Paccar MX-13 – Install engine

Remember that if any parts are removed, replace the gaskets and O-rings. DO NOT REMOVE ANY GASKET MATERIAL WITH ANYTHING OTHER THAN SCRAPERS OR RAZOR BLADES. DO NOT USE ANY CLEANING WHEELS OR ABRASIVE MATERIALS THAT MAY ALTER MACHINING MARKS. Check Rapido for bolt replacement guidelines. If unclear, check with the appropriate personnel for further guidance.

1. Install poly-V-belts and other accessories
– At this time reinstall all belts and accessories that were removed during out of chassis repair, including the PCI.

2. Install rear lifting bracket

– Reinstall the lifting bracket special tool (1453180)/(1903016)
As mentioned previously, it is recommended that the valve cover be removed during this step to allow for chain clearance.

3. Engine into chassis
Securely affix the engine onto the shop hoisting device. Position the engine back into the chassis, taking care to not damage any components, wiring, or air lines. Allow the rear of the engine to rest slightly above the rear engine mounts.
Options at this point:
– Start the threads of one or more of the rear engine mount bolts in order to secure and stabilize the engine for installation of the front engine mount.
– Install the front engine mount and passenger-side brackets in order to stabilize the engine for installation of the rear engine mount bolts.

Look for metal shavings and/or other debris, including liquids other than oil.

The presence of debris or foreign liquids could indicate additional issues other than the original complaint.

4. Mate transmission bell housing to engine
– Once the engine is safely supported and secured, lift the transmission into place using an approved transmission jack.
– Secure the transmission onto the flywheel housing using the bell housing bolts.

If equipped with an Allison transmission, take notice and align the torque converter mounting holes in the correct orientation, install the bolts and torque to proper specifications.

If equipped with an Ultrashift or manual transmission, slide the clutch forward and install the clutch bolts. Torque all bolts to the flywheel using proper torque specifications.

5. Remove rear lifting bracket and transmission jack
– With the engine and transmission secured and bolted, remove the rear engine lifting bracket and the transmission jack/support.

6. Install the transmission-mounted components and wiring
– Reconnect the electronic actuators (Eaton Ultrashift) or hydraulic slave cylinders (Eaton manual 10-speed transmission).

Review the previously noted orientation of the clutch fork and ensure that it is reinstalled properly to prevent damage to the clutch parts.

When installing the hydraulic slave cylinder on manual transmissions, be sure to insert the ball on the hydraulic cylinder into the socket on the bottom of the clutch fork.

7. Install exhaust pipe
– Reposition the exhaust pipe between the DOC inlet and the BPV outlet.

Always use new exhaust gaskets and V-clamps.

8. Reattach power steering lines
– Connect the power steering supply and return lines to the power steering pump.

9. Connect starter wires and chassis ground
– Securely route and secure the power and ground harnesses to the starter and reconnect the proper wires to the proper terminals.
– Reconnect the chassis ground wire to the connection point on the outside of the frame rail.

10. Install valve cover
– Reinstall the valve cover.
Use a new gasket when reinstalling the valve cover.

11. Install rear of engine components
– Reconnect the coolant lines, fuel lines (HC Doser and injector return lines), harnesses (HC Doser), and any other accessories on the rear side of the engine.

Portions of this step may not be necessary depending on which rear lifting bracket is being used.

12. Route and connect J2/OEM harness
– Route the large gray and small white engine harness connectors back toward their respective locations on the firewall.

– Reconnect the engine harnesses by pushing the locking tabs upward toward the cab windshield.
– Route the chassis grounds to their respective posts on the underside of the cab (below the harness connections mentioned above).
– Reconnect the aftertreatment harness at the rear of the engine and make all other connections at this point.
– Connect the air line at the air shutoff valve on the fuel module and the air line for the unloader sensing valve.

13. Connect fuel lines
– Reconnect the fuel supply and return lines to the fuel interface module located on the driver’s side of the engine.

Ensure that the O-rings for the fuel lines are not cracked or split and the line clips are installed correctly. This will ensure that the lines will not leak fuel and also prevent air from entering the fuel system.

14. Reinstall fan blade and fan shroud with brackets
– Reinstall the fan shroud and fan on the front of the engine.

15. Reinstall radiator and cooler pac
– With the radiator/cooler pac assemblies safely supported, use the attachment bolts on the underside of the cooler pac to secure it to the chassis.

– Reinstall the upper bolts for the side supports to the cooler pac.
If equipped with a fuel cooler, connect the fuel lines at this time.

16. Connect the cold/hot side charge air cooler tubes
– Reinstall the boost tubes.

When installing the charge air cooler pipes to the engine, be sure to use a new gasket and V-band clamp where required.

17. Install radiator hoses
– Locate and reinstall the coolant hoses from the engine coolant module to the radiator outlets. This includes the Reservoir fill line.

18. Install A/C condenser lines
– Connect the A/C condenser lines at this point, along with other A/C lines that were disconnected.

You can connect the machine and begin the vacuum and leak test on the A/C system at this time. The vacuum and leak test takes a substantial amount of time to complete. It is recommended that other components be reinstalled during the completion of the cycles.
Charging of the A/C system will be addressed in a later step.

19. Install air filter box
– Reconnect all harnesses, air lines, and support brackets for the air filter box.

Be sure to reinstall all fasteners affixing the box to the firewall.

20. Replace all necessary filters
– Depending on the type of repair performed, vehicle miles, etc., replace all required filters (potentially includes air, fuel, and oil filters).

21. Reconnect batteries
– Re-establish all battery connection points that were removed during engine removal.

Ensure that any unique/chassis specific battery cable configurations are reinstalled in the same location from which they were removed.

22. Fill oil and coolant
– Refill the oil and coolant to their respective levels.
Oil capacities per engine type may be located within Rapido.

23. Prime fuel system
Following the recommended Rapido procedure, prime the fuel system to eliminate air pockets.

24. Start truck
– Briefly start the engine and let it run to stabilize the oil pressure. Once the pressure is stable, shut off the engine and check the oil level. Add oil if required.
– Restart the engine and allow it to idle for 15 minutes (per fuel priming steps). During this time check all fluid systems for leaks.
– Follow the coolant bleeding procedure as outlined by Rapido to evacuate air pockets in the coolant system.

25. Install hood

– Be sure that adequate support (overhead hoist/additional manpower) is present to install the hood safely without causing personal injury or component damage.

26. Install bumper
– Once the bumper attachment bolts have been installed, ensure that all lights, sensors, etc. are reconnected.
– Depending on the model and application, this may require the assistance of an additional technician to safely maneuver the bumper into position.

27. Charge A/C system
– With the A/C recovery machine connected to the high and low side A/C lines, begin charging the A/C system.

Overcharging of the A/C system can cause component damage.

28. Bleed power steering
– Follow all OEM recommended power steering system bleeding procedures before test driving the vehicle.

29. Connect to truck using DAVIE
– Perform a DAVIE quick check to view currently active codes.
– Cal ID and CVN: Verify that all components are listed and currently valid.
– Change Injector codes: Ensure that the codes are present within DAVIE to ensure optimum engine performance.
– Software: Verify that all software is up to date and valid for the chassis.
– Engine Integration Parameters: Ensure that the customer’s required specifications are applied.

30. Test drive
– Take the vehicle on a test drive to verify that the original complaint is repaired and addressed and to ensure that new issues have not developed during the repair procedure.

 

 

 

 

 

 

Leave a Reply

Your email address will not be published. Required fields are marked *