SERIES 60 SERVICE MANUAL 1.1.2 Removal and Disassembly of Engine from the Vehicle Before mounting an engine on an overhaul stand, it must be disconnected from the transmission. Details for removing an engine will vary from one application to another. However, the following steps will be necessary, regardless of application: 1. Disconnect the battery cable(s) from the battery(s). 2. Drain the cooling system completely by removing the drain plug in the oil cooler and opening the drain cocks in the cylinder block, thermostat housing and water pump housing. Refer to section 14.6.4. 3. Drain the lubricating oil. Refer to section 14.6.1. 4.
Disconnect the inlet fuel line from the primary fuel filter and the outlet line from the upper fitting at the rear of the cylinder head. Refer to section 2.10.1. 5. Remove the air cleaner ducting as necessary for engine removal. Refer to OEM guidelines. 6. Remove the charge air cooler ducting from the turbocharger and intake manifold. Refer to section 6.8.2. 7. Disconnect the exhaust piping from the turbocharger. Refer to section 6.5.2. 8. Disconnect DDEC: [a] For DDEC I, disconnect the 22-pin DDEC electrical connector. Refer to section 2.18.2.
[b] For DDEC II or III, disconnect the 30-pin DDEC vehicle electrical connector and the six-pin DDEC II power connector or DDEC III/IV five pin power connector. Refer to section 2.16.2, or refer to section 2.17.3. 9. For removal of DDEC V refer to section2.15.2. 10. Disconnect and remove the cranking motor. Refer to section 9.4.2. 11. Remove the alternator and other electrical equipment, as necessary. Refer to section 9.2.2. 12. Remove the air compressor and any air lines, as necessary. Refer to section 11.1.5. 13. Disconnect and remove the coolant hoses. 14. Remove the charge air cooler, radiator, fan guard and other cooling system related parts as necessary to remove the engine.
Refer to section 6.8.2. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION 1-7