Engine: Service and Repair

1. Mark locations of hood hinges, then remove hood.
2. Disconnect battery ground cables from both battery assemblies.
3. Disconnect battery ground cables from engine.
4. Drain coolant system.
5. Disconnect crankcase breather hose from rocker cover.
6. Disconnect intake hose between air cleaner and turbocharger assembly. Cap turbocharger inlet using cap set T85T-9395-A or equivalent.
7. Remove A/C compressor and position aside. Do not disconnect refrigerant lines from compressor.
8. Disconnect heater hoses from inlet and outlet fittings on heater core.
9. Remove cooling fan assembly.
10. Disconnect radiator hoses, then remove radiator assembly.
11. Disconnect electrical connector from fuel conditioner.
12. Disconnect fuel supply line from fuel conditioner and fuel return line from injection pump.
13. Mark, then disconnect all necessary vacuum lines and electrical connectors from engine assembly.
14. Disconnect coolant overflow hose from filler neck.
15. Disconnect throttle cable and speed control cable, if equipped, from injection pump.
16. Disconnect starter motor cables, then remove starter motor assembly.
17. Using a suitable jack, raise vehicle slightly and remove righthand wheel, tire and inner fender.
18. Disconnect oil pressure switch electrical connector.
19. Disconnect cooler lines from oil filter adapter.
20. Raise and support vehicle.
21. Remove nut attaching engine insulators to engine support brackets.
22. Disconnect muffler inlet pipe from turbocharger exhaust outlet pipe.
23. Disconnect and cap power steering pump lines from pump assembly.
24. Disconnect clutch servo hydraulic line (red line) from clutch housing and position aside.
25. Remove transmission attaching bolts except the top two bolts.
26. Lower vehicle.
27. Attach suitable engine lifting equipment onto engine lifting eyes.
28. Remove top two transmission attaching bolts.
29. Carefully lift engine from vehicle.
30. Reverse procedure to install.