Removal & Installation
- Drain the engine cooling system
- Properly discharge the air conditioning system.
- Relieve the fuel system pressure.
Remove or disconnect the following:
Negative battery cable
- Drain the engine oil and reinstall the oil pan drain plug with a new gasket. Tighten the plug to 10-12 ft. lbs. (13-16 Nm).
Remove or disconnect the following:
Bolt retaining the right-hand engine support insulator to the lower front sub-frame
- Position a jack and a block of wood under the oil pan, rearward of the oil drain hole. Raise the engine approximately 4 inches (100mm) and insert 2 wood blocks approximately 2 1 / 2 -2 3 / 4 inch (60-70mm) thick under each front engine support insulator. Lower the engine onto the wood blocks and remove the jack.
- Remove the oil pan.
- If necessary, remove the 2 bolts retaining the oil pick-up tube to the oil pump and remove the bolt retaining the pick-up tube to the main bearing stud spacer. Remove the pick-up tube.
- Clean the engine oil pan and inspect for damage. Clean the sealing surfaces of the front cover and cylinder block. Clean and inspect the oil pick-up tube and replace the O-ring.
- If removed, position the oil pick-up tube on the oil pump and hand start the 2 retaining bolts. Install the bolt retaining the pick-up tube on the main bearing stud spacer, hand tight.
- Tighten the pick-up tube-to-oil pump bolts to 72-108 inch lbs. (8-12 Nm), then tighten the pick-up tube-to-main bearing stud spacer bolt to 15-22 ft. lbs. (20-30 Nm).
Position a new gasket on the oil pan. Apply silicone sealer to where the front cover meets the cylinder block and the crankshaft rear oil seal and retainer meets the cylinder block. Position the oil pan to the engine and install the retaining bolts. Tighten the bolts in sequence, to 14 ft. lbs. (20 Nm), then rotate the oil pan retaining bolts, in sequence an additional 60 degrees within 4 minutes of applying the silicone sealer.
- Position the jack and wood block under the engine oil pan, rearward of the oil drain hole, and raise the engine enough to remove the wood blocks. Lower the engine and remove the jack.
Install or connect the following:
Left-hand and right-hand engine support insulator through-bolts and tighten to 15-22 ft. lbs. (20-30 Nm)
- Fill the cooling system.
- Fill the engine crankcase with engine oil.
- Start the engine and check for leaks.
- Properly evacuate and recharge the air conditioning system.
- Road test the vehicle and check for proper engine operation.
- Disconnect the negative battery cable. Relieve the fuel system pressure; refer to Section 5.
- Disconnect the accelerator and throttle valve cables at the throttle body or carburetor.
- Remove the fan shroud attaching bolts, positioning the fan shroud back over the fan. Remove the dipstick and tube assembly.
- Disconnect the wiper motor electrical connector and remove the wiper motor. Disconnect the windshield washer hose and remove the wiper motor mounting cover.
- Remove the thermactor air dump tube-retaining clamp on 5.0L engine. Remove the thermactor crossover tube at the rear of the vehicle.
- Raise and safely support the vehicle. Drain the crankcase. Remove the filler tube from the oil pan and drain the transmission.
- Disconnect the starter cable and remove the starter. Disconnect the fuel line.
- Disconnect the exhaust system from the manifolds. Remove the oxygen sensors from the exhaust manifolds.
- Remove the thermactor secondary air tube to torque converter housing clamps. Remove the converter inspection cover.
- Disconnect the exhaust pipes to the catalytic converter outlet. Remove the catalytic converter secondary air tube; and the inlet pipes to the exhaust manifold.
- Loosen the rear engine mount attaching nuts and remove the engine mount through bolts. Remove the shift crossover bolts at the transmission.
- Remove the brake line retainer from the front crossmember and disconnect the transmission kick-down rod.
- Position a jack and wood block under the engine and raise the engine as high as it will go. Place wood blocks between the engine mounts and the chassis brackets, lower the engine, and remove the jack.
- Remove the oil pan retaining bolts and lower the oil pan. Remove the 2 bolts retaining the oil pump pickup tube and screen to the oil pump and the nut from the main bearing cap stud. Allow the pickup tube to drop into the oil pan.
- Rotate the crankshaft, as required, for clearance and remove the oil pan from the vehicle.
- Clean the oil pan and the gasket mating surfaces. Clean the oil pump pickup tube and screen assembly.
- Install a new oil filter. Position a new oil pan gasket on the cylinder block. Place the oil pickup tube and screen in the oil pan and position the oil pan on the crossmember.
- Install the pickup tube and screen with a new gasket. Install the bolts and tighten to 12-18 ft. lbs. (16-24 Nm). Position the oil pan and install the retaining bolts. Tighten to 7-10 ft. lbs. (9-14 Nm).
- Position the jack and wood block under the engine and raise the engine enough to remove the wood blocks. Lower the engine and remove the jack. Install the engine mount through bolts and tighten to 33-46 ft. lbs. (45-62 Nm).
- Connect the fuel lines. Install the converter inspection cover. Tighten the rear mount attaching nuts to 35-50 ft. lbs. (48-68 Nm).
- Install the shift crossover. Position the catalytic converters, secondary air tube and inlet pipes to the exhaust manifold and then install the retaining nuts.
- Install the catalytic converter outlet attaching bolts and install the secondary air tube on the converter housing. Install the starter and connect the starter cable.
- Install the oxygen sensors and lower the vehicle. Install the dipstick and tube. Install the thermactor air dump valve to exhaust manifold clamp.
- Connect the windshield wiper hose and install the wiper motor mounting plate. Install the wiper motor.
- Position the shroud and install the retaining bolts. Install the thermactor tube to the rear of the engine. Install the air cleaner assembly and air ducts.
- Fill the crankcase with the proper type and quantity of engine oil. Fill the transmission with the proper type and quantity of transmission fluid.
- Connect the negative battery cable. Start the engine and check for leaks.