Removal & Installation (Astro & Safari)
- Release fuel system pressure. See FUEL PRESSURE RELEASE under REMOVAL & INSTALLATION. Disconnect battery. Drain cooling system. Raise and support vehicle.
- Disconnect exhaust pipes from manifolds. Remove flywheel cover, torque converter bolts (A/T), starter and oil filter. Disconnect engine wiring harness from transmission and frame.
- Disconnect fuel lines from frame. Disconnect transmission fluid lines and engine oil cooler lines from radiator. Remove lower fan shroud bolts. Remove motor mount through-bolts. Lower vehicle.
- Remove headlight bezels and grille. Remove lower radiator close-out panel, radiator support braces and radiator cross brace. Remove hood latch mechanism. Discharge A/C system (if equipped) using approved refrigerant recovery/recycling equipment. Remove master cylinder, upper fan shroud, upper radiator core support and radiator.
- Remove radiator filler panels. Remove engine cover. Disconnect A/C hose from accumulator. Remove A/C compressor and bracket. Remove power steering pump.
- Disconnect vacuum hoses as necessary. Disconnect engine wiring harness clips from firewall. Remove right kick panel. Disconnect engine wiring harness connector from ESC module. Push connector and harness through firewall. Remove distributor cap and A/C accumulator. Disconnect fuel line from injection unit.
- Remove transmission dipstick tube. Disconnect heater hose from heater core. Remove horn. Support transmission. Support engine with adjustable jack. Remove bellhousing bolts. Lower engine from vehicle.
- To install, reverse removal procedure. Fill crankcase and cooling system. Evacuate and charge A/C system.