
  8.  
  9. Install the transmission-to-bellhousing bolts, or the converter housing-to-engine bolts.
  10.  
  11. Install the rear engine support.
  12.  
  13. Install the upper left engine mount insulator nut.
  14.  
  15. Remove the shop crane.
  16.  
  17. Install any electrical connections at the transmission.
  18.  
  19. Install the speedometer cable at the transmission.
  20.  
  21. Install the clutch torque shaft, or the shifter torque shaft and oil cooler lines.
  22.  
  23. Connect the shift rods.
  24.  
  25. Install the driveshaft.
  26.  
  27. Install the exhaust manifold.
  28.  
  29. Install the intake manifold with the carburetor attached.
  30.  
  31. Install the oil dipstick and tube.
  32.  
  33. Connect the fuel line at the pump.
  34.  
  35. Install the fan, pulley and drive belts.
  36.  
  37. Install the alternator.
  38.  
  39. Connect the throttle linkage.
  40.  
  41. Connect the coil.
  42.  
  43. Connect the alternator.
  44.  
  45. Connect the temperature sending unit.
  46.  
  47. Connect the oil pressure sending unit.
  48.  
  49. Connect the engine-to-body ground strap.
  50.  
  51. Connect all vacuum lines at the engine.
  52.  
  53. Install the heater blower motor.
  54.  
  55. Connect the heater hoses.
  56.  
  57. Install the power steering pump.
  58.  
  59. Install the air conditioning compressor.
  60.  
  61. Install the radiator and condenser as an assembly.
  62.  
  63. Connect the lower radiator hose.
  64.  
  65. Connect the upper radiator hose.
  66.  
  67. Install the grille and support brace.
  68.  
  69. Install the windshield washer reservoir.
  70.  
  71. Install the coolant overflow bottle.
  72.  
  73. Install the front bumper.
  74.  
  75. Connect the refrigerant lines at the condenser.
  76.  
  77. Evacuate, charge and leak test the air conditioning system. See General Information And Maintenance .
  78.  
  79. Install the distributor.
  80.  
  81. Install the lower right engine mount insulator nut.
  82.  
  83. Install the starter.
  84.  
  85. Install the lower bellhousing bolts.
  86.  
  87. Install the torque converter-to-flex plate bolts. Install the inspection cover.
  88.  
  89. Install the exhaust system.
  90.  
  91. Install the engine oil pan.
  92.  
  93. Install the engine-to-transmission strut.
  94.  

100.Fill the crankcase.

101.Install the air cleaner.

102.Install the engine cover.

103.Connect the battery.

104.Fill the cooling systme.

1980-88 V8 Engines

  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. Disconnect the battery.
  2.  
  3. Drain the engine oil.
  4.  


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 filter and oil dipstick.
  2.  
  3. Remove the engine-to-transmission strut.
  4.  
  5. Remove the engine cover.
  6.  
  7. Remove the air cleaner, and, on 1988 models, the throttle body.
  8.  
  9. Remove the starter.
  10.  
  11. If so equipped, discharge the air conditioning system. See General Information And Maintenance .
  12.  
  13. Disconnect the refrigerant lines at the condenser. Cap all openings at once.
  14.  
  15. Remove the front bumper.
  16.  
  17. Remove the grille and support brace.
  18.  
  19. Remove the fan shroud.
  20.  
  21. Disconnect the upper radiator hose.
  22.  
  23. Disconnect the lower radiator hose.
  24.  
  25. Remove the radiator and condenser as an assembly.
  26.  
  27. Remove the air conditioning compressor.
  28.  
  29. Remove the heater blower motor.
  30.  
  31. Remove the power steering pump from its bracket and position it out of the way, WITHOUT DISCONNECTING THE HOSES!
  32.  
  33. Disconnect the heater hoses.
  34.  
  35. Tag and disconnect all vacuum lines at the engine.
  36.  
  37. Disconnect the coil.
  38.  
  39. Disconnect the alternator and air pump.
  40.  
  41. Disconnect the temperature sending unit.
  42.  
  43. Disconnect the oil pressure sending unit.
  44.  
  45. Disconnect the engine-to-body ground strap.
  46.  
  47. Disconnect the throttle linkage and remove the operating lever from the accelerator bellcrank.
  48.  
  49. Remove the alternator.
  50.  
  51. Remove the fan, pulley and drive belts.
  52.  
  53. Disconnect the fuel line at the pump.
  54.  
  55. Remove the oil dipstick and tube.
  56.  
  57. Remove the heater blower motor.
  58.  
  59. Remove the intake manifold, and, on models through 1987, the carburetor.
  60.  
  61. Remove the left exhaust manifold.
  62.  
  63. Raise and support the van on jackstands.
  64.  
  65. Remove the entire exhaust system.
  66.  
  67. Matchmark and remove the driveshaft.
  68.  
  69. Disconnect the shift rods.
  70.  
  71. Remove the clutch torque shaft, or the shifter torque shaft and oil cooler lines.
  72.  
  73. Disconnect the speedometer cable at the transmission.
  74.  
  75. Disconnect the electrical connections at the transmission.
  76.  
  77. Remove the inspection plate or converter cover plate from the bellhousing.
  78.  
  79. Support the transmission on a transmission jack.
  80.  
  81. Remove the rear engine support.
  82.  
  83. Install an engine lifting fixture to the heads.
  84.  
  85. Attach a shop crane and take up the weight of the engine.
  86.  
  87. Remove the front engine mount insulator top stud nuts and washers.
  88.  
  89. Remove the transmission-to-bellhousing bolts, or the converter housing-to-engine bolts.
  90.  
  91. Roll the transmission back until it is clear of the engine or clutch, then lower it and move it away.
  92.  
  93. On vans with manual transmission, remove the clutch.
  94.  
  95. Remove the flywheel or flex plate.
  96.  
  97. Raise the rear of the engine about 2".
  98.  
  99. Turn the crankshaft until the cutout portion of the crankshaft flange is at the 3 o'clock position.
  100.  
  101. Remove the oil pan bolts, lower the pan just enough to reach the oil pick-up tube and turn the tube and strainer slightly to the right side to clear the pan. Remove the pan.
  102.  
  103. Lower the van to the ground.
  104.  
  105. Raise the engine and maneuver it through the front of the van. It may be necessary to raise the van slightly to keep the crane arm horizontal.
  106.  

To install:
  1. Lower the engine into the van.
  2.  
  3. Raise and support the front end on jackstands.
  4.  
  5. Install the oil pan. Torque the bolts to 15 ft. lbs.
  6.  
  7. Install the flywheel or flex plate. Torque the bolts to 55 ft. lbs.
  8.  
  9. On vans with manual transmission, install the clutch.
  10.  
  11. Position the transmission.
  12.  
  13. Install the transmission-to-bellhousing bolts, or the converter housing-to-engine bolts. Torque the 3 / 8 -16 bolts to 30 ft. lbs.; the -14 bolts to 50 ft. lbs.
  14.  
  15. Install the front engine mount insulator top stud nuts and washers. Torque the nuts to 75 ft. lbs.
  16.  
  17. Remove the shop crane.
  18.  
  19. Remove the engine lifting fixture.
  20.  
  21. Install the rear engine support. Torque the bolts to 50 ft. lbs.
  22.  
  23. Remove the transmission jack.
  24.  
  25. Install the inspection place or converter cover plate on the bellhousing.
  26.  
  27. Connect the electrical connections at the transmission.
  28.  
  29. Connect the speedometer cable at the transmission.
  30.  
  31. Install the clutch torque shaft, or the shifter torque shaft and oil cooler lines.
  32.  
  33. Connect the shift rods.
  34.  
  35. Install the transmission-to-engine strut.
  36.  
  37. Install the driveshaft.
  38.  
  39. Install the exhaust system.
  40.  
  41. Lower the van.
  42.  
  43. Remove the holding fixture.
  44.  
  45. If equipped with air conditioning, install the right valve cover.
  46.  
  47. Install the left exhaust manifold.
  48.  
  49. Install the intake manifold with the carburetor attached.
  50.  
  51. Install the heater blower motor.
  52.  
  53. Install the oil dipstick and tube.
  54.  
  55. Connect the fuel line at the pump.
  56.  
  57. Install the fan, pulley and drive belts.
  58.  
  59. Install the alternator.
  60.  
  61. Connect the throttle linkage and install the operating lever from the accelerator bellcrank.
  62.  
  63. Connect the engine-to-body ground strap.
  64.  
  65. Connect the oil pressure sending unit.
  66.  
  67. Connect the temperature sending unit.
  68.  
  69. Connect the alternator.
  70.  
  71. Connect the coil.
  72.  
  73. Connect all vacuum lines at the engine.
  74.  
  75. Connect the heater hoses.
  76.  
  77. Install the power steering pump.
  78.  
  79. Install the heater blower motor.
  80.  
  81. Install the air conditioning compressor.
  82.  
  83. Install the radiator and condenser as an assembly.
  84.  

100.Connect the lower radiator hose.

101.Connect the upper radiator hose.

102.Install the fan shroud.

103.Install the grille and support brace.

104.Install the front bumper.

105.Connect the refrigerant lines at the condenser.

106.Evacuate, charge and leak test the system.

107.Install the starter.

108.On 1988 models, install the throttle body.

109.Install the air cleaner.

110.Install the engine cover.

111.Install the oil filter.

112.Fill the crankcase.

113.Connect the battery.

114.Fill the cooling system.

1988 V6 Engine

  1. Drain the cooling system.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol and 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.
  2.  
  3. Drain the engine oil.
  4.  


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 oil filter and oil dipstick.
  2.  
  3. Remove the engine-to-transmission strut.
  4.  
  5. Remove the engine cover.
  6.  
  7. Remove the air cleaner.
  8.  
  9. Remove the throttle body.
  10.  
  11. Remove the starter.
  12.  
  13. If so equipped, discharge the air conditioning system. See General Information And Maintenance .
  14.  
  15. Disconnect the refrigerant lines at the condenser. Cap all openings at once.
  16.  
  17. Remove the front bumper.
  18.  
  19. Remove the grille and support brace.
  20.  
  21. Remove the fan shroud.
  22.  
  23. Disconnect the upper radiator hose.
  24.  
  25. Disconnect the lower radiator hose.
  26.  
  27. Remove the radiator and condenser as an assembly.
  28.  
  29. Remove the air conditioning compressor.
  30.  
  31. Remove the power steering pump from its bracket and position it out of the way, WITHOUT DISCONNECTING THE HOSES!
  32.  
  33. Disconnect the heater hoses.
  34.  
  35. Tag and disconnect all vacuum lines at the engine.
  36.  
  37. Disconnect the coil.
  38.  
  39. Disconnect the alternator and air pump.
  40.  
  41. Disconnect the temperature sending unit.
  42.  
  43. Disconnect the oil pressure sending unit.
  44.  
  45. Disconnect the engine-to-body ground strap.
  46.  
  47. Disconnect the throttle linkage.
  48.  
  49. Remove the alternator.
  50.  
  51. Remove the fan, pulley and drive belts.
  52.  
  53. Disconnect the fuel line at the pump.
  54.  
  55. Remove the oil dipstick and tube.
  56.  
  57. Remove the heater blower motor.
  58.  
  59. Remove the intake manifold.
  60.  
  61. Remove the left exhaust manifold.
  62.  
  63. Raise and support the van on jackstands.
  64.  
  65. Remove the entire exhaust system.
  66.  
  67. Matchmark and remove the driveshaft.
  68.  
  69. Disconnect the shift rods.
  70.  
  71. Remove the clutch torque shaft, or the shifter torque shaft and oil cooler lines.
  72.  
  73. Disconnect the speedometer cable at the transmission.
  74.  
  75. Disconnect any electrical connections at the transmission.
  76.  
  77. Remove the inspection plate or converter cover plate from the bellhousing.
  78.  
  79. Support the transmission on a transmission jack.
  80.  
  81. Remove the rear engine support.
  82.  
  83. Install an engine lifting fixture to the heads.
  84.  
  85. Attach a shop crane and take up the weight of the engine.
  86.  
  87. Remove the front engine mount insulator top stud nuts and washers.
  88.  
  89. Remove the transmission-to-bellhousing bolts, or the converter housing-to-engine bolts.
  90.  
  91. Roll the transmission back until it is clear of the engine or clutch, then lower it and more it away.
  92.  
  93. On vans with manual transmission, remove the clutch.
  94.  
  95. Remove the flywheel or flex plate.
  96.  
  97. Raise the rear of the engine about 2".
  98.  
  99. Turn the crankshaft until the cutout portion of the crankshaft flange is at the 3 o'clock position.
  100.  
  101. Remove the oil pan bolts, lower the pan just enough to reach the oil pick-up tube and turn the tube and strainer slightly to the right side to clear the pan. Remove the pan.
  102.  
  103. Lower the van to the ground.
  104.  
  105. Raise the engine and maneuver it through the front of the an. It may be necessary to raise the van slightly to keep the crane arm horizontal.
  106.  

To install:
  1. Lower the engine into the van.
  2.  
  3. Raise and support the front end on jackstands.
  4.  
  5. Install the oil pan. Torque the bolts to 15 ft. lbs.
  6.  
  7. Install the flywheel or flex plate. Torque the bolts to 55 ft. lbs.
  8.  
  9. On vans with manual transmission, install the clutch.
  10.  
  11. Position the transmission.
  12.  
  13. Install the transmission-to-bellhousing bolts, or the converter housing-to-engine bolts. Torque the 3 / 8 -16 bolts to 30 ft. lbs.; the -14 bolts to 50 ft. lbs.
  14.  
  15. Install the front engine mount insulator top stud nuts and washers. Torque the nuts to 75 ft. lbs.
  16.  
  17. Remove the shop crane.
  18.  
  19. Remove the engine lifting fixture.
  20.  
  21. Install the rear engine support. Torque the bolts to 50 ft. lbs.
  22.  
  23. Remove the transmission jack.
  24.  
  25. Install the inspection plate or converter cover plate on the bellhousing.
  26.  
  27. Connect any electrical connections at the transmission.
  28.  
  29. Connect the speedometer cable at the transmission.
  30.  
  31. Install the clutch torque shaft, or the shifter torque shaft and oil cooler lines.
  32.  
  33. Connect the shift rods.
  34.  
  35. Install the transmission-to-engine strut.
  36.  
  37. Install the driveshaft.
  38.  
  39. Install the exhaust system.
  40.  
  41. Lower the van.
  42.  
  43. Remove the holding fixture.
  44.  
  45. If equipped with air conditioning, install the right valve cover.
  46.  
  47. Install the left exhaust manifold.
  48.  
  49. Install the intake manifold.
  50.  
  51. Install the heater blower motor.
  52.  
  53. Install the oil dipstick and tube.
  54.  
  55. Connect the fuel line at the pump.
  56.  
  57. Install the fan, pulley and drive belts.
  58.  
  59. Install the alternator.
  60.  
  61. Connect the throttle linkage and install the operating lever from the accelerator bellcrank.
  62.  
  63. Connect the engine-to-body ground strap.
  64.  
  65. Connect the oil pressure sending unit.
  66.  
  67. Connect the temperature sending unit.
  68.  
  69. Connect the alternator.
  70.  
  71. Connect the coil.
  72.  
  73. Connect all vacuum lines at the engine.
  74.  
  75. Connect the heater hoses.
  76.  
  77. Install the power steering pump.
  78.  
  79. Install the air conditioning compressor.
  80.  
  81. Install the throttle body.
  82.  
  83. Install the radiator and condenser as an assembly.
  84.  

100.Connect the lower radiator hose.

101.Connect the upper radiator hose.

102.Install the fan shroud.

103.Install the grille and support brace.

104.Install the front bumper.

105.Connect the refrigerant lines at the condenser.

106.Evacuate, charge and leak test the system.

107.Install the starter.

108.Install the air cleaner.

109.Install the engine cover.

110.Install the oil filter.

111.Fill the crankcase.

112.Connect the battery.

113.Fill the cooling system.

 
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