Removal

ENGINE REMOVAL

Special Tools Needed: 5033, 5006, 5115, 5186, 5428, 5429.





Caution: Since work is carried out with engine freely suspended, ensure that lifting equipment is securely attached and is in perfect condition.





Disconnect Battery Wiring and Remove Battery

Disconnect / Remove:
- Battery ground lead.
- Wiring connected to positive terminal.
- Battery positive lead.
- Ground lead connection to body at top of side member.
- Clip on side member.
- Battery.





Remove Auxiliary Drive Belt

Remove Cooling Fan
- Release upper bolts and undo connector at relay in front of battery.
- Disconnect ground lead at righthand ground terminal.

Drain Coolant





Disconnect:
- Upper and lower coolant hoses from engine.
- Expansion vessel hose from radiator and return pipe.
- Transmission cooling pipes from radiator.





Undo Engine Mountings
- Undo top nut on both left and right-hand mountings.





Remove Air Mass Meter And Intake Hose

Disconnect / Remove:
- Large and small crankcase ventilation hoses.
- Idling hose and idling valve lead.
- EVAP valve hoses (two) at intake manifold.
- Air mass meter connector.
- Air preheater hose.
- Throttle pulley cover.





Remove Servo Pump
- Remove three bolts at front and two at rear.





Remove / Disconnect:
- Fuel return line at regulator.
- Fuel line at bulkhead.
- Throttle cable.
- Cruise control vacuum hose.
- Fuel line snap catches.





Separate Engine Wiring Harness
- Remove cover and undo connector.
- Undo relay connectors.
- Remove harness duct mounting nuts.





Disconnect:
- Cooling hoses (two) from branches on bulkhead.
- ECC hoses (two) at intake manifold.
- Camshaft sensor.
- Timing pickup.
- Brake servo vacuum hose.





Support Engine at Rear
- Use two 5033 support rails.
- Lifting beam 5006.
- Lifting hook 5115.
- Lifting yoke 5428.
- Attach lifting lug 5429 to rear of engine.
- Support engine.





Remove Splashguard and Air Baffle Under Engine
- Release radiator mounting bolts (two).
- Drain engine oil.





Disconnect Oil Thermostat Hoses
- Disconnect hoses at thermostat in cylinder block.





Undo AC Compressor
- Remove compressor mounting bolts (two) and disconnect lead.
- Support compressor from side member.





Remove Exhaust Pipe
- Undo exhaust pipe flanges at manifold.
- Remove lower section of air preheater pipe.
- Remove exhaust pipe shield.





Undo Oil Pipe Connections at Gearbox
- Plug pipe openings.

Disconnect gear selector lever
- Remove clips between lever and control rod / reaction arm.
- Withdraw rods from mounting.





Disconnect Oxygen Sensor Wiring
- Release oxygen sensor wiring and withdraw lead from connector.





Disconnect Propeller Shaft and Remove Transmission Support Member
- Use socket 5244.
- Separate front and rear couplings.
- Mark coupling halves for reassembly.
- Remove centre nut and bolts from side member.
- Remove transmission support member.





Place Jack Under Transmission
- Remove lifting tools.





Remove Radiator Upper Attachments
-Lift out radiator and transmission fluid cooling pipes.





Lift Engine
- Use lifting tool 2810.
- Adjust lifting yoke to ensure engine is balanced.
- Remove jack under transmission.

Note: Position wiring harnesses so as to avoid damage when lifting.





Lift Out Engine and Transmission
- Adjust angle of lift throughout operation.

Note: Carefully check that drive unit is free of body and other equipment (if any).