Isuzu Cars and Trucks 1981-1991

Engine

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REMOVAL AND INSTALLATION
Rear Wheel, 2WD Vehicles
  1. Disconnect both battery cables, the negative cable first.
  2.  
  3. Matchmark the hood-to-hinges and remove the hood.
  4.  
  5. Remove the undercover, if equipped. Open the drain plugs on the radiator and the cylinder and drain the cooling system.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the air cleaner by performing the following procedures:
  2.  
    1. Disconnect the air duct and PCV hose from the air cleaner.
    2.  
    3. Disconnect the air hose from the AIR pump.
    4.  
    5. Remove the air cleaner-to-bracket bolts and wing nut.
    6.  
    7. Lift the air cleaner, disconnect the vacuum hose(s) from the under side and remove the air cleaner.
    8.  
    9. Using a clean shop cloth, cover the air cleaner port to prevent dirt from entering the engine.
    10.  

  3. Disconnect the TCA hot air hose and remove the manifold cover.
  4.  
  5. Label and disconnect the electrical connector(s) from the alternator.
  6.  
  7. Remove the exhaust pipe-to-exhaust manifold nuts and separate the pipe from the manifold.
  8.  
  9. Loosen the clutch cable adjusting nut and relieve the tension, if equipped with a manual transmission.
  10.  
  11. Disconnect the heater hoses from the heater core.
  12.  
  13. If equipped with an oxygen sensor, disconnect the electrical connector.
  14.  
  15. If equipped with a vacuum switching valve, disconnect the rubber hose from the valve.
  16.  
  17. Disconnect the engine-to-chassis ground cable.
  18.  
  19. Disconnect the fuel hoses from the carburetor.
  20.  
  21. Disconnect the high-tension wire from the ignition coil, the vacuum hose from the rear connector of the intake manifold and the rubber hoses from the canister.
  22.  
  23. Disconnect the accelerator cable from the carburetor. Disconnect the electrical connectors from the starter, the thermo-unit, the oil pressure switch and distributor harness.
  24.  
  25. Disconnect the hose from the vacuum switch, if equipped, and the solenoid valve.
  26.  
  27. Disconnect the electrical connectors from the EFE heater, the carburetor solenoid valve and the electric choke.
  28.  
  29. From the rear of the engine, disconnect the back-up light switch and transmission wiring at the connector.
  30.  
  31. Using an engine hoist, connect it to the engine hangers and support the engine.
  32.  
  33. Remove the engine-to-mount nut. Raise the engine slightly and remove the left side engine mount stopper plate.
  34.  
  35. If equipped with air conditioning, remove the compressor from the engine and move it aside; do not disconnect the pressure hoses.
  36.  
  37. Disconnect the upper and lower radiator hoses and the reservoir tank hose.
  38.  
  39. Remove the radiator and fan blade assembly.
  40.  
  41. Raise and safely support the vehicle. Drain the oil from the engine.
  42.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the clutch return spring and the clutch cable, if equipped with a manual transmission.
  2.  
  3. Remove the starter motor. Disconnect the speedometer from the transmission.
  4.  
  5. Matchmark and remove the driveshaft. Remove the transmission mount bolts. Remove gearshift lever assembly.
  6.  
  7. Lift the engine slightly. Remove the exhaust pipe bracket from the transmission and the engine-to-mount nuts.
  8.  
  9. Make certain that all lines, hoses, cables and wires have been disconnected from the engine and frame.
  10.  
  11. Lift the engine/transmission assembly from the vehicle with the front of the engine raised slightly.
  12.  
  13. Remove the transmission-to-engine bolts and the transmission from the engine.
  14.  

To install:

  1. Lower the engine/transmission assembly into the vehicle, align it with the mounts and install the nuts/bolts.
  2.  
  3. Install the gearshift lever assembly and the driveshaft.
  4.  
  5. Connect the speedometer cable to the transmission. Install the starter motor.
  6.  
  7. If equipped with a manual transmission, install the clutch cable and clutch return spring.
  8.  
  9. Lower the vehicle. Install the fan blade assembly and the radiator.
  10.  
  11. Connect the upper and lower radiator hoses and the reservoir tank hose.
  12.  
  13. If equipped with air conditioning, install the compressor to the engine.
  14.  
  15. Install the left side engine mount stopper plate, lower the engine slightly and install the engine-to-mount nut.
  16.  
  17. Remove the engine hoist.
  18.  
  19. Connect the electrical connector to the back-up light switch and transmission wiring connector at the rear of the engine.
  20.  
  21. Connect the electrical connectors to the EFE heater, the carburetor solenoid valve and the electric choke.
  22.  
  23. Connect the hose to the vacuum switch, if equipped, and the solenoid valve.
  24.  
  25. Connect the accelerator cable to the carburetor. Connect the electrical connectors to the starter, the thermo-unit, the oil pressure switch and distributor harness.
  26.  
  27. Connect the high-tension wire to the ignition coil, the vacuum hose to the rear connector of the intake manifold and the rubber hoses to the canister.
  28.  
  29. Connect the fuel hoses to the carburetor.
  30.  
  31. Connect the engine-to-chassis ground cable.
  32.  
  33. If equipped with a vacuum switching valve, connect the rubber hose to the valve.
  34.  
  35. If equipped with an oxygen sensor, connect the electrical connector.
  36.  
  37. Connect the heater hoses to the heater core.
  38.  
  39. Tension the clutch cable and tighten the adjusting nut, if equipped with a manual transmission.
  40.  
  41. Install the exhaust pipe-to-exhaust manifold nuts.
  42.  
  43. Connect the electrical connector(s) to the alternator.
  44.  
  45. Install the manifold cover and connect the TCA hot air hose.
  46.  
  47. Install the air cleaner by performing the following procedures:
  48.  
    1. Lower the air cleaner and connect the vacuum hose(s) to the underside.
    2.  
    3. Install the air cleaner-to-bracket bolts and wing nut.
    4.  
    5. Connect the air hose to the AIR pump.
    6.  
    7. Connect the air duct and PCV hose to the air cleaner.
    8.  

  49. Refill the cooling system with the proper coolant and the crankcase with engine oil. Check and adjust the clutch pedal freeplay, if equipped with a manual transmission.
  50.  
  51. Install the hood and connect both battery cables, the positive cable first.
  52.  
  53. Adjust the belt tension. Start the engine, check for leaks.
  54.  
  55. Check and/or adjust the idle speed and ignition timing.
  56.  



Click image to see an enlarged view

Fig. Engine removal P'up similar

Rear Wheel Drive Impulse
  1. Relieve the fuel pressure. Disconnect both battery cables, the negative cable first. Remove the battery.
  2.  
  3. Matchmark the hood-to-hinges and remove the hood.
  4.  
  5. Remove the undercover, if equipped. Open the drain plugs on the radiator and the cylinder and drain the cooling system.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the air cleaner (4ZD1 engine) or air cleaner duct and hose (4ZE1 engine). Using a clean shop cloth, cover the air cleaner port to prevent dirt from entering the engine.
  2.  
  3. Label and disconnect the necessary hoses, electrical connectors, control cables and control rods from the engine.
  4.  
  5. Label and disconnect the following items:
  6.  
    1. Air switch valve hose.
    2.  
    3. Oxygen sensor wire.
    4.  
    5. Vacuum switch valve hose.
    6.  
    7. Thermal vacuum switching valve hose.
    8.  
    9. Pressure regulator vacuum hose.
    10.  
    11. Canister hose.
    12.  
    13. ECM harness.
    14.  
    15. Fuel hose(s).
    16.  

  7. Remove the clutch return spring (if equipped), the clutch control cable (if equipped), the back-up light switch connector and the speedometer cable from the transmission.
  8.  
  9. Remove the radiator grille from the deflector panel.
  10.  
  11. Disconnect the upper and lower radiator hoses and the reservoir tank hose.
  12.  
  13. Remove the fan shroud, fan blade assembly and the radiator.
  14.  
  15. If equipped with air conditioning, remove the compressor from the engine and move it aside; do not disconnect the pressure hoses.
  16.  
  17. Remove the gear shift lever by performing the following procedures:
  18.  
    1. Place the gear shift lever in N .
    2.  
    3. Remove the front console from the floor panel.
    4.  
    5. Pull the shift lever boot and grommet upward.
    6.  
    7. Remove the shift lever cover bolts and the shift lever.
    8.  

  19. Raise and safely support the vehicle. Remove the front wheels.
  20.  
  21. Drain the engine oil and the transmission fluid.
  22.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. If equipped with an automatic transmission, perform the following procedures:
  2.  
    1. Remove the oil level gauge and the tube.
    2.  
    3. Disconnect the shift select control link rod from the select lever.
    4.  
    5. Disconnect the downshift cable from the transmission.
    6.  
    7. Disconnect and plug the fluid coolant lines from the transmission.
    8.  

  3. If equipped with a 1-piece driveshaft, remove the driveshaft flange-to-pinion nuts, lower the driveshaft and pull it from the transmission.
  4.  
  5. If equipped with a 2-piece driveshaft, perform the following procedures:
  6.  
    1. Remove the rear driveshaft flange-to-pinion nuts.
    2.  
    3. Remove the rear driveshaft flange-to-front driveshaft flange bolts and the rear driveshaft.
    4.  
    5. Remove the center bearing-to-chassis bolts, move the front driveshaft rearward and from the transmission.
    6.  

  7. Remove the starter-to-engine bolts and the starter.
  8.  
  9. Remove the exhaust pipe-to-exhaust manifold nuts, the exhaust pipe bracket-to-transmission bolts, the front exhaust pipe-to-2nd exhaust pipe bolts and the front exhaust pipe from the vehicle.
  10.  
  11. Attach an engine hanger to the rear of the exhaust manifold.
  12.  
  13. Using an engine hoist, connect it to the engine hangers and support the engine.
  14.  
  15. If equipped with a manual transmission, perform the following procedures:
  16.  
    1. Using a transmission jack, place it under the transmission; do not support it.
    2.  
    3. Remove the rear mount-to-transmission nuts.
    4.  
    5. Remove the rear mount-to-crossmember nuts/bolts and the mount.
    6.  



NOTE
Further removal of the transmission may require an assistant.

  1. Remove the clutch cover and the transmission-to-engine bolts.
  2.  
  3. Move the transmission rearward into the crossmember and floor pan area; the transmission may rest on the crossmember.
  4.  
  5. Lower the front of the transmission toward the jack.
  6.  
  7. Firmly, grasp the transmission the rear cover while the assistant raises the jack toward the transmission.
  8.  
  9. Carefully lower the transmission onto the jack and center it.
  10.  
  11. Lower the jack and move the transmission rearward.
  12.  

  1. If equipped with an automatic transmission, perform the following procedures:
  2.  


NOTE
Removal of the transmission will require an assistant.

  1. Remove the torque converter-to-flex plate bolts through the starter hole.
  2.  
  3. Using a transmission jack, place it under the transmission; do not support it.
  4.  
  5. Remove the rear mount-to-transmission nuts.
  6.  
  7. Remove the rear mount-to-crossmember nuts/bolts and the mount.
  8.  
  9. Remove the transmission-to-engine bolts.
  10.  
  11. Move the transmission rearward into the crossmember and floor pan area; the transmission may rest on the crossmember.
  12.  
  13. Lower the front of the transmission toward the jack.
  14.  
  15. Firmly, grasp the transmission the rear cover while the assistant raises the jack toward the transmission.
  16.  
  17. Carefully, lower the transmission onto the jack and center it.
  18.  
  19. Lower the jack and move the transmission rearward.
  20.  

  1. Remove the engine-to-mount nuts/bolts.
  2.  
  3. Using the hoist, slowly, lift the engine; be sure to hold the front of the engine higher than the rear.
  4.  
  5. Place the engine on a work stand.
  6.  

To install:

  1. Using the hoist, slowly, lower the engine into the vehicle; be sure to hold the front of the engine higher than the rear.
  2.  
  3. Install the engine-to-mount nuts/bolts.
  4.  
  5. If equipped with an automatic transmission, perform the following procedures:
  6.  


NOTE
Installation of the transmission will require an assistant.

  1. Raise the transmission into position.
  2.  
  3. Raise the rear of the transmission and move it into position on the crossmember.
  4.  
  5. Move the transmission forward and engage it with the engine.
  6.  
  7. Install the engine-to-transmission bolts.
  8.  
  9. Install the mount and the rear mount-to-crossmember nuts/bolts.
  10.  
  11. Install the rear mount-to-transmission nuts.
  12.  
  13. Install the torque converter-to-flex plate bolts through the starter hole.
  14.  

  1. If equipped with a manual transmission, perform the following procedures:
  2.  


NOTE
Installation of the transmission may require an assistant.

  1. Raise the transmission into position.
  2.  
  3. Raise the rear of the transmission and move it into position on the crossmember.
  4.  
  5. Move the transmission forward and engage it with the engine.
  6.  
  7. Install the engine-to-transmission bolts.
  8.  
  9. Install the mount and the rear mount-to-crossmember nuts/bolts.
  10.  
  11. Install the rear mount-to-transmission nuts.
  12.  

  1. Remove the engine hoist and the engine hanger from the rear of the exhaust manifold.
  2.  
  3. Install the front exhaust pipe, exhaust pipe-to-exhaust manifold nuts, the exhaust pipe bracket-to-transmission bolts, the front exhaust pipe-to-2nd exhaust pipe bolts.
  4.  
  5. Install the starter and the starter-to-engine bolts.
  6.  
  7. If equipped with a 2-piece driveshaft, perform the following procedures:
  8.  
    1. Install the front driveshaft into the transmission and the center bearing-to-chassis bolts.
    2.  
    3. Install the rear driveshaft and the rear driveshaft flange-to-front driveshaft flange bolts.
    4.  
    5. Install the rear driveshaft flange-to-pinion nuts.
    6.  

  9. If equipped with a 1-piece driveshaft, install the driveshaft into the transmission and the driveshaft flange-to-pinion nuts.
  10.  
  11. If equipped with an automatic transmission, perform the following procedures:
  12.  
    1. Connect the fluid coolant lines to the transmission.
    2.  
    3. Connect the downshift cable to the transmission.
    4.  
    5. Connect the shift select control link rod to the select lever.
    6.  
    7. Install the oil level gauge and the tube.
    8.  

  13. Install the front wheels and lower the vehicle.
  14.  
  15. Install the gear shift lever by performing the following procedures:
  16.  
    1. Install the shift lever and the shift lever cover bolts.
    2.  
    3. Push the grommet and shift lever boot downward.
    4.  
    5. Install the front console to the floor panel.
    6.  

  17. If equipped with air conditioning, install the compressor to the engine.
  18.  
  19. Install the radiator, the fan blade assembly and the fan shroud.
  20.  
  21. Connect the upper and lower radiator hoses and the reservoir tank hose.
  22.  
  23. Install the radiator grille to the deflector panel.
  24.  
  25. Install the clutch return spring (if equipped), the clutch control cable (if equipped), the back-up light switch connector and the speedometer cable to the transmission.
  26.  
  27. Connect the following items:
  28.  
    1. Air switch valve hose.
    2.  
    3. Oxygen sensor wire.
    4.  
    5. Vacuum switch valve hose.
    6.  
    7. Thermal vacuum switching valve hose.
    8.  
    9. Pressure regulator vacuum hose.
    10.  
    11. Canister hose.
    12.  
    13. ECM harness.
    14.  
    15. Fuel hose(s).
    16.  

  29. Connect the necessary hoses, electrical connectors, control cables and control rods to the engine.
  30.  
  31. Install the air cleaner (2.3L) or air cleaner duct and hose (2.6L).
  32.  
  33. Refill the engine, the transmission and the cooling system. Install the undercover, if equipped.
  34.  
  35. Install the hood.
  36.  
  37. Install the battery and connect both battery cables, the positive cable first.
  38.  
  39. Adjust the belt tension. Start the engine, check for leaks.
  40.  
  41. Check and/or adjust the idle speed and ignition timing.
  42.  

Diesel Engines
P'UP
  1. Matchmark hinges to the hood and remove the hood.
  2.  
  3. Disconnect the battery cables, negative first and remove the battery from the vehicle.
  4.  
  5. Drain the cooling system.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the air cleaner assembly as follows: Remove the intake silencer. Remove the bolts mounting the air cleaner and loosen the clamp bolt. Lift the air cleaner slightly and disconnect the breather hose. Remove the air cleaner assembly.
  2.  
  3. Disconnect the upper radiator hose at the engine.
  4.  
  5. Loosen the air conditioning compressor drive belts by moving the power steering pump or idler.
  6.  
  7. Remove the cooling fan and fan shroud.
  8.  
  9. Disconnect the lower radiator hose at the engine.
  10.  
  11. Remove the radiator grille.
  12.  
  13. Remove the radiator attaching bolts and remove the radiator.
  14.  
  15. Disconnect the accelerator control cable from the injection pump.
  16.  
  17. If equipped with air conditioning, disconnect the air conditioning compressor control cable.
  18.  
  19. Disconnect and plug the fuel hoses from the injection pump.
  20.  
  21. Disconnect the ground cable from the engine.
  22.  
  23. Raise and safely support the vehicle. Disconnect and label the transmission wiring. Drain the engine oil.
  24.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Disconnect the vacuum hose from the fast idle actuator.
  2.  
  3. Disconnect the fuel cut solenoid wiring.
  4.  
  5. Disconnect the air conditioning compressor wiring, sensing resistor and thermoswitch connectors.
  6.  
  7. Disconnect the heater hoses extending from the heater unit from the dash panel side.
  8.  
  9. Disconnect the hose for power brake booster from the vacuum pump.
  10.  
  11. Disconnect vacuum hose from the vacuum pump.
  12.  
  13. Disconnect the alternator wiring.
  14.  
  15. Disconnect the exhaust pipe from the exhaust manifold at the flange.
  16.  
  17. Remove the exhaust pipe mounting bracket from the engine.
  18.  
  19. Disconnect and label the starter motor wiring.
  20.  
  21. Pull the gearshift lever boot upwards on the lever. Remove the 2 gearshift lever bolts and the lever.
  22.  
  23. Disconnect speedometer and ground cables from the transmission.
  24.  
  25. Matchmark and remove the driveshaft.
  26.  
  27. Remove the clutch fork return spring from the clutch fork.
  28.  
  29. Disconnect clutch cable from the hooked portion of clutch fork and pull it out forward through the stiffener bracket.
  30.  
  31. Remove 2 bracket-to-transmission rear mount bolts and nuts.
  32.  
  33. Raise the engine and transmission and remove the crossmember-to-frame bracket bolts.
  34.  
  35. Remove the rear mounting nuts from the transmission rear extension.
  36.  
  37. Disconnect electrical connectors at CRS switch and back-up lamp switch.
  38.  
  39. Raise the engine and remove the engine mounting bolts and nuts.
  40.  
  41. Remove the engine towards the front of the vehicle making sure the front of the engine is slightly above the level.
  42.  

To install:

  1. Install the engine towards the front of the vehicle making sure the front of the engine is slightly above the level.
  2.  
  3. Lower the engine and install the engine mounting bolts and nuts.
  4.  
  5. Connect electrical connectors at CRS switch and back-up lamp switch.
  6.  
  7. Install the rear mounting nuts to the transmission rear extension.
  8.  
  9. Lower the engine and transmission and install the crossmember-to-frame bracket bolts.
  10.  
  11. Install 2 bracket-to-transmission rear mount bolts and nuts.
  12.  
  13. Connect clutch cable to the hooked portion of clutch fork.
  14.  
  15. Install the clutch fork return spring to the clutch fork.
  16.  
  17. Install the driveshaft.
  18.  
  19. Connect speedometer and ground cables to the transmission.
  20.  
  21. Install the 2 gearshift lever bolts and the lever.
  22.  
  23. Connect the starter motor wiring.
  24.  
  25. Install the exhaust pipe mounting bracket to the engine.
  26.  
  27. Connect the exhaust pipe to the exhaust manifold at the flange.
  28.  
  29. Connect the alternator wiring.
  30.  
  31. Connect vacuum hose to the vacuum pump.
  32.  
  33. Connect the hose for power brake booster to the vacuum pump.
  34.  
  35. Connect the heater hoses extending to the heater unit to the dash panel side.
  36.  
  37. Connect the air conditioning compressor wiring, sensing resistor and thermoswitch connectors.
  38.  
  39. Connect the fuel cut solenoid wiring.
  40.  
  41. Connect the vacuum hose to the fast idle actuator.
  42.  
  43. Lower the vehicle. Connect the transmission wiring. Refill the engine oil.
  44.  
  45. Connect the ground cable to the engine.
  46.  
  47. Connect and plug the fuel hoses to the injection pump.
  48.  
  49. If equipped with air conditioning, connect the air conditioning compressor control cable.
  50.  
  51. Connect the accelerator control cable to the injection pump.
  52.  
  53. Install the radiator attaching bolts and radiator.
  54.  
  55. Install the radiator grille.
  56.  
  57. Connect the lower radiator hose at the engine.
  58.  
  59. Install the cooling fan and fan shroud.
  60.  
  61. Tighten the air conditioning compressor drive belts by moving the power steering pump or idler.
  62.  
  63. Connect the upper radiator hose at the engine.
  64.  
  65. Install the air cleaner assembly.
  66.  
  67. Refill the cooling system with antifreeze.
  68.  
  69. Install the battery. Connect the battery cables, positive first.
  70.  
  71. With the help of an assistant, install the hood to the matchmarked locations.
  72.  
  73. Start the engine, allow to reach operating temperature and check for leaks and proper performance.
  74.  
  75. Check and adjust the clutch pedal freeplay.
  76.  

4-Wheel Drive Vehicles
1981 and 1987 GASOLINE ENGINES
  1. Disconnect both battery cables, the negative cable first.
  2.  
  3. Matchmark the hood-to-hinges and remove the hood.
  4.  
  5. Remove the undercover. Open the drain plugs on the radiator and the cylinder and drain the cooling system.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the air cleaner by performing the following procedures:
  2.  
    1. Disconnect the air duct and PCV hose from the air cleaner.
    2.  
    3. Disconnect the air hose from the AIR pump.
    4.  
    5. Remove the air cleaner-to-bracket bolts and wing nut.
    6.  
    7. Lift the air cleaner, disconnect the vacuum hose(s) from the underside and remove the air cleaner.
    8.  
    9. Using a clean shop cloth, cover the air cleaner port to prevent dirt from entering the engine.
    10.  

  3. Disconnect the TCA hot air hose and remove the manifold cover.
  4.  
  5. Label and disconnect the electrical connector(s) from the alternator.
  6.  
  7. Remove the exhaust pipe-to-exhaust manifold nuts and separate the pipe from the manifold.
  8.  
  9. Loosen the clutch cable adjusting nut and relieve the tension, if equipped with a manual transmission.
  10.  
  11. Disconnect the heater hoses from the heater core.
  12.  
  13. If equipped with an oxygen sensor, disconnect the electrical connector.
  14.  
  15. If equipped with a vacuum switching valve, disconnect the rubber hose from the valve.
  16.  
  17. Disconnect the engine-to-chassis ground cable.
  18.  
  19. Disconnect the fuel hoses from the carburetor.
  20.  
  21. Disconnect the high-tension wire from the ignition coil, the vacuum hose from the rear connector of the intake manifold and the rubber hoses from the canister.
  22.  
  23. Disconnect the accelerator cable from the carburetor. Disconnect the electrical connectors from the starter, the thermo-unit, the oil pressure switch and distributor harness.
  24.  
  25. Disconnect the hose from the vacuum switch, if equipped, and the solenoid valve.
  26.  
  27. Disconnect the electrical connectors from the EFE heater, the carburetor solenoid valve and the electric choke.
  28.  
  29. From the rear of the engine, disconnect the back-up light switch and transmission wiring at the connector.
  30.  
  31. Using an engine hoist, connect it to the engine hangers and support the engine.
  32.  
  33. Remove the engine-to-mount nut. Raise the engine slightly and remove the left side engine mount stopper plate.
  34.  
  35. If equipped with air conditioning, remove the compressor from the engine and move it aside; do not disconnect the pressure hoses.
  36.  
  37. Disconnect the upper and lower radiator hoses and the reservoir tank hose.
  38.  
  39. Remove the radiator and fan blade assembly.
  40.  
  41. Raise and support the vehicle safely. Drain the oil from the engine.
  42.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Remove the starter motor and the flywheel cover pan.
  2.  
  3. Remove the bell housing-to-engine bolts and support the transmission.
  4.  
  5. Lift the engine slightly. Remove the exhaust pipe bracket from the transmission and the engine-to-mount nuts.
  6.  


NOTE
Make certain that all lines, hoses, cables and wires have been disconnected from the engine and frame.

  1. Lift the engine from the vehicle with the front of the engine raised slightly to clear the transmission input shaft.
  2.  

To install:

  1. Lower the engine into the vehicle, align it transmission assembly and install the nuts/bolts.
  2.  
  3. Install the starter motor and the flywheel cover pan.
  4.  
  5. If equipped with a manual transmission, install the clutch cable and clutch return spring.
  6.  
  7. Lower the vehicle. Install the fan blade assembly and the radiator.
  8.  
  9. Connect the upper and lower radiator hoses and the reservoir tank hose.
  10.  
  11. If equipped with air conditioning, install the compressor to the engine.
  12.  
  13. Install the left side engine mount stopper plate, lower the engine slightly and install the engine-to-mount nut.
  14.  
  15. Remove the engine hoist.
  16.  
  17. Connect the electrical connector to the back-up light switch and transmission wiring connector at the rear of the engine.
  18.  
  19. Connect the electrical connectors to the EFE heater, the carburetor solenoid valve and the electric choke.
  20.  
  21. Connect the hose to the vacuum switch, if equipped, and the solenoid valve.
  22.  
  23. Connect the accelerator cable to the carburetor. Connect the electrical connectors to the starter, the thermo-unit, the oil pressure switch and distributor harness.
  24.  
  25. Connect the high-tension wire to the ignition coil, the vacuum hose to the rear connector of the intake manifold and the rubber hoses to the canister.
  26.  
  27. Connect the fuel hoses to the carburetor.
  28.  
  29. Connect the engine-to-chassis ground cable.
  30.  
  31. If equipped with a vacuum switching valve, connect the rubber hose to the valve.
  32.  
  33. If equipped with an oxygen sensor, connect the electrical connector.
  34.  
  35. Connect the heater hoses to the heater core.
  36.  
  37. Tension the clutch cable and tighten the adjusting nut, if equipped with a manual transmission.
  38.  
  39. Install the exhaust pipe-to-exhaust manifold nuts.
  40.  
  41. Connect the electrical connector(s) to the alternator.
  42.  
  43. Install the manifold cover and connect the TCA hot air hose.
  44.  
  45. Install the air cleaner by performing the following procedures:
  46.  
    1. Lower the air cleaner and connect the vacuum hose(s) to the underside.
    2.  
    3. Install the air cleaner-to-bracket bolts and wing nut.
    4.  
    5. Connect the air hose to the AIR pump.
    6.  
    7. Connect the air duct and PCV hose to the air cleaner.
    8.  

  47. Refill the cooling system with the proper coolant and the crankcase with engine oil. Check and adjust the clutch pedal freeplay, if equipped with a manual transmission.
  48.  
  49. Install the hood and connect both battery cables, the positive cable first.
  50.  
  51. Adjust the belt tension. Start the engine, check for leaks.
  52.  
  53. Check and/or adjust the idle speed and ignition timing.
  54.  

1988 and 1991 GASOLINE ENGINES
  1. Relieve the fuel pressure. Disconnect both battery cables, the negative cable first. Remove the battery.
  2.  
  3. Matchmark the hood-to-hinges and remove the hood.
  4.  
  5. Remove the undercover, if equipped. Open the drain plugs on the radiator and the cylinder and drain the cooling system.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the air cleaner (2.3L engine) or air cleaner duct and hose (2.6L engine). Using a clean shop cloth, cover the air cleaner port to prevent dirt from entering the engine.
  2.  
  3. Label and disconnect the necessary hoses, electrical connectors, control cables and control rods from the engine.
  4.  
  5. Label and disconnect the following items:
  6.  
    1. Air switch valve hose.
    2.  
    3. Oxygen sensor wire.
    4.  
    5. Vacuum switch valve hose.
    6.  
    7. Thermal vacuum switching valve hose.
    8.  
    9. Pressure regulator vacuum hose.
    10.  
    11. Canister hose.
    12.  
    13. ECM harness.
    14.  
    15. Fuel hose(s).
    16.  

  7. Remove the clutch return spring (if equipped), the clutch control cable (if equipped), the back-up light switch connector and the speedometer cable from the transmission.
  8.  
  9. Remove the radiator grille from the deflector panel.
  10.  
  11. Disconnect the upper and lower radiator hoses and the reservoir tank hose.
  12.  
  13. Remove the fan shroud, fan blade assembly and the radiator.
  14.  
  15. If equipped with air conditioning, remove the compressor from the engine and move it aside; do not disconnect the pressure hoses.
  16.  
  17. If equipped with a V6 engine, perform the following procedures:
  18.  
    1. Remove the power steering pump-to-engine brackets and move the pump aside.
    2.  
    3. Remove the spark plug wire from the No. 1 spark plug.
    4.  
    5. Remove the distributor cap with the No. 1 spark plug wire.
    6.  
    7. Remove the ignition coil.
    8.  

  19. Remove the gear shift lever by performing the following procedures:
  20.  
    1. Place the gear shift lever in N .
    2.  
    3. Remove the front console from the floor panel.
    4.  
    5. Pull the shift lever boot and grommet upward.
    6.  
    7. Remove the shift lever cover bolts and the shift lever.
    8.  

  21. Remove the transfer shift lever by performing the following procedures:
  22.  
    1. Place the transfer shift lever in H (except V6 engine) or 2H (V6 engine).
    2.  
    3. Pull the shift lever boot and dust cover upward.
    4.  
    5. Remove the shift lever retaining bolts.
    6.  
    7. Pull the shift lever from the transfer case.
    8.  

  23. Raise and safely support the vehicle. Remove the front wheels. Drain the oil from the engine.
  24.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. Drain the transmission and transfer case fluid.
  2.  
  3. If equipped with an automatic transmission, perform the following procedures:
  4.  
    1. Remove the oil level gauge and the tube.
    2.  
    3. Disconnect the shift select control link rod from the select lever.
    4.  
    5. Disconnect the downshift cable from the transmission.
    6.  
    7. Disconnect and plug the fluid coolant lines from the transmission.
    8.  

  5. If equipped with a 1-piece driveshaft, remove the driveshaft flange-to-pinion nuts, lower the driveshaft and pull it from the transmission.
  6.  
  7. If equipped with a 2-piece driveshaft, perform the following procedures:
  8.  
    1. Remove the rear driveshaft flange-to-pinion nuts.
    2.  
    3. Remove the rear driveshaft flange-to-front driveshaft flange bolts and the rear driveshaft.
    4.  
    5. Remove the center bearing-to-chassis bolts, move the front driveshaft rearward and from the transmission.
    6.  

  9. Remove the front driveshaft's splined yoke flange-to-transfer case bolts and separate the front driveshaft from the transfer case; do not allow the splined flange to fall away from the driveshaft.
  10.  
  11. Remove the starter-to-engine bolts and the starter.
  12.  
  13. If equipped with a clutch slave cylinder, remove it from the transmission and move it aside.
  14.  
  15. Remove the exhaust pipe-to-exhaust manifold nuts, the exhaust pipe bracket-to-transmission bolts, the front exhaust pipe-to-2nd exhaust pipe bolts and the front exhaust pipe from the vehicle.
  16.  
  17. Attach an engine hanger to the rear of the exhaust manifold.
  18.  
  19. Using an engine hoist, connect it to the engine hangers and support the engine.
  20.  
  21. If equipped with a V6 engine, remove the catalytic converter and the parking brake cable bracket.
  22.  
  23. Remove the transmission/transfer case assembly by performing the following procedures:
  24.  
    1. Using a transmission jack, place it under the transmission and support the assembly.
    2.  
    3. Remove the rear mount-to-transmission nuts.
    4.  
    5. Remove the rear mount-to-side mount member nuts/bolts and the mount.
    6.  
    7. Remove the transmission-to-engine bolts.
    8.  
    9. Move the transmission assembly rearward.
    10.  
    11. Carefully lower the transmission.
    12.  

  25. Remove the engine-to-mount nuts/bolts.
  26.  
  27. Using the hoist, slowly, lift the engine; be sure to hold the front of the engine higher than the rear.
  28.  
  29. Place the engine on a work stand.
  30.  

To install:

  1. Using the hoist, slowly, lower the engine into the vehicle; be sure to hold the front of the engine higher than the rear.
  2.  
  3. Install the engine-to-mount nuts/bolts.
  4.  
  5. Install the transmission/transfer assembly by performing the following procedures:
  6.  
    1. Raise the transmission into position.
    2.  
    3. Move the transmission forward and engage it with the engine.
    4.  
    5. Install the engine-to-transmission bolts.
    6.  
    7. Install the rear mount and the rear mount-to-side mount member nuts/bolts.
    8.  
    9. Install the rear mount-to-transmission nuts.
    10.  
    11. Remove the transmission jack.
    12.  

  7. If equipped with a V6 engine, install the catalytic converter and the parking brake cable bracket.
  8.  
  9. Remove the engine hoist and the engine hanger from the rear of the exhaust manifold.
  10.  
  11. Install the front exhaust pipe, exhaust pipe-to-exhaust manifold nuts, the exhaust pipe bracket-to-transmission bolts, the front exhaust pipe-to-2nd exhaust pipe bolts.
  12.  
  13. If equipped with a clutch slave cylinder, install it onto the transmission.
  14.  
  15. Install the starter and the starter-to-engine bolts.
  16.  
  17. Install the front driveshaft's splined yoke flange-to-transfer case bolts.
  18.  
  19. If equipped with a 2-piece driveshaft, perform the following procedures:
  20.  
    1. Install the front driveshaft into the transmission and the center bearing-to-chassis bolts.
    2.  
    3. Install the rear driveshaft and the rear driveshaft flange-to-front driveshaft flange bolts.
    4.  
    5. Install the rear driveshaft flange-to-pinion nuts.
    6.  

  21. If equipped with a 1-piece driveshaft, install the driveshaft into the transmission and the driveshaft flange-to-pinion nuts.
  22.  
  23. If equipped with an automatic transmission, perform the following procedures:
  24.  
    1. Connect the fluid coolant lines to the transmission.
    2.  
    3. Connect the downshift cable to the transmission.
    4.  
    5. Connect the shift select control link rod to the select lever.
    6.  
    7. Install the oil level gauge and the tube.
    8.  

  25. Install the front wheels and lower the vehicle.
  26.  
  27. Install the transfer shift lever by performing the following procedures:
  28.  
    1. Position the shift lever into the transfer case.
    2.  
    3. Install the shift lever retaining bolts.
    4.  
    5. Push the dust cover and the shift lever boot downward.
    6.  

  29. Install the gear shift lever by performing the following procedures:
  30.  
    1. Install the shift lever and the shift lever cover bolts.
    2.  
    3. Push the grommet and shift lever boot downward.
    4.  
    5. Install the front console to the floor panel.
    6.  

  31. If equipped with a V6 engine, perform the following procedures:
  32.  
    1. Install the ignition coil.
    2.  
    3. Install the distributor cap with the No. 1 spark plug wire.
    4.  
    5. Install the spark plug wire from the No. 1 spark plug and reconnect the wires to the distributor cap.
    6.  
    7. Install the power steering pump-to-engine brackets.
    8.  

  33. If equipped with air conditioning, install the compressor to the engine.
  34.  
  35. Install the radiator, the fan blade assembly and the fan shroud.
  36.  
  37. Connect the upper and lower radiator hoses and the reservoir tank hose.
  38.  
  39. Install the radiator grille to the deflector panel.
  40.  
  41. Install the clutch return spring (if equipped), the clutch control cable (if equipped), the back-up light switch connector and the speedometer cable to the transmission.
  42.  
  43. Connect the following items:
  44.  
    1. Air switch valve hose.
    2.  
    3. Oxygen sensor wire.
    4.  
    5. Vacuum switch valve hose.
    6.  
    7. Thermal vacuum switching valve hose.
    8.  
    9. Pressure regulator vacuum hose.
    10.  
    11. Canister hose.
    12.  
    13. ECM harness.
    14.  
    15. Fuel hose(s).
    16.  

  45. Connect the necessary hoses, electrical connectors, control cables and control rods to the engine.
  46.  
  47. Install the air cleaner (2.3L engine) or air cleaner duct and hose (2.6L engine).
  48.  
  49. Refill the engine, the transmission, the transfer case and the cooling system. Install the undercover, if equipped.
  50.  
  51. Install the hood.
  52.  
  53. Install the battery and connect both battery cables, the positive cable first.
  54.  
  55. Adjust the belt tension. Start the engine, check for leaks.
  56.  
  57. Check and/or adjust the idle speed and ignition timing.
  58.  

 
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