Page 96
REPAIR INSTRUCTIONS
ENGINE REMOVAL
General Instructions
Details of the engine removal procedure vary
from one vehicle to another. This section provides
general guidelines for removing the engine from
the vehicle.
Before beginning engine removal, make sure all
equipment is available for use and has been
inspected for safety.
It is good practice to steam clean the engine to
remove road grime, grease and oil before starting
work. Steam cleaning the engine and engine area
allows more detailed inspection and improved
workmanship.
Care must be used to keep moisture from
entering the air intake system. If moisture does
enter the system, make sure it is removed (dried
out) before the engine is reinstalled.
1. Position vehicle on a flat and level surface in
an area with ample work space in and
around the vehicle. Ensure that a suitable
lifting device is available.
2. Apply the parking brake and block the
vehicle wheels to prevent vehicle from
moving. Observe all safety precautions.
3. Disconnect the battery negative (ground)
cable.
4. Drain the air tanks.
Removal from Vehicle
1. Remove the hood (if so equipped) and
position it away from the work area to
prevent accidents or hood damage to
conventional models. On cab over engine
models, tilt cab forward.
2. Place a suitable container beneath the
engine and drain the engine oil and coolant.
Open the coolant drain valves in the block, if
applicable.
3. Using an appropriated filter wrench, remove
the oil filters, fuel filters and coolant
conditioner.
4. Loosen clamps that secure the air intake
tube to the turbocharger and air filter.
Remove the intake tube.
5. If vehicle is equipped with air conditioning:
a. Recover the refrigerant using A/C
refrigerant recovery and recycling
equipment.
b. Disconnect the A/C compressor
discharge hose at the connection near
the radiator support.
c. Disconnect the A/C line at the receiver/
dryer.
d. Locate and disengage the electrical
connector from the binary pressure
switch on the receiver/dryer.
e. Locate and disengage the electrical
connector from the low-pressure cutout
switch in the A/C refrigerant line.
6. Disconnect the upper radiator hose from the
engine coolant outlet fitting.
7. Disconnect the lower radiator hose from the
coolant inlet of the oil cooler assembly.
8. Remove the clamps that retain the coolant
overflow tank and then remove the tank.
5_106_00.bk Page 96 Friday, August 4, 2000 11:17 AM
BDC for engine manuals and specs
https://barringtondieselclub.co.za/
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