8 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 al l pipes, hoses and electr ical 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.
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