Front Engine Access; Torque Requirements; (Unless Otherwise Specified) - Guardian 5240 Diagnostic Repair Manual

SECTION 6.1
MAJOR DISASSEMBLY

FRONT ENGINE ACCESS.

1. Follow Stator/Rotor/Engine removal procedures,
Steps 1-5.
2. Control Panel Removal: Using a 7mm socket remove
the four bolts from male C1 and C2 connectors. Remove
connectors from engine divider panel.
BACK PANEL C1 CONNECTOR
Figure 9. C1 and C2 Connectors Located on the
Engine Divider Panel
Using a 10mm socket, remove the six (6) nuts attach-
ing the control panel to the side/back enclosure and
the engine divider panel. Remove the two (2) nuts
connected to the back enclosure located on the top
side of control panel. Remove the two (2) nuts located
underneath the middle of the control panel, connecting
to the back/side enclosure and the engine divider panel.
Remove the two (2) nuts from the front top side of the
control panel, connecting to the back/side enclosure
and the engine divider panel. Remove the control panel.
3. Remove Engine Divider Panel: Using a 10mm socket,
remove the remove the two (2) nuts attached to the
back enclosure. Remove the two bolts attached to the
base enclosure. Remove the engine divider panel.
Page 136
C2 CONNECTOR
C3 CONNECTOR
PART 6
4. Remove Intake manifolds: Using a 6mm allen wrench,
remove the four (4) socket head cap screws from the
intake manifolds. Remove the intake manifolds. Remove
the air intake snorkel.
5. Remove Air Box: Using a 5/32 allen wrench, remove
the four (4) air box allen head shoulder bolts. While
removing the air box remove the four rubber washers
and disconnect the throttle linkage and anti-lash spring.
6. Unbolt Oil Cooler: Using a 10mm socket, remove the
four (4) oil cooler bolts.
7. Remove Blower Housing: Using an 8mm socket,
remove the nine (9) bolts around the blower housing.
Remove the blower housing.
8. Remove flywheel: Use a 36mm socket, a steering
wheel puller, two (2) M8x1.25 bolts and a 13 mm socket.
Remove the flywheel hex nut, remove the fan plate
and fan. Install the puller using the M8x1.25 bolts and
remove the flywheel.

TORQUE REQUIREMENTS

(UNLESS OTHERWISE SPECIFIED)

FLYWHEEL NUT ............................................................ 50 ft-lbs
STATOR BOLTS ............................................................. 12 ft-lbs
ROTOR BOLT ................................................................ 30 ft-lbs
ENGINE ADAPTER ....................................................... 25 ft-lbs
EXHAUST MANIFOLD .................................................. 18 ft-lbs
INTAKE MANIFOLD (TO CYLINDER HEAD) ................ 22 ft-lbs
M5-0.8 TAPTITE SCREW INTO ALUMINUM .......... 25-50 in-lbs
M5-0.8 TAPTITE SCREW INTO PIERCED HOLE ... 25-50 in-lbs
M6-1.0 TAPTITE SCREW INTO ALUMINUM .......... 50-96 in-lbs
M6-1.0 TAPTITE SCREW INTO PIERCED HOLE ... 50-96 in-lbs
M6-1.0 TAPTITE SCREW INTO WELDNUT ............ 50-96 in-lbs
M8-1.25 TAPTITE SCREW INTO ALUMINUM ........ 12-18 ft-lbs
M6-1.0 NYLOK NUT ONTO STUD .......................... 16-65 in-lbs
Note: torques are dynamic values with ±10% toler-
ance unless otherwise noted.
DISASSEMBLY