Operation and maintenance manual

Section 110-0030
SM 2121 Rev 1 11-03
9
REMOVAL
Numbers in parentheses refer to Fig. 1.
Note: Tag all cables, harnesses, lines and pipes
disconnected during removal to aid in installation.
WARNINGS
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
High electrical current can cause sparks
and personal injury from burns. Turn battery
master switch to the 'Off' position before
removing any components. Remove battery
ground cable first, and reconnect last, to avoid
damaging electrical components.
1. Position the vehicle in a level work area, ensure the
body is fully lowered, apply the parking brake and
switch off the engine. Turn steering wheel several
times to relieve any pressure in the steering circuit.
2. Block all road wheels and place the battery master
switch in the 'Off' position.
3. Disconnect battery cables from terminal posts
(earth cable first).
4. Pull on handle to release hood catch and lift up hood.
5. Remove mounting hardware securing air cleaner
assembly to right hand fender. Slacken mounting clamp
at air cleaner intake pipe and draw air cleaner, complete
with rubber hose, away from intake pipe. Cover open ends
to prevent entry of dirt.
6. With a suitable container in position, open shut-off
valve on the radiator assembly and drain the coolant.
7. Remove hood and goalpost from the vehicle. Refer
to Section 100-0040, HOOD AND MOUNTING.
Note: Radiator header tank will be removed as part of
the goalpost assembly.
8. Support engine sump guard with suitable blocking
and remove mounting hardware securing sump guard to
the frame. Remove sump guard from the frame.
9. Support guard plate under the engine at the front of
the frame with suitable blocking and remove mounting
hardware securing guard plate to the frame. Remove
guard plate from the frame.
10. Place a suitable container under the engine drain
port, remove drain plug and drain the oil. After
draining, reinstall drain plug in engine sump and
tighten securely.
WARNING
Before disconnecting any air conditioner lines,
refer to Section 260-0130, AIR CONDITIONING.
Refrigerant will rapidly freeze all objects with
which it comes into contact. It can cause
serious and permanent damage to the eyes
and skin.
11. Evacuate air conditioning system and disconnect
air conditioner lines at the engine compressor. Refer to
Section 260-0130, AIR CONDITIONING.
12. Remove the radiator assembly from the vehicle.
Refer to Section 210-0040, RADIATOR AND
MOUNTING.
13. With a suitable container in position, remove drain
cock on the transmission oil cooler flanges and drain
the coolant. Remove coolant pipes from the engine
water pump and engine oil cooler. Refer to Section
210-0060, TRANSMISSION OIL COOLER.
14. Remove charge air cooler pipes from engine
turbocharger and engine inlet manifold.
15. Disconnect exhaust piping from the engine
turbocharger.
16. Disconnect air cleaner intake pipe from engine
turbocharger and remove from the engine.
17. Identify heater lines for ease of installation and with a
suitable container in position, disconnect heater lines
from the engine. Cap open line ends and fittings.
18. Identify fuel lines for ease of installation and with a
suitable container in position, disconnect fuel lines
from the engine. Cap open line ends and fittings.
19. Identify all electrical harnesses and cables for ease
of installation and disconnect from the engine.
20. Disconnect clips securing items to the engine that
cannot be removed with the engine.
21. Disconnect driveline from the engine coupling and
secure clear of the engine. Refer to Section
Engine - Engine and Mounting