REMOVAL & INSTALLATION
See Figures 1, 2, 3, 4, 5, 6, 7, 8 and 9
In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as "disconnect the exhaust system'' or "remove the radiator.'' In most instances, a detailed removal procedure can be found elsewhere in this guide.
It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.
Removal and installation of the engine can be made easier if you follow these basic points:
- Properly relieve the fuel system pressure, as described in Fuel System .
- Disconnect the negative battery cable.
- Drain and recycle the engine coolant.
- Remove the engine cover.
- Remove the air cleaner assembly.
- Remove the oil dipstick tube.
- Remove the front bumper.
- Remove the grille and support brace.
- Remove the cowl plenum-to-upper radiator supports.
- Remove the coolant recovery and washer solvent bottles from the radiator support.
- Remove the fan shroud.
- Remove the fan, pulley and drive belts.
- Disconnect the upper radiator hose.
- Disconnect the lower radiator hose.
- Label, disconnect, and plug the transmission cooler lines (if equipped).
- Label and disconnect the heater hoses.
- If so equipped, have the air conditioning system discharged by an MVAC certified automotive technician.
- Disconnect the refrigerant lines at the condenser. Cap all openings at once to prevent contamination of the system.
- Remove the radiator and condenser (if equipped) as an assembly.
- Remove the air conditioning compressor (if equipped).
- Remove the power steering pump from its bracket and position it out of the way. It is not necessary to remove the lines.
- Label and disconnect the alternator wiring harness.
- Remove the alternator.
- Label and disconnect the hoses and remove the air pump (if equipped).
- Label and disconnect all vacuum lines at the engine.
- Disconnect and label the necessary engine electrical connectors.
- Remove the throttle body assembly.
- Disconnect the fuel line(s).
- Check for any other lines, vacuum hoses, or wiring harnesses that must be disconnected. Label and disconnect them.
- Raise and support the vehicle.
- Drain and recycle the engine oil.
- Remove the engine oil filter.
- Remove the engine-to-transmission struts.
- Remove the oil pan.
- Remove the oil pump and pickup tube assembly.
- Remove the starter.
- Disconnect the O2 sensor.
- Remove the exhaust crossover pipe.
- Remove the inspection plate or converter cover plate from the bell housing (automatic transmission). Remove the converter-to-flexplate bolts/nuts (automatic transmission).
- Support the transmission on a floor jack or equivalent.
- Remove the transmission-to-bell housing bolts, or the converter housing-to-engine bolts.
- Install an engine lifting fixture.
- Attach an engine crane and take up the weight of the engine.
- Remove the nuts and washers from the engine mounts.
- Remove the left exhaust manifold.
- Loosen the engine-to-transmission junction.
- 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.
- Installation is the reverse of removal.
Please note the following torque specifications:
Engine mount nuts-75 ft. lbs. (102 Nm)