1. Disconnect and remove batteries and tray.
2. Drain engine coolant.
3. Remove radiator upper and lower hoses.
4. Loosen crankshaft pulley belts.
5. Remove left and right splash shields.
6. Disconnect hood harness then remove hood with aid of helper. Place hinge pins in hinges after removal to avoid losing them.
7. Remove A/C condenser oil coolers, radiator, and fan shroud as assembly (Figure 2-21).
8. Loosen and remove serpentine drive belt. Use 1/2 in. drive breaker bar to rotate belt tensioner counterclockwise to loosen belt (Figure 2-15).
9. Disconnect heater, bypass and inlet hoses at water pump and coolant crossover (Figure 2-22).
10. Remove oil filler neck and coolant crossover (Figure 2-22).
11. Remove fan and fan clutch.
12. Remove crankshaft pulley (Figure 2-14).
13. Remove torsional damper attaching bolt and washer (Figure 2-17).
14. Remove torsional damper with tool J-23523-F (Figure 2-18).
15. Remove drive keys from crankshaft. Replace keys if worn, chipped, or distorted.
16. Remove water pump and adapter plate as assembly (Figure 2-23).
17. Remove bolts that attach front cover to oil pan (Figure 2-24).
18. Rotate crankshaft by hand until timing marks on sprockets and gears are aligned and number one piston is at TDC.
19. Remove injection pump driven gear (Figure 2-24).
20. Remove baffle from front cover (Figure 2-24).
21. Remove nuts and washers attaching fuel injection pump to studs on front cover (Figure 2-24).
NOTE: There are timing marks on the front cover and injection pump. Note position of these marks for installation reference.
22. Remove bolts that attach front cover to engine block. Then break sealer bead with putty knife and remove cover.
23. Cover oil pan opening to prevent dirt entry.
24. Check timing chain deflection with dial indicator.
Measure deflection mid-way between crankshaft and cam sprockets. Maximum allowable deflection is 0.810 in. (20.5 mm). Replace chain and sprockets if deflection is greater than specified.
25. Check camshaft end play with dial indicator. Maximum allowable end play is 0.012 in. (0.3 mm). Replace cam thrust plate and spacer if end play is greater than specified.
NOTE: Note position of timing marks on drive gear and crank and cam sprocket for installation reference.
26. Remove bolt and washer attaching injection pump drive gear to camshaft. Then remove gear (Figure 2-25).
27. Slide timing chain and sprockets off camshaft and crankshaft (Figure 2-25).
28. Remove drive keys from camshaft and crankshaft.
Replace keys if chipped, cracked, or distorted. Minor burrs can be removed with a stone or fine tooth file.
29. Clean all old sealer off engine block, front cover, and water pump/adapter plate with scraper.
