Part 1

DISASSEMBLY AND ASSEMBLY
Disassembly Note





1. Disconnect the engine control sensor wiring from the:
- Idle air control valve.
- DPFE sensor.
- EGR solenoid.





2. Disconnect the vacuum line from the:
- EGR solenoid.
- Upper intake manifold.
- EGR valve





3. Disconnect the crankcase ventilation tube.





4. Disconnect the vacuum lines.





5. Disconnect the throttle position sensor.





6. Disconnect the (6) spark plug wires.





7. Disconnect the engine control sensor wiring from the:
- Radio ignition interference capacitor.
- Ignition coil.





8. Disconnect the plug wires.





9. Remove the nuts.





10. Remove the upper intake manifold.





11. Inspect the intake manifold upper gasket and replace as necessary.





12. Disconnect the crankshaft position sensor.





13. Disconnect the engine control sensor wiring from the:
- Engine coolant temperature sensor.
- Water temperature indicator sender unit.





14. Disconnect the fuel injectors.





15. Disconnect the camshaft synchronizer.





16. Disconnect the oil pressure sensor





17. Remove the engine control sensor wiring.





18. Disconnect the vacuum line and remove the vacuum line harness.





19. Remove the bolt.





20. Remove the stud bolts.





21. Remove the fuel injection supply manifold and the (6) fuel injectors. Remove and discard the gasket.





22. Remove the bolts, the water hose connection and the Water thermostat.





23. Remove the bolts.





24. Disconnect the EGR valve tube to manifold connector.





25. Remove the nut and remove the oil level indicator tube.





26. Remove the stud.
1) Remove the EGR tube seal assembly.





27. Remove the (12) nuts.





28. Remove the exhaust manifolds.





29. Remove the exhaust manifold gaskets.





30. Remove the oil pressure switch adapter.





31. Remove the nuts and the bracket.





32. Remove the bolt.





33. Use crankshaft damper remover SST 49 UN01 001 and remove the crankshaft vibrating damper.





34. Remove the crankshaft position sensor.
1) Remove the bolts.
2) Remove the crankshaft position sensor.





35. Remove the oil filter.





36. Remove the halts





37. Remove the bolts and the nuts.





38. Remove the oil pan.





39. Remove the oil pan gasket and discard.





40. Remove the bolts and the studs.





41. Remove the engine front cover.





42. Remove the engine front cover gasket and discard.





43. Remove the bolts (14) and the studs (2).





44. Remove the valve covers.





45. Remove the valve cover gaskets and discard.





46. Remove the bolts.





47. Remove the intake manifold.





48. Remove the intake manifold gasket and discard.





49. Remove the bolt and the holddown.





50. Remove the synchronizer.





51. Remove the bolts and the rocker shaft assemblies.





52. Remove the push rods.

NOTE: Mark the push rods to ensure correct location on installation.





53. Remove the bolts.