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ENGINE2.2LDICOR
Place the vehicle on a flat, level surface and
engage the parking brake.
Remove the engine guards
Open the bonnet
Remove EngineTopCover
Disconnect Electrical Cable Connections for
ECU
Battery
Starter Motor
Alternator
AC compressor
Reverse switch
Vehicle speed sensor
Sedimenter
Unclip the hose connected between intake
manifold and air filter. Plug the openings.
Remove the air filter.
Disconnect the hose connected between VNT to
Intercooler.
Disconnect the vacuum lines connected to brake
booster and vacuum accumulator and vaccum
tank.
Disconnect fuel suction line connected to fuel filter
from sedimenter and fuel filter to hp pump.
Remove filter assembly.
Disconnect exhaust pipe connected to close
coupled Catalytic converter. Remove intercooler.
Drain the coolant from the cooling system.
Drain the engine oil.
Disconnect hoses from and to radiator.
Disconnect pipe from radiator to auxiliary tank.
Remove the radiator.
Drain the Power steering oil and disconnect the
pipelines.
Drain the AC gas / oil from the system. Disconnect
AC pipe lines and hot water pipe connections.
Remove radiator and condenser assembly.
Support the gear box from the lower side
Remove gear shift lever from inside the vehicle
Disconnect propeller shaft at gear box end
Remove SlaveCylinder
Removal&FitmentOfEngineOnVehicle
Remove Gear Box mounting bolts to the clutch
housing
Remove gear box mounting on cross member
Slightly move the gear box towards rear side of
the vehicle
Incase of 4x4 vehicle disconnect both propeller
shaft at transfercase end and slightly move the
transfercase along with the gearbox towards rear
side of the vehicle
Supprt the Engine from bottom side
Fix chain to front and rear engine lifting hooks and
hold chain in position with crane.
Unscrew and remove engine mounting bolts.
Lift the engine & Mount it on work stand.
Check engine mounting pads for wear. Replace
them if necessary.
InstallationOf EngineOn Vehicle
Lift the engine and mount it on a support stand.
Check the enginemounting pads for wear. Replace
if necessary.
Install the engine in place by sequentially carrying
out approximate procedures / steps (Followed
during engine removal).
Tighten engine mounting bolts to specified
torque.
Connect all pipes, hoses and electrical
connections.
Fit new oil filter.
Fill specified quantity of (recommended grade)
oil in engine.
Fill specified quantity of Power steering oil in
reservoir.
Fill coolant in the cooling system through radiator.
Refer cooling system filling procedures.
Charge the AC system.
Crank the engine momentarily. Let oil and coolant
circulate through the system.
Confirm whether oil pressure indicator light is
switching off when engine is started.
Check for any leakage, rectify if necessary.
Top up coolant between max. and min. mark in
auxiliary tank, if necessary.
Check HVAC system for correct functioning.