Steps 1 - 45

Engine








Special Tool(s)

Disassembly

All engines
1. Remove the accessory drive belt.
2. Remove the bolt and the battery ground cable from the engine.





3. Disconnect the fuel charging wiring electrical connector from the crankshaft position (CKP) sensor.





4. Disconnect the fuel charging wiring electrical connector from the A/C compressor.





5. Remove the oil bypass filter.





6. Disconnect the electrical connection from the engine oil pressure (EOP) sensor, the power steering pressure (PSP) switch and the harness position retainer.





7. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold connector.





8. Disconnect the differential pressure feedback EGR system connector.





9. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils.





10. Disconnect the fuel charging wiring electrical connectors from the eight fuel injectors.





Gasoline engines
11. Remove the bolts and the EGR tube heat shield.





12. Disconnect the vacuum hoses for the evaporative emission (EVAP) canister purge valve, the main chassis hose and the EGR valve.





13. Disconnect and remove the crankcase ventilation tube.





14. Disconnect the fuel charging wiring electrical connector from the EGR vacuum regulator solenoid.





15. Disconnect the electrical connector from the generator, generator cable and pin-type harness retainer.





16. Disconnect the electrical connector from the idle air control (IAC) and the throttle position (TP) sensor.





17. Remove the generator mounting bracket.
- Remove the bolts.
- Remove the bracket.





18. Disconnect the fuel charging wiring from the crash bracket and the wiring support bracket and remove the harness from the engine assembly.





19. Remove the generator.
1 Remove the bolts.
2 Remove the generator.





20. Disconnect the EGR tube from the EGR valve.





21. Remove the bolt and nut, and remove the transmission wiring support-bracket.





22. Remove the four bolts and the throttle body.





23. Remove the bolt and the stud. Remove the crash bracket.





24. Remove the studs and the fuel injection supply manifold and fuel injectors as an assembly.





25. Remove the eight bolts and the eight ignition coils.





26. Remove the bolts and the water outlet adapter.





27. Remove the water thermostat.





28. Remove the bolts and the intake manifold.





Natural gas engines
29. Disconnect the fuel charging wiring electrical connector to the fuel pressure sensor.





30. Disconnect the fuel charging wiring electrical connector from the fuel temperature sensor.





31. Disconnect the fuel charging wiring electrical connector from the engine coolant temperature sensor.





32. Separate the isolation valve wiring lead from the generator support bracket and disconnect.





33. Disconnect the fuel charging wiring electrical connector from the camshaft position sensor.





34. Disconnect the fuel charging wiring electrical connector from the generator.





35. Disconnect the fuel charging wiring electrical connector from the throttle position sensor.





36. Disconnect the fuel charging wiring from the radio ignition interference capacitor.





37. Disconnect the feel charging wiring from the EGR vacuum regulator solenoid.





38. Disconnect the fuel charging wiring from the differential pressure feedback EGR.





39. Disconnect the fuel charging wiring from the idle air control valve.





40. Remove the bolts and position the fuel charging wiring out of the way.





41. Disconnect the hoses from the differential pressure feedback EGR.





42. Disconnect the vacuum hose from the exhaust gas recirculation (EGR) valve.





43. Disconnect the main chassis vacuum supply hose from the throttle body adapter.





44. Disconnect the crankcase ventilation tube at two locations and remove.





45. Disconnect the vacuum hose from the throttle body adapter.