BIG CAM I ENGINE REMOVAL

TM 9-2815-225-34&P · Work Package 0007 00

INITIAL SETUP

Tools and Special Tools                              Equipment Condition (Contd)
 General mechanic’s tool kit: automotive              Steering system to proper level removed
    (Item 1, WP 0061 00)                                (TM 9-2320-283-12).
 Maintenance and repair shop equipment:               Transmission oil cooler lines removed
    automotive (Item 2, WP 0061 00)                     (TM 9-2320-283-20).
 Automotive maintenance and repair                    Steering system drained
    supplemental set no.2                               (TM 9-2320-283-12).
    (Item 3, WP 0061 00)                              Bumper and towing eyes removed
 Lifting brackets (Item 43, WP 0061 00)                 (TM 9-2320-283-20).
 Lifting sling (Item 42, WP 0061 00)                  Brush guard and spotter mirrors removed
                                                        (TM 9-2320-283-20).
Equipment Condition                                   Air reservoir draincocks opened
 Horn wire removed (TM 9-2320-283-20).                  (TM 9-2320-283-20).
 Grille shell removed (TM 9-2320-283-20).             Battery cables disconnected
 Air cleaner removed (TM 9-2320-283-20).                (TM 9-2320-283-20).
 Fan removed (TM 9-2320-283-20).                      Engine oil drained (TM 9-2320-283-12).
 Fenders removed (TM 9-2320-283-20).                  Hood removed (TM 9-2320-283-20).
 Upper radiator fan shroud removed                    Cooling system drained
   (TM 9-2320-283-20).                                  (TM 9-2320-283-12).
 Radiator support brackets removed
   (TM 9-2320-283-20).                               Personnel Required
 Radiator and support rods removed                    Two assistants
   (TM 9-2320-283-20).
 Turbocharger exhaust tube removed
   (TM 9-2320-283-20).
 Cooling system hoses removed
   (TM 9-2320-283-20).
 Power steering pump hydraulic lines removed
   (TM 9-2320-283-20).
TM page 0007 00-2

1. Position and secure suitable transmission jack under transmission (3). Ensure transmission weight is supported by transmission jack.

2. Remove flywheel bolt access cover screw (8) securing breather tube clamp (9) to flywheel housing (6) and position breather tube clamp (9), and breather tube (10) away from flywheel housing (6).

3. Remove flywheel bolt access cover screw (8) and flywheel bolt access cover (11) from flywheel housing (6).

NOTE Rotate engine using accessory drive pulley nut to gain access to flywheel bolts.

4. Remove twelve flywheel bolts (1) and washers (2) securing ring gear (5) to flywheel (4) through flywheel bolt access hole (7).

5. Loosen two lower alternator screws (12) securing alternator (30) to alternator mounting bracket (27).

6. Remove alternator bolt (25), washer (24), and nut (13) securing alternator (30) to alternator adjusting rod block (23).

7. Remove alternator adjusting rod bolt (18), lockwasher (17), washer (16), alternator adjusting rod (20), alternator adjusting rod block (23), three alternator adjusting rod nuts (21) and two washers (22) as an assembly, from engine (14). Discard alternator adjusting rod lockwasher (17).

NOTE Rotate alternator in towards engine to allow for clearance during engine removal.

8. Rotate alternator (30) in towards engine (14) and tighten two lower alternator screws (12) to retain alternator (30) in position.

9. Remove two belts (19) from alternator pulley (26) and crankshaft pulley (15). Discard belts (19).

10. Remove two lower alternator screws (12), nut (28), washer (29), and alternator (30) from alternator mounting bracket (27).

TM page 0007 00-3
Figure 1. Ring Gear Removal. Figure 2. Alternator Belt Removal.

Figure 1. Ring Gear Removal.

Figure 2. Alternator Belt Removal.

TM page 0007 00-4
Figure 3. Heater Valve Removal.

11. Remove heater hose clamp (2) and heater valve (1) from heater hose (3).

TM page 0007 00-5
Figure 4. Heater Hose and Starter Wiring Harness Removal.
Figure 4. Heater Hose and Starter Wiring Harness Removal.

12. Remove three heater hose nuts (4) and screws (8) retaining hoses (6) and (12), clamps (5), and starter battery cable (7) from mounting brackets (9).

13. Disconnect heater hose adapter (10) from water outlet fitting (11).

14. Position heater hose (6) and (12), clamps (5), and starter battery cable (7) aside to allow clearance for engine removal.

6 5 5 5

4 8

8 12 9

TM page 0007 00-6
Figure 5. Firewall Electrical Harness Disconnections.

15. Disconnect engine harness electrical connectors (1) at firewall (2).

16. Remove engine harness screw (3) and engine harness bracket (4) from engine (5).

17. Disconnect air compressor line (6) from air compressor (7).

18. Disconnect fuel line (10) from fuel filter and damper (11).

19. Disconnect tachometer shaft assembly (15) from tachometer (14).

20. Cut plastic tie (9) securing tachometer shaft assembly (15) to ether quick start kit bracket (8). Discard plastic tie (9).

21. Remove ether quick start kit bracket nut (17), screw (12), two clamps (13) and (16) and ether quick start kit bracket (8) from engine (5).

22. Cut plastic tie (21) securing speedometer shaft assembly (22) to fuel return line (20). Discard plastic tie (21).

23. Disconnect fuel return line (20) from fuel rail male branch tree (19).

24. Disconnect air compressor hose (23) from air compressor line (24).

25. Disconnect air compressor line (25) from air compressor line T-adapter (18).

1 2

TM page 0007 00-7
Figure 6. Air Compressor Disconnection. Figure 7. Fuel Filter and Lines Removal. Figure 8. Fuel and Air Compressor Lines Disconnection.

Figure 6. Air Compressor Disconnection. Figure 7. Fuel Filter and Lines Removal.

Figure 8. Fuel and Air Compressor Lines Disconnection.

TM page 0007 00-8
Figure 9. Accelerator Cable Disconnection.

26. Remove return spring (5) from transmission modulator control bracket (6) and return spring clip (4).

27. Remove accelerator link nut (2), washer (3), spring clip (4), and accelerator link (15) from fuel control lever pin (17).

28. Remove retaining pin (13), washer (14), and transmission modulator control link (16) from fuel control lever (18). Discard retaining pin (13).

29. Remove two nuts (12), washers (11), shim (10), and U-bolt (9) from transmission modulator control bracket (6).

30. Remove two transmission modulator control bracket bolts (8), lockwashers (7), and transmission modulator control bracket (6) from engine (1). Discard lockwashers (7).

31. Remove ground strap bolt (33), starwasher (32), ground strap (34), and starter motor ground strap (31) from engine (1). Discard star washer (32).

32. Remove two starter motor terminal nuts (30), lockwashers (29), negative battery cable (28), and positive battery cable (26) from starter motor (27). Discard lockwashers (29).

33. Remove front hose clamp screw (35), nut (38), and hose clamp (36) from cooler hose bracket (37).

34. Remove middle cooler hose bracket screw (25) and middle cooler hose bracket (23) from oil pan (24).

35. Remove rear cooler hose bracket screw (22), washer (21), and rear cooler hose bracket (20) from transmission (19).

6 9

2 3

16 13 18 14

TM page 0007 00-9
Figure 10. Starter Cables Removal.
TM page 0007 00-10
Figure 11.Shifter Removal.

36. Remove two locknuts (10), lockwashers (9), U-bolt (5), shim (4), and cable mounting bracket (11) from shift control cable (12). Discard locknuts (10) and lockwashers (9).

37. Remove trunnion retaining pin (7) and trunnion (8) from transmission shift lever (6).

38. Remove floor mat (2) from floor pan access cover (1).

39. Remove ten screws (3), floor pan access cover (1), and shifter (13) from cab floor.

40. Remove transmission temperature sending unit nut (35), washer (36), and electrical connector (37) from transmission temperature sending unit (38).

41. Remove twelve transmission bolts (30) securing transmission (26) to engine (18).

42. Install two lifting brackets (17) on top of engine (18) with four bolts (16).

43. Install lifting sling and lifting device on engine lifting brackets (17).

44. Remove two rear engine mount nuts (29), washers (31) and bolts (14) from frame (32).

45. Remove two front engine mount nuts (27), bolts (24) and washers (23) from crossmember (25).

WARNING Use extreme care when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good operating condition and of suitable load capacity. Keep clear of heavy components supported only by lifting device. Failure to do so may result in death or injury to personnel. **CAUTION** Raise engine slowly and carefully to prevent damage to splined shaft. Failure to comply may result in damage to engine.

46. Using lifting device and lifting sling, raise engine and remove two rear frame flat washers (34) and rear vibration insulators (33) from rear engine mounting brackets (15).

1 2

12 5

8 7 6

Figure 11. Shifter Removal.

TM page 0007 00-11/12 blank
Figure 12.Engine Removal.

47. Remove two front frame flat washers (20) and front vibration insulators (21) from front engine crossmember (25).

48. Using lifting device and lifting sling, remove engine (18) from frame (32). Ensure there is proper clearance between frame (32), alternator (28), engine (18), and power steering pump (22).

49. Install engines in approved engine container.

LIFTING
DEVICE
LIFTING
16             SLING

33 19 32 20 21 35 36 31 37 28 30 29 27

25 23 22

Figure 12. Engine Removal.

END OF WORK PACKAGE

PDF page 90
TM page 0008 00-1