Service Manual

Engine Removal and Installation
1. Put machine on a level surface and engage parking
brake. Turn engine OFF and remove key from ignition
switch. Allow engine and radiator to cool.
2. Open the hood. Disconnect hood stop cable from
engine.
Lower the hood. Remove left and right hinge
plates. Lift hood off chassis.
3. Disconnect positive (+) and negative (–) battery ca-
bles
from battery. Loosen battery securing bolt and
remove battery.
4. Open the radiator cap. Open radiator drain valve or
r
emove lower radiator hose and allow coolant to drain
into a pan.
DO NOT open radiator cap or drain coolant if
engine or radiator is hot. Pressurized, hot
coolant can escape and cause burns.
CAUTION
5. Loosen hose clamps and disconnect upper and lower
radiator hoses from engine and radiator.
6. Loosen hose clamp and remove fuel hose from
injector pump. Plug end of fuel line to prevent fuel
leakage. Disconnect injector return hose.
7. Loosen hose clamp and disconnect PCV hose from
engine.
8. Disconnect and tag electrical wires that attach to the
engine or
engine components: alternator, starter motor
and solenoid, ground cable, oil pressure switch, tem-
perature gauge sender, thermoswitch, fuel stop (ETR)
solenoid, glow plugs.
9. Disconnect drive coupling from flywheel end of en-
gine.
10. Remove upper fan shroud from radiator.
11. Disconnect throttle cable from speed control lever
on f
uel injection pump. Loosen clamp and remove throt-
tle cable and from engine bracket.
12. Remove fasteners securing engine to engine
m
ounts.
13. Attach a short section of chain between the two lifting
brackets on the engine. Connect hoist, or block and
tackle chain at center of the short section of chain. One
person should operate hoist or block and tackle and
other person should help guide engine out of chassis.
Remove engine from chassis. Be careful when remov-
ing engine to prevent damage to engine, radiator or
other parts. Mount engine in an engine rebuilding stand.
14. Remove muffler, brackets, coolant expansion tank
and
accessories from engine as necessary. Drain oil
from engine and remove engine oil filter.
Engine
Groundsmaster 455-D Page 3 - 43
Rev. B
Engine