Removal
REMOVAL1. Disconnect battery ground cable (14301).
2. Drain engine cooling system. Remove fan blade (8600) and fan clutch (8A616) as an assembly. Remove fan shroud (8146). Refer to Cooling System.
3. Remove air cleaner outlet tube (9B659).
4. Relieve fuel system pressure and disconnect fuel lines. Refer to Powertrain Management.
5. Remove windshield wiper governor (17C476).
6. Release drive belt tensioner (6B209) and remove accessory drive belt (8620).
7. Raise and support vehicle.
8. Disconnect fuel charging wiring (9D930) from crankshaft position sensor (CKP)(6C315) and A/C clutch (2884).
9. Remove oil bypass filter (6714).
10. Disconnect fuel charging wiring from oil pressure sensor (9278), oil filter adapter bracket and power steering pump (3A674) and move fuel charging wiring out of the way.
11. Disconnect EGR valve to exhaust manifold tube (9D477) from RH exhaust manifold (9430).
12. Disconnect EGR back pressure transducer hoses from EGR valve to exhaust manifold tube.
13. Disconnect fuel charging wiring from heated oxygen sensors (HO2S)(9F472).
14. Lower vehicle.
CAUTION: Do not pull on ignition wires as they may separate from the connectors in the ignition wire boots.
15. Disconnect all ignition wires from spark plugs (12405). Refer to Powertrain Management.
16. Disconnect ignition wire set and retainers from valve cover studs and generator bracket.
17. Disconnect all ignition wires from both ignition coils (12029). Refer to Powertrain Management.
18. Disconnect fuel charging wiring from both ignition coils and camshaft position sensor (CMP)(6B288).
19. Disconnect fuel charging wiring from generator (GEN)(10300).
20. Disconnect generator wiring harness from power distribution box at front fender apron (16054) and from generator.
21. Remove two bolts retaining generator mounting bracket (10153) to intake manifold (9424).
22. Remove two bolts retaining generator to cylinder block (6010) and remove generator.
23. Remove positive crankcase ventilation valve (PCV valve)(6A666) from valve cover (6582).
24. Disconnect vacuum hose from throttle body adapter vacuum port.
Accelerator Cable:
25. Disconnect fuel pressure regulator coolant hoses from heater water hoses (18472).
26. Remove heater water hoses.
27. Disconnect engine control sensor extension wire (12A522) from 42-pin connector and eight-pin transmission connector located at power brake booster (2005).
28. Remove fuel charging wiring retainers from valve cover stud bolts.
29. Remove fuel charging wiring and transmission wiring from bracket on rear of LH cylinder head (6049).
Accelerator Cable:
30. Disconnect accelerator cable (9A758) and speed control actuator cable (9A825) using a screwdriver or similar tool.
31. Remove two bolts retaining water hose connection (8592) to intake manifold. Position water hose connection and upper radiator hose (8260) out of way.
NOTE: The throttle body adapter, accelerator cable bracket (9723), EGR valve, idle air control valve and EGR valve to exhaust manifold tube can remain attached to the intake manifold. The fuel charging wiring, fuel injection supply manifold and fuel injector nozzle tip (9E527) can also remain attached to the intake manifold.
32. Remove nine bolts retaining intake manifold to the cylinder heads and remove intake manifold.
33. Remove intake manifold gaskets (9461).