C. Sill Repair Procedure
^ The engine must be removed from the vehicle for working access to properly repair the affected sill area.^ This repair procedure is required only on vehicles where cracking is detected at the track bar inner reinforcement attachment area of the sill. If cracking has progressed to metal separation, the sill assembly must be replaced.
1. Remove the hood.
2. Disconnect the battery cables and remove the battery.
3. Remove the skid plate, if equipped.
4. Drain the engine coolant.
5. Remove the air cleaner assembly.
6. If equipped with air conditioning, turn service valve stems to the front-seated (full-in) position and remove the valves from the compressor.
7. Disconnect the radiator hoses and remove the "E" clip from the bottom of the radiator.
8. Raise the vehicle.
9. Disconnect the automatic transmission cooler lines (if equipped).
10. Remove the splash shield from the oil pan.
11. Lower the vehicle.
12. Loosen the radiator shroud and remove the radiator fan.
13. Remove the shroud and splash shield.
14. Remove the radiator/condenser assembly and set to one side.
15. Remove the intercooler.
16. Remove the exhaust shield from the manifold.
17. Disconnect the oil hoses at the remote oil filter.
18. Remove the oil filter.
19. Tag and disconnect all vacuum hoses and electrical connections.
20. Disconnect and plug the fuel inlet and return lines.
21. Remove left motor mount cushion through-bolt retaining nut (automatic transmission only).
22. Remove the motor mount cushion retaining bolts.
23. Disconnect the accelerator cable.
24. Raise the vehicle.
25. Disconnect and drain the power steering hose at the power steering pump.
26. Disconnect the exhaust pipe at the exhaust manifold.
27. Remove the motor mount cushion retaining nuts.
28. Support engine, remove left motor mount bolts (automatic transmission only) and remove the motor mount.
29. Disconnect starter wires and remove starter motor.
30. Mark the converter and drive plate for future reference and remove the converter-to-drive plate bolts through the starter opening (automatic transmissions only).
31. Install left motor mount and retaining bolts finger tight. Install motor mount cushion through-bolt (automatic transmissions only).
32. Remove engine support (automatic transmissions only).
33. Remove the transmission-to-engine retaining bolts.
NOTE:
THE TOP TRANSMISSION-TO-ENGINE RETAINING BOLT CANNOT BE REMOVED FROM THE UNDERSIDE OF THE VEHICLE.
34. Lower the vehicle.
35. Remove the power steering reservoir and set aside.
36. Remove the oil separator and disconnect the hoses.
37. Disconnect the heater hoses.
38. Remove the top transmission-to-engine retaining bolt.
39. Remove the reference pressure regulator from the dash panel. Connect the engine lifting device and position a jack under the transmission.
40. Lift the engine out of the engine compartment.
41. Inspect for any sill cracking -- stop drill both ends of crack(s) with a 3/32 inch drill.
42. Position the sill reinforcement plate as shown in Figure 1 and bolt in place using the motor mount and track bar bracket mounting holes.
43. Weld the reinforcement plate to the sill.
^ Weld 1 inch at the front edge of plate.
^ Weld 1 inch at the rear edge of plate.
^ Apply (3) 1/2 inch welds across the top edge of plate.
44. Remove bolts that were used to hold plate in place.
45. Grind off excess weld in the motor mount attachment area.
46. Wash the reinforcement plate and surrounding area with soap and water.
47. Apply a rust preventive coating to the entire repaired area.
48. Lower the engine into the engine compartment.
NOTE:
IT MAY BE NECESSARY TO REMOVE THE ENGINE MOUNT CUSHIONS FROM THE ENGINE MOUNT BRACKET TO FACILITATE ALIGNMENT OF THE ENGINE TO THE TRANSMISSION.
49. If equipped with a manual transmission:
^ Insert the transmission shaft into the clutch spline.
^ Align the flywheel housing with the engine.
^ Install and tighten the flywheel housing lower bolts finger-tight.
50. If equipped with an automatic transmission:
^ Align the transmission torque converter housing with the engine.
51. Install the top engine-to-transmission retaining bolt.
52. Install the motor mounts if removed and install the motor mount retaining bolts.
53. Remove the engine lifting device.
54. Raise the vehicle.
55. Install the remaining transmission-to-engine bolts.
56. If equipped with automatic transmission:
^ Support engine, remove left motor mount.
^ Install the converter-to-drive plate bolts.
^ Ensure that the installation reference marks are aligned.
^ Install starter and connect wires.
^ Install motor mount and retaining bolts.
^ Install the converter housing access cover.
^ Remove engine support.
57. Install the motor mount cushion retaining nuts.
58. Connect the power steering hoses.
59. Connect the exhaust pipe to the exhaust manifold.
60. Lower the vehicle.
61. Connect the oil hoses to the remote oil filter.
62. Install the new oil filter.
63. Mount the power steering reservoir.
64. Connect all electrical connections.
65. Connect the fuel lines.
66. Connect the vacuum hoses and install the reference pressure regulator.
67. Connect the heater hoses.
68. Install the oil separator and connect the hoses.
69. Install the accelerator cable.
70. Install the exhaust pipe shield.
71. Install the intercooler and hoses.
72. Install the radiator/condenser assembly with the fan and shroud. Connect the radiator hoses.
73. If equipped with air conditioning, connect the hoses to the A/C compressor and backseat the service valves.
74. Install and connect the battery.
75. Install the turbocharger hoses.
76. Install and connect the air cleaner and hoses.
77. Raise the vehicle.
78. Connect the lower radiator hose and install the radiator retaining "E" clip.
79. Install the splash shield to the oil pan.
80. Install the skid plate, if equipped.
81. Lower the vehicle.
82. Fill the engine with coolant.
83. Fill the power steering reservoir.
84. Fill the engine with engine oil.
85. Start the engine and check for leaks.
86. Install the hood.