Snowmobile Polaris 2006 - 2007 FS / FST. Manual - part 26

Engine Removal and Installation

5.1

CHAPTER 5

Engine Removal and Installation

Rev. 1 07/2006

ENGINE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2

5.2

Engine Removal and Installation

Rev. 1 07/2006

ENGINE REMOVAL AND
INSTALLATION

Before You Begin

The following procedures and/or components can be performed
or removed with the engine installed in the chassis:

• Engine Oil / Filter Change

• Engine Coolant Change

• Valve Lash Adjustment

• Exhaust System

• Charge Air Cooler (Intercooler) / Charge Air Pipe - FST

Models

• Alternator / Alternator Belt

• Cooling System Radiator

• Engine Oil Cooler

• Air Intake Box (Air Filter - FST Models)

• Oil Storage Tank

• Chaincase Assembly / Reverse System

• All Engine Management Sensors (Excluding: Crank

Position, Knock, and Coolant Temperature Sensors)

• Intake Manifold / Throttle Body Assembly

• Chassis Wiring Harness (Located Underneath Engine)

• Oil Supply Hose (Storage Tank-to-Engine)

• Coolant Hose (Water Outlet Manifold-to-Oil Cooler

(Bypass Route))

The following procedures and/or components can be performed
or removed with the engine suspended inside the engine
compartment or completely removed from the chassis using a
lifting hoist:

• Crank Position, Knock, and Coolant Temperature

Sensors

• Oil Separator Drain Hose

• Starter Motor

• Rubber Engine Mounts

• Bulkhead - Engine Mount Support Plates

• Steering Linkage (Tie Rods, Pitman Arms, etc.)

NOTE: The use of an overhead or portable engine
lifting hoist is the only recommend method for
removing and installing the engine assembly. The
hoist must be capable of lifting a minimum of 200
lbs. (91 Kg.) Have an assistant (other than hoist
operator) help guide the engine in and out of the
engine compartment when using the lifting hoist.

Suspending Engine

Several procedures can be accomplished when the engine is
suspended with an overhead or portable engine lifting hoist.

Remove the exhaust silencer.

Insert a screw into the cylinder head, then attach the lifting
chain.

Secure the other end of the lifting chain with a screw around
or through one of the exhaust manifold spring eyelets.

Slowly lift the hoist just enough to suppor the weight of the
engine.

Engine Removal

NOTE: The use of a digital camera is highly
recommended in aiding the identification of
components during re-assembly. Always label
wiring, cooling system, and oil system hoses and
connectors.

Remove the engine oil from the engine and storage tank.
(Reference oil change procedure in maintenance chapter.)

Remove the battery by first removing the positive (RED)
cable, then the negative (BLACK) cable from the battery.

Disconnect the RED wire from the alternator.

WARNING

Always disconnect the positive (RED) and then

negative (BLACK) battery cables from the battery after

removing the engine oil from the engine.

Never operate the engine in an enclosed environment.

Always operate engine in a well-ventilated area.

Keep fuel and fuel vapors away from open flame and

extreme sources of heat. Extinguish cigarettes prior to

working with any part of the fuel system.

Always dispose of excess fuel, engine oil, and engine

coolant in appropriate containers.

5.3

Engine Removal and Installation

Rev. 1 07/2006

Remove the engine coolant from the engine.

Remove the air intake plenum assembly.

Remove the drive belt, drive and driven clutch assemblies.

Remove the seat / storage bucket assemblies from the
tunnel.

Remove the console.

Remove the fuel tank assembly.

10. Remove the exhaust system. (The exhaust manifold and

turbocharger assembly can remain on the engine.)

11. Remove the oil storage tank / coolant recovery bottle

assembly.

12. Remove the boost box (FST) or intake air box (FS).

Remove the charge air pipe connecting the boost box to the
intercooler (FST).

13. Disconnect the engine wiring harness from the sensors and

actuators on the engine. Take digital photos or label each
connector to aid in the reassembly process.

14. Wrap the ends of the fuel hoes with a clean shop towel.

Remove the fuel supply and return hoses from the fuel rail.

15. Attach an engine lifting hoist to the engine assembly.

Support the engine weight so the engine remains stationary
when the engine mounts are removed from the engine.

16. Remove the MAG-side rubber engine mount bolt. The

bulkhead support plate can remain attached to the bulkhead.

17. Remove the PTO-side rubber engine mount bolt located in

the middle of the bulkhead support plate.

18. Remove the bulkhead support plate.

19. Remove the front PTO-side rubber engine mount bolt.

20. Remove the steering linkage rod from the bottom of the

steering post and bulkhead pivot.

21. Carefully and slowly lift the engine upwards until access

can be gained to the thermostat housing inlet and outlet
hoses.

22. Remove the engine cooling inlet and outlet hoses from the

thermostat housing.

23. Locate the power cable attached to the starter motor and

remove it from the post.

24. Remove the cyclone oil return hose from the crankcase

banjo fitting.

25. Continue lifting the engine out of the engine compartment

making sure the intake-side of the engine clears under the
console frame.

26. With the engine removed from the snowmobile, attach the

engine stand adapter plate, PW-46984, to the PTO-side of
the engine.

Engine installation is the reverse of removal. Reference the
following installation notes:

• Verify the position of the engine cooling hoses will not

be pinched when the engine is installed back into the
bulkhead.

• The fuel supply and return hoses must be connected to

the fuel rail before the wiring harness is connected to
the engine. (The harness lays over the fuel hoses).

• Position the thermostat housing inlet and outlet hose

clamps so the open-ends face upwards.

5.4

Engine Removal and Installation

Rev. 1 07/2006

MAG-Side Engine Mounting

RESONATOR BRACKET

ENGINE MOUNT

ENGINE STRAP PLATE

22Ft.Lb. (30 Nm)

14Ft.Lb. (19 Nm)

70Ft.Lb. (95 Nm)

15Ft.Lb. (20 Nm)

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