Page 142
REPAIR INSTRUCTIONS, PART 1
ENGINE REMOVAL
General Instructions
Details of the engine removal procedure vary
from one vehicle to another. This section
provides general guidelines for removing the
engine from the vehicle.
Before beginning engine removal, make sure all
equipment is available for use and has been
inspected for safety.
It is good practice to steam clean the engine to
remove road grime, grease and oil before starting
work. Steam cleaning the engine and engine area
allows more detailed inspection and improved
workmanship.
Care must be used to keep moisture from
entering the air intake system. If moisture does
enter the system, make sure it is removed (dried
out) before the engine is reinstalled.
1. Position the vehicle on a flat and level
surface in an area with ample work space in
and around the vehicle. Ensure that a
suitable lifting device is available.
2. Apply the parking brake and block the
vehicle wheels to prevent the vehicle from
moving. Observe all safety precautions.
3. Disconnect the battery negative (ground)
cable.
4. Drain the air tanks.
Removal from Vehicle
1. Remove the hood (if so equipped) and
position it away from the work area to
prevent accidents or hood damage to
conventional models. On cab over engine
models, tilt the cab forward.
2. Place a suitable container beneath the
engine and drain the engine oil and coolant.
Open the coolant drain valves in the block
and the EGR cooler.
3. Using an appropriated filter wrench, remove
the oil filters, fuel filter(s) and coolant
conditioner.
4. If the vehicle is equipped with air
conditioning:
a. Recover the refrigerant using A/C
refrigerant recovery and recycling
equipment.
b. Disconnect the A/C compressor
discharge hose at the connection near
the radiator support.
c. Disconnect the A/C line at the
receiver/dryer.
d. Locate and disengage the electrical
connector from the binary pressure
switch on the receiver/dryer.
e. Locate and disengage the electrical
connector from the low-pressure cutout
switch in the A/C refrigerant line.
5. Disconnect and remove the upper radiator
tube from the engine.
6. Disconnect the cab heater and fuel heater
coolant return lines from the radiator lower
tube (if applicable). The cab heater and
optional fuel heater coolant return hoses
were relocated from the thermostat housing
to the radiator lower tube during mid-2004.
7. Disconnect the lower radiator tube from the
Y-hose at the oil cooler coolant inlet on the
engine and from the radiator outlet. Remove
the tube from the engine.
8. Remove the clamps that retain the coolant
overflow tank and then remove the tank.
9. Disconnect and remove the
chassis-mounted charge air cooler inlet tube
and hoses.
10. Disconnect and remove the
chassis-mounted charge air cooler outlet
tube and hoses.
11. Locate the engine coolant temperature
sensor and disengage the electrical
connector, if applicable. Remove the sensor
harness from the radiator support.
12. Remove the fastener from the bracket that
secures the radiator fan clutch air solenoid
valve to the radiator support, if so equipped.
Set the solenoid valve aside.
5-111.bk Page 142 Monday, July 10, 2006 2:26 PM
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