Series 40E – Section 2.5 ECM

Section 2.5
ECM

The ECM wiring harness removal and installation procedures follow. ‪

Section 2.5.1
ECM Removal

Remove the ECM as follows:‪

1. Disconnect batteries.
2. Remove screws and connector cover shields from the ECM connector covers, see Figure "ECM Connector Cover Removal" .
   

   1. Connector Shield Screw‪	3. Connector Cover‪
   2. Connector Shield‪	4. Wiring Harness Connector‪

   Figure 1. ECM Connector Cover Removal

3. Remove ECM connector covers, see Figure "ECM Connector Covers" , from the wiring harness connectors.
   

   1. Connector Shield Screw‪	3. Connector Cover‪
   2. Connector Shield‪	4. Wiring Harness Connector‪

   Figure 2. ECM Connector Covers

4. Loosen the chassis wiring harness connector mounting bolt and remove wiring harness from the ECM.
5. Loosen engine wiring harness connector mounting bolt and disconnect engine wiring harness from the ECM; see Figure "Engine Wiring Harness" , and see Figure "Remove Engine Wiring Harness" .
   

   1. ECM‪

   2. Engine Wiring Harness Connector‪

   Figure 3. Engine Wiring Harness

   Note: If it is not necessary to remove the ECM from the mounting bracket, refer to step .

6. Remove the ECM wiring harness connector gaskets from the ECM unit. See Figure "Remove Engine Wiring Harness" .
   

   1. ECM‪

   2. Engine Wiring Harness Connector‪

   Figure 4. Remove Engine Wiring Harness

7. If it is necessary to remove the ECM from the mounting bracket, remove the four ECM mounting bolts and lift the ECM from the bracket, see Figure "Front ECM Unit" , and see Figure "Rear ECM Unit" .
   

   1. ECM Mounting Bolts‪

   2. Front Mounted ECM‪

   Figure 5. Front ECM Unit

8. Remove the bottom mounting bolts of the ECM mounting bracket, see Figure "Rear ECM Unit" .
   

   1. Rear Mounted ECM‪

   2. ECM Mounting Bolts‪

   Figure 6. Rear ECM Unit

9. Remove the three top mounting nuts of the ECM mounting bracket and lift bracket away from engine, see Figure "ECM Bushings, Pins and Nuts" .
10. If required, remove bushings and pins from mounting bracket, see Figure "ECM Bushings, Pins and Nuts" .
    

    1. Bushings and Pin Location‪	3. ECM Mounting Bracket‪
    2. ECM Mounting Bracket Nuts‪	‪

    Figure 7. ECM Bushings, Pins and Nuts

Section 2.5.1.1
ECM Inspection

Inspect ECM mounting bushings and pins for cracks, cuts, worn spots, etc. Replace as required, see Figure "ECM Bushings and Pin" .‪

1. Bushings‪

2. Pin‪

Figure 8. ECM Bushings and Pin

Inspect the engine wiring harness connectors, connector covers, and cover shields for cracks, cuts or worn areas. Replace as required, see Figure "Connector Cover Parts" .‪

1. Wiring Connector Cover‪	4. Wiring Harness Connector‪
2. Connector Cover Shield‪	5. ECM Gasket‪
3. Screw‪	‪

Figure 9. Connector Cover Parts

Section 2.5.2
Installation of ECM and Mounting Bracket as a Single Unit

Installation procedures for the front mounted or rear mounted ECM are identical, except where noted. The ECM and mounting bracket are installed as a single unit.‪

1. Install the ECM and mounting bracket to the engine. Torque the three top mounting nuts to the specification, see Figure "ECM Bushings, Pins and Nuts" . Refer to "Additional Information" , Specifications.
   

   1. ECM‪	3. ECM Mounting Bracket Nuts‪
   2. ECM Mounting Bracket‪	‪

   Figure 10. ECM Bushings, Pins and Nuts

2. Install the two (2) bottom bolts for the mounting bracket and torque to the specification; see Figure "Bottom ECM Bracket Bolts" . Refer to "Additional Information" , Specifications.
   

   Figure 11. Bottom ECM Bracket Bolts

3. Install the two ECM gaskets into the ECM connector receptacles.

   NOTICE:
   Do not use bearing grease or other non-dielectric grease on the ECM connectors as this may result in improper terminal contact and inefficient ECM operation.‪

4. Apply a 3/8 in. bead of quality dielectric grease, such as Navistar® P/N 1831731C1 or equivalent, to the ECM wiring harness connector. Use approximately 1/4 ounce of dielectric grease on the connector. Begin applying grease from the bolt, and move toward the ends of the ECM connector. See Figure "Application of Dielectric Grease to ECM Harness Connector" .

   Note: Dielectric grease P/N 1831731C1 is available from authorized Navistar parts distributors. It is not marketed by Detroit Diesel parts distributors.

   

   1. Location of Dielectric Grease‪

   Figure 12. Application of Dielectric Grease to ECM Harness Connector

5. Install the connector into the ECM. The dielectric grease will coat the terminals and overflow the sides of the connector, producing a moisture-tight seal.
6. Connect the engine wiring harness, see Figure "Install Engine Wiring Harness" , to the ECM and torque the connector retaining screw to the specification. Refer to "Additional Information" , Specifications.
   

   1. ECM‪

   2. Engine Wiring Harness Connector‪

   Figure 13. Install Engine Wiring Harness

7. Apply a 3/8 in. bead of quality dielectric grease to the ECM wiring harness connector. Use approximately 1/4 ounce of dielectric grease on the connector. Begin applying grease from the bolt, and move toward the ends of the ECM connector. Connect the second wiring harness to the ECM and torque the connector retaining screw.
8. Install the ECM connector covers, see Figure "Install ECM Connector Covers" , over the wiring harness connectors.
   

   1. Connector Shield Screw‪	3. Connector Cover‪
   2. Connector Shield‪	4. Wiring Harness Connector‪

   Figure 14. Install ECM Connector Covers

9. Place the connector shields onto the connector covers and secure with the connector cover shield screw, see Figure "ECM Bushings, Pins and Nuts" .
   

   1. ECM Mounting Bracket‪	3. ECM Mounting Bracket Nuts‪
   2. Bushings and Pin Location‪	‪

   Figure 15. ECM Bushings, Pins and Nuts

10. Connect the batteries.

Section 2.5.3
Installation of ECM and Mounting Bracket as Separate Units

Installation procedures for the front mounted or rear mounted ECM are identical, except where noted. The ECM and mounting bracket are installed separately.‪

1. Install the four pins and eight mounting bushings into the mounting bracket. See Figure "Bottom ECM Bracket Bolts" .
   

   Figure 16. Bottom ECM Bracket Bolts

2. Install the mounting bracket to the engine. Torque the top three mounting bolts. See Figure "Bottom ECM Bracket Bolts" . Refer to "Additional Information" , Specifications.
3. Install the two bottom bolts for the mounting bracket and torque. See Figure "Bottom ECM Bracket Bolts" . Refer to "Additional Information" , Specifications.
   

   Figure 17. Bottom ECM Bracket Bolts

   NOTICE:
   Do not use bearing grease or other non-dielectric grease on the ECM connectors as this may result in improper terminal contact and inefficient ECM operation.‪

4. Apply a 3/8 in. bead of quality dielectric grease, such as Navistar® P/N 1831731C1 or equivalent, to the ECM wiring harness connector. Use approximately 1/4 ounce of dielectric grease on the connector. Begin applying grease from the bolt, and move toward the ends of the ECM connector. See Figure "Application of Dielectric Grease to ECM Harness Connector" .

   Note: Dielectric grease P/N 1831731C1 is available from authorized Navistar parts distributors. It is not marketed by Detroit Diesel parts distributors.

   

   1. Location of Dielectric Grease‪

   Figure 18. Application of Dielectric Grease to ECM Harness Connector

5. Install the connector into the ECM. The dielectric grease will coat the terminals and overflow the sides of the connector, producing a moisture-tight seal.
6. Install the front mounted ECM onto the mounting bracket and torque the four mounting bolts. See Figure "Install Engine Wiring Harness" . Refer to "Additional Information" , Specifications.
   

   1. Front Mounted ECM‪

   2. ECM Mounting Bolts‪

   Figure 19. Install Engine Wiring Harness

7. Install the rear mounted ECM onto the mounting bracket and torque the four mounting bolts; see Figure "Install ECM Connector Covers" . Refer to "Additional Information" , Specifications.
   

   1. Rear Mounted ECM‪

   2. ECM Mounting Bolts‪

   Figure 20. Install ECM Connector Covers

8. Install the two ECM gaskets into the ECM connector receptacles.
9. Apply a 3/8 in. bead of quality dielectric grease to the ECM wiring harness connector. Use approximately 1/4 ounce of dielectric grease on the connector. Begin applying grease from the bolt, and move toward the ends of the ECM connector. Connect the engine wiring harness to the ECM, see Figure "Install ECM Connector Covers" .
   

   1. Connector Shield Screw‪	3. Connector Cover‪
   2. Connector Shield‪	4. ECM Unit‪

   Figure 21. Install ECM Connector Covers

10. Torque the connector retaining screw; see Figure "Securing ECM Connector" . Refer to "Additional Information" , Specifications.
    

    Figure 22. Securing ECM Connector

11. Install and connect the second wiring harness to the ECM. Torque the connector retaining screw. Refer to "Additional Information" , Specifications.
12. Install the ECM connector covers over the wiring harness connectors. See Figure "Install ECM Connector Covers" .
    

    1. Connector Shield Screw‪	3. Connector Cover‪
    2. Connector Shield‪	4. Wiring Harness Connector‪

    Figure 23. Install ECM Connector Covers

13. Place the connector shields onto the connector covers and secure with the connector cover shield screw. See Figure "Install ECM Connector Covers" .
14. Connect the batteries.