Notice: If the engine is damaged internally and a new engine assembly is installed in the vehicle, ensure that all foreign material is flushed out of the cooling system. You must also flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage.

Notice: On some vehicles it may be necessary to support the transmission as the engine is removed to prevent the transmission from falling, causing damage to the unit.

The procedure required to replace an engine varies according to the optional equipment and available shop facilities. The following procedure is intended only as a guide for performing the work. The technician must determine what additional work is needed.

1. Tilt the cab. Refer to Cab Tilting in General Information.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

2. Disconnect the negative battery cables.
3. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

Caution: If the vehicle is equipped with air conditioning, removal of the refrigerant line must be done by trained personnel. Injuries may result from improper procedures.

4. Remove the air conditioning compressor.
5. Remove the air inlet pipes.
6. Remove the air intake housing from the cab bridge.
7. Remove the coolant reservoir, hose and bracket.
8. Remove the cab support bridge.
9. Remove the oil level indicator tube.
10. Remove the power steering pump from the engine.
11. Remove the air compressor and lines, if equipped.
12. Remove the radiator and charge air cooler assemblies.
13. Remove the radiator and heater hoses.
14. Remove the engine electrical harness from all the electrical connectors.
15. Remove all ground straps from the engine to the frame.
16. Remove the engine stop and throttle cables.

Important: Cap the fuel line and the fittings to prevent the fuel from leaking and dirt from entering the fuel system.

17. Remove the fuel line and connectors from the fuel supply pump. Refer to Fuel Injection Pump Replacement .
18. Remove the engine tachometer drive cable.
19. Remove the engine brake rod, if equipped.
20. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
21. Remove the exhaust pipe from the turbocharger.
22. Remove the exhaust pipe from the muffler.
23. Remove the starter assembly.
24. Remove the torque convertor bolts from the torque convertor, if equipped.
25. Lower the vehicle.
26. Using a suitable support, support the transmission.
27. Attach a suitable overhead hoist.
28. Remove the front engine mounting bolts.
29. Remove the bolts from the transmission to the engine.
30. Remove the engine from the transmission assembly.
31. Remove the engine from the vehicle.

1. Install the engine to the transmission.
2. Install the engine to the engine mounts.
3. Install the bolts from the engine to the transmission.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the front engine mount through bolts.

Tighten
Tighten the front engine mount through bolts to 245 N·m (180 lb ft).

5. Install the front engine mount bolts.

Tighten
Tighten the front engine mount bolts to 36 N·m (26 lb ft).

6. Remove the overhead hoist.
7. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
8. Install the torque convertor bolts to the torque convertor.
9. Install the starter assembly.
10. Install the exhaust from the muffler to the turbocharger.
11. Install the turbocharger to the exhaust.
12. Lower the vehicle.
13. Install the engine stop and throttle cables.
14. Install the engine brake rod.
15. Install the engine tachometer drive cable.
16. Install the fuel lines and connectors to the fuel supply pump.
17. Install the ground straps to the frame and engine.
18. Install the engine electrical harness to all the connectors.
19. Install the engine electrical harness to the retainers and the brackets.
20. Install the radiator, charge air cooler and the air conditioning condenser assembly.
21. Install the radiator and heater hoses to the engine.
22. Install the air compressor and the lines.
23. Install the power steering pump.
24. Install the air conditioning compressor to the mounting bracket.
25. Install the engine oil level indicator tube.
26. Install the cab bridge.
27. Install the coolant reservoir, hose and bracket.
28. Install the air intake housing to the cab bridge.
29. Install the air inlet pipes.
30. Connect the negative battery cables.
31. Lower the cab.

Important: Inspect all fluid levels before starting the engine.

32. Fill the engine cooling system with the proper type and quantity of coolant.
33. Fill the engine crankcase with the proper grade and quantity of engine oil.
34. Charge the A/C system.