Engine Without Transmission, Remove and Install
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
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. | |||
|---|---|---|---|
| .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. U8185.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 (1) from intake manifold.
Fuel lines (2) from fuel distributor pipe.
| .D. ICON11.tif | 0,75 | 0,75 | tiff;; Important! |
Fuel escapes, observe safety regulations and national legislation.
| Depressurize using Fuel Pressure Gauge KM - J - 34730 - 91 via test connection - collect escaping fuel in suitable container. | |||
|---|---|---|---|
| .P. E5313.tif | 9 | 7,5 | tiff;; |
| .D. ICON01.tif | 0,75 | 0,75 | tiff;; Remove, Disconnect |
| Coolant hose (1) from throttle body. | |||
| .P. E5326.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 transfer case assembly - see operation 'Transmission, Remove and Install' in group K.
Attach cables to engine transport brackets.
| Engine damping blocks from engine brackets - note position of heat protectors (arrowed) on left side damping block. | |||
|---|---|---|---|
| .P. U9590.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. - ensure heat protectors (arrow) are correctly positioned on the left side damping block.
| .D. ICON09.tif | 0,75 | 0,75 | tiff;; Tighten (Torque) |
|---|---|---|---|
| Engine damping block to engine bracket - 85 Nm / 63 lbf ft. | |||
| .P. U9590.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Install 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 (1). | |||
| .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 (1) 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 (2) to intake manifold.
Accelerator cable to cable bracket (1)
| Air intake hose to intake throttle chamber. | |||
|---|---|---|---|
| .P. U8116.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. U8185.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.
| .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. U8189.tif | 9 | 7,5 | tiff;; |
| .D. ICON02.tif | 0,75 | 0,75 | tiff;; Install, Connect |
Engine earth strap (arrowed).
| 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;; |