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13. Disconnect the EGR cooler pipe behind the inner timing cover. 14. Remove generator (Refer to 8 - ELECTRICAL/CHARGING/GENERATOR - REMOVAL), and generator rear sup- port bracket. 15. Remove the accessory drive belt Idler pulleys L.H.Thread. 16. Remove the drive belt tensioner. 17. Remove the power steering pump pulley. 18. Remove the vibration damper. CAUTION: Before removing the cylinder head cover/intake manifold (2) the witness mark on the crankshaft 19. Rotate the crankshaft hub to 90° after TDC (3 O’clock position). 20. Remove heater hose pipe fasteners. NOTE: It may be necessary to rotate the camshaft gear bolt slightly to gain proper camshaft alignment pin 21. Install the intake camshaft locking pin VM.1052 and exhaust camshaft locking pin VM.1053 (Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE). 22. Remove outer timing belt cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). 23. Remove timing belt (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL). 24. Install special tool VM.1085 and remove camshaft gears. 25. Remove timing belt idler pulleys L.H.Thread. 26. Remove inner timing belt cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). 27. Disconnect coolant temperature sensor, camshaft position sensor, boost pressure/intake air temperature sensor, fuel injectors, fuel temperature sensor, fuel rail solenoid, and EGR air flow electrical connectors. 28. Disconnect the main engine harness connectors at the right inner fender well and position the harness over the left side of the engine and aside. 29. Disconnect the brake booster vacuum pipe from the EGR air control valve. 30. Disconnect the EGR cooler pipe from the EGR air control valve. 31. Separate the main engine harness from the bracket on the EGR air control valve. 32. Remove the EGR tube from the underside of the EGR air control valve. 33. Separate the block heater wiring harness from the oil level indicator tube. 34. Remove the oil level indicator tube from the EGR air control valve. 35. Remove fuel injectors (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/FUEL INJECTOR - REMOVAL). 36. Remove fuel rail (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/FUEL RAIL - REMOVAL). 37. Disconnect oil separator outlet hose at separator. 38. Remove the oil separator from the intake manifold/cylinder head cover (2). 39. Disconnect the return fuel junction block from the intake manifold/cylinder head cover (2). 40. Remove cylinder head cover/intake manifold retaining bolts. 41. Lift cylinder head cover/intake manifold (2) from cylinder head (3). NOTE: When removing rocker arm and lifter assemblies, Always keep lifters in an upright position and in 42. Remove rocker arm and lifter assemblies from cylinder head (3). 43. Remove cylinder head cover/intake manifold gasket (4) from cylinder head (3). 9 - 1622 ENGINE - 2.8L DIESEL KJ |