Removal & Installation
See Figure 1
In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as "disconnect the exhaust system'' or "remove the radiator.'' In most instances, a detailed removal procedure can be found elsewhere in this guide.
It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.
Removal and installation of the engine can be made easier if you follow these basic points:
- Disconnect the battery cables (negative cable first) and remove the battery. Remove the hood.
- On fuel injected engines only, relieve the fuel system pressure.
- Remove the air cleaner assembly.
- Drain the coolant and engine oil.
If your vehicle is equipped with air conditioning, refer to General Information & Maintenance for information regarding the implications of servicing your A/C system yourself. Only an MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.
- On models equipped with air conditioning, have the system discharged and evacuated by an MVAC, EPA-certified, automotive technician. Have the A/C compressor removed from the engine.
- Remove the radiator assembly. If equipped with air conditioning, remove the condenser assembly.
- Remove the engine cooling fan and install a 5 / 16 x 1 / 5 inch capscrew through the fan pulley into the water pump flange. This will maintain the pulley and water pump in alignment when the crankshaft is rotated.
- Remove the heater hoses from the engine.
- Tag and disconnect all hoses, wires, cables and linkages connected to the engine.
- If necessary, remove the power brake vacuum check valve from the booster, if equipped.
- If necessary, remove the distributor cap and wiring.
- If necessary, remove the throttle body assembly.
- If equipped with A/C, disconnect the hoses, then cap the compressor ports and hose openings.
- Disconnect and plug the fuel lines at the fuel pump (diesel or carbureted engines) or at the fuel rail (on fuel injected engines).
- If equipped, disconnect and drain the power steering hoses at the power steering pump or steering gear, whichever is the most convenient. Plug the hose openings to prevent system contamination.
- If necessary, remove the power steering pump.
- Raise and support the vehicle safely.
- Remove the starter.
- Remove the alternator.
- Disconnect the exhaust pipe(s) from the manifold(s).
- If necessary, remove the oil filter.
- Remove the flywheel/converter housing access cover.
- On vehicles equipped with an automatic transmission, matchmark the torque converter to the driveplate and remove the bolts.
- If necessary, attach a C-clamp to the bottom of the torque converter housing to prevent the torque converter from coming out.
- Remove the upper transmission housing-to-engine bolts and loosen the bottom bolts.
- Lower the vehicle.
- Attach a lifting device to the engine.
- Take up the weight of the engine with the lifting device.
- Remove the engine mount bolts.
- Raise the engine off the mounts.
- Place a support jack under the transmission housing.
- Remove the remaining engine-to-flywheel housing bolts.
- On diesel models only, remove the reference pressure regulator from the dash panel.
- Move the engine forward to clear the transmission, and carefully lift it out of the engine compartment.
- Once the engine is removed from the vehicle, mount it on a suitable workstand.
- If removed earlier, install the oil filter to keep foreign material out of the engine.
Lightly oil all bolts and stud threads, except those specifying special sealant, prior to installation.
- Using the hoist or engine crane, slowly and carefully position the engine in the vehicle. Make sure the exhaust manifolds are properly aligned with the exhaust pipes.
It may be easier to align the engine and transmission if you remove the engine mount cushions from the brackets.
- Align the engine to the transmission and install two engine-to-transmission bolts.
Install any engine mount cushions previously removed. Lower the engine onto the front engine mount cushions/insulators. Tighten the engine mount cushion nuts/bolts to the following values:
All, except 5.2L/5.9L engines: 30 ft. lbs. (41 Nm)
- Detach the engine crane or hoist from the engine.
- Remove the floor jack from beneath the transmission.
- Tighten the two installed engine-to-transmission bolts, then raise and securely support the vehicle on jackstands.
Install and tighten the remaining engine-to-transmission bolts to the following values:
2.1L Engine: 30 ft. lbs. (41 Nm)
If equipped with automatic transmission, tighten the torque converter-to-drive plate bolts to the following values:
2.1L Engine: 40 ft. lbs. (54 Nm)
Install and tighten the front engine mount through-bolts to the following values:
2.1L Engine: 48 ft. lbs. (65 Nm)
- The remainder of installation is the reverse of the removal procedure. Be sure to tighten the fasteners to the values presented in the torque specification chart. Torque specifications not found in this section can be found in other sections covering those specific components.
- Fill the crankcase with the proper type and quantity of engine oil. If necessary, adjust the transmission and/or throttle linkage.
- Check to make sure that all electrical wiring harnesses, linkages, ground wires, hoses, vacuum and fuel lines have been properly connected.
- Check to make sure that all components have been installed properly.
- Check to make sure that all adjustments have been performed, as well as all fasteners tightened properly.
- Install the air intake duct assembly.
- Install the battery into the vehicle. Connect the positive battery cable first, then connect the negative battery cable.
- Fill and bleed the cooling system.
- Start the engine and allow it to reach normal operating temperature, then check for leaks and proper operation.
- Stop the engine and check all fluid levels.
- Install the hood, aligning the marks that were made during removal.
- If equipped, have the A/C system properly leak-tested, evacuated and charged by a MVAC-trained, EPA-certified, automotive technician.
- Road test the vehicle.