Engine: Service and Repair

NOTE: If vehicle is equipped with manual transmission, transmission must be removed prior to engine removal. Refer to ``Clutch & Manual Transmission Section'' for transmission removal procedure.




1980-81 TRAIL DUSTER & 1980-87 RAMCHARGER & CONVENTIONAL CAB

1. Disconnect battery cables and remove battery, then drain cooling system.
2. Mark position of hinges for reassembly, then remove hood.
3. Remove radiator and heater hoses, then the radiator. Position fan shroud aside.
4. On models equipped with A/C, discharge refrigerant from system.
5. On all models, remove vacuum lines, then the distributor with spark plug wires attached.
6. Remove throttle linkage, then the carburetor.
7. Remove all engine electrical connectors.
8. Remove air conditioning hoses and power steering hoses, if equipped.
9. Remove starter motor, alternator, charcoal canister and horns.
10. Disconnect exhaust pipe at manifold.
11. Remove bell housing attaching bolts and inspection plate.
12. Attach C-clamp on bottom of transmission torque converter housing to prevent torque converter from falling out.
13. Remove torque converter drive plate attaching bolts from torque converter drive plate. Mark converter and drive plate to aid in reassembly.
14. Support transmission using suitable floor jack, then disconnect engine from torque converter drive plate.
15. Install suitable lifting fixture to cylinder head.
16. Install suitable engine hoist to lifting fixture, then remove engine front mount bolts.
17. Remove engine from vehicle.
18. Reverse procedure to install.




MOTOR HOME

1. Disconnect battery ground cable and drain cooling system.
2. Disconnect radiator hoses, then remove radiator.
3. Remove engine cover, passenger seat and other fixtures that may limit access to top of engine.
4. Disconnect heater hoses and all engine electrical connectors.
5. Remove air cleaner, fuel lines and carburetor.
6. Install engine lifting adapter to carburetor mounting pad on intake manifold.
7. Disconnect throttle linkage at transmission, then the exhaust pipes at both manifolds.
8. Remove line to fuel pump inlet.
9. Support engine using tool No. C-3487A or equivalent. With engine and transmission slightly raised, disconnect transmission rear mount, speedometer cable and hand brake.
10. Remove front bumper and frame front crossmember.
11. Install suitable engine hoist to lifting fixture, then disconnect front engine mounts from frame.
12. Remove engine from vehicle.
13. Reverse procedure to install.