REMOVAL & INSTALLATION
The factory recommended procedure for engine removal is to remove the engine/transmission as a unit, then separate them outside of the car. 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, i.e. "Disconnect the exhaust system" or "Remove the radiator." In all of these instances, a detailed removal procedure can be found elsewhere in this section, or in some cases, in another section which deals with the specific component in question.
- Remove the hood. Scribe lines around the hinges so that the hood can be installed in its original location.
- Remove the air cleaner.
- Disconnect the battery cables at the battery.
- Remove the radiator and shroud.
- Remove the fan blade and pulley.
Disconnect and label wires at:
- CEC solenoid
- Temperature switch.
- Starter solenoid.
- Oil pressure sending unit.
- Accelerator linkage at the pedal.
- Oil pressure gauge line, if so equipped.
- Exhaust pipes at the manifold flanges.
- Engine cooler lines, if so equipped.
- Vacuum line to the power brake unit, if so equipped.
- Fuel line (front tank) at the fuel pump.
- Hoses at the carbon canister.
- If the car has air conditioning, unbolt the compressor, leaving the hoses attached. Set the compressor out of the way. Do not disconnect any air conditioning refrigerant lines. Escaping refrigerant can freeze any surface it contacts, including your skin and eyes.
- Remove the power steering pump, leaving the hoses attached to the pump. Set the pump aside, out of the way.
- Raise the car on a hoist.
- Drain the oil out of the crankcase.
- Remove the driveshaft.
If a plug for the driveshaft opening in the transmission is not available, drain the transmission.
- Shift linkage at the transmission.
- Speedometer cable at the transmission.
- Transmission cooler lines, if so equipped.
- TCS switch at the transmission.
- On vehicles with manual transmissions, disconnect the clutch linkage at the cross-shaft, then remove the cross-shaft at the frame bracket.
- Lower the vehicle, remove the rocker arm covers and install an engine lifting adapter on the cylinder heads.
- Raise the engine enough to take the weight off the front mounts, then remove the front mount through-bolts.
- Remove the rear mount to crossmember bolts.
Make sure, on 1977 and later models, that the same number of transmission mount shims are reinstalled. These are used to adjust driveshaft angle.
- Raise the engine enough to take the weight off the rear mount, then remove the crossmember.
It is necessary to remove the mount from the transmission before the crossmember can be removed.
- Remove the engine/transmission assembly as a unit.
If applicable, remove the clutch and manual transmission from the engine as follows:
- Remove the clutch housing cover plate screws.
- Remove the clutch housing-to-engine attaching bolts, then remove the transmission and clutch housing as a unit.
- Remove the starter and clutch housing rear cover plate.
- Loosen the clutch mounting bolts one turn at a time (to prevent distortion of the clutch cover) until the spring pressure is released. Remove all the bolts, clutch disc and pressure plate assembly.
If applicable, remove the automatic transmission as follows:
- Remove the starter and the converter housing underpan.
- Remove the flywheel-to-converter attaching bolts.
- Supporting both the engine and transmission, remove the transmission-to-engine mounting bolts.
- Slowly guide the engine from the transmission.
- Attach the engine to the transmission in the reverse order of removal.
- Bolt the engine lifting tool to the engine and lower the engine and the transmission into the chassis as a unit. Guide the engine so as to align the front engine mounts with the mounts on the frame.
- Install one rear transmission crossmember side bolt, swing the crossmember up under the transmission mount and install the bolt in the opposite side rail.
- Align and install the rear mount bolts.
- Install the engine front mount bolts and remove the lifting tool from the engine.
- Installation of the remaining components is in the reverse order of removal.