Engine Without Transmission, Remove and Install
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Gearbox - see operation in group K.
Bonnet and battery - see operation in group C.
Reserve tank hose (1) from water manifold - clips.
Crankcase ventilation valve (4) and hose (6) from air cleaner pipe (3) - clips.
Intercooler hose (2) from intake manifold and intercooler hose - clips.
Air cleaner pipe (3) from air cleaner and turbocharger - clips.
| Intercooler hose (5) from turbocharger and intercooler - clips. | |||
|---|---|---|---|
| .P. U9575.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Crankcase ventilation hose from oil separator connection (arrowed).
| Illustration shows engine room harness removed for clarity. | |||
|---|---|---|---|
| .P. U9576.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Heater hose (1) from water manifold - clip.
Heater hose (2) from heater pipe assembly - clip.
Radiator hose (3) from thermostat cover - clip.
Radiator hose (4) from water pump - clip.
Reserve tank hose from water pump connection (5) - clip.
| Radiator - see corresponding operation. | |||
|---|---|---|---|
| .P. U9577.tif | 9 | 16 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Oil cooler hoses - banjo bolts and seal rings.
| Exhaust front pipe from turbocharger exhaust outlet elbow - two nuts and gasket. | |||
|---|---|---|---|
| .P. U9578.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Vacuum hose from exhaust gas recirculation valve connection (arrowed).
| Brake servo cylinder vacuum pipe at bulkhead. | |||
|---|---|---|---|
| .P. U9605.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Engine room harness (1) from engine harness connections.
Return hose from connection (2) on power steering pump - drain pump reservoir.
| High - pressure hose from connection (3) on power steering pump. | |||
|---|---|---|---|
| .P. U9649.tif | 12 | 11 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Fuel feed hose (1) from fuel injection pump.
| Fuel return hose (2) from fuel injection pump. | |||
|---|---|---|---|
| .P. U9650.tif | 9 | 7,5 | tiff;; |
Attach lifting equipment to engine and to hoist.
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Engine earth strap from chassis - bolt.
Engine mounting blocks, left and right, from chassis brackets - four bolts.
Engine assembly - lift with front of engine higher than rear, taking care not to damage fuel pipes, brake pipes, etc.
| Left side mounting block illustrated. | |||
|---|---|---|---|
| .P. U9651.tif | 9 | 7,5 | tiff;; |
Attach lifting equipment to engine and to hoist.
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Engine assembly into vehicle - taking care not to damage fuel pipes, brake pipes etc.
Engine mounting blocks, left and right, to chassis brackets - four bolts.
Engine earth strap to chassis - bolt.
Left side mounting block illustrated.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
Mounting block bolts - 50 Nm / 37 lbf ft.
| Engine earth strap bolt - 22 Nm / 16 lbf ft. | |||
|---|---|---|---|
| .P. U9651.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Fuel return hose (2) to fuel injection pump.
| Fuel feed hose (1) to fuel injection pump. | |||
|---|---|---|---|
| .P. U9650.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
High - pressure hose to connection (3) on power steering pump.
Return hose to connection (2) on power steering pump.
Engine room harness (1) to engine harness connections.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
|---|---|---|---|
| Power steering high - pressure hose nut - 28 Nm / 21 lbf ft. | |||
| .P. U9649.tif | 12 | 11 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Vacuum hose to exhaust gas recirculation valve connection (arrowed).
| Brake servo cylinder vacuum pipe at bulkhead. | |||
|---|---|---|---|
| .P. U9605.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Exhaust front pipe to turbocharger - new gasket and two nuts, lubricate studs with B040086 before installing nuts.
Oil cooler hoses - banjo bolts and seal rings.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
Exhaust front pipe nuts - 67 Nm / 49 lbf ft.
| Oil cooler hoses banjo bolts - 33 Nm / 24 lbf ft. | |||
|---|---|---|---|
| .P. U9578.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Radiator - see corresponding operation.
Reserve tank hose to water pump connection (5) - clip.
Radiator hose (4) to water pump - clip.
Radiator hose (3) to thermostat cover - clip.
Heater hose (2) to heater pipe assembly - clip.
| Heater hose (1) to water manifold - clips. | |||
|---|---|---|---|
| .P. U9577.tif | 9 | 16 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
| Crankcase ventilation hose to oil separator connection (arrowed). | |||
| .P. U9576.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Intercooler hose (5) to turbocharger and intercooler - clips.
Air cleaner pipe (3) to turbocharger and air cleaner - clips.
Intercooler hose (2) to intercooler and intake manifold - clips.
Crankcase ventilation valve (4) and hose (6) from air cleaner pipe (3).
Reserve tank hose (1) to water manifold - clips.
Bonnet and battery - see operation in group C.
Gearbox - see operation in group K.
Refill and bleed power steering system - see operation in group M.
| Fill up and bleed cooling system, check for leaks and measure coolant temperature - see corresponding operations. | |||
|---|---|---|---|
| .P. U9575.tif | 9 | 7,5 | tiff;; |