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TM 10-3930-671-24
4.11. Engine Removal
General Procedures
Truck Preparation Check List .........................................................................F-111
Engine Mounts ...............................................................................................F-112
Engine Removal Preparation ..........................................................................F-112
Engine Removal .............................................................................................F-116
Engine Installation ..........................................................................................F-117
Engine Installation Checklist ...........................................................................F-117
CAUTION
It is recommended that the engine be
removed only as a separate assembly
disconnected
from
the
transaxle.
Generally, because of height (clearance)
limitations, removal of the engine and
transaxle as a unit requires extensive
disassembly of the front structure of the
truck, including removal of the dash and
instrument panel. It is much easier and
simpler to remove the engine by itself.
Engine removal is also made easier with
less chance of accidental damage to
components when the counterweight and
radiator are removed.
For
safety
and
convenience,
it
is
recommended whenever possible to use
an overhead hoist to remove the engine
from the truck.
NOTE
•
The information in this section
describes general engine removal
procedures Illustrated with typical
views of the subject activity. Please
check your engine model for specific
component
arrangement
and
corresponding service requirement.
•
Prior to performing this service procedure,
it is recommended that you first:
• Park truck on a hard, level and solid
surface, such as a concrete floor with no
gaps or breaks.
• Put upright in a vertical position and fully
lower the forks or attachment.
• Put all controls in neutral. Turn key
switch OFF.
• Apply the parking brake. Block drive
wheels.
Truck Preparation Checklist
The major part of engine removal consists of preparation
(undressing) of the truck as necessary to allow engine
removal. The following check list outlines the major
steps.
1.
Turn ignition switch OFF.
2.
Open engine compartment. Remove side doors.
Remove floor boards.
3.
Disconnect battery ground (-) cable from engine
connection first. Disconnect battery (+) cable
from starter connection. Remove battery, as
necessary for access.
4.
Remove overhead guard.
5.
Remove counterweight.
6.
Remove top hood and seat assembly.
7.
Remove main hydraulic valve cover. Loosen
and remove firewall.
8.
Loosen main hydraulic control valve mounting
plate and tilt plate and main valve forward.
Leave
hoses
attached
to
main
valve.
Disconnect selected hydraulic lines, only as
determined by inspection as necessary for
clearance.
9.
Disconnect intake air cleaner hose. Remove air
cleaner assembly for clearance and better
access.
10.
Remove
muffler
and
tail
pipe
assembly.
Disconnect and remove exhaust pipe from
engine.
11.
Remove radiator cover trim, sound seals, engine
compartment sound seal plate, and radiator
upper support.
12.
Drain the radiator. Remove upper and lower
radiator hoses. Disconnect coolant overflow line
from radiator.
13.
Disconnect transmission cooling lines at the
radiator.
14.
Remove radiator.
15.
Remove wiring connections from alternator,
starter, starter relay, coil, and engine sending
units. Disconnect or remove wiring harness(es),
as determined by inspection as necessary.
16.
Disconnect
accelerator
control
rod
from
carburetor or fuel control. Disconnect choke
control wire (gasoline).
17.
Disconnect fuel line(s) from engine.
18.
Remove engine flywheel to torque converter
attachment.
19.
Remove flywheel housing or mounting plate to
transmission housing attachment.
20.
Remove front engine support mountings.
21.
Move engine rearwards to disengage from
transaxle. Carefully remove (hoist) engine from
truck chassis.
F-111
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