REMOVAL & INSTALLATION
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 repair 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:
- Drain the cooling system and the crankcase into suitable containers.
- Disconnect the negative and positive battery cables.
- On 4.9L engines, remove the front bumper and lower gravel or air deflector.
- On some engines, it may be necessary to remove the headlight and side market light assemblies.
- If necessary, remove the grille.
- Remove the engine cover.
- Remove the air cleaner housing and ducts.
- Disconnect the radiator hoses.
- If equipped with an automatic transmission, disconnect the oil cooler lines from the radiator.Remove the radiator and shroud.
- Disconnect the heater hoses from the engine.
- Disconnect the alternator and move it aside.
- Remove the drive belts.
- Disconnect power steering pump and support from the engine and set them aside with the lines still attached, if possible. If necessary disconnect the lines.
- Relieve the fuel system pressure and disconnect the fuel line from the fuel rail. Cover the end of the fuel rail and line to prevent contamination.
- Tag and disengage the vacuum hoses and electrical connections that will interfere with engine removal.
- Discharge the air conditioning system and remove the air conditioning condenser.
- Tag and disconnect the accelerator and transmission kickdown cable (if equipped).
- Loosen the upper transmission-to-engine bolts and the automatic transmission dipstick tube support bolt from the intake manifold.
- On 7.5L engines, remove the distributor.
- On equipped diesel engines, remove the turbocharger.
- Raise the vehicle and support it safely with jackstands.
- Tag and disconnect the starter motor wires and remove the starter.
On manual transmission equipped vans:
- Remove the flywheel housing lower attaching bolts.
- Disconnect the clutch return spring.
On automatic transmission equipped vans:
- Remove the converter housing access cover assembly.
- Remove the flywheel-to-converter attaching nuts.
- Secure the converter in the housing.
- Remove the oil filter.
- On some diesel engines it may be necessary to remove the fan and clutch assembly. Be careful, the fan clutch may have a right-hand thread nut on some later model engines. Try turning the nut counterclockwise first without using an excessive amount of force.
- Remove all engine to transmission nuts.
- Disconnect the exhaust pipe(s) from the exhaust manifold.
- Loosen the engine mount retainers.
- Lower the vehicle.
- Lower the vehicle and position a jack under the transmission and support it.
- Remove the remaining bell housing-to-engine attaching bolts. Make sure no other component interferes with the engine removal.
- Attach an engine lifting device and raise the engine slightly and carefully pull it from the transmission. Lift the engine out of the vehicle.
- Installation is the reverse of removal but please note the following steps.
- On some later model diesel engines where the fan and clutch are removed, the clutch nut may have a right-hand thread. Install the nut by hand turning it clockwise to ensure it threads properly, then tighten the nut.
- After all the components are installed, have the air conditioning system charged by a qualified technician using a recovery/recycling station.
On newer model vehicles when the battery is disconnected it may cause some abnormal drive symptoms until the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more for the PCM to relearn its strategy.
- Refill the cooling system with the proper type and amount of coolant. If necessary, bleed the cooling system.
- Refill the engine with the proper amount and grade of engine oil.
- Check all the other vehicle fluids and replenish as necessary.