Replacing the Engine with a Replacement Engine
Remove engine - see operation "Engine, Remove and Install".
Attach the engine to the engine assembly stand (KM�412) - see operation "Attaching the engine to the engine assembly stand (KM�412)".
Detach the ground connections (2) and (3) from the transmission. Separate the wiring harness plug (1) from the reversing light switch.
Hook the transmission (4) into the jib crane and detach from the engine.
Detach the cable connections (5) from the starter.
Open the wiring harness bracket (6) and expose the starter wiring harness.
Detach the wiring harness plug from the glow plugs.
Detach the ground lead (2) and wiring harness bracket (1) from the timing case.
Detach/separate the cable connections (3) from the generator.
Disconnect wiring harness plug from oil pressure switch (4).
Expose and remove the wiring harness on the timing side.
Separate the wiring harness plug (5) from the additional heater and unclip the wiring harness from the brackets (4).
Separate the wiring harness plug (1) from the additional heater and expose the wiring harness (2). Unclip the wiring harness plug (1) from the bracket.
Detach and remove the expansion tank coolant hose (3) from the thermostat housing coolant filler neck.
Detach the engine undershield from the cylinder head cover.
Pull off/separate the vacuum pipes from the:
- wastegate unit vacuum diaphragm (1)
- exhaust gas recirculation valve (4)
- switchover valve vacuum diaphragm unit (3)
- vacuum pump (2)
Separate the leak�off pipe (1).
Separate the wiring harness plug (4) from the solenoid valves - observe colour coding.
Remove the solenoid valves with vacuum pipes.
Detach the wiring harness plug (2) from the temperature sensor.
Detach the wiring harness plug (3) from the coolant temperature sensor.
Detach the front cable duct (intake side) from the cylinder head cover.
Detach the wiring harness plug (1) from the boost pressure sensor.
Separate the wiring harness plug (2) for the crankshaft position sensor.
Release the injection pump wiring harness plug (3) in the direction of the arrow and pull it from the injection pump.
Expose the wiring harness and remove it completely.
Detach the additional heater coolant hose (2) from the coolant flange or generator bracket.
Detach and remove the additional heater (4) from the cylinder block.
Detach and remove three turbocharger heat shields (1) from the turbocharger or exhaust manifold.
Detach the generator (3) from the timing case and coolant flange or generator bracket. Remove the generator.
Detach the V�belt tensioner (5) from the main bracket for ancillary components.
Detach and remove the fuel lines (3) from the injection pump.
Remove the retaining bolts (1) and (2). Remove the wiring harness bracket.
Detach the main bracket for ancillary components (4) from the cylinder block.
Detach the right�hand engine damping block (engine side) (6) from the oil sump.
Attach the right�hand engine damping block (engine side) to the oil pan - 58 Nm.
Attach the main bracket for ancillary components to the cylinder block.
Attach the wiring harness bracket to both engine transport shackles. Fit the fuel pipes and attach them to the injection pump - 25 Nm.
Attach the ribbed V�belt tensioner to the auxiliary mounting bracket - torque 42 Nm. Attach the vibration damper to the auxiliary mounting bracket - torque 20 Nm.
Attach the generator to the timing case and coolant flange or generator bracket - 35 Nm.
Attach three turbocharger heat shields (1) to the turbocharger or exhaust manifold. Fit the additional heater and attach it to the cylinder block. Attach the additional heater coolant hose to the coolant flange or generator bracket.
Attach the wiring harness to the engine and route it approximately - note the cable routing. Fit the injection pump wiring harness plug and lock it.
Connect the wiring harness plug to the boost pressure sensor and crankshaft position sensor (or plug them together). Attach the front cable duct (intake side) to the cylinder head cover.
Connect the wiring harness plug to the temperature sensor and the coolant temperature sensor.
Fit the solenoid valves with vacuum pipe and attach the wiring harness plug to the solenoid valves - note colour coding.
Connect the leak�off pipe. Attach the vacuum pipes to the vacuum pump, vacuum diaphragm unit switchover valves, exhaust gas recirculation valve and wastegate unit vacuum diaphragm - note the routing of the vacuum pipes. Attach the engine undershield with vacuum pipes to the cylinder head cover.
Attach the expansion tank coolant hose to the thermostat housing coolant filler neck.
Route the outlet side wiring harness and attach to the bracket. Connect the wiring harness plug to the additional heater (two).
Fit and route the wiring harness on the timing side. Connect the wiring harness plug to the oil pressure switch. Attach the cable connections to the generator. Attach the ground lead and wiring harness bracket to the timing case.
Push wiring harness plugs onto glow plugs. Route the starter wiring harness and attach to the bracket.
Attach cable connections to starter.
Attach the transmission to the engine using a jib crane. Attach the ground connection to the transmission. Connect the wiring harness plug to the reversing lamp switch.
Detach the engine from the engine assembly stand (KM�412) - see operation "Detaching the engine from the engine assembly stand (KM�412)".
Install engine - see operation "Engine, Remove and Install".