Remove
EngineService Repair No - 12.41.01
Remove
1. Park vehicle on level ground and apply park brake.
2. De-pressurize fuel system.
3. Remove hood.
4. Remove battery.
5. Remove radiator/oil coolers.
6. Place an absorbent cloth around fuel feed hose at fuel rail and release compression nut. Remove feed hose from rail, seal end of pipes with masking tape to prevent ingress of dirt.
7. Release fuel return hose clamp and remove hose from pressure regulator, seal both openings with masking tape to prevent ingress of dirt.
8. Remove vacuum hose from rear of regulator.
9. Manual vehicles: Disconnect throttle cable from bracket. Automatic vehicles: Detach throttle bracket from plenum chamber and lay assembly to one side.
10. Remove ram housing.
11. Remove air flow sensor.
12. Remove air cleaner assembly.
13. Remove Generator.
14. Release air conditioning compressor from its mounting and lay to one side. DO NOT discharge air conditioning system.
NOTE: Release bolts securing compressor mounting bracket to engine and remove bracket to enable temporary lifting eye ETC 5964 to be fitted. Secure lifting eye to mounting bracket fixing points with suitable bolts of equivalent size, pitch and thread. Leave lifting eye attached until engine is reinstalled in vehicle.
15. Place drain tray underneath vehicle.
16. Disconnect hose from reservoir to power steering pump. Secure hose end above level of fluid reservoir to avoid unnecessary loss of fluid.
17. Disconnect power steering pump to power steering box hose. Seal hose and pump openings with masking tape to prevent ingress of dirt. Wipe away any fluid spillage from chassis or steering box.
18. Disconnect fuel temperature and coolant temperature sensor multi-plugs.
19. Disconnect leads from coil.
20. Identify each injector multi-plug for re-assembly and disconnect plugs from injectors.
21. Maneuver harness from behind fuel rails and place to one side clear of engine assembly.
22. Remove two clamps securing gearbox oil cooler pipes to engine block.
23. Remove engine mounting fixings on both sides of cylinder block.
Lifting Chains:
24. Fit lifting chains to engine lifting eyes as shown in illustration RR1780E.
1. L/H Front chain 356 mm total overall length.
2. R/H Front chain 330 mm total overall length.
3. R/H Rear chain 457 mm total overall length.
NOTE: All chain dimensions are measured from end of lifting hook to end of last link in chain.
25. Install the chain lifting eye to a suitable engine hoist. Raise hoist high enough to enable engine mountings to be removed, and withdraw rubber mountings.
26. Lower hoist until engine rests securely on engine mounting brackets. Remove lifting chains and hoist.
27. Disconnect two heater hoses located on top of right hand valve cover.
28. Remove ground strap from rear of left hand cylinder head. DO NOT remove from retaining clip.
29. Remove all electrical harnesses from retaining clips at rear of engine.
30. Remove transmission breather pipes from retaining clip on rear lifting eye.
31. Remove top two bolts securing bell housing to cylinder block.
32. Raise front of vehicle, lower vehicle on to axle stands.
33. Remove bell housing bottom cover. Remove gasket from bell housing face.
34. Remove nuts securing exhaust downpipes to manifolds, remove heat shield from right hand side downpipe.
35. Remove electrical leads from starter motor solenoid. Disconnect multi-plug from-oil level sensor on side of oil pan, if fitted.
NOTE: Instructions 37, 38 and 39 refer to automatic vehicles only.
Drive Plate Access Holes:
36. With assistance rotate engine at crankshaft pulley until two access holes in drive plate/ring gear assembly are visible.
37. Remove two bolts visible through access holes. Mark one access hole and one bolt hole to ensure unit is reassembled in its original position
38. Rotate crankshaft 180° until two remaining access holes are visible, remove two bolts.
39. Remove remaining bell housing to cylinder block bolts.
40. Remove starter motor ground strap from chassis.
41. Remove stands and lower vehicle.
42. Position hydraulic trolley jack under bell housing to support gearbox when engine and gearbox are separated.
43. Fit lifting chains to engine. Carefully raise hoist a little, ease engine and gearbox apart, steady engine on hoist.
44. Ensure no components remain that will prevent engine being removed.
45. Slowly raise engine clear of engine compartment. Move engine away from vehicle and place on a suitable engine stand.