Removal & Installation ("G" Series)
- Disconnect batteries. Remove headlight bezels, grille, bumper and lower grille valance. Remove hood latch, coolant recovery bottle, upper fan shroud and tie bar. Remove engine cover. On A/C equipped models, discharge system, disconnect A/C condenser lines and remove condenser.
- Drain cooling system and remove radiator hoses at radiator. Disconnect engine oil and automatic transmission cooler lines. Remove radiator and fan assembly. Remove intake manifold. See INTAKE MANIFOLD in 6.2L DIESEL ENGINE article. Scribe mark on front cover at injection pump flange and remove fuel injection pump.
- Raise vehicle. Disconnect exhaust pipe at manifold. Remove inspection cover, flexplate-to-converter bolts (if equipped), and motor mount through bolts. Disconnect block heater and ground wire at element. Remove starter and bellhousing-to-engine bolts.
- Lower vehicle. Remove cruise control transducer (if equipped). On A/C equipped models, disconnect lines at compressor. Remove brackets and compressor. Remove power steering pump and set aside (if equipped). Remove oil filler tube upper bracket and glow plug relay. Disconnect oil pressure sender.
- Remove air cleaner resonator with bracket. Remove transmission filler tube and position out of way. Disconnect heater, radiator and by-pass hoses at crossover/thermostat assembly. Remove alternator upper bracket and coolant crossover. Disconnect fuel lines at fuel pump. Attach lift equipment and remove engine.
- To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS table in this article.