Steps 1 - 42

Special Tools:

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

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





Remove the right-hand exhaust manifold.
- Remove and discard the gasket.





3. Remove the bolts and the connecting shaft bracket.





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





5. Disconnect the EGR back pressure transducer electrical connector.





6. Disconnect the Electronic Vacuum Regulator (EVR) 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 unit control.
1 Disconnect the IMRC electrical connector.
2 Remove the IMRC retaining bolts.





10. Disconnect the six spark plug wires.





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





12. Remove the vacuum harness.
1 Disconnect the vacuum supply hoses from the upper intake manifold.
2 Disconnect the Electronic Vacuum Regulator (EVR) vacuum hoses.
3 Disconnect the fuel pressure regulator vacuum hoses.
4 Disconnect the EGR back pressure transducer vacuum hose.
5 Disconnect the EGR valve vacuum hose and remove the vacuum harness.





13. Disconnect the 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.
- Remove and 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 Detach the harness from the stud.
2 Disconnect the electrical connector.





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





21. Disconnect the engine coolant temperature warning light electrical connectors





22. Disconnect the fuel charging wiring harness electrical connectors.





23. Remove the bolts in the indicated sequence and remove the lower intake manifold.
- Remove and 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 left-hand 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 hose.
1 Remove the bracket nut.
2 Remove the hose.





30. Remove the coolant crossover tube.
1 Remove the bolt and the nut.
2 Remove the crossover tube.
- Remove and discard the O-ring seals.





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





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





33. Install the special tool.





34. Using the special tool, remove the crankshaft oil seal.
1 Install the special tool.
2 Remove the seal.





35. Remove the generator.
1 Remove the bracket bolt.
2 Remove the generator bolts.





36. Remove generator bracket.





37. Remove the oil filter.





38. Remove the bolts and the left-hand exhaust manifold.
- Remove and discard the gasket.





39. Remove the oil cooler.
1 Remove the oil cooler bolt and the oil cooler.
2 Remove the oil pressure switch.





40. Remove the studs and the oil pan heat shields.

41. NOTE: Remove the bolts and studs in the indicated sequence.





Remove the oil pan.
- Remove and discard the gasket.
- Clean and inspect oil pan and cylinder block using Metal surface cleaner.





42. Remove the inline connector bracket.
1 Remove the nuts.
2 Remove the bracket.