REMOVAL AND INSTALLATION
See Figures 1 through 9
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:
- Relieve the fuel system pressure on fuel injected models. Disconnect the negative battery cable first, the positive battery cable second, then remove the battery from the vehicle.
- Mark the position of the hood on the hinges and remove the hood.
- Raise and safely support the vehicle. Drain the engine oil and coolant. Remove the splash shields, as necessary.
- Remove the starter and the transmission.
- Disconnect the exhaust system from the exhaust manifold.
- Remove the converter inspection cover and disconnect the converter from the flywheel.
- Remove the converter housing-to-engine block bolts and the adapter plate-to-converter housing bolt. Lower the vehicle.
- Remove the air cleaner assembly, if carburetor equipped. Disconnect the accelerator cable.
- Remove the cooling fan and the radiator shroud. Disconnect the radiator hoses and transmission oil cooler lines, if equipped, and remove the radiator.
- Disconnect the fuel lines, heater hoses and brake vacuum hose.
- Tag and disconnect the necessary electrical connectors and vacuum hoses. Remove the ground wires from the cylinder block.
- If carburetor equipped, disconnect the secondary air pipe assembly. On 1989-93 2.6L engine, remove the resonance chamber.
- Remove the accessory drive belt(s). Remove the alternator and mounting bracket, then position the alternator aside.
- If equipped, remove the power steering pump pulley and the power steering pump. Position the pump aside, leaving the hoses connected.
- If equipped, remove the air conditioning compressor and position aside, leaving the hoses attached.
- Remove the gusset plates, if equipped. Remove the transmission oil cooler line retainers, if equipped.
- If necessary, remove the radiator grille. Remove the shroud upper plate and the additional condenser fan, if equipped.
- Position a jack under the transmission and install suitable engine lifting equipment to the engine. Remove the engine mount nuts and raise the engine slightly, then carefully pull it from the transmission. Carefully lift the engine out of the engine compartment.
- Install the engine on a workstand.
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.
- Align the engine to the transmission and install two engine-to-transmission bolts.
Seat the left-hand side, front engine mount insulator locating pin prior to the right-hand side, front engine mount insulator.
- Lower the engine onto the front engine mount insulators.
- 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.
- 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.
- 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 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.