General Information
The procedures required to replace an engine will vary with different engine models, the type of equipment, optional equipment, and the shop facilities. Use the following procedures as a guide:
NOTE: All replacement steps will not apply to all types of equipment. Complete only the steps which apply to the
equipment involved. Use the equipment manufacturer’s recommendations and precautions for removal of chassis parts to gain access to the engine.
Engine – Removal (9-01)
Place a tag on all hoses, lines, li linkage, and electrical connections as they are removed to identify their locations.
Disconnect the battery cables.
Drain the engine coolant.
Drain the lubricating oil.
Disconnect the starter cable, engine ground straps, cab or chassis to engine hoses, tubing, electrical wires and
hydraulic lines.
Disconnect the intake and exhaust pipes.
Disconnect all chassis mounted engine driven accessories.
Disconnect the throttle linkage from the fuel injection pump control lever.
Disconnect the drive units from the flywheel.
Warning: If a liquid refrigerant system (air conditioning) is used, wear eye and face protection and wrap a cloth
around the fittings before removal. Liquid refrigerant can cause serious eye and skin injury.
Remove all chassis components necessary to remove the engine from the equipment.
NOTE: On applications where the rear engine mounts are attached to the transmission, it may be necessary to remove
the engine and transmission as an assembly.
Warning: The engine lifting equipment must be designed to safely lift the engine and transmission as an assembly.
The dry weight of the standard 6BTA5.9 without accessories is 411 kg [905 lb]. Refer to the equipment manufacturer’s specifications for the transmission weight.
Use a properly rated hoist and engine lifting fixture, attached to the engine mounted lifting brackets to remove
the engine.
NOTE: If the transmission is not removed, place a support under the transmission to prevent it from falling.
Cover all engine openings to prevent dirt and debris from entering the engine.
Place the engine on suitable engine support stands.
Remove all remaining accessories and brackets to use with the replacement engine.
