both batteries. Cover and isolate ends of cables.
(2) Thoroughly clean fuel lines at cylinder head
and injection pump ends.
(3) Remove cable cover (Fig. 39). Cable cover is
attached with 2 Phillips screws, 2 plastic retention
clips and 2 push tabs (Fig. 39). Remove 2 Phillips
screws and carefully pry out 2 retention clips. After
clip removal, push rearward on front tab, and
upward on lower tab for cover removal.
Do not
remove any cables at lever.
(
(4) Disconnect wiring harness (clip) at bottom of
Accelerator Pedal Position Sensor (APPS) mounting
bracket (Fig. 40).
(5) Using 2 small screwdrivers, pry front wiring
clip (Fig. 41) from cable bracket housing. Position
wiring harness towards front of engine.
(6) Remove electrical connector from APPS by
pushing connector tab rearward while pulling down
on connector (Fig. 42
(7) Disconnect 2 electrical cables from cable
mounting studs (Fig. 43) at intake air heater on top
of intake manifold.
(8) Remove engine oil dipstick from engine.
(9) Remove engine oil dipstick tube support
mounting bolt (Fig. 43) and position tube to side.
(10) Disconnect clamps and remove air tube
(intake manifold-to-intercooler) (Fig. 41).
(11) Remove 4 air intake housing mounting bolts
and remove housing (Fig. 44) and (Fig. 43). Position
ground cable at top of air intake housing to front of
engine.
(
(12) Remove intake manifold air heater element
block from engine (Fig. 45). Discard old upper and
lower gaskets
(13) Remove 3 cable bracket housing mounting
bolts (Fig. 44). Carefully position cable bracket and
cable assembly to side of engine.
Leave cables connected
to lever.
(14) Remove engine lifting bracket at rear of
intake manifold (2 bolts) (Fig. 46).
(15) Remove bolts from all fuel injection line support
brackets at intake manifold.
(16) Place shop towels around fuel lines at fuel
injectors. Do not allow fuel to drip down side of
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Lower rear of driver side. It has two wires and points down and out at a 45 deg angle.