3.42
ENGINE SERVICE
ACCESSIBLE ENGINE COMPONENTS
Components serviceable with engine installed:
• Flywheel
• Alternator (Stator)
• Starter Motor / Solenoid
• Cylinder Head / Valves
• Camshaft / Camshaft Carrier
• Rocker Arms
• Water Pump
Components that require engine removal for service:
• Counterbalance Shaft(s)
• Piston / Rings
• Connecting Rod
• Crankshaft / Main Bearings
• Oil Pump
• Crankcase
• Crankshaft End Seals (Use Driver PA-49320)
TOP-END SERVICE (ENGINE IN CHASSIS)
The top-end of the engine can be serviced while the
engine is mounted in the chassis. A removable upper
right-hand frame support allows access to the valve
cover and cylinder head.
To service the top-end of the engine refer to the “Valve
Clearance Adjustment” procedure in Chapter 2, which
provides detailed steps to access the valve cover.
ENGINE REMOVAL
IMPORTANT
Some engine repair procedures can be performed
without removing the engine from the vehicle. Refer to
“Accessible Engine Components” for further
information.
NOTE
Upon engine removal, use a mechanical lift or have an
assistant help remove the engine from the vehicle to
prevent personal injury or damage to vehicle
components.
1. If vehicle was recently operated, allow it to cool down
before attempting to perform any work.
2. Thoroughly clean the engine and chassis.
3. Clean your work area.
4. Drain the engine oil (see Chapter 2 “Maintenance”).
5. Remove the following body components. Refer to
Chapter 9 “Body / Frame” for component removal.
• Seat
• Side Panels (upper and lower)
• Footwells
• Mud Guards (both sides)
• Front Rack or Storage Box
• Front Cab
6. Disconnect negative (-) battery cable.
7. Pull the shift linkage rod straight outward while
pushing on the two ears of the snap retainer
q
to
disconnect the rod from the shift lever. Allow the
linkage to hang down out of the way.
ENGINE / COOLING SYSTEM
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