Service Manual User Manual

Section 8B
8B-20
25. In four locations, remove the nuts, washers and
capscrews securing the engine mounts (Fig. 8B–1) to
the hydraulic reservoir/engine mount subframe.
26. Remove either the fan or the radiator to help prevent
damage to the radiator when the engine is removed.
27. Begin removing the engine from the vehicle with the
hoist or overhead crane.
28. As the engine is lifted away and removed, reposition
the debris shield at the base of the radiator to prevent
damage and allow engine removal. Avoid damaging
the oil filter and oil filter housing.
29. Carefully lift the engine out and away from the
vehicle. Place the engine safely onto ground
supports, or in a suitable engine stand. DO NOT rest
the engine on its oil pan, or damage will occur.
8B.9.2 Engine Disassembly, Inspection and
Service
Engine disassembly, internal inspection, service, repair
and assembly procedures are covered in the Cummins
4BT3.9 service manual. Several special engine service
tools are required to properly service the Cummins
engine. Contact the local Cummins parts distributor for
further information.
8B.9.3 Engine Installation
Removal and installation of the engine can be done with
or without the transmission attached. For information on
installing the transmission to the engine, refer to
Section
7 Transmission
.
1. Place the engine mounts (items 17 and 26,
Fig. 8B–1) into the appropriate locations within the
hydraulic reservoir/engine mount subframe on the
vehicle.
2. Attach a suitable engine hoist to the engine lift plates
(Fig. 8B–22).
3. Carefully install the engine onto the engine mounts
(Fig. 8B–1). Make sure the bracket-type engine
mounts align properly with the engine mounts in the
subframe.
4. In four locations, install the nuts, washers and
capscrews securing the engine mounts (Fig. 8B–1) to
the hydraulic reservoir/engine mount subframe.
Torque the 7/16-14 x 3-1/4" Grade 8 capscrews to 60
lb/ft (81 Nm). Torque the 5/8-11 x 4" Grade 8
capscrews to 180 lb/ft (244 Nm).
5. Install the fan and/or radiator as required.
6. At the hydraulic fluid reservoir, connect the engine
harness wire lead (Fig. 8B–11) to the hydraulic fluid-
level sending unit.
7. Secure the throttle cable to the bracket (Fig. 8B–21),
located just above the starter.
8. Connect the throttle cable (Fig. 8B–21) at the engine
mount bracket.
9. Connect the fuel inlet line (Fig. 8B–20) to the fuel lift
pump.
10. Connect the fuel return line to the fuel injector pump.
11. Attach the wiring connectors at the auxiliary function
valve solenoids (Fig. 8B–19).
12. Connect the wiring harness leads to the steer select
valve leads (Fig. 8B–18).
13. Connect the engine wiring-harness bulkhead
connector to the bulkhead receptacle along the
vehicle frame.
14. Working from beneath the vehicle, connect all engine
wire harness leads (refer to
Section 10 Electrical
System
as required for detailed views of harness
leads). Secure with plastic tube clips and tie wraps as
required to prevent the wiring harness and wire leads
from hanging below the vehicle and from coming into
contact with moving parts.
15. If the engine and transmission were NOT installed as
a unit, attach the transmission to the engine at this
time. Follow the procedure in
Section 7
Transmission
.
Note: The drive shaft is a balanced assembly. The yokes
at each end of the drive shaft must be in the same plane
to help prevent excessive vibration (Fig. 8B–23).
Figure 8B–23. Align yokes in the same plane as shown.
16. Coat the M12 transmission driveshaft yoke retaining
capscrews with Loctite #242 (blue), install
lockwashers and torque to 83 lb/ft (112,5 Nm).
17. Connect all transmission wire leads.
Align yokes in same plane as shown
(note angled notch in yoke)
Angled
notch
Straight
edge
MS1120
Model 3606 • Origin 10/99