BIG CAM III ENGINE REMOVAL

TM 9-2815-225-34&P · Work Package 0008 00

INITIAL SETUP

Tools and Special Tools                                Personnel Required
 General mechanic’s tool kit: automotive               Three assistants
    (Item 1, WP 0061 00)
 Maintenance and repair shop equipment:
    automotive (Item 2, WP 0061 00)
 Automotive maintenance and repair
    supplemental set no. 2 (Item 3, WP 0061 00)
 Tilt sling (Item 67, WP 0061 00)
 Lifting sling (Item 42, WP 0061 00)

Equipment Condition
 Horn wire disconnected (TM 9-2320-283-20).
 Grille shell removed (TM 9-2320-283-20).
 Fenders removed (TM 9-2320-283-20).
 Upper radiator fan shroud removed
   (TM 9-2320-283-20).
 Steering system to proper level removed
   (TM 9-2320-283-12).
 Transmission lines removed
   (TM 9-2320-283-20).
 Air reservoir draincocks opened
   (TM 9-2320-283-20).
 Bumper and towing eyes removed
   (TM 9-2320-283-20).
 Brush guard and spotter mirrors removed
   (TM 9-2320-283-20).
TM page 0008 00-2
Figure 1. Battery Cable Removal.

1. Disconnect two negative battery cable clamps (2) from two negative battery cable post (3) and remove negative battery cable (1) from battery (4).

2. Open drain valve (6) on cooling tube outlet (5) and drain engine coolant from engine. When finished, close drain valve (6).

3. Remove drain plug (7) from oil pan (8) and drain engine oil from oil pan (8). Install drain plug (7) in oil pan (8).

TM page 0008 00-3
Figure 2. Draining Engine Coolant. Figure 3. Oil Drain Plug Removal.

Figure 2. Draining Engine Coolant.

Figure 3. Oil Drain Plug Removal.

TM page 0008 00-4
Figure 4. Lighting Harness Removal.
CAUTION Mark and tag all wires, hoses, etc., removed from vehicle for proper reinstallation. Failure to comply may result in damage to equipment.

4. Disconnect four lighting harness electrical connectors (4).

5. Remove four lighting harness screws (3), washers (2), and clamps (1) from lights and hood (5).

6. Cut plastic tie (6) and remove lighting harness (7) from hood (5) and position aside. Discard plastic tie (6).

WARNING When removing hood tilt assist cables, hood must be supported. Failure to do so may result in damage to equipment or injury to personnel.

7. Support hood (5) and open two chain link nuts (10). Remove tilt assist cables (8) from chain links (9).

8. Close hood (5) and remove two hood hinge locknuts (11) and bolts (12) from hood hinges (13). Discard locknuts (11).

NOTE Use three assistants or lifting strap and lifting device to remove hood from vehicle.

9. Remove hood (5) from vehicle.

4 2

3 1

1 1 7 6

TM page 0008 00-5
Figure 5. Tilt Assist Cables Removal. Figure 6. Hood Hinge Removal.

Figure 5. Tilt Assist Cables Removal.

Figure 6. Hood Hinge Removal.

TM page 0008 00-6
Figure 7. Air Cleaner Removal.

10. Release three air cleaner element clamps (1) and remove air cleaner element (2) from air cleaner housing (9). Discard air cleaner element (2).

11. Loosen three clamps (4) and remove air cleaner duct assembly (5) from turbocharger outlet (8) and air cleaner outlet elbow (3).

12. Remove vent tube screw (11), locknut (18), and washer (12) from air duct support bracket (17). Discard locknut (18).

13. Remove two air vent hose clamps (13), air vent hose (14), and air vent tube (10) from air duct support bracket (17).

14. Remove four air cleaner housing bracket locknuts (22), washers (21), and screws (20) from support brackets (17) and air cleaner housing (9). Discard locknuts (22).

15. Remove indicator tube (16) and elbow (15) from air cleaner housing (9).

16. Remove six air cleaner housing locknuts (31), washers (30), and air cleaner housing (9) from adapter duct (25). Discard locknuts (31).

17. Disconnect air duct door spring (32) from air duct door (29) and firewall (19).

18. Remove ten adapter duct locknuts (27), washers (26) and (24), screws (23), four reinforcement plates (28), and adapter duct (25) from air cleaner box (19). Discard locknuts (27).

3 4 1 2 5

9 1

8 4

TM page 0008 00-7
Figure 8. Air Duct Removal. Figure 9. Air Cleaner Housing Removal.

Figure 8. Air Duct Removal.

Figure 9. Air Cleaner Housing Removal.

TM page 0008 00-8
Figure 10. Turbocharger Hose Removal.

19. Loosen exhaust S-pipe clamp (3) and remove from turbocharger outlet flange (4).

20. Loosen two exhaust pipe nuts (6), screws (2), and exhaust S-pipe clamp (1). Remove exhaust S-pipe (5) from exhaust pipe (7).

21. Loosen heater hose clamp (9) and remove heater hose (8) and heater hose clamp (9) from heater hose tube (10).

22. Loosen heater hose clamp (12) and remove heater hose (13) and heater hose clamp (12) from heater hose tube adapter (11).

23. Loosen two vent hose clamps (16) and remove vent hoses (17) and vent hose clamps (16) from radiator (15).

24. Loosen bypass hose clamp (18) and remove bypass hose (19) from radiator (15).

25. Loosen two lower radiator hose clamps (23) and remove lower radiator tube (28) and lower radiator hose clamps (23) from radiator (15).

26. Loosen three cooling outlet tube clamps (24) at water pump inlet (31) and cooling outlet tube (29).

27. Remove cooling outlet tube nut (26) and screw (27) from support bracket (25).

28. Remove cooling outlet tube (29) from water pump (30).

29. Loosen two upper radiator hose clamps (20) and remove upper radiator hose (22) and upper radiator hose clamps (20) from thermostat housing elbow (21) and radiator inlet tube (14).

2 3

6 5

TM page 0008 00-9
Figure 11. Heater Hose Removal. Figure 12. Upper Radiator Hose Removal. Figure 13. Lower Radiator Tube Removal. Figure 14. Water Pump and Water Pump Inlet.

Figure 11. Heater Hose Removal. Figure 12. Upper Radiator Hose Removal.

Figure 13. Lower Radiator Tube Removal. Figure 14. Water Pump and Water Pump Inlet.

TM page 0008 00-10

30. Disconnect A/C compressor clutch electrical connector (7) from engine wiring harness (6).

31. Loosen two A/C compressor mounting bracket locknuts (23), bolts (26), and washers (24).

32. Loosen two jam nuts (11) on A/C compressor adjusting rod (15).

33. Push A/C compressor (5) in towards engine (20). Remove A/C drive belt (19) from A/C clutch pulley (25) and accessory drive pulley (17).

34. Remove A/C compressor adjusting rod locknut (12), two washers (13), bolt (18), and A/C compressor adjusting rod (15) from front cover (16). Discard locknut (12).

35. Remove A/C compressor hose locknut (21) washer (22), screw (2), and clamp (1) from top of engine (20). Discard A/C compressor hose locknut (21).

36. Remove two A/C compressor line screws (9), washers (10), and clamps (8) and (14) from A/C compressor (5).

37. Remove two A/C compressor mounting bracket locknuts (23), bolts (26), and washers (24) from A/C compressor mounting bracket (27). Discard A/C compressor mounting bracket locknuts (23).

NOTE Do not disconnect A/C lines or hoses. A/C compressor can be removed and positioned on passenger side of vehicle for engine removal with A/C lines and hoses attached.

38. Remove A/C compressor (5) with A/C compressor lines (3) and A/C compressor hoses (4) and position A/C compressor (5) aside.

TM page 0008 00-11
Figure 15. A/C Compressor Mounting Bracket Removal. Figure 16. A/C Compressor Mounting Bolts Removal.

Figure 15. A/C Compressor Mounting Bracket Removal.

Figure 16. A/C Compressor Mounting Bolts Removal.

TM page 0008 00-12
Figure 17. A/C Condenser Hoses Removal.
NOTE Do not disconnect A/C lines or hoses from A/C condenser. A/C condenser can be removed from radiator and positioned on outside of passenger side frame rail for engine removal.

39. Remove three A/C condenser line locknuts (6), washers (7), screws (1), and clamps (8) from radiator support brackets (9). Discard locknuts (6).

40. Remove four A/C condenser locknuts (2) and A/C condenser (4) with A/C compressor lines (5) attached, from two support brackets (3) on front of radiator (10). Discard locknuts (2).

41. Remove coolant temperature sender terminal nut (12) and coolant temperature sender electrical connector (13) from coolant temperature sender terminal (14).

42. Remove coolant temperature sender terminal screw (11) and coolant temperature sender electrical connectors (15) from coolant temperature sender terminals (14) on radiator (10).

3 4

6 2 5

TM page 0008 00-13
Figure 18. A/C Condenser Lines Removal.

6 7

Figure 18. A/C Condenser Lines Removal. 11

13 12

Figure 19. Temperature Sender Electrical Connectors Removal.

TM page 0008 00-14
Figure 20.Radiator Ground Strap Removal.

43. Attach chains and lifting device on radiator (1).

44. Remove two ground strap locknuts (3), washers (2), isolators (5), and ground strap (4) from radiator (1) and frame front crossmember (15). Discard locknuts (3).

45. Remove four radiator support rod locknuts (10), eight washers (8), four spacers (7), four screws (9), and three radiator support rods (11) from radiator (1) and firewall brackets (6). Discard locknuts (10).

46. Remove two radiator crossmember mount locknuts (14), washers (12), and isolators (13) from crossmember (15). Discard locknuts (14).

47. Using lifting device and chains, remove radiator (1) from front crossmember (15) and lower radiator (1) to floor.

48. Remove lifting device, chains, two isolators (13), and washers (12) from radiator (1).

5 5

Figure 20. Radiator Ground Strap Removal.

TM page 0008 00-15
Figure 21.Radiator Removal.

Figure 21. Radiator Removal.

TM page 0008 00-16
Figure 22. Cooling Fan Removal.

49. Remove six cooling fan nuts (1), lockwashers (2), washers (3), and cooling fan (4) from cooling fan clutch studs (5). Discard lockwashers (2).

50. Position container under power steering reservoir (8), remove drain plug (9) and drain power steering fluid. Install drain plug (9).

NOTE Cap and plug all openings, hoses, and lines to prevent fluid contamination.

51. Loosen two power steering hose clamps (7) and remove power steering hoses (6) and clamps (7) from power steering reservoir (8) and power steering pump (12).

52. Remove power steering hose (11) from elbow (10) on power steering reservoir (8).

53. Remove fuel return line (20) from fuel return line T-fitting (19) on engine (16).

54. Remove fuel supply line (24) from fuel filter fitting (25).

55. Remove retaining pin (15) and transmission modulator cable (23) from throttle lever (27).

56. Remove two throttle position sensor cable clamp locknuts (26), screws (18), four washers (21), clamp (17), and transmission modulator cable (23) from mounting bracket (22). Discard locknuts (26).

57. Remove two accelerator return springs (31), accelerator rod locknut (32), screw (30), and accelerator rod (28) from lower throttle lever (29). Discard locknut (32).

58. Remove tachometer cable (14) from fuel pump tachometer drive (13).

TM page 0008 00-17
Figure 23. Power Steering Hoses Removal. Figure 24. Throttle Lever Removal.

Figure 23. Power Steering Hoses Removal.

Figure 24. Throttle Lever Removal.

TM page 0008 00-18
Figure 25. Air Compressor Hose Removal.
Figure 27. Air Compressor Lines Removal.

59. Disconnect air compressor hose (1) at top of transmission (2).

60. Disconnect oil sample hose (3) from elbow fitting (4) on oil filter housing (5).

61. Disconnect two air lines (6) from air compressor (7).

62. Disconnect air line (9) from fan temperature switch (8).

63. Disconnect two transmission oil cooler hoses (10) and (11) from transmission (2).

64. Remove transmission oil cooler hose nut (13), washer (12), screw (15), clamp (16), and transmission oil cooler hoses (10) and (11) from transmission oil cooler base mounting bracket (14).

2 3

Figure 26. Engine Oil Sampling Hose Removal.

6 7

TM page 0008 00-19
Figure 29. Figure 28. Fan Temperature Switch Removal. Transmission Oil Cooler Hoses Removal. Figure 30. Transmission Oil Cooler Hose Clamp Removal.

Figure 28. Fan Temperature Switch Removal. Transmission Oil Cooler Hoses Removal.

Figure 30. Transmission Oil Cooler Hose Clamp Removal.

TM page 0008 00-20
Figure 31.
Figure 31.
Figure 32.

65. Remove transmission oil temperature sensor electrical connector nut (4), washer (3), and transmission oil temperature sensor electrical connector (1) from transmission oil temperature sensor (2).

66. Disconnect engine speed sensor electrical connector (6) from engine speed sensor (5) on transmission (7).

67. Disconnect turbine speed sensor electrical connector (9) from turbine speed sensor jumper harness (10) on transmission (7).

68. Disconnect output speed sensor electrical connector (11) from output speed sensor (12) on transmission (7).

69. Remove transmission electrical harness nut (17), screw (14), clamp (13), two washers (15), and transmission electrical harness (8) from transmission (7).

70. Disconnect control valve module electrical harness (16) from transmission electrical harness (8).

Figure 31. Transmission Oil Temperature Sensor Removal.

6 5

9 7

Figure 32. Engine Speed and Turbine Sensor Removal.

TM page 0008 00-21
Figure 33. Output Speed Sensor Removal. Figure 34. Transmission Electrical Harness Removal.

Figure 33. Output Speed Sensor Removal.

Figure 34. Transmission Electrical Harness Removal.

TM page 0008 00-22
Figure 35. Alternator Belt Removal.

71. Loosen two alternator mounting bracket screws (3).

72. Loosen two alternator jam nuts (1) on alternator adjusting rod (6).

73. Push alternator (5) in towards engine (2) and remove two drive belts (4).

74. Remove alternator terminal nut (19), washer (18), and engine electrical harness positive lead (15) from alternator positive terminal (17).

75. Remove alternator terminal nut (7), washer (8), and engine electrical harness negative lead (9) from alternator negative terminal (16).

76. Remove alternator terminal nut (10), washer (11), and engine electrical harness transformer/rectifier positive lead (14) from alternator transformer/rectifier positive terminal (21).

77. Remove alternator terminal nut (12), washer (13), and engine electrical harness transformer/rectifier negative lead (22) from alternator transformer/rectifier negative terminal (20).

1 2

TM page 0008 00-23
Figure 36. Alternator Electrical Connections Removal.
TM page 0008 00-24
Figure 37. Fan Temperature Switch Electrical Connections.

78. Disconnect temperature sensor electrical connector (1) from temperature sensor (11).

79. Remove fan temperature switch screw (4), washer (5), pressure harness lead (6), and solenoid lead (8) from fan temperature switch (10), terminal A.

80. Remove fan temperature switch screw (3), washer (2), pressure harness lead (9), and engine harness lead (7) from fan temperature switch (10), terminal B.

81. Remove 12V power stud grommet (12), nut (15), washer (14), two engine harness leads (16) and (17), and 12V power lead (18) from 12V power stud (13).

2 5 6

A

B

TM page 0008 00-25
Figure 38. 12V Harness Leads Removal.
TM page 0008 00-26
Figure 39. Starter Motor Electrical Connections Removal.

82. Remove starter S-terminal nut (15), lockwasher (16), and starter electrical harness lead no. 74 (17) from starter S-terminal (18). Discard lockwasher (16).

83. Remove starter positive terminal nut (4), lockwasher (6), battery positive cable (5), and three starter electrical harness leads no. 202 (7), no. 82 (8), and no. 421 (9) from starter positive terminal (19). Discard lockwasher (6).

84. Remove starter ground terminal nut (1), lockwasher (2), battery ground cable (22), ground jumper cable (3), and starter electrical harness lead no. 83 (21) from starter ground terminal (20). Discard lockwasher (2).

85. Remove A/C electrical harness ground lead screw (13), two starwashers (11) and (12), A/C electrical harness ground lead (10), and ground jumber cable (3) from engine (14). Discard starwashers (11).

86. Remove fuel solenoid terminal nut (25), lockwasher (24), and fuel solenoid electrical harness lead (26) from fuel solenoid (23). Discard lockwasher (24).

87. Disconnect fuel pump pressure sensor electrical connector (28) from fuel pump pressure sensor (27).

11 14

6 15 16 4 5

1 2

20 18

TM page 0008 00-27
Figure 40. Solenoid and Pressure Sensor Wiring Removal.
TM page 0008 00-28
Figure 41. Jacob Brake Harness Removal.
Figure 42. Front Jacob Brake Electrical Connector.

88. Disconnect jacob brake electrical connector (1) from engine harness connector (2).

89. Disconnect front (4), middle (5), and rear (6) jacob brake electrical connectors from cylinder heads (3).

90. Disconnect transmission TPS harness electrical connector (8) from vehicle TPS harness electrical connector (7).

TM page 0008 00-29
Figure 43. Figure 45. Transmission Harness Electrical Connector.

3 5

Figure 43. Middle Jacob Brake Electrical Connector.

Figure 44. Rear Jacob Brake Electrical Connector.

8 7

Figure 45. Transmission Harness Electrical Connector.

TM page 0008 00-30
Figure 46. Ether Quick Start Tube.

91. Disconnect ether quick-start tube (3) from atomizer (4) on intake manifold (1).

92. Position and secure suitable transmission jack under transmission (11). Ensure transmission weight is supported by transmission jack.

93. Remove flywheel bolt access cover screw (5) from P-clamp (6) and flywheel housing (13) and position P-clamp (6) away from flywheel housing (13).

94. Remove flywheel bolt access cover screws (5) and flywheel bolt access cover (7) from flywheel housing (13).

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

95. Remove twelve flywheel bolts (8) and washers (9) from flywheel (10) and torque converter (12).

96. Remove twelve transmission bolts (25) from transmission (11) and flywheel housing (13).

97. Attach tilt sling and lifting device to engine lifting brackets (2).

98. Remove two front engine crossmember mount nuts (23), four washers (19), two insulators (20), and bolts (22) from front engine crossmember mount (21).

99. Remove four mounting bracket nuts (26), insulators (28), eight washers (27), and four bolts (15) from mounting brackets (16).

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. Use pry bars to free engine hangups or snags. Do not use hands. Failure to do so may result in damage to equipment or death or injury to personnel.

100. Using lifting device and lifting sling, remove engine (17) from frame (14). Ensure there is proper clearance between frame (14), alternator (24), engine (17), and power steering pump (18). 101. To mount engine on maintenance stand refer to WP 0009 00.

TILT
SLING

1 2

4 3

TM page 0008 00-31/32 blank
Figure 47. Disconnect Flywheel from Torque Converter.
Figure 48. Engine Removal from Frame. 
FLYWHEEL BOLT
ACCESS HOLE

7 11

LIFTING DEVICE
CHAINS

14 15 16

25 26

23 18 19 20

END OF WORK PACKAGE

PDF page 122
TM page 0009 00-1