Removing And Installing The Engine; Removing And Installing The Engine; Removing The Engine - Toro Reelmaster 5100-D Service Manual

Removing and Installing the Engine

Removing the Engine

1. Put machine on a level surface, lower the cutting
units, stop the engine, engage the parking brakes and
remove key from ignition switch. Allow engine and ra ­
diator to cool.
2. Open hood. Disconnect hood stop cable from frame.
Lower 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. Remove rear lift arm down pressure springs (see
Chapter 8 - Cutting Units).
5. Open radiator cap. Put a drain pan under left side of
radiator. Open radiator drain valve and allow coolant to
drain into drain pan.
CAUTION
DO NOT open radiator cap or drain coolant if
engine or radiator is hot. Pressurized, hot
coolant can escape and cause burns.
Ethylene-glycol antifreeze is poisonous. Dis ­
pose of it properly or store in
labeled container away from children or pets.
6. Loosen hose clamps and disconnect upper and lower
radiator hoses from engine and radiator. Lift coolant
expansion tank off of bracket.
7. Remove plug from right side cylinder block to drain
coolant from engine.
8. Loosen hose clamps and disconnect air intake hose
from engine and air cleaner.
9. Remove muffler. Keep muffler bracket on engine.
10. Loosen hose clamp and remove fuel hose from
injector pump. Plug end of fuel line to prevent fuel

Removing and Installing the Engine

leakage. Loosen hose clamp and remove fuel return
hose from rear fuel injector on engine.
11. Disconnect and tag wires that attach to engine or
engine components:
Alternator
Starter motor and solenoid
Ground cables
Oil pressure switch
Temperature gauge sender
Thermoswitch
Engine stop solenoid
Glow indicator
12. Remove two (2) capscrews and lockwashers to
disconnect drive shaft coupler from engine crankshaft
pulley.
13. Remove four (4) capscrews, washers and locknuts
to remove fan shroud from radiator.
14. Loosen cap screw and nut to disconnect throttle
cable from governor lever on engine. Loosen clamp and
remove throttle cable and from fan bracket.
15. Remove locknut, flat washer, bolt and rebound
washer securing engine to each of four (4) rubber
engine mounts.
a properly
16. Attach a short section of chain between lifting holes
in fan bracket and muffler bracket. Connect hoist or
block and tackle chain at center of short section of chain.
One person should operate hoist or block and tackle and
the other person should help guide engine out of chas­
sis. Remove engine from chassis. Be careful when
removing engine to prevent damage to engine, radiator,
fan or other parts. Mount engine in an engine rebuilding
stand.
17. Remove fan, brackets and accessories from engine
as necessary. Drain oil from engine and remove engine
oil filter.
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Reelmaster 223-D/5100-D