GM Blazer/Jimmy/Typhoon/Bravada 1983-1993 Repair Guide

Engine

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CAUTION
Please refer to General Information & Maintenance before discharging the compressor or disconnecting air conditioning lines. Damage to the air conditioning system or personal injury could result. Consult your local laws concerning refrigerant discharge and recycling. In many areas it may be illegal for anyone but a certified technician to service the A/C system. Always use an approved recovery station when discharging the air conditioning.

The following procedures require the use of an engine hoist with sufficient capacity to safely lift and support 500-1000 lbs.

REMOVAL & INSTALLATION



Gasoline engines, except 4.3L
  1. Properly relieve the fuel system pressure and disconnect the negative battery cable.
  2.  

Refer to Fuel System for special procedures to release fuel system pressure.

  1. Matchmark the hood hinges for installation reference and remove the hood.
  2.  
  3. If equipped with power steering, disconnect the power steering reservoir from the fan shroud, then disconnect the power steering pump from its brackets and lay it aside.
  4.  
  5. Remove the upper fan shroud and the fan. On automatic transmission equipped vehicles, disconnect and plug the transmission cooler lines.
  6.  
  7. Position a drain pan under the radiator, open the drain cock and drain the cooling system. Disconnect the upper and lower radiator hoses from the radiator, then remove the radiator from the vehicle.
  8.  
  9. If equipped with air conditioning, remove the compressor from the engine and place aside with the lines intact.
  10.  

DO NOT disconnect the fluid or refrigerant lines.

  1. Remove the air cleaner assembly and cover the carburetor/throttle body with a rag.
  2.  
  3. Remove the fuel line bracket at the filter, then remove the fuel line and vacuum hoses from the engine.
  4.  
  5. Raise and support the vehicle safely. Disconnect the exhaust pipes at the manifold.
  6.  
  7. Disconnect the throttle cable, transmission TV cable and cruise control cable (if equipped).
  8.  
  9. Disconnect the heater hoses from the engine.
  10.  
  11. Label and disconnect the electrical components from the oxygen sensor and other necessary electrical components.
  12.  
  13. Raise and safely support the front of the vehicle with jackstands.
  14.  
  15. On the 2WD models, disconnect the strut rod.
  16.  
  17. On the 4WD models, disconnect the brake line clip from the crossmember. Remove the crossmember, the front driveshaft from the front axle and the automatic transmission cooler lines from the flywheel cover.
  18.  
  19. Disconnect the exhaust pipe from the catalytic converter hanger and the exhaust manifold(s).
  20.  
  21. Remove the drive belt splash shield, if equipped, and the starter. If equipped with an automatic transmission, remove the lower bell housing cover and the torque converter-to-flywheel bolts.
  22.  
  23. Remove the two left side outer air dam bolts, the lower fan shroud and the left side body (cab) mounting bolts. Raise and support (block) the left side of the body with wooden blocks.
  24.  
  25. Remove the upper transmission-to-engine bolts, then the body-to-chassis wooden blocks and lower the body.
  26.  
  27. Remove the lower transmission-to-engine bolts and engine-to-mount through bolts. Lower the vehicle and safely support the transmission with a floor jack.
  28.  
  29. Verify that nothing else is attached to the engine and, if necessary, disconnect the remaining component(s).
  30.  
  31. Attach a suitable lifting device to the engine, raise it slightly and move it forward.
  32.  
  33. From the rear of the engine, remove the wiring harness clips and the ground straps.
  34.  
  35. Lift the engine from the vehicle, pausing several times to make sure no hoses or wiring have been snagged by the powerplant.
  36.  

To install:
  1. Using the lifting device, carefully lower the engine into position. Loosely install the engine mount bolts at this time to hold the engine in position.
  2.  
  3. Install the wiring harness clips and ground straps to the rear of the engine.
  4.  
  5. Install the upper transmission-to-engine bolts.
  6.  
  7. Raise and safely support the vehicle. Install the lower transmission-to-engine bolts and engine-to-mount through bolts. Torque the engine mount through bolts to 50 ft. lbs. (68 Nm) for 4 cylinder engine or 85 ft. lbs. (115 Nm) for V6 engines and the rear engine mount-to-crossmember nut to 24 ft. lbs. (33 Nm).
  8.  
  9. Install the two left side outer air dam bolts, the lower fan shroud and the left side body (cab) mounting bolts.
  10.  
  11. If equipped with an automatic transmission, install the torque converter-to-flywheel bolts and the lower bellhousing cover.
  12.  
  13. Install the drive belt splash shield, if equipped, and the starter.
  14.  
  15. Connect the exhaust pipe to the catalytic converter hanger and the exhaust manifold(s).
  16.  
  17. On the 2WD models, connect the strut rod.
  18.  
  19. On the 4WD models, connect the automatic transmission cooler lines to the flywheel cover, the front driveshaft to the front differential. Install the crossmember and connect the brake line clip to the crossmember.
  20.  
  21. Lower the vehicle.
  22.  
  23. Engage the electrical connectors to the Oxygen sensor and other necessary electrical components.
  24.  
  25. Connect the throttle cable, the transmission TV cable and the cruise control cable (if equipped). Connect the heater hoses to the engine.
  26.  
  27. Install the air cleaner, the fuel line bracket at the filter, the fuel line and the vacuum hoses to the engine.
  28.  
  29. Install the air conditioning compressor (if equipped).
  30.  
  31. Install the radiator, then connect the upper and lower radiator hoses to the radiator.
  32.  
  33. Install the upper fan shroud and the fan. If equipped with an automatic transmission, connect the transmission oil cooler lines to the radiator.
  34.  
  35. If equipped with power steering, connect the power steering reservoir to the fan shroud, then connect the power steering pump to it's brackets.
  36.  
  37. Align and install the hood using the matchmarks made during removal.
  38.  
  39. Connect the negative battery cable, then properly refill the engine cooling system.
  40.  
  41. Check all powertrain fluid levels and add, as necessary.
  42.  

4.3L Engines
2WD BLAZER AND JIMMY
  1. Disconnect the negative battery cable and properly relieve the fuel system pressure.
  2.  
  3. Scribe matchmarks for installation purposes, then remove the hood.
  4.  
  5. Properly drain the engine cooling system, then disconnect the upper radiator hose from the radiator.
  6.  
  7. Disconnect the overflow hose, then remove the upper fan shroud.
  8.  
  9. If equipped, disconnect the automatic transmission cooler lines from the radiator assembly. Plug the openings to prevent system contamination or excessive fluid loss.
  10.  
  11. Remove the radiator assembly from the truck.
  12.  
  13. Remove the engine cooling fan, then disconnect and plug the heater hoses.
  14.  
  15. Remove the air cleaner assembly, then tag and disconnect all necessary vacuum hoses.
  16.  
  17. Tag and disconnect all necessary wires at the bulkhead, ground wires and main feed wires.
  18.  
  19. Disconnect the throttle and cruise control cables, as equipped.
  20.  
  21. Remove the distributor.
  22.  
  23. Raise and safely support the front of the vehicle safely using jackstands.
  24.  
  25. Remove the catalytic converter-to-exhaust pipe bolts, then disconnect the exhaust pipes at the manifold.
  26.  
  27. Disconnect the strut rods at the bell housing.
  28.  
  29. If equipped, remove the flywheel cover, then remove the torque converter bolts.
  30.  
  31. Remove the shield at the rear of the catalytic converter.
  32.  
  33. Disconnect the converter hanger at the exhaust pipe.
  34.  
  35. Remove the lower fan shroud.
  36.  
  37. Disconnect the fuel lines and loosen all fuel line clamps from the TBI or CMFI unit and engine. Move the lines to the rear of the engine compartment and tie them in place, but take care not to stress or damage the lines.
  38.  
  39. Remove the two outer air dam bolts.
  40.  
  41. Remove the left body mount bolts, then carefully raise the body from the frame and support using an additional set of jackstands.
  42.  
  43. Remove the bell housing retaining bolts, then remove the jackstands and carefully lower the body back to the frame.
  44.  
  45. Remove the motor mount through bolts, then remove the jackstands and lower the truck.
  46.  
  47. Remove the A/C compressor and/or power steering pump from the engine, then position them aside with the lines intact.
  48.  

Do not disconnect the fluid or refrigerant lines
  1. Support the transmission using a floor jack, then install a suitable lifting device and carefully lift the engine from the vehicle. Pause several times while lifting the engine to make sure no wires or hoses have become snagged.
  2.  

To install:
  1. Carefully lower the engine into the vehicle and engage it with the transmission. Remove the floor jack from the transmission and the lifting device from the engine.
  2.  
  3. Raise and support the truck safely using jackstands.
  4.  
  5. Install the motor mount through bolts.
  6.  
  7. Use the floor jack to raise the body from the frame for access, then install and tighten the bell housing bolts. Lower the body back into position and install the body mount bolts.
  8.  
  9. If equipped, reposition and secure the power steering pump and/or A/C compressor.
  10.  
  11. Install and tighten the two outer air dam bolts.
  12.  
  13. Reposition the fuel lines and connect them to the TBI or CMFI unit. Be sure to properly secure the lines using the clamps.
  14.  
  15. Install the lower fan shroud, then install the converter hanger to the exhaust pipe.
  16.  
  17. Install the shield at the rear of the converter
  18.  
  19. If applicable, install the torque converter bolts, then install the flywheel cover.
  20.  
  21. Connect the strut rods at the bell housing.
  22.  
  23. Connect the exhaust pipes to the manifolds, then install the converter-to-exhaust pipe bolts.
  24.  
  25. Remove the jackstands and carefully lower the truck.
  26.  
  27. Install the distributor cap.
  28.  
  29. Connect the throttle and, if equipped, cruise control cables.
  30.  
  31. Engage all wires at the bulkhead, ground wires and main feed wires as tagged during removal.
  32.  
  33. Install the vacuum hoses as noted during removal, then install the air cleaner assembly.
  34.  
  35. Connect the heater hoses, then install the fan.
  36.  
  37. Install the radiator and the upper fan shroud.
  38.  
  39. Connect the overflow hose, the radiator hoses and, if equipped, the transmission cooler lines.
  40.  
  41. Align and install the hood, then check all powertrain fluid levels.
  42.  
  43. Connect the negative battery cable, then properly fill the engine cooling system.
  44.  
  45. Start and run the engine, then check for leaks.
  46.  

4WD BLAZER AND JIMMY

You will need new O-rings when connecting the oil filter pipe at the remote oil filter.

  1. Disconnect the negative battery cable and properly relieve the fuel system pressure.
  2.  
  3. If equipped, disconnect the underhood light.
  4.  
  5. Scribe matchmarks for installation purposes, then remove the hood.
  6.  
  7. Properly drain the engine cooling system, then raise and support the front of the truck safely using jackstands.
  8.  
  9. Loosen the front and remove the two body mounts located near or under the cab.
  10.  
  11. Remove the outer bolts from the front air dam.
  12.  
  13. Raise the body away from the frame to gain the necessary clearance for transmission bolt removal. Remove the top transmission-to-engine bolts, then carefully lower the body back into position.
  14.  
  15. Support the transmission using a floor jack, then remove the remaining transmission-to-engine bolts.
  16.  
  17. Remove the 2nd crossmember (located 2nd back from the front of the truck) from the vehicle.
  18.  
  19. Disconnect the exhaust pipes at the manifolds, then remove the catalytic converter hanger.
  20.  
  21. Remove the torque converter cover bolts and disconnect the front driveshaft from the front differential, then remove the torque converter cover.
  22.  
  23. Release the transmission oil cooler lines at the engine clips.
  24.  
  25. Remove the motor mount bolts.
  26.  
  27. Remove the flexplate-to-torque converter bolts.
  28.  
  29. Remove the front splash shield, then remove the lower fan shroud retaining bolts.
  30.  
  31. Remove the jackstands and carefully lower the truck.
  32.  
  33. Remove the upper fan shroud, then disconnect the hoses from the radiator.
  34.  
  35. Disconnect the oil filter pipe at the remote oil filter.
  36.  
  37. Remove the radiator assembly, then remove the engine cooling fan.
  38.  
  39. Remove the air cleaner assembly.
  40.  
  41. Remove the A/C compressor and/or power steering pump from the engine, then position them aside with the lines intact.
  42.  

Do not disconnect the fluid or refrigerant lines.

  1. Disconnect the fuel lines and loosen all fuel line clamps from the TBI or CMFI unit and engine. Move the lines to the rear of the engine compartment and tie them in place, but take care not to stress or damage the lines.
  2.  
  3. Tag and disconnect all necessary wires, vacuum lines and emission hoses.
  4.  
  5. Disconnect the accelerator cable and, if equipped, the cruise control cable.
  6.  
  7. Disconnect the engine wiring harness at the bulkhead connector.
  8.  
  9. Disconnect the heater hoses at the engine.
  10.  
  11. Make sure the transmission is supported using a floor jack, then install a suitable lifting device and carefully lift the engine from the vehicle. Pause several times while lifting the engine to make sure no wires or hoses have become snagged.
  12.  

To install:
  1. Carefully lower the engine into the vehicle and engage it with the transmission. Remove the floor jack from the transmission and the lifting device from the engine.
  2.  
  3. Raise and support the truck safely using jackstands.
  4.  
  5. Install the motor mount through bolts.
  6.  
  7. Use the floor jack to raise the body from the frame for access, then install and tighten the bell housing bolts. Lower the body back into position and install the body mount bolts.
  8.  
  9. Install the flexplate-to-torque converter bolts, then install the torque converter cover.
  10.  
  11. Install the front driveshaft assembly, then install the catalytic converter hanger.
  12.  
  13. Connect the exhaust pipe to the manifolds.
  14.  
  15. Install the crossmember.
  16.  
  17. Install the lower fan shroud retaining bolts, then install the front splash shield.
  18.  
  19. Secure the transmission oil cooler lines at the engine clips.
  20.  
  21. Install the front air dam bolts, then remove the jackstands and carefully lower the vehicle.
  22.  
  23. Engage the engine wiring harness at the bulkhead connector.
  24.  
  25. Connect the accelerator cable, and if equipped, the cruise control cable.
  26.  
  27. Connect the heater hoses, then connect the wires, vacuum lines and emission hoses as noted during removal.
  28.  
  29. Reposition and connect the fuel lines making sure they are properly routed in their clamps.
  30.  
  31. If equipped, reposition and secure the power steering pump and/or A/C compressor.
  32.  
  33. Install the engine cooling fan, then install the radiator assembly.
  34.  
  35. Connect the oil filter pipe at the remote oil filter using new O-rings.
  36.  
  37. Connect the radiator hoses and install the drive belt(s).
  38.  
  39. Install the upper fan shroud.
  40.  
  41. Install the hood and underhood light (if equipped); check all powertrain fluid levels.
  42.  
  43. Connect the negative battery cable and properly refill the engine cooling system.
  44.  
  45. Start and run the engine, then check for leaks.
  46.  

MFI-TURBO
  1. Disconnect the negative battery cable, followed by the positive cable, then properly relieve the fuel system pressure.
  2.  
  3. Properly drain the engine cooling system and the turbocharger air cooler system Refer to General Information & Maintenance of this guide for details.
  4.  
  5. Scribe matchmarks for installation purposes, then remove the hood.
  6.  
  7. Remove the air cleaner and duct assembly.
  8.  
  9. Remove the turbocharger air inlet elbow.
  10.  
  11. Remove the upper fan shroud, then remove the fan and pulley.
  12.  
  13. Remove the serpentine drive belt, then remove the fan and pulley.
  14.  
  15. Remove the battery tray and vacuum tank.
  16.  
  17. Raise and support the front of the vehicle safely using jackstands.
  18.  
  19. Remove the front tire and wheel assemblies, then remove the wheelhouse panels.
  20.  
  21. Disconnect the mufflers and tailpipe from the catalytic converter, then remove the catalytic converter support bolts.
  22.  
  23. Remove the turbocharger outlet pipe bracket and outlet pipe nuts. Move the outlet pipe and catalytic converter away from the turbocharger.
  24.  
  25. Disengage the electrical wiring connector from the charge air cooler radiator temperature sensor, then disconnect the radiator hoses.
  26.  
  27. Remove the charge air cooler radiator.
  28.  
  29. Disconnect the exhaust crossover pipe. Underhood access is necessary, either install the front wheels and lower the vehicle, or adjust the jackstands for access.
  30.  
  31. Disconnect the transmission oil cooler lines from the radiator. Plug the openings to prevent system contamination or excessive fluid loss.
  32.  
  33. Remove the upper and lower radiator hoses.
  34.  
  35. Disconnect the engine oil cooler lines from the radiator. Plug the openings to prevent system contamination or excessive fluid loss.
  36.  
  37. Disconnect the heater hoses and the overflow hoses from the radiator.
  38.  
  39. Remove the radiator.
  40.  
  41. Disconnect the oil pipes at the filter adapter.
  42.  
  43. Remove the power steering pump hoses from the steering gear. Plug the openings to prevent system contamination or excessive fluid loss.
  44.  
  45. Remove the engine coolant reservoir.
  46.  
  47. Disconnect the A/C compressor from the bracket and position aside with the lines intact.
  48.  
  49. Loosen the charge air cooler clamps, then disconnect the ducts and hoses.
  50.  
  51. Remove the charge air cooler from the supports.
  52.  
  53. Remove the throttle body, gasket and cable bracket from the upper intake manifold and position aside.
  54.  
  55. If not done already, disconnect the heater hose from the lower intake manifold.
  56.  
  57. Tag and disengage the electrical connectors from the upper intake manifold assembly.
  58.  
  59. Disconnect the fuel pipes from the fuel rail assembly.
  60.  
  61. Tag and disengage the remaining electrical connectors and vacuum hoses from the engine assembly.
  62.  
  63. If additional access is needed, further raise and support the front of the truck using the jackstands.
  64.  
  65. Remove the rear driveshaft.
  66.  
  67. Position a support under the transmission, then remove the transmission crossmember and mount.
  68.  
  69. Remove the front driveshaft.
  70.  
  71. Remove the torque converter cover, then disconnect the shift linkage from the transmission.
  72.  
  73. Remove the torque converter bolts.
  74.  
  75. Disconnect the fuel pipes from the hoses near the transfer case, then remove the fuel line bracket from the transfer case.
  76.  
  77. Disengage the fuel line clip, then the electrical clips and connectors from the transmission and transfer case.
  78.  
  79. Remove the transfer case and gasket.
  80.  
  81. Disconnect the TV cable from the transmission.
  82.  
  83. Disconnect the transmission cooler lines from the transmission. Be sure to plug all openings.
  84.  
  85. Remove the torque converter housing bolts, then carefully lower the transmission from the vehicle.
  86.  
  87. Remove the transmission oil cooler lines from the oil pan.
  88.  
  89. Remove the fuel line clip, oil line and electrical harness clips from the cylinder heads.
  90.  
  91. Tag and disengage the starter motor electrical connections, then remove the starter from the engine.
  92.  
  93. Remove the engine mount through-bolts and nuts. Underhood access is necessary, either install the front wheels and lower the vehicle, or adjust the jackstands for access.
  94.  
  95. Disengage the electrical connections from the oil pressure and knock sensors, then remove the ground strap.
  96.  
  97. Install a suitable lifting device and carefully lift the engine from the vehicle. Pause several times while lifting the engine to make sure no wires or hoses have become snagged.
  98.  

To install:
  1. Carefully lower the engine into the vehicle.
  2.  
  3. Engage the electrical connections to the oil pressure and knock sensors, then install the ground strap.
  4.  
  5. Make sure the engine is properly positioned on the engine mounts, then route the wiring harnesses into position.
  6.  
  7. If further access is needed, further raise and support the front of the truck using the jackstands.
  8.  
  9. Install the engine mount through bolts and nuts, then tighten the bolts to 61 ft. lbs. (83 Nm) or the nuts to 52 ft. lbs. (70 Nm).
  10.  
  11. Install the fuel line clip, oil line and electrical harness clips to the cylinder heads.
  12.  
  13. Install the starter motor and engage the wiring as noted during removal.
  14.  
  15. Carefully raise the transmission into position in the vehicle, then install the torque converter housing bolts and tighten to 35 ft. lbs. (41 Nm).
  16.  
  17. Connect the transmission oil cooler lines to the transmission housing and tighten to 21 ft. lbs. (28 Nm).
  18.  
  19. Connect the TV cable to the transmission.
  20.  
  21. Install the transfer case and gasket, then tighten the retaining bolts to 39 ft. lbs. (53 Nm).
  22.  
  23. Install the transmission cooler lines to the oil pan clip.
  24.  
  25. Install the fuel line pipes to the hoses, then connect the fuel line bracket to the transfer case. Tighten the fuel line hose fittings to 19 ft. lbs. (26 Nm) and the bracket bolt to 26 ft. lbs. (35 Nm).
  26.  
  27. Engage the fuel line clip, along with the electrical wiring clips and connectors to the transmission and transfer case.
  28.  
  29. Install the torque converter bolts and tighten to 46 ft. lbs. (63 Nm), then connect the shift linkage to the transmission.
  30.  
  31. Install the torque converter cover and tighten the retaining bolts to 35 ft. lbs. (47 Nm).
  32.  
  33. Install the front driveshaft and tighten the retaining bolts to 52 ft. lbs. (70 Nm).
  34.  
  35. Install the transmission crossmember and mount, then tighten the crossmember bolts to 35 ft. lbs. (47 Nm).
  36.  
  37. Install the rear driveshaft and tighten the retainers to 15 ft. lbs. (20 Nm).
  38.  
  39. Install the turbocharger outlet pipe and nuts, then install the turbocharger outlet pipe bracket. Tighten the pipe nuts to 41 ft. lbs. (55 Nm) and the pipe support bolt to 22 ft. lbs. (30 Nm).
  40.  
  41. Install the catalytic converter support bolts, then install the mufflers and tailpipe to the converter. Tighten the support bolts to 25 ft. lbs. (34 Nm) and the tailpipe bolts to 24 ft. lbs. (32 Nm).
  42.  
  43. Connect the crossover pipe and tighten the nuts to 12 ft. lbs. (16 Nm).
  44.  
  45. Install the charge air cooler radiator, connect the cooler radiator hoses and engage the electrical connection.
  46.  
  47. Underhood access is necessary, either install the front wheels and lower the vehicle, or adjust the jackstands for access.
  48.  
  49. Engage the electrical connectors and vacuum lines to the engine.
  50.  
  51. Connect the fuel pipes to the fuel rail assembly, then install the upper intake manifold assembly and gasket. Tighten the upper intake manifold bolts (starting at the 2 middle bolts, moving outward to each side) to 18 ft. lbs. (24 Nm).
  52.  
  53. Engage the electrical connectors to the upper intake manifold assembly, then connect the heater hose to the lower intake manifold.
  54.  
  55. Install the throttle body, gasket and cable bracket to the upper intake manifold assembly. Tighten the throttle body bolts to 18 ft. lbs. (24 Nm).
  56.  
  57. Install the charge air cooler to the supports, then install the charge air cooler ducts and hoses (secure using the clamps).
  58.  
  59. Reposition the A/C compressor to the bracket and secure.
  60.  
  61. Install the engine coolant reservoir.
  62.  
  63. Install the power steering pump hoses to the steering gear and tighten the fittings to 21 ft. lbs. (28 Nm).
  64.  
  65. Install the oil pipes to the filter adapter and tighten the retaining bolt to 26 ft. lbs. (35 Nm).
  66.  
  67. Install the radiator assembly.
  68.  
  69. Connect the heater hoses and the overflow hose to the radiator.
  70.  
  71. Install the engine oil and transmission fluid cooler lines to the radiator. Tighten the engine oil line fittings to 26 ft. lbs. (35 Nm) and the transmission fluid lines to 20 ft. lbs. (27 Nm).
  72.  
  73. Connect the upper and lower radiator hoses.
  74.  
  75. Install the battery tray and the vacuum tank.
  76.  
  77. Install the fan, pulley and nuts.
  78.  
  79. Install the serpentine drive belt, then tighten the pulley nuts to 18 ft. lbs. (24 Nm).
  80.  
  81. Install the upper radiator shroud.
  82.  
  83. Install the turbocharger air inlet elbow.
  84.  
  85. Install the air cleaner and duct.
  86.  
  87. Align and install the hood using the matchmarks made during removal.
  88.  
  89. Install the front wheelhouse panels.
  90.  
  91. Install the front tire an wheel assemblies, then remove the jackstands and carefully lower the vehicle.
  92.  
  93. Check all powertrain fluid levels and add, as necessary.
  94.  
  95. Connect the positive battery cable, followed by the negative battery cable.
  96.  
  97. Properly refill the charge air cooling system and bleed the air.
  98.  
  99. Properly refill the engine cooling system.
  100.  
  101. Start and run the engine, then check for leaks.
  102.  

BRAVADA
  1. Properly relieve the fuel system pressure and disconnect the negative battery cable.
  2.  
  3. Remove the underhood light.
  4.  
  5. Scribe matchmarks for installation purposes, then remove the hood.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Drain the cooling system and the oil pan.
  10.  
  11. Disconnect the exhaust pipes from the exhaust manifold.
  12.  
  13. Remove the front driveshaft from the front differential.
  14.  
  15. Disengage the electrical connectors from the starter. Remove the starter.
  16.  
  17. Remove the torque converter cover bolts and the cover. Matchmark the torque converter to the flywheel. Remove the torque converter-to-flywheel bolts; it will be necessary to rotate the flywheel to access the other bolts.
  18.  
  19. Remove the engine mount through bolts.
  20.  
  21. Remove the oil filter adapter from the engine.
  22.  
  23. Remove the transmission-to-engine bolt at the strut rod, the transfer case bolt at the strut rod and the strut rod.
  24.  
  25. Remove the transmission-to-engine bolts.
  26.  
  27. Disconnect the transmission cooler lines from the engine clips.
  28.  
  29. Disconnect the transmission-to-engine support braces and lower the vehicle.
  30.  
  31. Remove the air cleaner assembly and cover the fuel injection system with a rag.
  32.  
  33. Remove the upper fan shroud and the accessory drive belt.
  34.  
  35. Remove the fan and fan clutch assembly. Remove the upper cooling inlet hose from the radiator and the engine.
  36.  
  37. Remove the air conditioner compressor and lay it aside.
  38.  

Do not disconnect the refrigerant lines.

  1. Remove the lower cooling outlet hose from the radiator and the engine.
  2.  
  3. Disconnect and drain the transmission and engine oil cooler lines from the radiator.
  4.  
  5. Disconnect the heater hoses from the engine. Remove the radiator-to-chassis bolts and the radiator.
  6.  
  7. Disconnect and plug the power steering hoses from pump.
  8.  
  9. Label and disconnect the necessary electrical connectors from the engine.
  10.  
  11. Label and disconnect the necessary vacuum connectors from the engine.
  12.  
  13. Disconnect the accelerator cable, the TV cable and the cruise control cable from the engine.
  14.  
  15. Disengage the electrical connectors and remove the alternator from the engine.
  16.  
  17. Disconnect and plug the fuel lines from the fuel injection system and remove the left side bracket.
  18.  
  19. Label and disconnect the wiring from the distributor cap, then remove the distributor cap.
  20.  
  21. Using a floor jack, safely support the transmission.
  22.  
  23. Remove the oil bracket from the oil cooler.
  24.  
  25. Connect a vertical lifting device to the engine and lift the engine from the vehicle.
  26.  
  27. If necessary, remove the flywheel-to-crankshaft bolts and the flywheel.
  28.  

To install:
  1. If the flywheel was removed, install it and torque the bolts to 75 ft. lbs. (100 Nm).
  2.  
  3. Carefully lower the engine into the vehicle, install the engine-to-engine mount bolts and torque the bolts to 35-52 ft. lbs. (47-70 Nm) and the nuts to 35 ft. lbs. (47 Nm).
  4.  
  5. Install the oil bracket from the oil cooler.
  6.  
  7. Install the distributor cap and connect the wiring to the distributor cap.
  8.  
  9. Install the left side bracket and connect, and the fuel lines to the throttle body.
  10.  
  11. Install the alternator and engage the electrical connectors.
  12.  
  13. Connect the accelerator cable, the TV cable and the cruise control cable to the engine.
  14.  
  15. Connect the necessary vacuum connectors to the engine.
  16.  
  17. Engage the necessary electrical connectors to the engine.
  18.  
  19. Connect the power steering hoses to the pump.
  20.  
  21. Install the radiator and connect the heater hoses to the engine.
  22.  
  23. Connect the transmission and engine oil cooler lines to the engine.
  24.  
  25. Connect the lower cooling outlet hose to the radiator and the engine.
  26.  
  27. Install the air conditioner compressor.
  28.  
  29. Install the upper cooling inlet hose to the radiator and the engine. Install the fan clutch assembly and the fan.
  30.  
  31. Install the upper fan shroud and the accessory drive belt.
  32.  
  33. Install the air cleaner assembly.
  34.  
  35. Remove the floor jack from the transmission. Connect the transmission cooler lines to the engine clips. Raise and safely support the vehicle.
  36.  
  37. Install the transmission-to-engine bolts.
  38.  
  39. Install the strut rod, the transfer case bolt to the strut rod and the transmission-to-engine bolt at the strut rod.
  40.  
  41. Install the oil filter adapter to the engine.
  42.  
  43. Align the flywheel to the torque converter matchmarks and install the bolts.
  44.  
  45. Install the starter and connect the electrical connectors.
  46.  
  47. Install the front driveshaft to the front differential.
  48.  
  49. Connect the exhaust pipes to the exhaust manifold.
  50.  
  51. Lower the vehicle. Refill the cooling system and the engine crankcase.
  52.  
  53. Align and install the hood using the matchmarks made during removal.
  54.  
  55. Install the underhood light. Connect the negative battery cable.
  56.  
  57. Start the engine, allow it to reach normal operating temperatures and check for leaks.
  58.  

Diesel Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Scribe matchmarks for installation purposes, then remove the hood.
  4.  
  5. Remove the battery assembly.
  6.  
  7. If equipped, remove the splash shield. Position a drain pan under the radiator, open the drain cock and properly drain the cooling system.
  8.  
  9. Remove the air cleaner assembly as follows:
    1. Remove the intake silencer.
    2.  
    3. Remove the bolts fixing the air cleaner and loosen the clamp bolt.
    4.  
    5. Lift the air cleaner slightly and disconnect the breather hose, then remove the air cleaner assembly.
    6.  

  10.  
  11. Disconnect the upper radiator hose from the engine.
  12.  
  13. Loosen the A/C compressor drive belt(s) (if equipped) by moving the power steering oil pump or the idler.
  14.  
  15. Remove the cooling fan and the fan shroud.
  16.  
  17. Disconnect the lower water hose from the engine.
  18.  
  19. Remove the radiator grille and the radiator mounting bolts, then remove the radiator.
  20.  
  21. From the injection pump, disconnect the accelerator control cable and the fuel lines.
  22.  
  23. If equipped, disconnect the A/C compressor control cable.
  24.  
  25. Disconnect the battery from the cylinder block.
  26.  
  27. Disconnect the electrical connectors from the transmission and the fuel cut solenoid.
  28.  
  29. If equipped, unbolt the A/C compressor and position aside with the lines intact.
  30.  

DO NOT disconnect the refrigerant lines.

  1. Disconnect the vacuum hose from the fast idle actuator.
  2.  
  3. From the cowl, disconnect the heater hoses at the heater unit.
  4.  
  5. If equipped with a vacuum pump, disconnect the mastervac hose and the vacuum hoses from the vacuum pump.
  6.  
  7. Disconnect the electrical wiring connector(s) from the alternator.
  8.  
  9. Disconnect the exhaust pipe from the exhaust manifold. Remove the exhaust pipe mounting brake from the engine back plate.
  10.  
  11. Disconnect the electrical wiring connectors from the starter.
  12.  
  13. At the gearshift lever, slide the boot upwards, then remove the 2 gearshift lever mounting bolts and the lever.
  14.  
  15. Position an oil catch pan under the transmission, then remove the drain plug for manual transmissions or the oil cooling lines for automatic transmissions, and drain the fluid.
  16.  
  17. Disconnect the speedometer cable and the ground cable from the transmission.
  18.  
  19. Disconnect the driveshaft at the differential side, then slide the driveshaft from the transmission and remove it from the vehicle.
  20.  
  21. If equipped with a manual transmission, remove the return spring from the clutch fork, then disconnect the clutch cable from the hooked portion of the clutch fork and pull it forward, out through the stiffener bracket.
  22.  
  23. Remove the transmission-to-rear bracket mount bolts and nuts.
  24.  
  25. Attach a suitable lifting device to the engine/transmission assembly, then raise, as required, to remove the crossmember-to-frame bolts. Remove the mounting nuts from the transmission rear extension.
  26.  
  27. Disengage the electrical connectors from the CRS switch and back-up lamp switch.
  28.  
  29. Be sure the engine is slightly lifted, then remove the engine mount nuts/bolts.
  30.  
  31. To remove the engine, perform the following procedures:
    1. Make sure that all of the parts have been removed or disconnected from the engine that are fastened to the frame side.
    2.  
    3. Remove the engine toward the front of the vehicle, maneuvering the hose, so the front part of the engine is lifted slightly.To install:
    4.  

  32.  
  33. Carefully lower the engine into the vehicle and install the engine mount nuts/bolts. Torque engine mount bolts to the following:
  34.  
  35. Engine mount-to-engine - 35 ft. lbs. (47 Nm)
  36.  
  37. Engine mount-to-frame mount - 52 ft. lbs. (70 Nm)
  38.  
  39. Transmission mount-to-transmission - 45 ft. lbs. (61 Nm)
  40.  
  41. Transmission mount-to-crossmember - 24 ft. lbs. (33 Nm)
  42.  
  43. Engage the electrical connectors to the CRS switch and back-up lamp switch.
  44.  
  45. Connect the transmission rear extension mounting nuts, then connect the crossmember-to-frame bolts.
  46.  
  47. Connect the transmission-to-rear bracket mount bolts and nuts.
  48.  
  49. If equipped with a manual transmission, connect the clutch cable to the hooked portion of the clutch fork and connect the return spring.
  50.  
  51. Slide the driveshaft to the transmission, then connect it to the differential side.
  52.  
  53. Connect the speedometer cable and the ground cable to the transmission.
  54.  
  55. For manual transmissions, install the transmission drain plug; for automatic transmissions, connect the oil cooling lines.
  56.  
  57. At the gearshift lever, install the lever then connect the 2 gearshift lever mounting bolts and slide the boot down to its proper position.
  58.  
  59. Engage the electrical wiring connectors to the starter.
  60.  
  61. Install the exhaust pipe mounting brake to the engine back plate, then connect the exhaust pipe to the exhaust manifold.
  62.  
  63. Engage the electrical wiring connectors to the alternator.
  64.  
  65. If equipped, connect the vacuum hoses and mastervac hose to the vacuum pump.
  66.  
  67. To the cowl, connect the heater hoses at the heater unit.
  68.  
  69. Connect the vacuum hose to the fast idle actuator.
  70.  
  71. Engage the electrical connectors to the transmission, the fuel cut solenoid and the A/C compressor (if equipped).
  72.  
  73. Connect the battery cable to the cylinder block.
  74.  
  75. If equipped, connect the A/C compressor control cable.
  76.  
  77. Connect the fuel lines and the accelerator control cable to the injection pump.
  78.  
  79. Install the radiator and connect the radiator mounting bolts, then install the radiator grille.
  80.  
  81. Connect the lower radiator hose to the engine.
  82.  
  83. Install the cooling fan and the fan shroud.
  84.  
  85. If equipped, move the power steering oil pump or the idler to correctly tension the A/C compressor drive belt(s).
  86.  
  87. Connect the upper radiator hose to the engine.
  88.  
  89. Install the air cleaner assembly as follows:
    1. Position the air cleaner assembly then connect the breather hose.
    2.  
    3. Connect the clamp and retaining bolts fixing the air cleaner.
    4.  
    5. Install the intake silencer.
    6.  

  90.  
  91. Close the radiator drain cock then install the splash shield (if equipped).
  92.  
  93. Install the battery assembly.
  94.  
  95. Align and install the hood then refill and check all powertrain levels.
  96.  
  97. Connect the negative battery cable, then properly fill the engine cooling system.
  98.  
  99. Start and run the engine, then check for leaks.
  100.  

 
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