B5.9G, B5.9LPG – Troubleshooting and Repair Manual – 000-001   Engine Removal

WARNING  If natural gas leaks are present, do not store the vehicle inside or in any area that is covered. Severe personal injury can result from asphyxiation or explosion.

WARNING  Fuel is flammable. Keep all cigarettes, flames, pilot lights, arcing equipment, and switches out of the work area and areas sharing ventilation to reduce the possibility of severe personal injury or death when working on the fuel system.

Shut off the fuel supply at the tanks.

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

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

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.

Disconnect the battery cables, negative (-) cable first.

Drain the engine coolant. Refer to Procedure
008-018.

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.

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

Drain the lubricating oil. Refer to Procedure
007-025.

Disconnect the starter cable, engine ground straps, cab or chassis to engine hoses, tubing, electrical wires, wire harnesses, and hydraulic lines.

Disconnect the intake and exhaust pipes. Refer to Procedure
010-024.

Disconnect all chassis-mounted engine-driven accessories.

Disconnect the throttle linkage from the throttle body. Refer to Procedure
005-052.

Disconnect the drive units from the flywheel.

Disconnect the OEM connector at the engine.

WARNING  To protect the environment, liquid refrigerant systems must be properly emptied and filled using equipment that prevents the release of refrigerant gas into the atmosphere. Federal law requires capturing and recycling the refrigerant.

WARNING  If a liquid refrigerant system (air conditioning) is used, wear eye and face protection, and wrap a cloth around the fittings before removing. Liquid refrigerant can cause serious eye and skin injuries.

For environmental protection, federal regulations require that freon be recycled, and
not vented into the atmosphere.

Remove all chassis components necessary to remove the engine from the equipment.

WARNING  The engine lifting equipment must be designed to lift the engine and transmission safely as an assembly without causing personal injury. The dry weight of the standard 6B5.9G and 6B5.9LPG without accessories is 458 kg [1010 lb]. Refer to the equipment manufacturer’s specifications for the transmission weight.

NOTE: On applications where the rear engine mounts are attached to the transmission, it will, perhaps, be necessary to remove the engine and transmission as an assembly.

WARNING  Use a stand or skid that contacts the engine mounts. The stand must hold the weight of the engine and provide permanent support to prevent the engine from falling.

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.