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4 DLT ENGINE
REMOVAL OF ENGINE FROMVEHICLE
Remove bonnet.
Disconnect electrical cable connections for :
- Battery
- Starter Motor
- Alternator
- Fuel injection pump solenoid switch
- FICD (Fast idling control device (if fitted)
- Oil pressure switch
- Glow plugs
- EGR System (if fitted)
- Water temperature transducer
- Reversing switch
Disconnect cables for :
- Accelerator
- Clutch
- Speedometer drive
Disconnect pipe lines from :
- Fuel filter to fuel injection pump
- Fuel injection pump to fuel tank
- Vacuum pump to vacuum booster
- Power steering pump
Disconnect exhaust pipe from exhaust manifold
Drain engine lubricating oil from oil sump
Drain coolant from cooling system.
Disconnect hoses from and to radiator, Intercooler
Disconnect pipe from radiator to auxiliary tank.
Disconnect A.C. pipe lines and hot water pipes
connections.
Disconnect propeller shaft front end.
Remove following sub assemblies :
- Air filter, if necessary
- Starter motor
- Radiator with fan shroud
- Clutch slave cylinder
- Gear shift lever
- Gear box with clutch housing and transfer
case (for procedure see gear box group)
Fix chain to front and rear engine lifting hooks and
hold chain in position with crane.
Unscrew and remove engine mounting bolts.
Lift engine from vehicle with the help of crane.
Mount engine on work stand.
INSTALLATION OF ENGINE ON VEHICLE
-
Check engine mounting pads for wear.
Replace them if necessary.
-
Install the engine in reverse sequence of
removal.
-
Tighten engine mounting bolts to specified
torque.
-
Connect all pipes, hoses and electrical
connections.
-
Fill specified quantity of oil in engine of
recommended grade.
-
Fill coolant in the cooling system through
radiator.
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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 upto FULL mark in auxiliary
tank, if necessary.
-
Check HVAC system for correct functioning.
REMOVAL OF RADIATOR FROMVEHICLE
Note :
Before proceeding for removal of radiator ensure
that cooling system is at room temperature.
Remove radiator cap.
Drain coolant from cooling system through radiator
drain cock.
Fit back radiator cap and drain cock.
Remove hoses :
-
Radiator to water pump.
-
Radiator to upper cooling line.
Disconnect pipe from radiator to auxiliary tank.
Remove fan shroud bottom and top halves.
Check fan shroud for cracks, damage etc.
Replace if necessary.