Engine: Service and Repair

Fig. 4 Engine removal:

1. Disconnect both battery ground cables from batteries and engine.
2. Scribe hood hinge locations and remove hood.
3. Drain cooling system.
4. Disconnect air intake hose from air cleaner and intake manifold, then the upper and lower radiator hoses from engine.
5. Remove engine cooling fan, then the radiator and fan shroud.
6. Disconnect radio ground strap, if equipped.
7. Disconnect No. 2 glow plug relay from dash and position aside with electrical connector attached.
8. Disconnect engine wiring harness from connector on left fender apron.
9. Disconnect starter cable from starter motor.
10. Disconnect accelerator cable and speed control cable, if equipped, from injector pump.
11. Disconnect cold start cable from injector pump.
12. On models equipped with A/C, discharge refrigerant from system, then disconnect A/C lines and position aside.
13. On models equipped with power steering, disconnect pressure and return lines from power steering pump.
14. On all models, disconnect vacuum fitting from vacuum pump and position fitting and hoses aside.
15. Disconnect and cap fuel return line at fuel heater and return line at air injection pump.
16. Disconnect heater hoses from engine, then loosen engine mount attaching nuts.
17. Raise and support vehicle.
18. Drain engine oil and remove primary oil filter.
19. Disconnect oil pressure sender hose from oil filter mounting adapter.
20. Disconnect exhaust pipe from manifold, then remove lower engine mount attaching nuts.
21. Remove transmission-to-engine attaching bolts, then lower vehicle.
22. Attach suitable lifting equipment to engine. Ensure bolt, nut and washer are installed as shown, Fig. 4.
23. Lift engine assembly from vehicle.
24. Reverse procedure to install.