REMOVAL & INSTALLATION
These instructions provide for removal of the engine and transmission as a unit.
All operations involving hoisting the engine-transmission unit should be done with extreme care and should be carefully planned beforehand. Read the procedure through before beginning. It is best to use fender covers on both fenders and on the firewall cowl to protect the metal and paint form damage or scratches during removal or installation.
- Disconnect the battery cables, negative (ground) cable first. Remove the battery hold-down and the battery.
- Mark the location of each hood hinge with a scribe, this will help you with alignment when reinstalling the hood.
- Support the hood so that its weight is not on the hinge bolts. Then, remove the bolts. With the help of an assistant, remove the hood from the car and store in a safe place.
- Remove the air cleaner assembly and mounting supports.
- Drain the radiator, the engine crankcase, and the transmission fluid. On some models where splash shields interfere with easy access while working under the car, remove the shields.
- If your car has an automatic transmission, disconnect and plug the cooler lines from the radiator.
- Disconnect the radiator hoses from the radiator. On some six cylinder models, an auxiliary engine oil cooler is mounted on the radiator support, disconnect and remove it. Models that have an expansion tank: remove the hose to the radiator and remove the tank.
- On some four cylinder models, it may be necessary to remove the radiator grille and headlight bezels.
- Remove the radiator shroud, the hood lock base and support, the upper radiator supports and the condenser (models with air conditioning). Remove the radiator.
On some models it may be possible to remove the radiator and shroud as an assembly.
- On some models with air conditioning, loosen the compressor mounting bolts and remove the drive belt. Unbolt the compressor and move it aside, but do not disconnect any of the refrigerant lines. If there is not enough slack in the lines (this may be the case on some older models), the system will have to be discharged and the lines disconnects.
- On models with power steering, loosen the mounting bolts and remove the drive belt. Remove the mounting bolts and move the pump away from the engine. Do not disconnect the power steering hoses unless there is not enough slack.
- Disconnect the accelerator linkage on carbureted models.
- Disconnect and label:
- battery ground cable at engine.
- starter wiring.
- coil to distributor high tension cable.
- primary wiring harness to the distributor.
- wire to temperature sender.
- all other sensor wire connectors.
- alternator wiring.
- choke heat wire or hoses connecting the choke housing.
- fuel lines: on fuel injected systems, bleed line at lower fuel filter hose before disconnecting (see , Fuel Filter).
- EGR solenoid connector wire, if equipped.
- all wiring harness and air hoses to the fuel injection.
- heater hoses.
- vacuum lines to the power brake unit from the intake manifold.
- all other wires harnesses and vacuum lines connected to the engine that would interfere with removal.
- heater control cable at valve, if equipped.
- On cars equipped with an hydraulic clutch. Disconnect the line from the master cylinder to the slave cylinder and cap the line.
- Remove the clutch slave cylinder (manual transmission).
- Disconnect the speedometer cable from the transmission.
- Disconnect the transmission control linkage or cross shaft, if equipped (column shift and automatic).
- Disconnect the wiring to the neutral safety switch, or any other wiring or vacuum lines to the transmission that would interfere with removal.
- Remove the shift lever (floor mounted controls). On some models it may be necessary to remove the center console.
- To remove the center console: take out the mounting screws, remove the gear shift knob and the boot. Disconnect the wiring and lift the console off over the shift lever.
- Remove the shift lever by loosening and removing the four mounting screws and lifting the lever form the shift tower.
- Automatic transmission models with a floor mounted gear selector: unfasten the connecting rod swivel nut and detach the control rod from the gear selector lever.
- Disconnect the parking brake lever rod, return spring, intermediate rod and the cable from the equalizer.
- Disconnect the exhaust pipe from the exhaust manifold. Remove the front splash shield.
On some models, it may be necessary to disconnect and remove the steering relay rod. If so, disconnect the idler arm from the frame, etc.
- Mark the driveshaft companion flange and the driveshaft (for installation in the same place). Disconnect the driveshaft at the rear by removing the four bolts. Remove the driveshaft. Plug the rear of the transmission with a clean rag to prevent any fluid form spilling.
- Support the transmission carefully to remove all weight from the rear mounts. Remove the bolts securing the mounts and crossmember. Remove the rear crossmember and the mounts.
- Attach an adequate cable or chain between the lifting points on the engine. Hook the cable or chain to a hoist and apply just enough lift to take the weight off of the front mounts. Remove the front motor mount bolts.
- Work carefully to avoid damage to the engine or body parts. Tilt the engine, lowering the transmission as necessary, until the engine/transmission unit can be pulled up and out of the engine compartment. Mount the engine on a secure stand as soon as possible. Do not work on the engine while it is hanging on the hoist.
- Before reinstalling the engine, carefully inspect the front and rear mounts. If any part of the mount is damaged or if the bonded surface is deteriorated or separated, replace the mount.