Engine: Service and Repair

REMOVAL
1. Disconnect the battery ground cable and drain the cooling system.
2. Remove the hood.
3. Remove the air cleaner intake hose.
4. Disconnect the radiator upper and lower hoses at the radiator.
5. Remove the fan shroud attaching bolts and position the shroud over the fan. Remove the radiator and shroud.
6. Remove the alternator and bracket. Position the alternator out of the way. Disconnect the alternator ground wire from the cylinder block.
7. Remove air conditioner compressor and power steering and position out of way.
8. Disconnect the heater hoses at the intake manifold and water pump.
9. Remove the ground wires from the cylinder block.
10. Disconnect the fuel tank-to-fuel rail fuel lines at the fuel rail.

CAUTION: Before disconnecting fuel lines, relieve fuel system pressure.

11. Disconnect the throttle cable shield and linkage at the throttle body and intake manifold.
12. Disconnect all vacuum connections from rear vacuum fitting in upper intake manifold.
13. Disconnect the primary wires from the ignition control module. Disconnect the brake booster vacuum hose. Disconnect the wiring from the oil pressure and engine coolant temperature senders. Also disconnect injector harness, air charge temperature sensor and throttle position sensor.
14. Raise the vehicle and secure with safety stands.
15. Disconnect the muffler inlet pipes at the exhaust manifolds.
16. Disconnect the starter cable and remove the starter.
17. Remove the engine front support-to-crossmember attaching nuts or through bolts.
18. Remove the torque converter inspection cover and disconnect the flywheel from the converter.
19. Remove the converter housing-to-cylinder block bolts and the adapter plate-to-converter housing bolt.
20. Lower the vehicle.
21. Install lifting brackets on the exhaust manifolds. Attach Rotunda Engine Lifting Sling 014-00036 or equivalent.
22. Position a jack under the transmission.
23. Raise the engine slightly and carefully pull it from the transmission. Carefully lift the engine out of the engine compartment so that the rear cover plate is not bent or components damaged. Install the engine on a work stand.

INSTALLATION
1. Attach Rotunda Engine Lifting Sling 014-00036 or equivalent and hoist to lifting brackets at exhaust manifolds. Remove engine from work stand.
2. Lower the engine carefully into the engine compartment. Make sure exhaust manifolds are properly aligned with the muffler inlet pipes.
3. At the automatic transmission, start the converter pilot into the crankshaft.
4. Install the converter housing upper bolts, making sure that the dowels in the cylinder block engage the flywheel housing. Tighten bolts to 45-61 Nm (33-45 ft lb). Remove the jack from under the transmission.
5. Remove the lifting sling.
6. Position the kickdown rod on the transmission and engine.
7. Raise the vehicle and secure with safety stands.
8. Position the transmission linkage bracket and install the remaining converter housing bolts. Install the adapter plate-to-converter housing bolt. Install the converter-to-flywheel nuts and install the inspection cover. Connect the kickdown rod on the transmission.
9. Install the starter and connect the cable.
10. Connect the muffler inlet pipes at the exhaust manifolds.
11. Install the engine front support nuts and washer attaching it to the crossmember or through-bolts.
12. Lower the vehicle.
13. Install ground wires to cylinder block.
14. Connect the ignition control module primary wires, then connect the coolant temperature sending unit and oil pressure sending unit. Connect brake booster vacuum hose.
15. Install the throttle linkage.
16. Connect the fuel tank lines at the fuel rail.
17. Connect the ground cable at the cylinder block.
18. Connect the heater hoses to the water pump and cylinder block.

Drive Belt Routing:

19. Install the alternator and bracket. Connect the alternator ground wire to the cylinder block. Install the drive belt.
20. Install air conditioner compressor and power steering pump.
21. Position the fan shroud over the fan. Install the radiator and connect the radiator upper and lower hoses. Install the fan shroud attaching bolts.
22. Fill and bleed the cooling system. Fill the crankcase with the proper grade and quantity of oil.
23. Connect battery ground cable.

NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

24. Charge air conditioning system.
25. Operate the engine at fast idle until it reaches normal operating temperature and check all gaskets and hose connections for leaks.
26. Install the intake hose. Install and adjust the hood.