B
80
Repair and Service Manual
ENGINE
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
699322
ENGINE REMOVAL
Tool List
Qty.
Socket, 10 mm.............................................................1
Socket, 12 mm.............................................................1
Socket, 14 mm.............................................................1
Socket, 1/2" .................................................................1
Socket, 5/8" .................................................................1
Impact Socket, 19 mm.................................................1
Wrench, 8 mm .............................................................1
Wrench, 10 mm ...........................................................1
Wrench, 12 mm ...........................................................1
Wrench, 13 mm ...........................................................1
Wrench, 14 mm ...........................................................2
Wrench, 15 mm ...........................................................1
Wrench, 19 mm ...........................................................1
Combo Wrench, 19 mm...............................................1
Pliers............................................................................ 1
Extension 6" ................................................................1
Ratchet ........................................................................ 1
Flat Ratchet .................................................................1
Impact Tool ..................................................................1
Straight Blade Screwdriver ..........................................1
Drip Pan....................................................................... 1
This section covers the removal and installation of the
engine, for information on rebuilding the engine please
see the Engine Shop Rebuild Manual for this vehicle.
NOTICE: In the following text, there are references
to removing/installing bolts etc. Additional hardware
(nuts, washers etc.) that are removed must always
be installed in their original positions unless other-
wise specified. Non specified torque specifications
are as shown in the table contained in the General
Information and Routine Maintenance section.
This operation will remove the engine through the top of the
engine compartment. The weight of the engine exceeds nor-
mal OSHA limits for one person; therefore, a second person or
an engine hoist will be needed to remove the engine. If a hoist
is employed, it will be necessary to remove the sun top.
1. Disconnect Battery ground wire.
2. Disconnect air hose at throttle body.
3. Jack up rear of vehicle as directed in the SAFETY
Section of this manual. Use jack stands for stability.
4. Remove the drive belt by rotating clutch toward rear of
vehicle when the belt is slipped off the top of the
clutch. Remove belt from vehicle.
5. Disconnect the ’DF’ wire from the starter using 8mm
wrench, lay harness out of the way
6. Remove the ground strap from the Starter/Generator
using a 10 mm socket.
7. Disconnect the F2 power cable from the top of the
starter.
8. Starter/Generator (See Starter/Generator Replace-
ment in this section).
9. Remove the ground strap at the crankcase using the
10 mm socket. Route ground strap through bracket
and under the throttle rod and cover.
10.Disconnect the fuel line from the injector, use drip pan
to catch any fuel leakage.
11. Remove throttle rod cover using a 6" extension and a
10 mm socket. Remove the throttle rod at the throttle
plate using a pliers to pop the retaining tab from the
throttle rod and lift throttle rod out of hole. Remove
throttle rod at rear by rotating 45 degrees from the
bracket and lift through the bracket slot and remove
rod from vehicle.
12.Remove both bolts from starter/generator bracket
using a 15 mm wrench.
13.Remove the 12mm hardware that secures the header
flange to the muffler flange.
14.Remove the four 15 mm bolts from the engine support
bracket connecting the engine to the differential and
the engine to the inner frame.
15.Remove the 15 mm bolts from the bottom of the skid
plate. Access the forward two nuts through the oil
drain access hole.
Controls and Wiring
Disconnect the 12 pin engine-harness connector joining
the main harness to the engine harness.
Removing the Engine from the Vehicle
NOTICE: Place suitable blocks under the engine
frame for support. the alignment of the frames and
simplify engine installation.
NOTICE: It is not necessary to remove the muffler as
part of the engine removal.
