With Automatic Transmission

REMOVAL
1. Raise hood. Disconnect ground cable at negative battery terminal.
2. Loosen draincock and drain coolant from radiator.
3. Disconnect upper and lower radiator hoses.
4. Remove air cleaner hose assembly.

NOTE: Removal should take place at clamp retaining hose to air cleaner housing assembly.

5. Remove engine fan retaining nut and remove fan.
6. Remove fan shroud retaining screws and remove shroud.
7. Disconnect the Barometric Manifold Absolute Pressure (BMAP) sensor electrical connection and vacuum line located on the dash panel.

Throttle Linkage Shroud:

8. Remove shroud covering throttle linkage. Disconnect throttle linkage at the throttle body.

Belt Idler Arm:

9. Loosen belt idler arm and alternator jack screw retaining bolts. Remove accessory drive belts.
10. Disconnect injector harness connector from main EEC harness.

Engine Coolant Sensor:

11. Disconnect Engine Coolant Temperature (ECT) sensor, located near the thermostat housing, and the engine coolant temperature sender.
12. Disconnect canister purge solenoid hoses from both sides of the solenoid.

Power Steering Pressure Switch:

13. Disconnect power steering pump pressure switch.

Heater Hoses:

14. Mark inlet and outlet heater hoses with chalk prior to removing them from the engine side of the ballast tube.

Breather Tube Assembly:

15. Remove breather tube from air cleaner assembly.
16. Remove breather tube from rocker cover.
17. Remove four transmission oil cooler lines from bottom of radiator (two on each side of vehicle).
18. Remove four radiator retaining bolts, two lower and then two upper bolts. Remove radiator from top of vehicle.
19. Remove two bolts retaining A/C compressor to bottom of vehicle. Remove two upper A/C compressor retaining bolts.
20. Retain A/C compressor to sidemember by tying a piece of wire around compressor. Locate a suitable place on sidemember to tie compressor.

Oil Fill Tube Retaining Stud:

21. Remove nut retaining oil fill tube to alternator bracket.
22. Remove transmission oil fill tube retaining bolt from top of manifold. Gently pull out from top of vehicle.

Alternator Connectors:

23. Disconnect two electrical connectors located on back side of alternator.
24. Remove brake booster vacuum line from brake booster.

Steering Gear Retaining Bolt:

25. Remove bolt retaining steering gear at top of shaft.
26. From inside of vehicle, remove engine cover.

Radio Frequency Interference Suppressor/TFI Module/Oil Pressure Sender:

27. Disconnect Radio Frequency Interference (RFI) suppressor.
28. Disconnect connector to distributor TFI module.
29. Disconnect oil pressure sender.
30. Remove nylon fuel lines from fuel supply manifold at engine.
31. Raise vehicle on hoist.

Fuel Sender Line:

32. Disconnect fuel lines at sender.

Low Oil Sender:

33. Disconnect oil level sensor connector from oil pan.

Drive Shaft:

34. Mark the driveshaft to flange position. From rear of vehicle remove four bolts retaining drive shaft. Slide drive shaft forward, pull down, then pull out to release. Set drive shaft aside.

Speedometer Cable At Transmission:

35. Remove bolt retaining speedometer cable bracket to transmission. Pull speedometer cable/gear out of rear of transmission.

Starter Ground Strap:

36. Remove starter ground strap.
37. Remove battery connection to starter.
38. Remove three bolts retaining starter and remove starter.

Neutral Start Switch/3-4 Shift Solenoid/Kickdown Cable:

39. Disconnect electrical connector for neutral start switch, and 3-4 shift solenoid connector. Disconnect selector and kickdown cable from transmission lever.

Vacuum Modulator:

40. Disconnect vacuum hose from transmission vacuum modulator.
41. Remove the converter access cover and adapter plate bolts from the lower end of the converter housing.

Flywheel To Converter Nut:

42. Remove flywheel-to-converter attaching nuts by placing a 22mm socket and breaker bar on the crankshaft pulley attaching bolt. Rotate pulley clockwise (as viewed from front) to gain access to each of the nuts.
43. Disconnect Exhaust Gas Oxygen (EGO) sensor.
44. Disconnect transmission oil cooler lines from transmission.

Transmission Jack Under Transmission:

45. Position a transmission jack under transmission. Place a safety chain around transmission. Slightly raise transmission.
46. Remove insulator-to-crossmember retaining nuts.
47. Remove the nuts and bolts retaining the crossmember to the two mounting brackets and remove crossmember. If required, remove bolts retaining insulator to transmission and remove insulator.
48. Remove converter housing-to-engine fasteners.

Transmission Removal:

49. Move transmission to rear so it disengages from dowel pins and converter is disengaged from flywheel. Lower transmission from vehicle.
50. Loosen and remove exhaust manifold stud nuts. Remove bolts retaining catalytic converter pipe to muffler and outlet pipe. Disconnect and remove exhaust pipe and catalytic converter.
51. Remove lug nuts and remove both front wheel and tire assemblies.
52. Remove engine block ground straps. One is located on cylinder head just behind power steering pump. The other is located just above where exhaust manifold and exhaust pipe connect.

Stabilizer Bar:

53. Remove bar nuts and disconnect stabilizer bar from lower control arms. Discard bar nuts.
54. Behind spindles, disconnect and plug brake lines at bracket on frame.

Jack Under Lower Control Arm:

55. Position a jack under lower control arm and raise arm until tension is applied to coil spring. Remove bolt and nut retaining spindle to upper control arm ball joint. Slowly lower jack under lower control arm to disconnect spindle from ball joint.

Drive Train Removal Lift:

56. Position drive train removal lift 109-00002 or equivalent under crossmember and engine assembly.
57. Slowly lower vehicle until crossmember rests on removal lift. Place wood blocks under front crossmember and rear of engine block to keep engine and crossmember assembly level. Install safety chains around crossmember and lift.

Front Frame And Crossmember Assembly:

58. With engine and crossmember securely supported on lift, remove three nuts from bolts that retain engine crossmember assembly to frame on each side of vehicle.
59. Slowly lower engine assembly out of vehicle, making sure A/C compressor and wiring harnesses do not interfere with the process.
60. With engine and crossmember assembly clear of vehicle, roll lift out from under vehicle.

Engine Lifting Eyes:

61. Attach engine lifting eyes D81L-6001-D or equivalent to LH rear cylinder with a bolt.
62. The engine lifting eye should still be on the RH front cylinder head. If not, install a second lifting bracket.
63. To eliminate tilt:
a. For forward tilt, attach a chain from the left (front) support bar to the stud on the No. 4 exhaust runner.
b. For rearward tilt, attach a chain from the right (rear) support bar to the exhaust manifold between the No. 2 and No. 3 exhaust runner.

NOTE: When only two support points are used, the engine assembly will hang slightly down at the rear with the transmission attached. With the transmission removed, the engine assembly will hang slightly down at the front because of the weight of the accessories.

CAUTION: The support hook or chain must angle rearward to the rear attaching point. Damage will result if chain runs across throttle cable or throttle valve mechanism.

INSTALLATION
1. Install engine lifting eyes D81L-6001-D or equivalent on side of exhaust manifold. Connect a chain to lifting eye and attach to a floor crane.
2. Remove attaching bolts and remove engine from work stand.
3. With front crossmember securely positioned on drive train removal lift 109-0002 or equivalent, slowly lower engine until motor mount studs are piloted in crossmember holes. Install retaining nuts and tighten to 96-127 Nm (71-94 ft lb). Remove chain and lifting eyes.

NOTE: Install wood blocks under oil pan and crossmember.

4. Roll removal lift under vehicle. Ensure vehicle is supported on hoist. Align lift, engine and crossmember assembly so three mounting bolts on each side of frame are in alignment with holes in crossmember.
5. Slowly lower vehicle so bolts are piloted in crossmember holes. Raise lift or lower hoist so crossmember is against frame. Install nuts retaining crossmember to frame and tighten to 196-264 Nm (145-195 ft lb). Raise vehicle and remove lift.
6. Position converter to transmission making sure converter hub is fully engaged in pump gear.

NOTE: Ensure torque converter rotates freely and is not bound up.

Torque Converter Alignment:

7. When the torque converter is fully installed, check dimension "A".
^ minimum: 10.23 mm (7/16 in.)
^ maximum: 14.43 mm (9/16 in.)
8. Once converter is properly installed, place transmission on jack and secure with safety chains.
9. Rotate converter so drive studs are in alignment with holes in flywheel.
10. Lift transmission into position to connect transmission oil cooler lines to case.

Automatic Transmission Alignment:

11. Move converter and transmission assembly forward into position being careful not to damage flywheel and converter pilot. The converter housing is piloted into position by dowels in rear of engine block.

NOTE: During this move, to avoid damage, do not allow transmission to get into a nosed down position as this will cause converter to move forward and disengage from pump gear. The converter must rest squarely against flywheel. This indicates that converter pilot is not binding in engine crankshaft.

Automatic Transmission Bolt Locations:

12. Install converter housing-to-engine attaching fasteners. Tighten to 38-51 Nm (28-38 ft lb).
13. Position crossmember in two mounting brackets. Markings on crossmember indicate direction of installation. Install nuts and bolts and tighten.
14. Slowly lower transmission so the insulator studs are installed in proper slots in crossmember. Install nuts and tighten to 97-127 Nm (71-94 ft lb). Remove safety chain and remove transmission jack.
15. Position starter assembly on housing. Install ground cable and starter ground strap. Tighten mounting bolts to 21-27 Nm (15-20 ft lb). Connect relay-to-starter cable and tighten nut and washer.
16. On RH side of the transmission, connect vacuum hose to modulator.
17. Position selector cable in bracket on transmission case. Press end of cable on ball stud on lower portion of selector lever. Install retainer in bracket.
18. Install kickdown and selector cable. Adjust selector cable, with shifter in overdrive position.
19. Connect neutral start switch plug to switch. Install converter clutch solenoid connector.
20. Connect vacuum hose to transmission modulator.
21. Insert speedometer driven gear into transmission and retain with a clamp. Tighten retaining screw to 2.25-2.82 Nm (20-25 in lb).
22. Position a 22mm socket and breaker bar on crankshaft pulley bolt. Rotate crankshaft pulley clockwise (as viewed from front) to gain access to each of the torque converter studs. Install nut on each stud and tighten to 27-46 Nm (20-34 ft lb).
23. Position converter access cover and adapter plate on converter housing. Install and tighten attaching bolts to 16-22 Nm (12-16 ft lb).
24. Remove safety chains from around lower control arms and spring seat.
25. Install a jack under lower control arms. Slowly raise control arm until coil spring is under tension. Continue to raise arm until spindle upper arm can be connected to the lower arm ball joint. Install a new nut and bolt and tighten to 37-50 Nm (27-37 ft lb).
26. Connect stabilizer bar to lower control arms. Install new bar nuts and tighten to 16-24 Nm (12-18 ft lb).

Brake Line Connection:

27. Connect front brake lines to caliper hoses at frame brackets.
28. Install wheel and tire assemblies on rotors. Install and tighten lug nuts to 115-155 Nm (85-115 ft lb).
29. Connect drive shaft to rear axle and transmission observing alignment marks made during removal. Install nuts and bolts retaining drive shaft to rear axle end yoke.
30. Install new non-asbestos gaskets on exhaust manifold and catalytic converter. Install two nuts and bolts retaining converter to muffler and outlet pipe and tighten to 25-35 Nm (18-26 ft lb). Install nuts retaining pipe to exhaust manifold. Tighten alternately to 34-46 Nm (25-34 ft lb).
31. Connect electrical connector for Exhaust Gas Oxygen (EGO) sensor.
32. Position two ground straps on engine and tighten two ground strap bolts.
33. Connect fuel pump pressure line and fuel return line at fuel sender.
34. Connect fluid lines at transmission.
35. Connect low-oil level sensor at oil pan.
36. Route transmission oil fill tube from engine compartment to transmission. Connect to transmission.
37. Lower vehicle.
38. From inside vehicle, connect Radio Frequency Interference (RFI) suppressor.
39. Connect connector leading to TFI module.
40. Connect oil pressure sender.
41. Install cover over engine compartment.
42. From inside engine compartment, in front of vehicle, connect two electrical connectors in back of alternator.
43. Connect brake booster vacuum line to brake booster.
44. Connect breather tube to oil filler tube assembly.
45. Attach bolt retaining steering gear to top of shaft.
46. Connect power steering pump pressure switch.
47. Connect heater hoses to ballast tube by matching chalk lines to specific inlet and outlet hoses.
48. Install radiator and attach retaining bolts; two on lower portion of radiator and two on upper portion of radiator.
49. Connect four transmission cooler lines to lower portion of radiator (two on each side of vehicle).
50. Connect canister purge solenoid hoses from both sides of solenoid.
51. Connect Engine Coolant Temperature sensor (ECT), located near thermostat housing. Connect engine coolant temperature sender.
52. Untie compressor from vehicle sidemember.
53. Position compressor on retaining bracket and attach with four retaining bolts; two on lower portion and two on upper portion.
54. Place alternator belt into position and tighten alternator idler arm.
55. Place injector harness behind belt tension idler arm and tighten idler arm.
56. Connect throttle linkage to ball stud located on throttle body. Connect shroud covering throttle body.
57. Connect Barometric Manifold Absolute Pressure (BMAP) sensor electrical connection, and vacuum line located on dash panel.
58. Install engine fan and tighten using retaining nut.
59. Install fan shroud over fan and in position on radiator. Install and tighten retaining nut.
60. Connect upper and lower hoses to radiator.
61. Connect ground cable to negative battery terminal.
62. Install air cleaner and intake duct assembly on throttle body.
63. Fill cooling system to specified level.
64. Check and adjust all fluid levels.
65. Bleed brakes.
66. Check and, if required, adjust front alignment.
67. Start and run engine to check for proper operation and leaks. Service as required.