Part 1 of 2

Special Tools:

General Equipment:

Materials:

Disassembly

1. Disconnect the Exhaust Gas Recirculation (EGR) tube from the EGR valve.
1 Disconnect the hoses from the EGR tube to the differential pressure feedback EGR.
2 Unscrew the tube fitting.

2. NOTE: Remove the nuts in the indicated sequence.

Remove the RH exhaust manifold.
^ Discard the gasket.

3. Remove the bolts and the connecting shaft bracket from the cylinder block.

4. Disconnect the generator electrical connections.
1 Remove the battery positive voltage retaining nut.
2 Disconnect the voltage regulator electrical connector.
3 Disconnect the stator circuit electrical connector.

5. Disconnect the differential pressure feedback EGR electrical connector.

6. Disconnect the electronic vacuum regulator solenoid.

7. Disconnect the Engine Coolant Temperature (ECT) sensor and remove the wiring harness.

8. Disconnect the Intake Manifold Runner Control (IMRC) cable.
1 Disconnect the IMRC cable from the retainer.
2 Disconnect the IMRC cable end.

9. Remove the IMRC.
1 Disconnect the IMRC electrical connector.
2 Remove the IMRC bolts and the IMRC.

10. Disconnect the six spark plug wires.

11. Remove the coil and ignition wires.
1 Disconnect the coil electrical connector.
2 Remove the bolts and the coil.

12. Remove the vacuum harness.
1 Disconnect the vacuum supply hoses from the upper intake manifold.
2 Disconnect the EGR vacuum regulator solenoid vacuum hoses.
3 Disconnect the fuel pressure regulator vacuum hoses.
4 Disconnect the differential pressure feedback EGR vacuum hose.
5 Disconnect the EGR valve vacuum hose and remove the vacuum harness.

13. Disconnect the Positive Crankcase Ventilation (PCV) hose from the throttle body.

14. Disconnect the Throttle Position (TP) sensor electrical connector.

15. Disconnect the Idle Air Control (IAC) valve electrical connector.

16. NOTE: Remove the bolts in the indicated sequence.

Remove the upper intake manifold.
^ Discard the gaskets.

17. Disconnect the Heated Oxygen Sensor (H02S) electrical connector.

18. Disconnect the oil pressure switch electrical connector.

19. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
1 Unclip the harness from the stud.
2 Disconnect the electrical connector.

20. Disconnect the Camshaft Position (CMP) sensor electrical connector.
1 Unclip the harness from the stud.
2 Disconnect the electrical connector.

21. Disconnect the engine coolant temperature warning light electrical connector.

22. Disconnect the fuel injector electrical connectors and remove the wiring harness.

23. NOTE: Remove the bolts in the indicated sequence.

Remove the lower intake manifold.
^ Discard the gaskets.

24. Disconnect the coolant hoses and remove the thermostat housing.

25. Disconnect the coolant distribution tube.
^ Remove the nuts.

26. Remove the LH engine lifting eye.
1 Remove the nut.
2 Remove the engine lifting eye.

27. Remove the oil level indicator tube.
^ Remove the nut.

28. Remove the water pump drive belt.
^ Rotate the belt tensioner clockwise to relieve tension on the drive belt.

29. Remove the PCV valve and hoses.
1 Remove the nut.
2 Remove the PCV valve and hoses.

30. Remove the water bypass.
1 Remove the bolts.
2 Remove the water bypass.

31. Remove the water pump.
1 Disconnect the coolant hose.
2 Disconnect the oil cooler hose.
3 Remove the bolts.
4 Remove the pump.