Note. Reliable lifting equipment with approved rigging will be required to perform engine removal and installation procedures.
Removing
The general view of the engine and the arrangement of auxiliary equipment and units on it are shown in the accompanying illustrations.
1. Raise the hood and take care of the reliable protection of the front body panels of the car.
2. Circle the hood hinges with a marker to facilitate subsequent installation. Disconnect the windshield washer fluid supply hose from the hood.
3. Give fixing bolts and by means of the assistant remove a cowl from the car.
4. Disconnect the negative cable from the battery.
5. Empty the cooling system and remove the radiator and fan assembly from the vehicle (see chapter Refrigeration, heating and air conditioning systems).
6. Remove the air cleaner and air intake sleeve (see chapter Power supply and exhaust systems).
7. Loosen the clamps securing the fuel supply and return hoses to the fuel pump. Disconnect the hoses. Seal the open ends of the hoses to prevent dirt from entering the power system.
8. Disconnect the heating hoses from the nozzles on the bulkhead of the engine compartment - try not to accidentally damage the latter. If necessary, cut the hoses to facilitate their removal.
9. Loosen the throttle cable mounting nuts on your bracket, rotate the lever to move the throttle to the fully open position and remove the end of the cable from the holder. Move the cable to the side, laying it in such a way that it does not interfere with further work.
10. Disconnect the vacuum hoses of the brake booster and clutch servo from the intake manifold.
11. Disconnect the main power wire of the starter and disconnect the electrical connector of the traction relay.
12. Disconnect the generator main wire terminal, disconnect the generator electrical connector. Give a nut of fastening on the generator of a ground wire.
13. Disunite the electric socket of a control lamp of pressure of oil and the measuring gauge sensor located under the inlet pipeline.
14. Disconnect the electrical connector on the carburetor and disconnect the temperature sensor wiring. Remove the wiring harness from under the intake manifold and lay it away from the work area.
15. Give a bolt and disconnect a ground wire from an arm of a directing tube of the dipstick of measurement of level of impellent oil.
Note. If the transmission harness is routed between the dipstick and cylinder block, it will need to be moved to the opposite side of the dipstick to avoid snagging when the engine is removed.
16. On models equipped with air conditioning, disconnect the idle speed stabilizer vacuum hoses from the throttle damper and intake manifold.
17. In the left side of the engine compartment, disconnect the ground wires from the lifting eye of the power unit and the ignition coil bracket.
18. Disconnect the electrical connector of the distributor and the connector of the electrical wiring of the clutch of the air conditioner compressor (if one is included).
19. Disconnect the carbon canister hoses from the steel tubes on the engine.
20. Place a drain pan under the steering pump, loosen the return hose clamp, disconnect the hose and drain the power steering hydraulic fluid. Give the hollow bolt on the pump - try not to lose the copper sealing washers.
21. Tie up the power steering hoses away from the work area, wrapping them in a clean, lint-free rag to prevent dirt from entering the system.
22. Jack up the front of the car and place it on jack stands.
23. Give bolts and release plastic screw clips of fastening of protection of a case. Remove protection.
24. On models equipped with air conditioning:
- Loosen the tension roller locknut and, turning the adjusting bolt with a screwdriver, remove the drive belt from the compressor pulley.
- Give the bottom bolts and nuts of fastening of the compressor.
- Turn out the top fixing bolts, lift the compressor and fix it on the mudguard of the left wing.
Note. Do not loosen the high pressure lines of the compressor to avoid injury and frostbite damage from direct contact with the refrigerant. In addition, the loss of refrigerant will result in the need to recharge the system.
25. Give nuts of fastening of a flange of a reception pipe of system of release of the fulfilled gases to a final collector, undock a reception pipe, without changing its position on the car.
26. Give fixture of a dome of coupling to an engine plate. Turn out bolts of fastening of intensifying brackets, remove brackets from the engine.
27. Give the mounting bolts and remove the starter from the engine - you may have to overcome some resistance associated with the need to destroy the sealant layer.
28. On models with АТ give fixing bolts and remove a plate of a cover of the converter of rotation. Using a suitable lever, turn the motor by the drive plate so that one of the converter mounting bolts is accessible. After removing the bolt, repeat the procedure for the remaining fasteners. Press the rotation converter towards the transmission.
29. Hang the engine with suitable lifting equipment, taking the weight of the power package off its supports.
30. Give nuts of fastening of support of the engine to the block of cylinders and bolts of fastening of support to the chassis.
31. Slightly raise the engine and remove the supports. Lower the engine onto the chassis for easy access to the upper clutch dome mounting bolts.
32. Give the top bolts of fastening of a dome of coupling to the engine.
33. Using a thin knife or other suitable tool, cut the sealant layer around the perimeter of the clutch dome - try not to damage the mating surfaces.
34. Carefully lift the engine assembly and slide it forward on the vehicle. On models with a manual transmission, make sure that the input shaft of the gearbox comes out freely from the clutch assembly. On models with AT, take care that the rotation converter does not fall out of its crankcase.
35. With extreme care, being careful not to damage fragile components, remove the engine assembly from the vehicle. In the event of the slightest uncertainty, it makes sense to spend time on the preliminary removal of interfering nodes.
Installation
Installation is basically done in reverse order.
1. Take care of a thorough cleaning of the mating surfaces of the clutch dome and the engine. Apply a pad of sealant to the dome flange.
Note. The tight fit of the rear plate to the engine is also extremely important, as it prevents water from leaking into the clutch dome.
2. On models with a manual transmission, do not forget to center the clutch disc on the flywheel using a special tool, only then tighten the basket fasteners (see chapter Clutch).
3. Before installing the front power unit mounts, install the upper bolts securing the clutch dome to the motor.
4. With the weight of the engine on the supports, tighten the bolts and nuts securing them to the chassis and engine.
5. Fill the engine with the required amount of oil of the required grade. Recharge the cooling system (see chapter Refrigeration, heating and air conditioning systems).
6. Connect a reception pipe of system of release of the fulfilled gases to a final collector, having established a new lining.
7. Lubricate the starter mounting flange with sealant and install the starter in its place.
8. Adjust throttle cable (see chapter Power supply and exhaust systems).
9. Before starting the engine for the first time, check the correctness of all settings and adjust the tension of the drive belts.
10. After starting, monitor engine temperature and oil pressure. Check the engine for leaks, if any, eliminate their causes.
Late Years 4.2L Models Equipped with Fuel Injection (EFI)
The removal and installation procedures for 4.2L engines equipped with the EFI system are basically identical to those for carbureted engines, except for the points listed below.
1. Before disconnecting the battery, it is necessary to relieve the pressure in the power system, for which:
- Give screws and lift the relay panel located in an impellent compartment located in the neighborhood to the battery. Remove the cover and remove the 15A fuel pump fuse;
- Start the engine and let it idle until it stops spontaneously. To ensure complete pressure relief, turn on the starter for 10 seconds;
- Switch off the ignition.
2. Remove the air duct and muffler installed between the throttle body and the air flow meter.
3. Instead of disconnecting the fuel hoses from the fuel pump, loosen the clamps and disconnect the fuel return line from the fuel pressure regulator and the fuel supply hose from the fuel line.
4. Except the generator disconnect electroconducting also from the air regulator located under the right forward corner of the inlet pipeline. Disconnect the main ground bar from the bracket at the front of the intake piping, and disconnect the ground wires from the piping wall.
5. Instead of disconnecting the electrical wiring from the carburetor and temperature sensor, disconnect the three electrical connectors located on the bracket at the front of the intake manifold.
6. Skip the procedure for disconnecting the idle speed stabilizer vacuum hoses on models equipped with air conditioning.
Note. Remember that before disconnecting all wires and hoses, they must be marked.
7. Install in the reverse order, taking into account the following points:
- Make sure that no wires, cables and hoses are pinched during installation of the unit.
- When refueling the cooling system, pay attention to the presence of an air bleed plug located in the front of the air path pressure chamber, as on models with a 3.0 l engine (see accompanying illustration).
- Installing a radiator on 4.2 l EFI engines is carried out in the same way as on 3.0 l engines.