81-124

Engine con't





81. NOTE: Left side shown, right side similar.

Disconnect the eight fuel injectors. Remove the nut and position aside the fuel injector wiring harness.





82. Disconnect the fuel line fittings.





83. NOTE: It is necessary to remove the filter and drain the housing.

Remove the four bolts and the oil filter housing.





84. Remove the bolt and the oil filter return tube.





85. Remove the fuel line.
^ Remove the bolt, and the banjo fitting from the fuel line.
^ Discard the sealing washers and remove the fuel line.





86. Remove the nuts and the turbocharger beat shield.





87. NOTE: Align the flat edge with the index feature located on the coolant supply port.

Twist the EGR cooler clamp and slide the EGR cooler hose down.





88. NOTE: Intake removed for clarity.

Remove the EGR cooler V-clamp and gasket.





89. Remove the bolts and the intake manifold.





90. Remove the intake manifold gaskets.
^ Clean and inspect the sealing surfaces.





91. Disconnect the heater hose at the coolant pump.





92. Remove the clips and disconnect the fuel lines.





93. Remove the power steering upper mounting bolts.





94. NOTE: Bolts need to be removed evenly.

Remove the lower bolts and position the power steering pump out of the way and remove LH standoff for the stator.





95. Remove the nut and the battery cable bracket, and remove the RH standoff for the stator.





96. Remove the ground stud and the ground cable.





97. NOTE: Late build shown, early build similar.

Disconnect the glow plug electrical connector.





98. Remove the nuts and the glow plug controller.





99. Disconnect the wiring retainer from the valve cover studs.

Vehicles with A/C





100. Disconnect the A/C high pressure switch and the A/C clutch electrical connectors.





101. Remove the A/C compressor.





102. Disconnect the air conditioning manifold lines from the A/C compressor.





103. Disconnect the Crankshaft Position (CKP) sensor electrical connector, and all wiring retainers from the engine block and head.





104. NOTE: Late build shown, early build similar.

Disconnect the RH glow plug electrical connector, and place wiring harness out of the way.

Vehicles with automatic transmission





105. Remove the automatic transmission fluid indicator and tube.

All vehicles





106. Remove the ground strap at the back of the right head.

Vehicles with automatic transmission





107. Remove the torque converter cover.





108. Remove the torque converter nuts.

All vehicles





109. NOTE: Left side shown, right side similar.

Remove the bolts for the turbocharger adapter pipe.





110. NOTE: LH shown, RH similar.

Remove the motor mount nuts.





111. Loosen the nuts at the turbocharger adapter pipe flange.
112. Drain the engine oil.

Vehicles with automatic transmission





113. Remove the nine bell housing bolts.

All vehicles





114. Remove the turbocharger adapter pipe.





115. Remove the left rear valve cover stud.





116. NOTE: Position the block heater and starter wiring harness out of the way.

Remove the transmission cooler line bracket.





117. Secure the turbocharger outlet pipe.





118. Remove the manufacturer's lifting eye.





119. Install the engine lifting eye on the RH cylinder head.





120. Install the front lifting brackets.

Vehicles with automatic transmission
121. Position a suitable jack under the transmission.

All vehicles
122. Install the Heavy Duty Floor Crane and Diesel Engine Lifting Bracket on the engine.





123. Raise the engine high enough to clear the No. 1 crossmember and pull the engine forward and clear of the vehicle.
124. Remove the engine lifting equipment from the engine.