Removal and Installation

ENGINE REMOVAL

CAUTION: Use the equipment manufacturer's recommendations and precautions for removal of chassis parts to gain access to the engine.

Preparatory Steps
^ Remove the hood.
^ Disconnect the battery.
^ Drain the coolant.
^ Remove, Fan/Fan Clutch Assembly, Fan Shroud, Radiator.
^ Disconnect the air intake and exhaust pipes.
^ Disconnect the air conditioner connections.
^ Disconnect the alternator.
^ Disconnect the accelerator linkage.
^ Disconnect throttle linkage from the control lever. Do not remove control lever from the injection pump.
^ Disconnect the ground cable.
^ Disconnect the starter.
^ Disconnect all engine driven accessories.
^ Disconnect the torque converter.
^ Drain the lubricating oil.
^ Disconnect the transmission cooler lines.
^ Hoist the engine.
^ Disconnect the power steering lines.
^ Disconnect the fuel lines.
^ Remove the motor mounts.
^ Remove the transmission bolts.


ENGINE REPLACEMENT
Listing of Steps
^ Hoist engine.
^ Install the motor mounts.
^ Install the transmission bolts.
^ Bolt-up the torque converter.
^ Connect the transmission cooler lines.
^ Connect power steering lines.
^ Connect the fuel lines.
^ Connect all engine driven accessories.
^ Install the starter.
^ Connect the ground cable.
^ Connect the accelerator linkage.
^ Connect the throttle linkage to the control lever. Do not remove the control lever from the injection pump.
^ Connect the air conditioner connections.
^ Connect the alternator.
^ Connect the air intake and exhaust pipes.
^ Install fan/fan clutch assembly, fan shroud and radiator.
^ Install the lubricating oil.
^ Install coolant.
^ Install transmission fluid (automatic).
^ Connect the battery.
^ Test engine assembly.
^ Install the hood.

ENGINE REMOVAL - PROCEDURE





Disconnect all electrical connections. Put tags on the connections to identify their locations.





Disconnect all lines including fuel lines to the lift pump and fuel return. Use tags to identify the lines.





Put a cover or tape over all engine openings.





Use the lifting eyes to lift the engine. Apply tension to the hoist to hold the engine while you disconnect the engine mounts from the chassis. Lift the engine from the equipment.

Dry Engine Weight: 399 Kg [880 lb]

NOTE: Remove all accessories and brackets not previously removed to use with the replacement engine.

ENGINE REPLACEMENT - PROCEDURE





CAUTION: Do not exceed the torque value for the engine supports.

Torque Value: 77 N-m [57 ft-lb]

Check the data plate to verify that the replacement engine is the same model and rating as the engine that was removed.

NOTE: Install all accessories and brackets that had been removed from the previous engine.




Use the lifting eyes to lift the engine. Keep tension on the hoist while you align the engine in the chassis and tighten the engine mounts.





Connect the engine and chassis parts in the reverse order of removal.





When connecting the cable/rod to the control lever, adjust the length so the lever has stop-to-stop movement.





NOTE: Make sure the air intake and exhaust pipe connections are tight and free of leaks.





Fill the engine with the required amount of lubricating oil.

Oil Pan Capacity: 10.5 liters [11 - U.S. quarts]
Engine Oil Filter Capacity: 0.95 liters [1 - U.S. quart]

NOTE: Check the oil level after the engine has run for 2 to 3 minutes. Oil held in the oil filter and oil passages will cause the oil level in the oil pan to be lower.





Fill the cooling system with a mixture of 50% water and 50% ethylene-glycol base antifreeze.

Truck Coolant Capacity
Liters U.S. Quarts Automatic 15.7 [16.5]* Manual 14.7 [15.5]*
*Coolant recovery tank not included.





Operate the engine at idle for 5 to 10 minutes and check for leaks and loose parts.