Removal
REMOVAL1. Disconnect the battery cables. Remove the battery.
2. Mark the hinge locations on the hood panel for alignment reference during installation. Remove the engine compartment lamp. Remove the hood.
WARNING: The coolant in a recently operated engine is HOT AND PRESSURIZED. Use care to prevent scalding by hot coolant. Carefully release the pressure BEFORE removing the radiator draincock and cap.
3. Remove the radiator drain cock and radiator cap to drain the coolant.
NOTE: DO NOT waste usable coolant. If the solution is clean, drain the coolant into a clean container for reuse.
4. Remove the lower radiator hose.
Fig. 13 Upper Radiator Hose, Coolant Recovery Hose, Fan Shroud & Heater Hoses:
5. Remove the upper radiator hose and coolant recovery hose.
6. Remove upper radiator support retaining bolts and remove radiator support.
7. Remove the fan shroud and electric cooling fan.
8. Disconnect the transmission fluid cooler tubing (automatic transmission).
9. Disconnect radiator fan switch wire connector.
10. Vehicles with Air Conditioning:
a. Discharge the A/C condenser.
b. Remove the service valves and cap the compressor ports.
11. Remove the radiator or radiator and condenser (if equipped with A/C).
12. Remove the fan assembly from the idler pulley
Fig. 14 Heater Hoses (RH Drive Vehicle):
13. Disconnect the heater hoses at the engine thermostat housing and water pump.
Fig. 15 Accelerator Cable, Speed Control Cable, Automatic Transmission Control Cable & Quick-Connect Fuel Lines:
14. Disconnect the throttle linkages.
15. Disconnect the speed control cable (if equipped).
16. Disconnect the line pressure cable (if equipped with automatic transmission).
17. Disconnect injection system wire harness connector at the dash panel.
18. Disconnect the distributor electrical connection and the oil pressure switch connector.
19. Perform the Fuel System Pressure Release procedure. Refer to Powertrain Management/Fuel Delivery and Air Induction/Service and Repair.
20. Disconnect the quick-connect fuel lines at the fuel rail and return line by squeezing the two retaining tabs against the fuel tube. Pull the fuel tube and retainer from the quick-connect fitting. Refer to Powertrain Management/Fuel Delivery and Air Induction/Service and Repair for the proper procedure.
21. Remove the fuel line bracket from the intake manifold.
Fig. 16 Air Cleaner Assembly & Power Steering Pump:
22. Remove the air cleaner assembly.
23. Remove the power brake vacuum check valve from the booster, if equipped.
24. If equipped with power steering:
a. Disconnect the hoses from the fittings at the steering gear.
b. Drain the pump reservoir.
c. Cap the fittings on the hoses and steering gear to prevent foreign objects from entering the system.
25. Identify, tag and disconnect all necessary wire connectors and vacuum hoses.
26. Raise and support the vehicle.
27. Disconnect the wires from the starter motor solenoid.
28. Remove the starter motor.
29. Disconnect the exhaust pipe from the manifold.
30. Disconnect the engine speed sensor wire connection.
31. Remove the exhaust pipe support.
32. Remove the flywheel and converter housing access cover.
33. Vehicles with Automatic Transmission:
a. Mark the converter and drive plate location.
b. Remove the converter-to-drive plate bolts.
34. Remove the upper flywheel and converter housing bolts and loosen the bottom bolts.
Fig. 6 Front Mounts - XJ Vehicles:
35. Remove the engine mount cushion-to-engine compartment bracket bolts.
36. Lower the vehicle.
37. Attach a lifting device to the engine.
38. Raise the engine off the front supports.
39. Place a support or floor jack under the converter (or flywheel) housing.
40. Remove the remaining converter (or flywheel) housing bolts.
41. Lift the engine out of the engine compartment.