Diesel Data: Automotive Repair

Engine: Service and Repair

1. Disconnect battery cables and remove battery from vehicle.
2. Drain engine coolant.
3. Remove hood and windshield washer container.
4. Disconnect accelerator, cruise control and throttle cables.
5. Disconnect air cleaner hoses and intake air connector pipe, then remove air cleaner assembly and air flow meter from engine.
6. Disconnect high tension wire from ignition coil, igniter connector, A/C and alternator connectors and cruise control vacuum hose.
7. Disconnect brake booster and charcoal canister vacuum hoses.
8. Disconnect radiator hoses and transmission oil cooler lines, then remove radiator.
9. Remove A/C compressor from mounting bracket and suspend compressor assembly from radiator core support. Do not disconnect refrigerant lines from compressor.
10. Remove power steering pump and position aside. Do not disconnect hydraulic lines from pump.
11. Remove glove compartment, then disconnect engine wiring harness connectors from engine/transmission control processor (ECU).
12. Pull out the wiring harness from the cowl panel and disconnect harness clamps and ground strap.
13. Disconnect heater hoses, then raise and support vehicle and remove engine undercover and drain engine oil.
14. Remove exhaust pipe and driveshaft, then disconnect speedometer cable and shift linkage.
15. Disconnect starter cable and ground straps at stiffener plate and LH engine mount.
16. Disconnect fuel lines, then remove front wheels.
17. Disconnect ground strap, then remove eight bolts and engine rear support member.
18. Lower vehicle and remove four bolts securing engine mounting to suspension member, then remove engine with transmission.
19. Remove stiffener plates, exhaust pipe stay, engine rear end plates and transmission oil cooler lines.
20. Remove starter and six torque converter to flywheel bolts, then separate engine and transmission.
21. Reverse procedure to install. Ensure 1.039 inches is between installed surface of converter and front surface of transmission housing.