B
116
Repair and Service Manual
ENGINE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
668061
Tool List Qty.
Hoist ............................................................................1
Ratchet ........................................................................ 1
Socket, 10mm.............................................................. 1
Socket,19mm............................................................... 1
Wrench, 19mm ............................................................ 1
NOTICE: Hardware that is removed must always be
installed in its original position unless otherwise
specified. If torque values are not specified, refer to
the Torque Specifications Table. See TORQUE
SPECIFICATIONS on page ix.
Note the location of wires, wire ties and clamps
before removal. Always install them in their original
location. Use of masking tape to label wires is rec-
ommended.
To prevent the possibility of per-
sonal injury, disconnect the nega-
tive (-) battery cable before
beginning engine removal procedure.
See the appropriate sections of this manual to remove or
disconnect the following components:
• Truck Bed - See TRUCK BED REMOVAL on
page 46.
• Rear Wheels - See Wheel Removal on page 54.
• Body Panels - See BODY on page 15.
• Cargo Floor Panel - See Cargo Tray Removal on
page 27.
• Skid Plate - See Skid Plate Removal on page 28.
• Prop Shaft - See Prop-shaft Removal on page 106.
• Muffler and Exhaust - See EXHAUST SYSTEM
REMOVAL on page 117.
• Rear Frame Crossmember - See Rear Shock Tower
Brace Removal on page 33.
• CV Shafts - See CV Shaft Replacement on page 88.
• Oil Tank - See ENGINE on page 109.
• Clutch - See CONTINUOUSLY VARIABLE TRANS-
MISSION (CVT) on page 99.
• Transmission/rear Differential - See Rear Differential
Replacement on page 93.
Disconnect:
• Battery Cables - See Battery Removal on page 137.
• Fuel Line - See FUEL SYSTEM on page 131.
• Main Wire Harness - See ELECTRICAL SYSTEM on
page 135.
• Engine Ground Wire - See ELECTRICAL SYSTEM
on page 135.
• Starter Wire - See ELECTRICAL SYSTEM on
page 135.
• Air Intake Hose - See AIR INTAKE on page 121.
• Coolant Hoses - See COOLING SYSTEM on
page 125.
• Oxygen Sensor - See EXHAUST SYSTEM
REMOVAL on page 117.
• Shifter Cable - See Adjusting the Shift Lever Cable
on page 96.
Remove the lock nut (27), washer (25) and bolt (26) that
secure the engine to each side of the frame (Ref. Fig. 14).
The following step involves lifting
substantial weight, and requires the
use of a hoist.
Use a hoist to remove the engine. With a person on each
side of vehicle, rotate and lean engine back, and carefully
maneuver engine out of vehicle.
Engine installation is the reverse order of removal.
Replace all lock nuts with new lock nuts.
Tighten the engine to the sub frame mounting hardware
to the torque specified below.
Item Torque Specification
26, 27 68 - 72 ft. lbs. (92 - 98 Nm)