TM 5-3805-254-34
3-1.
ENGINE REPLACEMENT.
This Task Covers:
a. Removal
Initial Setup:
Equipment Conditions:
• Batteries disconnected. (see TM 5-3805-254-20).
• Front fenders .removed (see paragraph 15-24).
• Grille guard removed (See TM 5-3805-254-20).
• Front bumper removed (see TM 5-3805-254-20).
• Turbocharger piping removed (see TM 5-3805-254-20).
6 Ail cleaner housing removed (see TM 5-3805-254-
20).
• Turbocharger crossover tube removed (see TM 5-
2815-241-34&P).
• Alcohol evaporator removed (see TM 5-3805-254-20).
• Primary fuel filter housing removed (see TM 5-3805-
254-20).
• Primer pump fuel hose disconnected from fuel pump
(see TM 5-3805-254-20).
• ·Preheater fuel hose disconnected from preheated
nozzle (see TM 5-3805-254-20).
• Glow plug wire disconnected from glow plug (see TM 5-
3805-254-20).
• Accelerator control disconnected from fuel pump (see
TM 5-3805-254-20).
• Auxiliary oil filter hoses disconnected from left side of
engine (see TM 5-3805-254-20).
• Tachometer drive cable disconnected from fuel pump
(see TM 5-3805-254-20).
• Ground strap removed from left side of engine
crankcase (see TM 5-3805-254-20).
• Oil pressure switch wire disconnected from fuel
solenoid of fuel pump (see TM 5-3805-254-20).
• Engine compression brake throttle switch removed
from fuel pump (see TM 5-3805-254-20).
• Steering pump bypass hose and fittings removed (see
TM 5-3805-254-20).
• Torque converter cooler removed (see paragraph 6-6).
•· Radiator bypass coolant line removed (see TM 5-
3805-254-20).
b. Installation
Equipment Conditions (Con’t):
• Heater core hoses disconnected from water pump and
water manifold (see TM 5-3805-254-20).
• Engine water temperature switch wires disconnected
(see TM 5-3805-254-20).
• Radiator removed (see paragraph 4-4).
• Exhaust pipe elbow disconnected from turbocharger
(see TM 5-3805-254-20).
• Water temperature gage line removed (see TM 5-3805-
254-20).
• Air compressor to air dryer hose disconnected from air
compressor (see TM 5-3805-254-20).
• Air compressor governor to air dryer air line
disconnected from air compressor (see TM 5-3805-
254-20).
• Air compressor governor to wet air reservoir line
disconnected from air compressor governor (see TM
5-3805-254-20).
• Power steering oil reservoir removed (see TM 5-3805-
254-20).
• Engine cover removed (see paragraph 15-1).
•·Floorboards and inserts removed (see para-graph 15-
3).
Materials/Parts:
• Two cotter pins
•· Two locknuts
•· Sixteen lockwashers
Tools/Test Equipment:
• General mechanic's tool kit
• Field automotive shop set
• Lifting eye
Personnel Required: Two
References:
• TM 5-3805-254-20
3-2
