Engine Assembly Replace
J450100
Remove
Warning: The diesel common rail system is under very high pressure. Damage or personal injury may result if the safety procedures are not followed. The system is very sensitive to contamination; damage may result if the precautions regarding cleanliness are not followed. Do not loosen or remove fuel lines when the engine is running. As soon as the fuel circuit is open, all openings must be plugged using kit available from Parts and Accessories, to prevent pollutants from penetrating the fuel circuit. Do not clean the engine using a high pressure washer; this may damage connections and moisture may collect in the connections causing electrical problems.
1. Before performing ANY work on fuel system or its components, switch OFF ignition and wait until pressure has dropped sufficiently.
Important: Observe the relevant safety regulations when working on air conditioning systems.
2. Evacuate refrigerant from air conditioning system.
3. Remove battery from vehicle.
• Remove 2x cover from 2x terminal.
• Disconnect negative and positive cable.
• Remove clamp.
• Release 2x nut.
4. Remove engine cover.
• Remove 4x nut.
5. Disconnect 2x connector from engine control unit (ECU).
6. Remove ECU from support bracket.
• Release clip, then pull up.
7. Remove ECU support bracket from battery tray.
• Remove 2x nut
8. Release intake pipe from engine and turbocharger.
• Remove bolt.
• Release clip.
• Disconnect harness from mass air flow meter.
9. Remove intake pipe with air cleaner assembly from engine compartment.
• Release air cleaner assembly from inner wing.
• Remove 2x bolt.
• Release from locator.
10. Release power steering reservoir from coolant expansion tank, then move to one side.
• Remove 2x bolt, slide off locator.
• Release transmission breather hose from coolant expansion tank.
• Release from clip.
11. Remove outlet pipe assembly from intercooler and turbocharger.
• Remove 2x bolt.
• Release 2x clip.
12. Remove cap from coolant expansion tank.
13. Remove intake hose from turbocharger.
• Disconnect breather hose.
• Release 2x clip, then pull off.
• Remove clip.
14. Remove hose from intercooler and intake manifold.
• Remove 2x clip.
15. Disconnect harness connector from coolant temperature sensor.
16. Release 2x earth lead from intake manifold.
• Remove bolt
17. Disconnect harness connector from intake manifold pressure sensor.
18. Disconnect harness connector from camshaft position sensor.
19. Disconnect harness connector from fuel temperature sensor.
20. Disconnect harness connector from fuel pressure sensor.
21. Disconnect 2x harness connector from 2x cooling fan.
22. Disconnect harness connector from alternator.
23. Disconnect harness connector from high pressure pump.
24. Release fuse box for 4x glow plug from upper front panel, then move to one side.
• Release cover.
• Release clip.
• Remove 2x bolt.
25. Disconnect harness connector from throttle position sensor.
26. Disconnect harness connector from air conditioning pressure sensor.
27. Disconnect harness from transmission shift selector.
• Disconnect 2x connector.
28. Disconnect gear shift cable from transmission.
• Prise off, using suitable tool.
29. Release gear shift cable from support bracket.
• Press clip, then pull off.
30. Release harness from top of transmission, then move to one side.
• Disconnect from input speed sensor.
• Release from 2x clip.
31. Disconnect 4x connector from 4x injector.
32. Disconnect harness connector from vacuum switching valve.
33. Disconnect harness connector from fuel filter housing.
34. Disconnect harness connector from fuel pipe sensor.
35. Disconnect harness connector from exhaust pressure sensor.
36. Disconnect engine harness from harness for 4x glow plug.
37. Disconnect harness connector from turbocharger wastegate.
38. Disconnect harness connector from crankshaft position sensor.
39. Disconnect harness connector from output speed sensor at rear of transmission.
40. Disconnect brake servo hose from vacuum pump.
• Release clip.
41. Raise vehicle.
42. Remove engine and transmission undershield from vehicle.
• Remove 2x clip, 5x bolt.
Important: Observe the relevant environmental regulations when disposing of used coolant.
43. Drain cooling system.
• Place collecting container below.
• Open radiator drain plug.
• Allow coolant to drain into collecting container.
• Close radiator drain plug.
44. Remove front exhaust pipe.
• Disconnect oxygen sensor, then release from subframe.
• Remove 6x nut, gasket.
• Release from rubber mount.
Important: Observe the relevant environmental regulations when disposing of used transmission oil.
45. Drain oil from transmission.
• Place collecting container below.
• Remove drain plug from transmission.
• Remove sealing washer.
46. Install drain plug to transmission 40 Nm.
• Install new sealing washer.
47. Release 2x oil cooler pipe from transmission, then move to one side.
• Place collecting container below.
• Remove bolt.
• Remove 2x O ring.
• Install 4x Blanking Plug KM-6320.
48. Disconnect harness connector from oil pressure switch below oil filter housing, then release clip.
49. Disconnect harness connector from air conditioning compressor.
50. Disconnect harness connector from oil quality sensor.
51. Release 2x earth lead from engine.
• Remove 2x bolt.
52. Release harness from starter.
• Disconnect connector.
• Remove nut.
53. Release harness for alternator from starter.
• Remove nut.
54. Release harness from oil level dipstick tube.
• Release clip.
55. Disconnect 2x refrigerant pipe from air conditioning compressor.
• Remove nut.
• Remove 2x O ring.
• Install 4x new blanking plug.
56. Disconnect 2x power steering hose from 2x power steering pipe.
• Place collecting container below.
• Release 2x clip.
• Install 4x new blanking plug.
57. Lower vehicle to suitable working height.
58. Remove 2x front wheel from vehicle.
• Remove 10x bolt.
59. Lower vehicle.
60. Release 2x drive shaft from 2x hub/knuckle assembly.
• Remove 2x hub nut using Holding Tool KM-468-C.
61. Release harness from rear of engine, then move to one side.
• Release 2x clip.
62. Release 2x battery lead from support bracket.
• Release clip.
63. Release harness trunking from 2x bracket on intake manifold.
• Release fuel return hose from harness trunking.
• Release from 2x clip.
• Release 2x harness trunking clip.
64. Release harness from front of engine , then move to one side.
• Release 2x clip.
65. Release harness for 4x glow plug from engine.
• Release 4x clip.
66. Disconnect radiator upper coolant hose from engine.
• Release clip.
67. Disconnect upper refrigerant pipe from lower refrigerant pipe.
• Remove nut.
• Remove O ring.
• Install 2x new blanking plug.
68. Release lower refrigerant pipe from upper front panel.
• Remove bolt.
69. Release power steering pipe assembly from upper front panel, then position to engine.
• Remove 2x bolt.
70. Disconnect radiator lower coolant hose from engine.
• Release clip.
71. Support radiator assembly using a suitable strap to the bonnet landing panel.
Warning: Fuel escapes - observe safety measures and national legislation.
Important: Clean all connections before disconnecting; use only lint-free cleaning cloths.
72. Disconnect fuel feed pipe from high pressure pump.
• Place collecting container below.
• Release 2x clip.
• Install 2x new blanking plug.
73. Disconnect fuel return pipe from fuel leak off pipe assembly.
• Release 2x clip.
• Install 2x new blanking plug.
74. Disconnect 2x heater matrix coolant hose from engine.
• Release 2x clip.
75. Disconnect return hose for coolant expansion tank from engine.
• Release clip.
76. Disconnect lower hose from coolant expansion tank.
• Release clip.
77. Raise vehicle to suitable working height.
78. Remove wheelarch splash shield, right side.
• Remove 3x clip.
79. Release tie rod end from steering knuckle, right side.
• Remove nut.
• Use Remover KM-507-C.
80. Release lower control arm fulcrum, right side.
• Release nut and nut, bolt.
81. Release lower ball joint from hub assembly, right side.
• Remove split pin.
• Remove nut.
• Use Remover KM-507-C.
82. Remove drive shaft, right side.
• Lever out using a suitable tool.
83. Remove wheelarch splash shield, left side.
• Remove 3x clip.
84. Disconnect harness for power steering gear from body harness.
85. Disconnect intermediate shaft from steering gear.
• Remove bolt.
86. Release tie rod end from steering knuckle, left side.
• Remove nut.
• Use Remover KM-507-C.
87. Release lower control arm fulcrum, left side.
• Release nut and nut, bolt.
88. Release lower ball joint from hub assembly, left side.
• Remove split pin.
• Remove nut.
• Use Remover KM-507-C.
89. Remove drive shaft, left side.
• Lever out using a suitable tool.
90. Raise vehicle.
91. Install Engine Support Tool CH-48492 to engine and subframe.
92. Lower vehicle.
93. Release mount from transmission.
• Remove 3x bolt.
94. Release mount from engine.
• Remove 3x bolt.
95. Raise vehicle.
96. Release 2x stabiliser link rod from stabiliser bar, left side, right side.
Note: If ball joint turns when removing nut, counter-hold centre of stabiliser rod using suitable allen key.
• Remove 2x nut.
97. Release propeller shaft from transfer box
• Apply alignment marking.
• Remove 6x bolt with 3x washer, then secure to vehicle.
98. Install Subframe Support Tool CH-48491 to Base Frame KM-904 and hydraulic lift
Note: 2x technician are required.
99. Position Subframe Support Tool CH-48491 with Base Frame KM-904 and hydraulic lift to subframe.
100. Remove engine with subframe from vehicle.
• Remove 8x bolt, 2x triangular plate.
• Lower and remove.
Install
101. Install engine with subframe to vehicle.
• Raise and position.
• Install 2x triangular plate, 8x bolt; do not tighten at this stage.
102. Secure subframe to vehicle.
Tighten
• Secure 4x bolt for subframe 150 Nm.
• Secure 4x bolt for 2x triangular plate 50 Nm.
103. Remove Subframe Support Tool CH-48491 with Base Frame KM-904 and hydraulic lift from subframe.
104. Remove Subframe Support Tool CH-48491 from Base Frame KM-904 and hydraulic lift.
Note: 2x technician are required.
105. Secure propeller shaft to transfer box.
• Release from vehicle.
• Align marking.
Tighten
• Install 6x bolt with 3x washer 25 Nm.
106. Secure 2x stabiliser link rod to stabiliser bar, left side, right side.
Note: If ball joint turns when installing nut, counter-hold centre of stabiliser rod using suitable allen key.
Tighten
• Install 2x nut 60 Nm.
107. Lower vehicle.
108. Secure mount to engine.
Tighten
• Install 3x bolt 50 Nm.
109. Secure mount to transmission.
Tighten
• Install 3x bolt 90 Nm.
110. Raise vehicle.
111. Remove Engine Support Tool CH-48492 from engine and subframe.
112. Connect intermediate shaft to steering gear.
Tighten
• Install bolt 30 Nm.
113. Connect harness for power steering gear to body harness.
114. Install front exhaust pipe.
• Secure to rubber mount.
• Install new gasket.
Tighten
• Install 6x nut 40 Nm.
• Connect oxygen sensor, then secure to subframe.
115. Secure 2x oil cooler pipe to transmission.
• Place collecting container below.
• Remove 4x Blanking Plug KM-6320.
• Install 2x new O ring.
Tighten
• Install bolt 10 Nm.
116. Connect 2x power steering hose to 2x power steering pipe.
• Place collecting container below.
• Remove 4x blanking plug.
• Secure 2x clip.
117. Lower vehicle to suitable working height.
118. Install drive shaft, right side.
• Push in.
• Install hub nut; do not tighten at this stage.
119. Secure lower ball joint to hub assembly, right side.
Tighten
• Install nut 10 Nm.
• Install new split pin.
120. Secure tie rod end to steering knuckle, right side.
Tighten
• Install nut 50 Nm.
121. Install wheelarch splash shield, right side.
• Install 3x clip.
122. Install drive shaft, left side.
• Push in.
• Install hub nut; do not tighten at this stage.
123. Secure lower ball joint to hub assembly, left side.
Tighten
• Install nut 10 Nm.
• Install new split pin.
124. Secure tie rod end to steering knuckle, left side.
Tighten
• Install nut 50 Nm.
125. Install wheelarch splash shield, left side.
• Install 3x clip.
126. Lower vehicle.
127. Remove support from radiator assembly.
128. Secure 2x drive shaft to 2x hub/knuckle assembly using Holding Tool KM-468-C.
Tighten
• Secure 2x nut 200 Nm.
129. Connect 2x heater matrix lower coolant hose to engine.
• Secure 2x clip.
130. Connect return hose for coolant expansion tank to engine.
• Secure clip.
131. Connect lower hose to coolant expansion tank.
• Secure clip.
132. Connect brake servo hose to vacuum pump.
• Secure clip.
133. Connect fuel return hose to fuel leak off pipe assembly.
• Remove 2x blanking plug.
• Secure 2x clip.
134. Connect fuel feed pipe to high pressure pump.
• Remove 2x blanking plug.
• Secure 2x clip.
135. Secure power steering pipe assembly to upper front panel.
Tighten
• Install 2x bolt 10Nm.
136. Secure lower refrigerant pipe to upper front panel.
Tighten
• Install bolt 10 Nm.
137. Connect upper refrigerant pipe to lower refrigerant pipe.
• Remove 2x blanking plug.
• Install new O ring.
Tighten
• Install nut 10 Nm.
138. Secure harness for 4x glow plug to engine.
• Secure 4x clip.
139. Secure harness to front of engine.
• Secure 2x clip.
140. Secure harness trunking to 2x bracket on intake manifold.
• Secure 2x harness trunking clip.
• Secure fuel return hose to harness trunking.
• Secure to 2x clip.
141. Secure 2x battery lead to support bracket.
• Secure clip.
142. Secure harness to rear of engine.
• Secure 2x clip.
143. Raise vehicle.
144. Connect 2x refrigerant pipe to air conditioning compressor.
• Remove 4x blanking plug.
• Install 2x new O ring.
Tighten
• Install nut 10 Nm.
145. Secure harness to oil level dipstick tube.
• Secure clip.
146. Secure harness to starter.
Tighten
• Install nut 15 Nm.
• Connect connector.
147. Secure harness for alternator to starter.
Tighten
• Install nut 15 Nm.
148. Secure 2x earth lead to engine.
• Install 2x bolt 25 Nm.
149. Connect harness connector to oil quality sensor.
150. Connect harness connector to air conditioning compressor.
151. Connect harness connector to oil pressure switch below oil filter housing.
152. Connect radiator lower coolant hose to engine.
• Secure clip.
153. Lower vehicle.
154. Connect harness connector to output speed sensor at rear of transmission.
155. Connect harness connector to crankshaft position sensor.
156. Connect harness connector to turbocharger wastegate.
157. Connect engine harness to harness for 4x glow plug.
158. Connect harness connector to exhaust pressure sensor.
159. Connect harness connector to fuel pipe sensor.
160. Connect harness connector to fuel filter housing.
161. Connect harness connector to vacuum switching valve.
162. Connect 4x connector to 4x injector.
163. Secure gear shift cable to support bracket.
• Push on.
164. Connect gear shift cable to transmission.
• Push on.
165. Connect harness to transmission shift selector.
• Connect 2x connector.
166. Secure harness to top of transmission.
• Connect to input speed sensor.
• Secure to 2x clip.
167. Connect harness connector to air conditioning pressure sensor.
168. Connect harness connector to throttle position sensor.
169. Secure fuse box for 4x glow plug to upper front panel.
Tighten
• Install 2x bolt 10 Nm.
• Secure cover.
• Secure clip.
170. Connect harness connector to high pressure pump.
171. Connect harness connector to alternator.
172. Connect 2x harness connector to 2x cooling fan.
173. Connect harness connector to fuel pressure sensor.
174. Connect harness connector to fuel temperature sensor.
175. Connect harness connector to coolant temperature sensor.
176. Secure 2x earth lead to intake manifold.
Tighten
• Install bolt 25 Nm.
177. Connect harness connector to intake manifold pressure sensor.
178. Connect harness connector to camshaft position sensor.
179. Connect radiator upper coolant hose to engine.
• Secure clip.
180. Install intake hose to turbocharger.
• Install clip.
• Connect breather hose.
• Push on, then secure 2x clip.
181. Install outlet pipe assembly to intercooler and turbocharger.
Tighten
• Install 2x bolt 8 Nm.
• Secure 2x clip.
182. Secure power steering reservoir to coolant expansion tank.
Tighten
• Slide on locator, install 2x bolt 9 Nm.
• Secure transmission breather hose to coolant expansion tank.
• Secure to clip.
183. Install intake pipe with air cleaner assembly to engine compartment.
• Secure air cleaner assembly to inner wing.
• Secure to locator.
• Install 2x bolt 6 Nm.
184. Secure intake pipe to engine and turbocharger.
• Install bolt 8 Nm
• Secure clip.
• Connect harness to mass air flow meter.
185. Raise vehicle.
186. Fill transmission with oil.
• Place collecting container below.
• Remove bolt.
• Remove filler plug from transmission.
187. Install filler plug to transmission.
Tighten
• Install bolt 10 Nm.
188. Lower vehicle to suitable working height.
189. Install 2x front wheel to vehicle.
• Install 10x bolt 125 Nm.
190. Lower vehicle.
191. Install hose to intercooler and intake manifold.
• Install 2x clip.
192. Install ECU support bracket to battery tray.
• Install 2x nut 15 Nm.
193. Install ECU to support bracket.
• Push in.
194. Connect 2x connector to ECU.
195. Install engine cover.
Tighten
• Install 4x nut 8 Nm.
196. Settle front suspension.
197. Raise vehicle.
198. Secure lower control arm fulcrum, right side.
Tighten
• Secure nut 70 Nm.
• Secure nut, bolt 120 Nm.
199. Secure lower control arm fulcrum, left side.
Tighten
• Secure nut 70 Nm.
• Secure nut, bolt 120 Nm.
200. Install engine and transmission undershield to vehicle.
Tighten
• Install 5x new bolt 10 Nm.
• Install 2x clip.
201. Lower vehicle.
202. Install battery to vehicle.
• Install clamp.
Tighten
• Secure 2x nut 10 Nm.
• Connect negative and positive cable.
• Install 2x cover to 2x terminal.
203. Program all volatile memories.
204. Refill air conditioning system.
Important: The power steering pump must not be allowed to run dry.
205. Fill fluid reservoir for power steering, then allow fluid to settle for at least two minutes.
• Remove cap from fluid reservoir.
• Use Dexron II D.
Important: Do not run the engine at this stage; this procedure primes the hydraulic system.
206. Slowly turn steering wheel to full lock left and right; add fluid if necessary.
207. Start engine, then slowly turn steering wheel to full lock left and right.
208. Stop engine.
209. Check fluid level and refill as required.
Note: If the fluid is very foamy, allow to stand for a few minutes, then repeat the procedure.
• Install cap to fluid reservoir.
210. Bleed cooling system.
• Place collecting container below.
• Fill cooling system to maximum level.
• Install cap to coolant expansion tank.
• Start engine and allow to run until normal operating temperature attained.
211. Refill coolant expansion tank to maximum level.