REMOVAL & INSTALLATION
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 fuel system pressure.
- Disconnect the negative battery cable.
- Remove the engine undercover if equipped.
- Matchmark the hood and hinges and remove the hood assembly.
- Remove the air cleaner assembly and all adjoining air intake duct work.
- Drain the engine coolant, remove the radiator hoses, and remove the radiator assembly, coolant reservoir, and intercooler, as equipped.
- Remove the transaxle and transfer case as equipped.
- Tag and detach the following electrical connections:
- Accelerator cable
- Heater hoses
- Brake booster vacuum hose
- Vacuum hoses
- Fuel lines
- Engine ground cables
- Any applicable sensors
- Coolant temperature and oil pressure sending units
- Exhaust Gas Recirculation (EGR) temperature sensor
- Connection for the idle speed control motor
- Fuel injectors
- Power transistor
- Ignition coil and any applicable distributor connections
- The connections for the alternator
- Power steering pressure switch
- A/C compressor
- Refrigerant temperature switch
- Remove the air conditioner drive belt and the air conditioning compressor. Leave the hoses attached. Do not discharge the system. Place the compressor aside and secure it using a suitable device.
- Remove the power steering pump and place the pump aside and secure it using a suitable device.
- Remove the exhaust manifold-to-exhaust pipe nuts. Discard the gasket.
- Install the engine hoist equipment and make certain the attaching points on the engine are secure.
- Raise the hoist enough to support the engine.
- Remove the front and rear engine roll stoppers.
- Remove the left engine mount and support bracket.
- Slowly lift the engine and remove it from the vehicle.
- Install the engine and secure all control brackets and mounts.
- Install the transaxle, and transfer case if equipped.
- The balance of the installation is the reverse of removal with the addition of the following notes:
- Use new clamps or O-rings to connect the high pressure fuel line and the fuel return line.
- Use new gaskets to connect the exhaust system to the engine.
- Fill the engine with the proper amount of engine oil and coolant.
- Start the engine, allow it to reach normal operating temperature.
- Check for leaks.
- Check the ignition timing and adjust if necessary.
- Road test the vehicle and check all fluid levels and functions for proper operation.