04 engine installation, not enough room!

[TPro]

My partner and I inherited a 'basket case' from a customer who was denied warranty on a failed engine (sound familiar?). It came to us with the motor on the bed (flat bed) and all assorted parts. Head was removed by dealership.

We overhauled the engine, bored 1mm oversize, assembled and painted and proceeded to install today only to find out... . we can't fit it in the chassis. My question is this, how do dealership techs remove and install these common rail engines? Do you have to lift the cab? Remove valve cover and rocker housing?

Thanks in advance.

 

[brista]

Valve cover has to be off, push tubes, rockers and pedestals for 4, 5 and 6 must be off (from the 06 service manual).

 

[Snoxracer]

I have had my motor out of my 05 so I have been where you are going. I have a service manual and in that they tell you to remove the valve cover, #6 injector and rockers. But they are also using a lifting block that bolts to the top of the head above 4-5 cylinder. (helps so the lifting chain doesn't hit the fire wall) They do not use the factory lifting lug that is in the back of the motor.

So what I did, since I didn't have their lifting lug is remove the oil pan and the oil pick up tube, plus I had the transmission adapter plate off the back of the motor. This allowed me enough room to get the motor under the fire wall. But before you lower it down in the motor mounts you have to put the pick up tube on and the oil pan. I don't know if this will work for you or not, because I also had my transmission out so I was able to put the adapter plate on with the motor in the truck.



Well I hope this helps,

Snoxracer

 

[Gary - K7GLD]

Didn't one of the members here with a truck at the dealership with engine issues comment on how unusual it was to see the truck cab lifted off the frame? Maybe in some situations it's easier to do it that way - or else the mechanics didn't know any better way?

 

[TPro]

figured it out, piece o' cake now

thanks to all who replied. We removed the radiator core support crossmember in the front with the help of a die grinder. Now there's no need to remove the valve cover to remove/install the engine in this 04. Don't have to remove the oil pan either. I took pictures but I don't know how to post them here. Very easy to do and no harm to the integrity of the core support. Thanx again guys.

 

[Snoxracer]

Yeah I have seen guys do that with cam installs, but I just couldn't get my self to cut my truck apart. I personally would rather take a little more time removing something, I know that you cant see it once the truck is together but I would know that it there and that would keep me up at night!

 

[MMeier]

- or else the mechanics didn't know any better way?

Naw... . say it isn't so !!!

 

[WPeschel]

thanks to all who replied. We removed the radiator core support crossmember in the front with the help of a die grinder. Now there's no need to remove the valve cover to remove/install the engine in this 04. Don't have to remove the oil pan either. I took pictures but I don't know how to post them here. Very easy to do and no harm to the integrity of the core support. Thanx again guys.

I would like to see pics of this... I am planning on pulling my engine next year to do some heavy mods... . Wes