Engine: Service and Repair

EXC. VAN
1. Disconnect batteries and raise vehicle.
2. Remove transmission dust cover and disconnect torque converter and exhaust.
3. Disconnect wires from starter and remove starter.
4. Remove transmission bellhousing bolts and motor mount bolts.
5. Disconnect block heaters, then remove wiring harness, transmission cooler lines and front battery cable clamp at oil pan.
6. Disconnect fuel return lines and oil cooler lines from engine, remove lower fan shroud bolts and lower vehicle.
7. Scribe hood hinge locations and remove hood.
8. Drain cooling system, remove air cleaner with resonator attached and primary filter from cowl, if equipped.
9. Disconnect ground cable at alternator bracket and remove alternator wires and clips.
10. Disconnect TPS, EGR-EPR and fuel cut-off electrical connectors at injection pump.
11. Remove harness from clips at rocker covers and disconnect glow plugs.
12. Disconnect EGR-EPR solenoids, glow plugs, controller and temperature sender. Move harness aside.
13. Disconnect ground strap from left side.
14. Remove fan, upper radiator hoses from engine, fan shroud, power steering pump and belt, and power steering reservoir, and secure pump assembly aside.
15. Disconnect vacuum at cruise servo and accelerator cable at injection pump.
16. Disconnect heater hose and lower radiator hose from engine and oil cooler lines from radiator.
17. Disconnect heater hose and overflow at radiator, automatic transmission cooler lines, upper radiator cover and radiator.
18. Remove detent cable.
19. Support transmission and remove engine.
20. Reverse procedure to install. If fuel filters were removed, they must be filled with clean diesel fuel.