Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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1. Remove the auxiliary battery. For additional information, refer to Section 414-01. 2. Remove the air cleaner assembly. For additional information, refer to Section 303-12. 3. Remove the cooling fan-blade, clutch and shroud, 6.0L diesel engine. For additional information, refer to Section 303-03. 4. Remove the coolant reservoir. For additional information, refer to Section 303-03. 5. Remove the upper radiator hose. 6. NOTE: Engine side shown, charge air cooler (CAC) side similar. Remove the turbocharger-to-charge air cooler pipe. 7. NOTE: Engine side shown, charge air cooler side similar. Remove the charge air cooler-to-engine pipe. Vehicles with dual generators 8. Remove the accessory drive belt. 9. Remove the bolt and the accessory drive belt tensioner. 10. Remove the accessory drive belt. 11. Remove the bolts, bracket and accessory drive belt idler pulley. 12. Remove the bolts and the accessory drive belt tensioner. 13. Disconnect the wire retainer, generator electrical connector and B+ wire. 14. Remove the bolts and the generator with mounting bracket. Vehicles with single generator 15. Remove the accessory drive belt. All vehicles 16. Position the boot back and disconnect the generator B+ wire and electrical connector. 17. Remove the three bolts and the generator. 18. Remove the turbocharger and the turbocharger pedestal. For additional information, refer to Section 303-04F. 19. Remove the bolts and position the heater hose tube aside. ? Remove and discard the O-ring. 20. Disconnect the manifold absolute pressure (MAP) sensor hose. 21. Disconnect the engine coolant vent hose. 22. Remove the fuel injector control module. For additional information, refer to Section 303-14C. 23. Disconnect the wiring retainer, injector pressure regulator and injector control pressure (ICP) sensor electrical connector. 24. Disconnect the exhaust gas recirculation (EGR) valve electrical connector. 25. Disconnect the oil pressure sensor electrical connector. 26. Disconnect the oil temperature sensor electrical connector.

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Idle Air Control (IAC) Valve Removal 1. Disconnect the vacuum line from the exhaust gas recirculation valve. 2. Disconnect the idle air control (IAC) valve electrical connector. 3. Detach the wiring harness from the IAC valve stud. 4. Disconnect the vacuum supply lines from the upper intake manifold. 5. Remove the IAC valve. 6. Remove and discard the IAC valve gasket. Installation 1. NOTE: Install a new IAC valve gasket. To install, reverse the removal procedure.

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Removal 1. Disconnect the battery ground cable. 2. Remove the camshaft position sensor (CMP sensor) (6B288); refer to Camshaft Position (CMP) Sensor—4.2L in this section. 3. Remove the exhaust gas recirculation (EGR) valve vacuum hose. 4. Remove the EGR tube upper fitting. 5. Remove the EGR valve (EGR valve) (9D475) and adapter. 1. Remove the bolts. 2. Remove the nut. 3. Remove the EGR valve and adapter assembly. 6. Remove the camshaft synchronizer adjustment bolt. 7. Remove the camshaft synchronizer (12A362). The oil pump drive shaft may come out with the camshaft synchronizer. Installation CAUTION: The Syncro Positioning Tool must be obtained prior to installation of the replacement camshaft synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. 1. Install the Syncro Positioning Tool on the camshaft synchronizer. Rotate the Syncro Positioning Tool until it engages the notch in the camshaft synchronizer housing. 2. NOTE: Rotate crankshaft to #1 cylinder TDC on compression stroke. Install the camshaft synchronizer housing assembly as shown. 3. NOTE: During installation, the arrow on the synchronizer alignment tool will rotate clockwise as the gears engage. Install the camshaft synchronizer housing assembly so the arrow on the Syncro Positioning Tool is 54 degrees from the centerline of the engine.

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All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Partially drain the cooling system. For additional information, refer toSection 303-03. 3. Remove the power steering fluid reservoir bracket. 1. Remove the bolts. 2. Position the power steering fluid reservoir bracket out of the way. 4. Remove the accelerator control splash shield. 1. Remove the bolts. 2. Remove the accelerator control splash shield. 5. Disconnect the fuel pressure regulator vacuum hose. CAUTION: After disconnecting, plug the fuel lines to prevent leakage. 6. Disconnect the fuel lines. For additional information, refer to Section 310-00. 7. Disconnect the eight fuel injector electrical connectors. 8. Disconnect the eight ignition coil electrical connectors. 9. Remove the brake booster bracket and tube. 1. Remove the nut. 2. Release and move the two hose clamps. 3. Remove the brake booster tube. 10. Remove the positive crankcase ventilation (PCV) hose. For vehicles equipped with 4.6L engine 11. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) connector, then disconnect the upper and lower EGR valve tube fitting.

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All vehicles 5. Remove the radiator. For additional information, refer to Section 303-03A. 6. If equipped, remove the A/C condenser core. For additional information, refer to Section 412-03. 7. If equipped, disconnect the climate control vacuum connector. All except supercharged vehicles 8. Remove the bolts and position the power steering reservoir aside. All vehicles 9. Disconnect the exhaust manifold to exhaust gas recirculation (EGR) valve tube lower fitting and remove the tube. 10. Disconnect the generator electrical connections and remove the generator. 11. NOTE: Battery removed for clarity. Disconnect the 38-pin, 42-pin and 16-pin electrical connectors. 12. Disconnect the electrical connector and remove the connector from the bracket. 13. Remove the bolts and the connector bracket cover. 14. Remove the 38-pin connector from the bracket. 15. Disconnect the starter relay electrical connections and position the cables aside. 16. Remove the bolts and connector bracket. 17. Compress the holding tabs and disconnect the heater hoses from the heater core. 18. Raise and support the vehicle. For additional information, refer to Section 100-02. 19. If equipped, remove the skid plate. 1. Remove the bolts. 2. Remove the skid plate. 20. Remove the A/C compressor, if equipped. For additional information, refer toSection 412-03. 21. Remove the drain plug and drain the engine oil. All except supercharged vehicles 22. Remove the starter motor. For additional information, refer to Section 303-06. 23. If equipped, install the A/C line (muffler) bracket. Manual transmission vehicles 24. Remove the clutch disc and pressure plate. For additional information, refer to Section 308-01. Automatic transmission vehicles 25. Remove the transmission fluid cooler tubes from the block mounted clip. 26. Remove the bolts and the flexplate inspection cover. 27. Remove the cylinder block opening cover. 28. Remove the torque converter-to-flexplate nuts. Discard the nuts. 29. NOTE: The upper two transmission-bolts will be removed later. Remove the lower five transmission-to-engine bolts. 30. Remove the nut and the transmission oil filler tube.