Steps 1 - 40

Engine

Special Tools:

Special Tool(s)

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 right-hand 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 cable 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 valve electrical connector.





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 electrical connector.
2. Remove the bolts.
10. Disconnect the six spark plug wires from the spark plugs.





11. Remove the coil and ignition wires.
1. Disconnect the coil electrical connector.
2. Remove the bolts and the coil.
^ Disconnect the ground cable and the radio suppressor.





12. Disconnect the vacuum supply hoses from the upper intake manifold, the EGR valve vacuum hose and the fuel injector pressure sensor vacuum hose.





13. Disconnect the Electronic Vacuum Regulator (EVR) hoses and remove the vacuum hose harness.





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





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





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





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

Remove the upper intake manifold.
^ Discard the gaskets.





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





19. Disconnect the oil pressure switch electrical connector.





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





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





22. Detach the in-line electrical connectors.





23. Remove two nuts and the wiring harness.





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





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

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





Remove the lower intake manifold.
^ Discard the gaskets.





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





28. Disconnect the coolant distribution tube.





29. Remove the oil level indicator tube.





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





31. Remove the positive crankcase ventilation valve and hoses.
1. Remove the nut.
2. Remove the positive crankcase ventilation valve and hoses.





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





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





34. Remove the flywheel.
1. Remove the bolts.
2. Remove the backing plate.





35. Install the special tool.





36. Remove the crankshaft oil seal.





37. Remove the generator.
1. Remove the bracket bolt.
2. Remove the generator bolts and remove the generator.





38. Remove the bolts and the generator bracket.





39. Remove the oil filter.

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





Remove the left-hand exhaust manifold.
^ Discard the gasket.