Engine Without Transmission, Remove and Install
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Battery.
Drain engine coolant - collect coolant.
| Bonnet - see operation 'Bonnet, Remove and Install' in group A. |
Coolant hose connections from:
Radiator hoses (3, 4 and 5).
Intake manifold coolant inlet pipe to expansion tank hose - (6).
Intake manifold coolant return hose - (1).
| Heater intake and return hoses - (7 and 8). | |||
|---|---|---|---|
| .P. U8049.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
| Engine ground cable (arrowed). | |||
| .P. U8050.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Engine wiring harness from:
Multiplug and pin connectors at bulkhead.
Multiplug and pin connectors at right hand front engine sub harness.
Fuse box.
Temperature switch.
Coolant fan.
Air temperature and air flow sensors.
| Oxygen sensor. | |||
|---|---|---|---|
| .P. U8176.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Radiator and cooling fan assembly - see corresponding operations.
| Ribbed V - belt - using ribbed V - belt tension roller - mark running direction of ribbed V - belt. | |||
|---|---|---|---|
| .P. U8051.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Power steering pump - see corresponding operation.
Do not disconnect steering pump hoses.
| Suspend pump at suitable point. | |||
|---|---|---|---|
| .P. E5143.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Air conditioning compressor (if fitted).
Do not disconnect refrigerant hoses.
| Suspend compressor at suitable point. | |||
|---|---|---|---|
| .P. U8147.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
| Accelerator cable - see corresponding operation. | |||
| .P. U8137.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Vacuum hose from intake manifold.
Brake servo vacuum line from intake manifold.
Fuel lines from fuel distributor pipe.
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Important! |
Fuel escapes, observe safety regulations and national legislation.
| Depressurize - use Fuel Pressure Gauge KM - J - 34730 - 91 via test connection (1) - collect escaping fuel in suitable container. | |||
|---|---|---|---|
| .P. E5282.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
| Oil cooler pipes from oil filter bracket. | |||
| .P. E8140.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Coolant hoses (2) from throttle body.
| Vacuum hose to controlled canister purge valve from throttle body. | |||
|---|---|---|---|
| .P. E5284.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Fastening bolts (1) from intake manifold.
| Throttle body from intake manifold. | |||
|---|---|---|---|
| .P. E3691.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
| Front exhaust pipe - bolts (1 and 2). | |||
| .P. E5054.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Transmission and transfer case assembly - see operation 'Transmission, Remove and Install' in group K.
Engine damping blocks from engine brackets, see corresponding operation.
| Coolant hose from coolant pipe. | |||
|---|---|---|---|
| .P. E5301.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
Engine upwards from engine compartment with suitable lifting equipment.
| Note: Ensure that attaching parts are not damaged. | |||
|---|---|---|---|
| .P. E5329.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Lower engine into engine compartment.
Attach engine bracket to engine damping blocks - ensuring heat protection (arrowed) is correctly positioned on left side damping block..
Coolant hose to DIS ignition module adapter.
Coolant hose to coolant pipe.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
|---|---|---|---|
| Engine damping block to engine bracket - 50 Nm / 37 lbf ft. | |||
| .P. U9587.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Transmission - see operation 'Transmission, Remove and Install' in group K.
Front exhaust pipe to exhaust manifold - new gasket.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
|---|---|---|---|
| Front exhaust pipe to manifold - 20 Nm / 15 lbf ft. | |||
| .P. E5054.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
| Harness connector for oxygen sensor. | |||
| .P. U8084.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Fuel lines (2) with new seal rings to fuel distributor pipe.
Brake servo vacuum line to intake manifold.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
|---|---|---|---|
| Vacuum line fixing nut - 20 Nm / 15 lbf ft. | |||
| .P. E5313.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Vacuum hose to intake manifold.
Accelerator cable to cable bracket.
| Air intake hose to intake throttle chamber. | |||
|---|---|---|---|
| .P. U8137.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
If fitted - air compressor.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
|---|---|---|---|
| Compressor bracket bolts - 35 Nm / 26 lbf ft. | |||
| .P. U8147.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Power steering pump.
Fixing bolt (1) to power steering pump.
Fixing bolts (2) to power steering pump.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
Fixing bolt (1) - 20 Nm / 15 lbf ft.
| Fixing bolt (2) - 25 Nm / 18 lbf ft. | |||
|---|---|---|---|
| .P. E5143.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
| Ribbed V - belt - tension ribbed V - belt - see corresponding operation. | |||
| .P. U8090.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Radiator and cooling fan.
| Harness connector to fan motor. | |||
|---|---|---|---|
| .P. U8051.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
| Coolant hoses. | |||
| .P. U8049.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Harness connectors to:
Air temperature and air flow sensors.
Temperature switch.
Fuse box.
| Multiplug and pin connectors at bulkhead and right hand front engine sub harness. | |||
|---|---|---|---|
| .P. U8176.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Engine earth strap.
| Bonnet - see operation 'Bonnet, Remove and Install' in group A. | |||
|---|---|---|---|
| .P. U8050.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Engine underguard and skid plate.
Top up cooling system - see operations 'Cooling System, Top up and Bleed' and 'Cooling System, Check for Leaks'.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
Underguard screws - 47 Nm / 35 lbf ft.
| Skid plate bolts - 57 Nm / 42 lbf ft. | |||
|---|---|---|---|
| .P. U8045.tif | 9 | 7,5 | tiff;; |