Motorhome Chassis

Special Tools:

Special Tools:

1. Disconnect the battery ground cable.
2. Drain the engine cooling system.
3. Recover the A/C system.
4. Remove the grille opening panel.





5. Remove the bolt.





6. Remove the transmission fluid level and engine oil level indicators.





7. Disconnect the air cleaner outlet tube from the air cleaner assembly.
8. Remove the engine cover.





9. Remove the air cleaner outlet tube.





10. Remove the accelerator cable snow shield.





11. Disconnect the throttle control cable, the speed control actuator cable and the throttle return spring.





12. Position the accelerator cable bracket aside.
^ Remove the bolts.
^ Position the bracket aside.





13. Disconnect the upper radiator hose.
^ Position the clamp.
^ Disconnect the upper radiator hose.





14. Disconnect the vacuum line.





15. Disconnect the vacuum lines.





16. Disconnect the fuel lines.





17. Disconnect the heated oxygen sensors.





18. Remove the nut and bolt.





19. Remove the transmission fill tube.





20. Disconnect the heater hoses.
^ Loosen the clamps.
^ Disconnect the heater hoses.





21. Disconnect the vacuum hoses.





22. Disconnect the oil fill hose.





23. Disconnect the generator wiring.





24. Remove the upper bolts.





25. Remove the bolt.
26. Raise the vehicle on the hoist.
27. Remove the engine cooling fan and position the fan in the fan shroud.





28. Remove the bolt.





29. Disconnect the connectors.





30. Disconnect the lower radiator hose.
^ Position the clamp.
^ Disconnect the hose.





31. Disconnect the vacuum lines.
32. Remove the drive belt.





33. Position the power steering pump aside.
^ Remove the three bolts.
^ Position the power steering pump aside.

34. Remove the A/C compressor.





35. Disconnect the crankshaft position sensor.
36. Remove the starter motor.





37. Disconnect the ground strap.





38. Position the cables forward.
^ Remove the nut.
^ Position the cables forward.

39. Cut the transmission cooler tubes and remove the rear portion of the transmission cooler tubes.
40. Raise and support the vehicle.
41. Remove the front axle.
42. Remove the oil filter.
43. Remove the transmission.





44. Disconnect the right front brake line.
45. Using a powertrain lift, support the engine.





46. Remove twelve bolts.
47. Lower the engine until the frame extensions are free of the crossmember.





48. Remove the frame extensions.
1. Remove the eight bolts.
2. Remove the frame extensions.
49. Lower the engine.





50. Remove the bolt (RH) and position the capacitor aside.





51. Disconnect the five RH fuel injector electrical connectors and five ignition coil electrical connectors.





52. Disconnect the idle air control motor electrical connector and the bypass hose.





53. Disconnect the EGR transducer and the throttle position sensor connectors.





54. Disconnect the EGR transducer vacuum lines.





55. Remove the EGR transducer
bracket.





56. Remove the EGR valve-to-exhaust manifold tube.
^ Disconnect the upper fitting.
^ Loosen the lower fitting.
^ Remove the tube.





57. Disconnect the EGR valve vacuum line.





58. NOTE: The EGR valve is shown removed for clarity.

Disconnect the EVR solenoid electrical and vacuum harness.





59. Remove the EVR bracket.
^ Remove the bolts.
^ Remove the bracket.





60. Disconnect the five LH fuel injector electrical connectors.





61. Disconnect the water temperature indicator sender unit electrical connectors.





62. Remove the ignition coils.
^ Remove the bolts.
^ Remove the ignition coils.





63. Position the radiator interference capacitor (LH) aside.
^ Remove the bolt.
^ Position the capacitor aside.





64. Disconnect the cylinder head temperature sensor.
65. Remove the water thermostat and housing.





66. Remove the bolts, the upper intake manifold and the intake manifold gaskets. Discard the intake manifold gaskets.
67. Clean all the mating surfaces.





68. Install the Modular Lifting Bar and lifting equipment.





69. Remove the four nuts.
70. Remove the engine from the second crossmember and engine mount assembly.





71. Remove the flywheel.





72. Use the Rear Crankshaft Slinger Remover and the Impact Slide Hammer to remove the crankshaft oil slinger.
73. Use the Rear Crankshaft Seal Remover and the Impact Slide Hammer to remove the crankshaft rear oil seal.





74. Remove bolts and the rear crankshaft seal retainer plate.
75. Place the engine on a suitable engine stand.
76. Remove the Modular Lifting Bar.