Steps 1-50

Engine

Disassembly

NOTE: This procedure assumes that the engine was removed using the recommended body off engine removal procedure. If it was necessary to remove the engine using the alternate body on engine removal procedure, some of the components in this procedure will have already been removed.

NOTE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel opening to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.

NOTE: For EXPORT ONLY vehicles (outside US/Canada) an Export Supplement is provided and should be referenced to identify differences that can impact service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US EPA or CARB Regulations".

1. Remove the engine. For additional information, refer to Engine - Body Off Body Off or Engine - Body On Body On.

2. NOTICE: Discard the engine support insulator bracket bolts and install new bolts or damage to the vehicle may occur. They are a torque-to-yield design and cannot be reused.

NOTE: Left side shown, right side similar.

Remove the 8 bolts and the LH and RH engine support insulator brackets.

- Discard the bolts.

3. NOTICE: Use a suitable engine stand with 6 mounting arms or equivalent to support the engine. Failure to correctly support the engine may result in engine damage.

Using the Heavy Duty Floor Crane, install the engine on a suitable engine stand.

4. Disconnect the EGR cooler hose retainer.

5. Remove the EGR cooler hose from the EGR cooler.

6. Disconnect the coolant hose from the vacuum hose retainer.

7. Disconnect and remove the EGR cooler hose and the vent hose.

8. Disconnect the fan clutch electrical connector.

9. Remove the fan clutch electrical connector bolt.

10. Using the Fan Clutch Nut Wrench and Wrench, remove the fan clutch.

11. NOTE: Single generator shown, dual generator similar.

Remove the accessory drive belt.

12. Disconnect the A/C compressor electrical connectors and the wire retainer.

13. Remove the 3 bolts and the A/C compressor.

14. Remove the bolt and the accessory drive belt tensioner.

15. Remove the 4 bolts and the secondary coolant pump assembly.

16. Remove the 4 bolts and the cooling fan drive assembly.

17. Disconnect the engine vacuum hose connector at the tee. If equipped, disconnect and remove the brake booster vacuum hose.

18. Remove the 2 stator standoffs.

19. NOTE: Hose retainer not shown.

Disconnect the oil cooler outlet hose from the lower radiator hose and hose retainer.

20. Remove the clip and the lower radiator hose.

21. Remove the engine fill hose from the engine front cover.

22. Remove the clip and the upper radiator hose.

23. NOTE: Use care when removing the hose from the oil cooler, damage to the oil cooler may occur during removal.

Remove the oil cooler inlet hose.

24. NOTE: Boot positioned back for clarity.

Disconnect the generator electrical connector, remove the terminal nut and B+ terminal.

25. Disconnect the lower engine wire harness retainer from the power steering bracket.

26. NOTE: RH side shown, LH side similar.

Remove the 2 lower engine wire harness ground bolts.

27. Disconnect the power steering tube from the retainer.

28. NOTE: Power steering pump mounting bracket removed for clarity.

Remove the 2 lower engine wire harness bolts.

29. Disconnect the Engine Oil Temperature (EOT) sensor and the Engine Oil Pressure (EOP) switch electrical connectors.

30. Remove the lower engine wire harness nut at the oil filter adapter.

31. Remove the lower engine wire harness nut.

32. Remove the 2 front retaining nuts and the lower engine wire harness from the engine.

33. Remove the bolt and oil fill pipe.
- Remove and discard the O-ring seal.

34. Remove the oil level indicator tube.
- Remove and discard the O-ring seals.

35. Remove the 2 bolts and EGR valve inlet tube bracket.
- Discard the bolts.

36. NOTE: Exhaust side shown, EGR cooler side similar.

Remove the 4 bolts and the EGR valve inlet tube.

- Remove and discard the gaskets.

37. Disconnect the Exhaust Gas Recirculation Temperature (EGRT) electrical connector and 2 wire retainers.

38. Remove the 4 bolts and the EGR bypass outlet tube.
- Remove and discard the gaskets.

39. NOTE: LH side shown, RH side similar.

Remove the 2 bolts and 2 ground straps from the back of the cylinder heads.

40. Disconnect the 2 wire harness retainers.

41. Disconnect the EGR valve, bypass solenoid and EGR Engine Coolant Temperature (ECT) sensor electrical connectors. Disconnect the vacuum hose and the wire retainer.