REMOVAL & INSTALLATION
See Figures 1 through 8
Label all wiring, vacuum hoses, fuel lines, etc. before disconnecting them; thereby making installation much easier.
The following procedure can be used on all years and models. Slight variations may occur due to extra connections, etc., but the basic procedure covers all years and models. Use this as a guide-read the entire service procedure before starting the repair.
- Disconnect the negative battery cable. Once disconnected, it is recommended that the positive battery cable be disconnected as well.
- Drain the crankcase and the cooling system into separate containers, and dispose of the fluids properly.
- Relieve the fuel system pressure, if fuel injected, then disconnect the fuel lines; refer to Fuel System .
- If the A/C compressor cannot be position out of the way without the compressor lines being removed, then discharge the air conditioning system into an approved recovery/recycling machine.
- Mark the position of the hood on the hinges and remove the hood.
- Unfasten the air cleaner by loosening the wing nut and/or the clips around the cover. On automatic transmission equipped vehicles, disconnect and plug the fluid cooler lines at the radiator.
- Remove the cooling fan, shroud and radiator, by loosening the upper and lower hose clamps and working the hoses off the radiator. Remove the shroud bolts, then lift the shroud out of the engine compartment. Finally, loosen and remove any remaining hardware securing the radiator, and pull the radiator out of the engine compartment.
- Remove the air inlet tube. Unclamp the fuel lines from the fuel pump, if carbureted.
- Tag, then disconnect the accelerator, cruise control cables and the throttle valve cable.
- Tag any vacuum, breather or wire harnesses on top of or around the engine.
- Unfasten the alternator harness from the fender apron and junction block. Unbolt the retaining hardware, and remove the alternator from the engine. Unbolt the air conditioning compressor from the engine and place aside. In some cases the compressor lines are not long enough. In this case, you must disconnect the air conditioning hoses from the compressor.
- Unfasten the Electronic Variable Orifice (EVO) sensor connector from the power steering pump, if equipped. Also disconnect the body ground strap from the firewall.
- Raise and safely support the vehicle on jackstands.
- Disconnect the exhaust system from the exhaust manifolds and support the exhaust section with wire hung from the crossmember.
- Remove the retaining nut from the transmission line bracket and remove the bolts retaining the engine to the transmission braces.
- Remove the starter and dust seal. Remove the bolts retaining the power steering pump to the engine block and position aside.
- On cars equipped with manual transmissions, remove the clutch retracting spring. Disconnect the clutch equalizer shaft and arm bracket at the underbody rail and remove the arm bracket and shaft from the vehicle.
- Remove the plug from the engine block to access the converter retaining nuts. Rotate the crankshaft until each of the nuts is accessible and remove the nuts.
- Remove the transmission-to-engine retaining bolts, including the flywheel or converter housing upper bolts. Remove the engine mount through-bolts.
- Lower the vehicle. Support the transmission with a floor jack and remove the bolt retaining the right and left engine mounts to the lower underbody bracket.
- Install an engine lifting bracket to the left cylinder head on the front and the right cylinder head on the rear. Connect suitable engine lifting equipment to the lifting brackets.
- Raise the engine slowly, then carefully separate the engine from the transmission.
- Carefully lift the engine out of the engine compartment and install it on an engine stand. Remove the engine lifting equipment.
- Install the engine lifting brackets to the cylinder head. Connect the engine lifting equipment to the brackets and remove the engine from the stand.
- Carefully lower the engine into the engine compartment. Make sure the studs on the converter align with the holes in the flexplate on automatic transmissions.
- Fully engage the engine to the transmission and slowly lower the engine onto the left and right engine mounts. Remove the engine lifting equipment and brackets. Install the bolts securing the left and right engine mounts to the frame.
- Raise and safely support the vehicle. Install the 6 engine-to-transmission bolts and tighten to 30-44 ft. lbs. (40-60 Nm).
- Install the engine mount through-bolts and tighten to 15-22 ft. lbs. (20-30 Nm). Install the converter retaining nuts and tighten to 22-25 ft. lbs. (20-30 Nm). Install the plug into the access hole in the engine block.
- Position the power steering pump on the engine block and install the retaining nuts. Tighten to 15-22 ft. lbs. (20-30 Nm). Install the starter.
- Position the engine-to-transmission braces and install the bolt. Tighten the bolts to 18-31 ft. lbs. (25-43 Nm).
- Position the transmission line bracket to the brace stud and install the retaining nut. Tighten to 15-22 ft. lbs. (20-30 Nm).
- Cut the wire securing the exhaust, and position the exhaust system to the manifolds. Use a new gasket. Install the nuts and tighten to 20-30 ft. lbs. (27-41 Nm).
Make sure the exhaust system does not interfere with the crossmember. Adjust as necessary.
- Lower the vehicle and connect the EVO sensor, if equipped.
- Connect the heater hoses and fasten the vacuum supply hose to the throttle body adapter vacuum port.
- Connect the power supply to the power distribution box and starter relay. Plug in and secure the remaining electrical connectors and vacuum hoses to their respective connections.
- Connect the alternator harness from the fender apron and junction block.
- Connect and if necessary, adjust the throttle valve, accelerator and cruise control cables.
- Install the wiper module and support bracket. Secure the fuel lines, including the connection to the fuel pump. if carbureted.
- Install the radiator, cooling fan and shroud. Install the air inlet tube.
- Fill the crankcase with the proper type and quantity of engine oil. Fill the cooling system.
- If the A/C lines were unfastened, connect the these lines to the compressor.
- Install the hood, aligning the marks that were made during removal. Connect the battery cables.
- Start the engine and adjust the timing and idle, if necessary. Check the levels of the coolant oil and transmission fluids. Check for leaks
- Road test the vehicle.
- Have the A/C system charged by a certified professional using an approved recovery/recycling machine.