Engine, Diesel - 2.4L (22-07)
DESCRIPTIONThe following Removal and Installation procedure is for the 2.4L Diesel engine. The references in parentheses in this procedure are references to existing 1984 Car Shop Manual and Supplement Sections. Refer to the referenced manual and section for detailed procedures.
Volume B: 1984 Car Shop Manual, Volume B, Body, Chassis, Electrical
Volume D1: 1984 Car Shop Manual Supplement, Volume D1, 2.4L Diesel Engine, ZF Transmission
REMOVAL AND INSTALLATION
Mark VII/Continental
Removal
1. Open hood and place cover on fenders, also disconnect battery ground cable.
2. Disconnect wiring assembly for engine underhood light.
3. Scribe hinge mark locations and remove hood.
4. Position pan under engine and drain oil pan.
5. Position pan under radiator and drain cooling system.
6. Remove intake manifold air cleaner assembly (D1, 25-41).
7. Remove fan shroud attaching bolts and remove fan shroud.
8. Remove engine cooling fan assembly (D1, 27-05).
9. Remove upper radiator hose.
10. Remove lower radiator hose.
11. Disconnect transmission oil cooler tubes (D1, 27-03).
12. Remove radiator assembly (D1, 27-03).
13. Discharge refrigerant from the A/C system at the service gauge port valve located on the suction line following approved safety precautions (B, 36-32).
14. Once refrigerant is discharged from system, remove high and low pressure hoses. Use backup wrench to prevent component damage. Cap the hose openings to prevent entrance of dirt and excessive moisture.
15. Disconnect muffler inlet pipe.
16. Disconnect vacuum hoses and wiring harnesses.
17. Disconnect engine oil cooler hoses (D1, 22-07).
18. Disconnect accelerator cable at fuel injection pump (D1, 25-60).
19. Disconnect fuel line from tank to fuel injection pump.
20. Disconnect transmission gear shift linkage (D1, 17-02, 17-12).
21. Disconnect battery ground cable at engine.
22. Remove coolant expansion bottle and position out of way.
23. Disconnect heater hoses at dash panel.
24. Disconnect wire to A/C compressor clutch.
25. Disconnect power steering pump hose(s) (D1, 13-51).
26. Disconnect fuel line to injectors.
27. Disconnect wiring harness to instrument panel.
28. Disconnect engine ground leads.
29. Install engine support Tool D79F-6000-A or equivalent.
30. Raise vehicle on hoist.
31. Remove muffler inlet pipe.
32. Remove lower engine oil cooler bracket and brace (D1, 22-07).
33. Remove stabilizer bar, bracket retaining bolts and position forward.
34. Remove left hand front fender splash shield.
35. Disconnect steering gear input shaft to steering column shaft coupling (B, 13-46).
36. Remove retainer nuts to engine insulator supports.
37. Position jack under engine.
38. Raise engine assembly.
39. Position steering gear out of way.
40. Lower engine assembly.
41. Remove converter housing access cover.
42. Remove converter assembly retainer nuts.
FIGURE 1 CLAMPING TORQUE CONVERTER:
43. Insert pair of locking pliers in converter housing to hold converter in place during engine removal (Figure 1).
NOTE: Make sure that the upper jaw of the locking pliers contacts the converter while clamped to the converter housing. This will apply adequate pressure on the converter to prevent separation during engine movements and removal.
44. Remove No. 3 crossmember retainer nuts.
45. Remove transmission gear shift lever bellcrank (D1, 17-02).
46. Raise transmission.
47. Remove No. 3 crossmember retainer bolts.
48. Lower transmission.
49. Remove engine to transmission converter housing retainer bolts.
50. Install crossmember (No. 3) retainer bolts.
51. Position jack and drain pan out of way.
52. Lower vehicle.
53. Install engine lifting equipment.
54. Remove engine support Tool D79T-6000-A or equivalent.
55. Remove engine assembly.
56. Position engine and install on engine work stand.
Installation
1. Install engine lifting equipment.
2. Raise engine and install in vehicle.
3. Install engine support Tool D79T-6000-A or equivalent.
4. Remove engine lifting equipment.
5. Raise vehicle on hoist.
6. Install steering gear assembly.
7. Position jack under engine.
8. Remove retainer bolts from No. 3 crossmember.
9. Lower transmission assembly, including converter.
10. Install engine to transmission retainer bolts.
11. Raise transmission assembly, including converter.
12. Install No. 3 crossmember retainer bolts.
13. Install flywheel to converter retainer nuts. Remove locking pliers.
14. Install converter housing access cover.
15. Connect steering gear input shaft to steering column shaft coupling (B, 13-46).
16. Install transmission gearshift lever bellcrank and connect gear shift linkage (D1, 17-02).
17. Install stabilizer bar bracket retainer bolts.
18. Install engine insulator support retainer nuts.
19. Install left hand front fender splash shield.
20. Install muffler inlet pipe.
21. Position jack from under vehicle.
22. Lower vehicle.
23. Remove engine support Tool D79T-6000-A or equivalent.
24. Install radiator assembly (D1, 27-03).
25. Install lower radiator hose.
26. Position fan shroud.
27. Install fan blade assembly.
28. Install upper radiator hose.
29. Connect transmission cooler tubes (D1, 27-03).
30. Connect power steering hose(s) (D1, 13-51).
31. Connect engine oil cooler hoses (D1, 22-07).
32. Connect A/C discharge compressor to condenser hose.
33. Connect A/C suction evaporator to compressor hose.
34. Connect heater hoses at dash panel.
35. Connect battery ground cable at engine and ground leads.
36. Connect vacuum hose and wiring harnesses.
37. Connect wiring harness to instrument panel.
38. Connect wire to A/C compressor clutch.
39. Connect accelerator cable at fuel injection pump (D1, 25-60).
40. Connect fuel line from tank to fuel injection pump and from pump to injectors.
41. Position and install coolant expansion bottle.
42. Install intake manifold air cleaner assembly.
43. Fill crankcase with specific quantity and quality of oil.
44. Fill power steering pump.
45. Fill cooling system to specification (D1, 27-03).
46. Connect battery cables.
47. Drain, evacuate, pressure check and recharge A/C system (B, 36-32).
48. Install and adjust hood as necessary.
49. Connect wiring assembly for engine underhood light.
50. Start engine and check for oil, coolant and fuel leaks.
51. Remove cover from fenders and close hood.