B5.9G, B5.9LPG – Troubleshooting and Repair Manual – 000-002   Engine Installation

Install all accessories and brackets that were removed from the previous engine.

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 install the engine and transmission as an assembly.

Remove covers from all openings that were covered during removal.

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.

Use a properly rated hoist and engine lifting bracket attached to the engine-mounted lifting brackets to install the engine.

Align the engine in the chassis and tighten the engine mounting capscrews. Refer to the equipment manufacturer’s torque specifications.

Connect all engine- and chassis-mounted accessories that were removed.

NOTE: Be sure all lines, hoses, and tubes are properly routed and fastened to prevent damage. Be sure the air intake and exhaust pipe connections are tight and free of leaks.

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

Fill the engine with clean lubricating oil. Refer to Section 7 – Lubricating Oil System, General Information for lubricating oil specifications.

NOTE: The total oil system capacity, including lubricating oil filters, is:

Fill the cooling system with a premixture of 50-percent water, 50-percent ethylene glycol-base antifreeze. Refer to Procedure 008-018.

NOTE: The total coolant capacity (engine only) is:

CAUTION  Installation of the radiator cap at this point is critical to proper purging of air trapped in the cooling system. Improper purging of air from the cooling system will result in engine damage from overheating.

Install the radiator cap.

Perform a final inspection to make sure that all hoses, wires, linkages, and components have been properly installed and tightened.

WARNING  If 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.

Turn on the fuel supply at the tanks and check for leaks. Turn the ignition switch to the ON position (do not engage the starting motor)
and check for leaks.

Make sure the OEM wiring harness to the engine is disconnected. This is necessary to prevent the engine from starting during the lubricating oil rifle pressure-charging operation.

CAUTION  Do not engage the starting motor for more than 30 seconds. Wait 2 minutes between starter engagements to cool the starting motor.

Crank the engine until the lubricating oil pressure gauge indicates a positive pressure.

After pressure is observed, connect the OEM wiring harness to the engine harness.

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.

Operate the engine at low idle for 2 to 3 minutes.

Shut off the engine and wait 5 to 7 minutes for the lubricating oil to drain to the lubricating oil pan and check the lubricating oil and coolant levels again.

Fill the engine to the correct lubricating oil and coolant levels if necessary.

Verify the throttle percent on INSITE™ reads at least 85 percent with the throttle pedal fully depressed.

Adjust the throttle linkage if necessary. Refer to Procedure 005-052.

Operate the engine at 1000 to 1200 rpm for 8 to 10 minutes. Check for proper operation, unusual noises, and coolant, fuel, or lubricating oil leaks.

Repair all leaks and component problems. Refer to the appropriate procedures.

Refer to Section 14 for the Engine Run-in and Test Procedures.