SAFARI

15 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. - 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.