Removal

Engine Removal w/ Automatic Transmission

Service Repair No - 12.41.01

1. Position vehicle on 4-post ramp (hoist).
2. Drain engine oil.
3. Remove bonnet.
4. Remove radiator.
5. Loosen 3 PAS pump pulley bolts.
6. Using a 15 mm ring spanner, release auxiliary drive belt tension and release belt from alternator pulley.
7. Remove drive belt.





8. Disconnect A/C compressor multiplug.
9. Remove 4 bolts securing compressor to mounting bracket.
10. Collect compressor heat shield.
11. Tie compressor aside with string.





12. Loosen clip screws securing heater return and feed hoses to pipes and disconnect.
13. Position cloth to collect fuel spillage.
14. Loosen fuel feed hose to rail union, allow fuel to spill and disconnect union.
15. Loosen clip screw securing fuel return hose to fuel rail and disconnect hose.

CAUTION: Plug the connections.

16. Remove cloth.
17. Remove plenum.





18. Remove bolt securing 2 breather pipe "P" clip to rear of RH cylinder head.





19. Loosen clip screw securing intake hose to MAP sensor housing and remove hose.
20. Remove nut securing kick-down cable clip to rear of LH cylinder head.
21. Remove 3 cable ties securing purge pipe to coolant hose and harness, position pipe aside.
22. Disconnect brake servo pipe from inlet manifold and position aside.





23. Remove 3 bolts securing PAS pulley and remove pulley.





24. Release knock sensor harness clip from PAS return hose.
25. Remove 3 bolts securing PAS pump and position aside.
26. Collect engine lifting bracket.





27. Position engine lifting bracket and secure with 3 (3/8" UNC x 1" MAX) bolts.
28. Raise vehicle on ramp.
29. Remove 6 nuts securing exhaust front pipe to manifolds.
30. Remove front bolt securing RH catalyst heat shield to chassis.
31. Remove bolt securing starter motor heat shield to RH engine mounting bracket.
32. Release starter motor heat shield clip from solenoid.
33. Release exhaust front pipe from manifold studs and remove and discard gaskets.
34. Remove starter motor heat shield.





35. Remove starter motor solenoid terminal nut.
36. Release 2 battery leads from terminal.
37. Disconnect solenoid connectors.
38. Disconnect multiplug from RH knock sensor.
39. Remove 2 cable ties securing engine harness to RH engine mounting bracket.





40. Disconnect multiplug from LH knock sensor.
41. Remove cable tie securing engine harness to LH engine mounting bracket.





42. Remove screw securing crankshaft position sensor heat shield and remove heat shield.
43. Disconnect multiplug from crankshaft position sensor.
44. Remove bolt securing gearbox cooler pipes to engine sump bracket.





45. Remove 7 bolts securing bell housing closing plate and remove plate.
46. Remove 3 bolts securing bell housing access.





47. Mark relationship between converter and drive plate.
48. Rotate crankshaft to access drive plate to converter retaining bolts.





49. Remove 4 bolts securing drive plate to converter.
50. Fit suitable piece of wood through bell housing access hole to retain converter.
51. Remove 2 bell housing lower retaining bolts.





52. Remove nut securing RH engine mounting to chassis bracket.
53. Remove nut securing LH engine mounting to chassis bracket.
54. Lower vehicle.





55. Loosen clip screw and disconnect radiator bottom hose from heater pipe.
56. Disconnect multiplug from camshaft position sensor.
57. Disconnect connector from oil pressure switch.
58. Release harness from front of engine.





59. Remove 2 alternator terminal nuts and disconnect connector.





60. Remove screw securing heater pipe to bracket.
61. Loosen clip screw and remove heater hose/pipe assembly from inlet manifold.
62. Remove 2 screws securing engine harness to RH side of inlet manifold.
63. Disconnect 4 RH injector multiplugs.
64. Disconnect RH rocker cover breather pipe from ram housing.





65. Release RH bank high tension leads from clips and disconnect from spark plugs.





66. Remove 2 screws securing engine harness to LH side of inlet manifold.
67. Disconnect multiplug from ECT sensor.
68. Disconnect multiplug from fuel temperature sensor.
69. Disconnect temperature sensor thermistor.
70. Disconnect 4 LH injector multiplugs.
71. Release ignition coil multiplug from mounting bracket and disconnect multiplug.
72. Position engine harness aside.





73. Fit engine lifting tool LRT-12-514 to hoist.
74. Lower hoist and connect lifting chains to engine brackets.
75. Raise hoist until lifting chains become taught and use a jack to support gearbox.
76. Remove 6 bell housing to engine bolts.
77. With assistance, raise engine on hoist from engine compartment.

CAUTION: During the engine removal procedure, ensure that the engine does not damage any surrounding components.

78. Move engine clear of vehicle and lower onto work bench.
79. Disconnect lifting chains from engine.
80. Raise hoist and position aside.