Remove and Replace

REMOVE
- Remove the engine/transmission assembly.
- Fit the engine to a suitable stand.
- Remove the cylinder heads and fit JD 41 or equivalent, cylinder liner retainers.

NOTE: Always support the cylinder heads on blocks of wood. This will prevent damage to the valves which, when open, protrude below the cylinder head face.

- Remove the oil pan plug and drain the oil into a suit- able container.

Oil Pan Bolts:

- Remove the oil pan securing bolts and remove the pan.

Fig. 10 Suction Elbow And Sandwich Plate Removal:

- Remove the suction elbow, remove the sandwich plate securing bolts and remove the plate, noting the different stud lengths.
- Rotate the crankshaft until numbers 1 and 6 journals are outermost.

NOTE: Be sure connecting rods are correctly numbered before removal.

- Remove the securing nuts, bearing cap and shell from one connecting rod, noting the cap to connecting rod relationship.
- Remove any carbon deposits from the top of the cylinder bore.
- Push the connecting rod up the cylinder bore and withdraw the piston/rod assembly.
- Remove the connecting rod bearing shell.

NOTE: Pistons are supplied complete with wrist pins and are matched assemblies. DO NOT interchange component parts.

- Remove the remaining connecting rod/piston assemblies.
- Thoroughly clean all components and examine for wear and damage. Replace worn or damaged components as necessary.

REFIT
- Clean all bearing surfaces and cylinder bores.
- Fit a new bearing shell half into the connecting rod, ensuring that the bearing shell tab is correctly located in the connecting rod. Coat the bearing shell with oil.
- Fit protective covers to connecting rod bolts (old spark plug boots work well).
- Coat the piston rings, wrist pins and cylinder bore liberally with clean engine oil.

Ring Gap Spacing:

- Be sure that the piston ring gaps are correctly spaced around the piston.
- Compress the piston rings using suitable ring compressor.
- Be sure the rod journal for the piston being fitted is close to or at bottom dead center.
- Enter the piston/connecting rod assembly into the cylinder bore, ensuring that 'FRONT' (stamped on the piston) faces the front of the engine.
- Firmly but without undue force, push the piston/connecting rod assembly down the cylinder bore guiding the connecting rod bolts over crankshaft journal.
- Fit a new bearing shell half into the connecting rod cap, ensuring that the bearing shell tab is correctly located. Coat the bearing shell with oil.
- Fit the connecting rod cap. Fit and tighten the securing nuts.
- Repeat the procedure to refit the remaining connecting rod/piston assemblies.
- Refit the sandwich plate.
- Refit the sump.
- Remove JD 41 cylinder liner retainers.
- Refit the cylinder heads.
- Remove the engine from the engine stand.
- Refit the transmission and refit the engine/transmission assembly to the vehicle.

TORQUE VALUES
Air pump adjuster bolt/locknut 20-27 Nm
Banjo connector bolts 12-14 Nm
Camshaft sprocket to camshaft 23-27 Nm
Camshaft cover 11 Nm
Connecting rod cap nuts 54-55.5 Nm
Cylinder head to block (9/l6"AF) 36 Nm
Cylinder head to block (5/8"AF) 70 Nm
EGR valve to throttle housing 9.5-12 Nm
Elbow to inlet manifold 12.2 Nm
Engine mounting bracket to crossmember 19-24 Nm
Engine mounting tie bolts 34-40 Nm
Exhaust down pipe to manifold 30-35 Nm
Fan/clutch to water pump 23-27 Nm
Fuel pipe unions (5/16" dia.) 8.5-9.5 Nm
Fuel pipe unions (3/8" dia.) 11-13.5 Nm
Fuel pipe unions (1/2" dia.) 27-33 Nm
Heat shield to manifold 23-27 Nm
Hose clips 2.5 Nm
Inlet manifold to cylinder head (nuts) 23-27 Nm
Inlet manifold to cylinder head (bolts) 23-27 Nm
Oil cooler pipes 54-6O Nm
PAS pump to mounting bracket 50 Nm
Rear engine mounting peg 34-4O Nm
Rear engine mounting rubbers 36-43 Nm
Rear engine mounting to body (5/16 bolt) 19-24 Nm
Rear engine mounting to body (3/8 bolt) 36-43 Nm
Silencer to compressor union 34 Nm
Sump drain plug 15-18 Nm
Sump set screws 16-2O Nm
Thermostat housing to cylinder head 23-27 Nm