Engine: Service and Repair

REMOVAL AND INSTALLATION
1. Relieve fuel system pressure as outlined under, Fuel Delivery Air Induction/ Service And Repair/ Fuel Pressure Relief Procedure.
2. Disconnect battery ground cable, then drain cooling system and engine oil.
3. Remove air filter assembly and tubes.
4. Remove air deflector, grille and lower grille panel.
5. Remove hood latch and position aside.
6. Remove headlamp assemblies, parking lamp and headlamp housings.
7. Remove stone deflector, front bumper and air deflector.
8. Remove drive belts, fan shroud, fan clutch and pulley.
9. On models equipped with A/C, discharge A/C system, then remove condenser.
10. Remove radiator and radiator upper support bracket.
11. Disconnect A/C compressor electrical connector and tubes.
12. Remove belt tensioner and electrical bracket behind power steering pump.
13. Disconnect power steering lines from steering pump.
14. Remove A/C compressor, power steering pump and bracket as an assembly.
15. Disconnect alternator electrical connectors, then remove one alternator adjusting bracket bolt from water pump.
16. Remove alternator and bracket as an assembly.
17. Disconnect heater hoses.
18. Disconnect electrical junction block, heater vacuum manifold and fuel pressure regulator vacuum line.
19. Remove oil filler tube, electrical harness support and oil dipstick and tube.
20. Remove distributor and ignition wires.
21. Remove heater bleed line and power brake booster hose.
22. Position A/C lines aside.
23. Remove throttle body.
24. Remove inside engine cover.
25. Disconnect transmission electrical connectors.
26. Remove EGR pipe, upper intake manifold and fuel supply manifold with injectors and wiring.
27. Remove rear lifting eye.
28. Remove PCV valve, hose and tube.
29. Raise and support vehicle, then remove starter.
30. Disconnect exhaust pipes from exhaust manifold.
31. On models equipped with automatic transmission, remove torque converter housing cover, torque converter to flex plate attaching nuts, bottom flywheel housing front plate bolts and bottom transmission to engine attaching bolts.
32. On models equipped with manual transmission, remove clutch housing bottom cover and bottom transmission to engine attaching bolts.
33. Support transmission using suitable jack.
34. Install suitable engine lifting equipment.
35. Remove front engine mount attaching nuts and through bolts.
36. Remove upper transmission to engine attaching bolt.
37. Remove engine.
38. Reverse procedure to install. Tighten attaching nuts and bolts to 40-50 ft lb.