Cummins ISX11.9 CM2250 – Service Manual 000-001   Engine Removal

Place a tag on all hoses, lines, linkages, and electrical connections as they are removed, to identify their locations on the engine.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

Disconnect the batteries. Refer to the OEM service manual.

Drain the engine coolant. Refer to Procedure 008-018 in Section 8.

WARNING  To reduce the possibility of personal injury, avoid direct contact of hot oil with your skin.

WARNING  Some state and federal agencies have determined that used engine oil can be carcinogenic and cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil. If not reused, dispose of in accordance with local environmental regulations.

Drain the lubricating oil. Refer to Procedure 007-037 in Section 7.

Disconnect the starting motor cable, the engine ground straps, the cab- or chassis-to-engine hoses, the tubing, the electrical wires, and the hydraulic lines.

Disconnect the intake and exhaust air pipes.

Disconnect all chassis-mounted, engine-driven accessories.

Disconnect the drive units from the flywheel.

Disconnect the OEM wiring harness from the electronic control module (ECM). Refer to Procedure 019-071 in Section 19.

NOTE: If the rear engine mounts are attached to the transmission, it will possibly be necessary to remove the engine and the transmission as an assembly.

Most cab-over configuration vehicles will have the Cummins Inc. factory-installed rear engine lifting bracket still installed.

Remove all chassis components necessary to remove the engine.

WARNING  The engine lifting equipment must be designed to lift the engine and the transmission as an assembly without causing personal injury.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

Use a correctly rated hoist, and attach the engine lifting fixture, Part Number 3162871, to the engine-mounted lifting brackets to remove the engine.

If the transmission is not removed, place a support under the transmission to prevent it from falling.

Remove the engine.

Cover all engine openings to prevent dirt and debris from entering the engine.

Place the engine on suitable engine support stands.

Remove and use all remaining accessories and brackets with the replacement engine.