Is there a write up on pulling a 4.0 engine for rebuild?

[abosely]

I looked and tried search function but couldn't find anything on this, probably using wrong search words. :-/
Is there a write up about pulling the 4.0 engine from a 4x4 2000? Need to pull the engine to take to shop for rebuild. Looking for info on the process.

Cheers, Allen

 

[Balloonist]

Since nobody else has answered, I'll throw in my two cents worth. I haven't done this, but I thought I might have to on my '02 4x4 AT (fortunately, now it looks like it's not going to be necessary). Here's what I came up with:

Remove battery. Remove driveshafts. Unplug oxygen sensors (x3). Remove Y pipe with cats, and next piece back with rest of cats (this won't come out until you drop the cross member). Disconnect shift linkage and electrical connections to trans and xfer. Remove cross member, with jack under trans. Remove starter. Remove torque converter nuts (4) thru starter hole. Remove trans/xfer assy, but leave on jack under truck - a couple of inches back is fine. (Much easier to remove bellhousing to engine bolts with cross member out!)

Remove intake air hose. Remove radiator and hoses, along with heater hoses and radiator fan. Disconnect engine wiring, mostly along left side. Disconnect vacuum lines from manifold, EGR, and heater valve - be careful as they crack easily. Remove brake booster vacuum line. Unbolt A/C compressor and lay aside - hopefully not necessary to evac A/C. Remove P/S pump and reservoir - may be able to lay aside without fully removing, but I suspect you'll have to disconnect the lines and get it all the way out.

Finally, unbolt motor mounts and lift engine out. Not sure of lift points - if probably use straps around some of the brackets in the front, and on a couple of bellhousing bolts in the back. Keep in mind that there's an oxygen sensor plug between the right side of the block and the firewall that needs to be pulled loose from the block.

I've probably missed a few steps, and there may be some interferences that will require you to remove other engine accessories it other things in the engine compartment. Proceed slowly, take lots of pictures, and label everything you take off (usually that's my downfall).

It may be possible to remove the engine without pulling the transmission first, but I don't think it's any extra work to pull the driveshafts and the wiring versus fighting to get to the bellhousing bolts out with the crossmember still in place. It'll also make the reinstall easier.

Hope that helps. It's a pretty basic overview.

 

[RobbieD]

^^^ Pretty good list. Only thing I don't see is fuel lines, and my suggestion is to label EVERYTHING, and also take good notes, for the reinstallation.

 

[Balloonist]

Good catch on the fuel lines! There's a quick disconnect on the driver's side for the line that goes up to the fuel lines, so it's fairly easy to get off with the little plastic tools that you can buy a parts store. Could also unscrew the flanges on the line from the fuel rails, if the quick disconnect won't pop loose, but that would end up leaving it in the way.

No matter how many labels you put on, and how many pictures you take, there'll be something that leaves you scratching your head. More is always better!