ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 000-001   Engine Removal

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  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.

WARNING  Coolant is toxic. Keep away from children and pets. 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.

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.

• Place a tag on all hoses, lines, linkages, and electrical connections as they are removed to identify their locations.
• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
• Drain the engine coolant. Refer to Procedure 008-018 in Section 8.
• Drain the lubricating oil. Refer to Procedure 007-037 in Section 7.
• Disconnect the starter cable, engine ground straps, cab or chassis to engine hoses, tubing, electrical wires, wire harnesses and hydraulic lines.
• Disconnect the drive units from the flywheel. Refer to the OEM service manual.
• Remove all chassis components necessary to remove the engine from the equipment.
• Cover all engine openings to prevent dirt and debris from entering the engine.

NOTE: On applications where the rear engine mounts are attached to the transmission, it will often be necessary to remove the engine and transmission as an assembly. Refer to the OEM service manual for instructions.

WARNING  The engine lifting equipment must be designed to lift the engine and transmission as an assembly without causing personal injury.

Use a properly rated hoist and engine lifting fixture, attached to the engine-mounted lifting brackets, to remove the engine. Refer to Procedure 018-015 in Section V.

NOTE: If the transmission is not removed with the engine, place a support under the transmission to prevent it from falling before removing the engine.

Place the engine on suitable engine support stands.

Remove all remaining accessories and brackets to use with the replacement engine.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To avoid arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

CAUTION  If the vessel remains in the water while the engine is being removed, make sure all sump or bilge pumps are operational while the engine is removed to prevent the vessel from taking on water and possibly sinking.

NOTE: Some of the graphics used in this procedure will not match all applications, but the procedure is the same unless otherwise noted.

Disconnect the battery cables, (-) negative cable first. Disconnect all unswitched power connections from the batteries and engine.

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

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.

CAUTION  Use caution when draining the cooling system that coolant is not spilled or drained into the bilge area. The coolant must be disposed of in accordance with local environmental regulations.

Shut off, disconnect, and cap the fuel supply line and fuel return line from the engine to the fuel tank(s). Refer to Procedure 100-002 in Section E.

NOTE: Some QSL engines are keel cooled and are not equipped with sea water supply to the engine.

Shut off the sea water supply line(s), if equipped.

CAUTION  Zinc plugs expand and can break off during removal. Inspect the zinc plug to make sure it is in one piece. If not, it must be replaced with a new zinc plug, and the broken pieces must be retrieved from the aftercooler to prevent damage to components downstream in the sea water system.

Drain the sea water system by removing the lower zinc plug from the aftercooler. Refer to Procedure 100-002 in Section E.

Disconnect the sea water supply lines. Refer to Procedure 100-002 in Section E.

CAUTION  Be sure to tie the exhaust piping up above the water line to prevent water from feeding back into the vessel while the exhaust piping is removed. Failure to do so can result in the vessel sinking.

Disconnect the exhaust piping from the exhaust outlet connection on the turbocharger.

WARNING  Coolant is toxic. Keep away from pets and children. 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 temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

CAUTION  Use caution when draining the cooling system that coolant is not spilled or drained into the bilge area. The coolant must be disposed of in accordance with local environmental regulations.

Drain the engine coolant. Refer to Procedure 008-018 in Section 8.

WARNING  Some state and federal agencies have determined that used engine oil can be carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact with used engine oil.

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

CAUTION  Use caution when draining the lubricating oil system that oil is not spilled or drained into the bilge area. The oil must be disposed of in accordance with local environmental regulations.

Drain the lubricating oil. Refer to Procedure 007-037 in Section 7.

Disconnect the transmission output shaft from the drive coupling. Refer to the OEM service manual.

Remove the engine mounting nuts from the engine mounts.

Remove all components necessary to remove the engine from the vessel.

Cover all engine openings to prevent dirt and debris from entering the 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 QSC8.3 marine engine is 896 kg [1975 lb]. The standard weight of the QSL9 marine engine is 907 kg [2000 lb].

Verify the engine weight specifications. Refer to Procedure 018-015 in Section V. Verify the marine gear weight specifications in the Marine Gear OEM service manual .

Use a properly rated hoist and engine lifting fixture, Part Number 3162871, attached to the engine-mounted lifting brackets, to remove the engine.

If the engine is to be replaced, remove all remaining accessories, brackets, and drive units that will be used with the replacement engine.