Engine: Service and Repair

2L & 2L-T

1. Disconnect battery ground cable, mark installation position of hood hinges, then remove hood.
2. Drain cooling system and engine oil.
3. Disconnect radiator hoses from engine and remove fan shroud.
4. Disconnect expansion tank hose, then remove radiator.
5. Remove transmission along with transfer case, if equipped.
6. On 2L engines, remove air cleaner assembly.
7. On all models, disconnect expansion tank and heater hoses from engine and secure aside.
8. Disconnect accelerator cable and remove A/C vacuum hose from vacuum switching valve, if equipped.
9. On 2L-T engines, remove turbocharger pressure hose from pressure switch.
10. On all models, disconnect and plug oil inlet hose to vacuum pump.
11. On models with A/C, remove 4 compressor mounting bolts and drive belt, then secure compressor aside, leaving refrigerant hoses connected.
12. Disconnect and plug fuel lines to engine.

Fig. 4 Engine harness removal. 1985 exc. Calif.:

Fig. 5 Engine harness removal. 1985 Calif.:

13. Release engine harness and secure aside after disconnecting the following electrical connectors, Figs. 4 and 5:
a. Glow plug current sensor.
b. Water temperature sensor.
c. Glow plug resistor.
d. Injection pump.
e. Water temperature gauge sender.
f. Starter motor.
g. Engine grounds.
h. Oil pressure switch.
i. Alternator.
j. Throttle position sensor.
k. EVR valve.
l. Water temperature switch.
14. Remove engine splash guard.
15. Remove power steering pump retaining bolts and drive belt, and secure pump aside leaving hoses connected.
16. On 2 wheel drive models, remove engine vibration damper from crossmember.
17. On all models, attach suitable lifting equipment to engine, remove bolts securing engine mount insulators to crossmember and lift engine from vehicle.
18. Reverse procedure to install.