Before You Begin: 4 Things To Do
Take A Picture, It Lasts...
Take A Picture, It Lasts Longer
The first step in any engine swap should be to take a few digital photos of the engine compartment. This will give you something to refer to in the event you forget how things go together. You'll also want to take some as you progress.
Consult The Manual
Acquire...
Consult The Manual
Acquire a repair manual for your specific truck because these are chock full of information like torque specs and can be a real lifesaver in a pinch.
Tag And Bag
Invest in a...
Tag And Bag
Invest in a roll of masking tape and a permanent marker. You will want to tag things with the masking tape to keep track of where they go. Seal up some parts in zipper seal bags. Have a pad of paper ready to write down notes or make a list of parts you need.
Drain Your Fluids
Drain...
Drain Your Fluids
Drain the fluids into separate containers for recycling. Empty the block and radiator of all the coolant, drain the oil from the pan, and also have your air conditioner system bled out.
The Dirty Work
The best advice I can pass on is to work your way from the front to the back; starting with the radiator, pulley system, and so on. To give me the most room possible, I removed the hood and set it safely out of the way. The radiator has delicate fins that can be damaged easily so I wanted it stashed in a safe spot as well. To prevent rounding off the tranny line fittings, I purchased a set of line wrenches. You can use a regular end wrench, but if it slips you'll have to turn to the vise grips and that can really mess up the fitting.
1. Even though special tools...
1. Even though special tools are made to unload the belt tensioner I found a large pry bar works just as well and I can still use it as a pry bar. I slipped the screwdriver between the tensioner body and the pulley to remove the belt.
2. Refrigerant is bad for...
2. Refrigerant is bad for the atmosphere of the Earth so If your A/C system is charged and in working condition, you might want to have it drained at a professional shop. My system was empty and not working so I felt fine cracking the lines.
3. The A/C compressor has...
3. The A/C compressor has special hardware that has a flat spot on one side so they will pass by the pulley. These are usually covered in gunk and might be hard to see. Just make sure to keep them with the compressor so you don't lose track of them.
4. It's a good idea to reinstall...
4. It's a good idea to reinstall any small clips or fasteners where they belong, like the clip for the throttle cable shown here. When its time hook it back up, the clip will be right there where it should be.
5. When you are working on...
5. When you are working on older vehicles, be very gentle with any plastic clips or tabs. As these parts age they get brittle. Remember, taking your time and being careful is free and new cables can be expensive.
6. When you get to the exhaust...
6. When you get to the exhaust system, it is a must to coat all the hardware with penetrating fluid. Let it soak for a while before trying to loosen the hardware. As rusty as my stuff was, everything came out without snapping thanks to this simple procedure.
7. Some things have to come...
7. Some things have to come off in a certain order like this bracket here. It looks like it should come right off, but come to find out the power steering pump needs to be removed first.