ENGINE
9. Remove the Engine cover.
10. Remove all connectors of Engine harness routed
on Engine and take it out.
11. Disconnect the fuel suction line connected to the
fuel filter from sedimentor and fuel filter to HP
pump. Remove the filter assembly.
12.Remove the following components.
a. Bonnet.
b. Wiper arms.
c. Leaf screen.
d. Wiper Motor.
e. Bonnet Latch and bracket.
f. Power steering reservoir
g. Fuel filter.
13. Drain the coolant and remove the Radiator along
with Condenser, Fan Shroud and header tank.
(For procedure refer Radiator removal in cooling
system section in this manual).
14.Disconnect the cab heater hose.
15.Drain the engine oil.
16.Remove Air filter assembly. (For procedure refer
Air filter assembly removal).
17. Disconnect the hose connected between turbo-
charger and intercooler.
18. Disconnect the vacuum line connected to brake
booster.
19. Disconnect the Exhaust pipe connected to as-
sembly DPF DOC.
20. Drain the power steering oil and disconnect the
pipelines.
40
21. Disconnect the refrigerant lines of the AC Com-
pressor.
22.Disconnect the heater lines.
23.Support the gearbox from lower side.
24.Disconnect the gear shifter lever from inside the
vehicle.
25.Disconnect the propeller shaft at gear box end.
26.Remove Slave Cylinder.
27. Remove Gear Box mounting bolts to the clutch
housing.
28.Remove gear box mounting on cross member.
29.Slightly move the gear box towards rear side of
the vehicle.
30.In case 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.
31.Support the Engine from bottom side.
32. Fix chain to front and rear engine lifting hooks
and hold chain in position with crane.
33.Unscrew and remove engine mounting bolts
34.Lift the engine & Mount it on work stand.
35. Check engine mounting pads for wear. Replace
them if necessary.
!CAUTION
While lifting the engine out from the engine bay take
extra care to avoid the suspended engine hitting the
windshield bottom.
FITMENT
For fitment follow the reverse order of removal.
Tighten the following fasteners to the recommended
torque.
i) Refrigerant lines on compressor.
ii) Engine mounts
iii) Exhaust pipe joints
iv) Clutch house mounting bolts.
 ENGINE
B. AIR FILTER ASSEMBLY REMOVAL FITMENT
1. Loosen and remove the Air reservoir mounting For fitment follow the reverse order of removal
bolts. procedure.
C. DRIVE BELT REMOVAL
POWER STEERING BELT REMOVAL
1. Pry out the power steering belt.

2. Disconnect the electrical connections of SIMAF

sensor.

INSPECTION
Inspect the belt for wear, cracks and signs of fail-
ures. Replace if necessary.
FITMENT
Place the belt over the power steering pulley and
crankshaft pulley properly and ensure proper belt
tension (Frequency 165±10Hz)
AC AND ALTERNATOR BELT REMOVAL
1. Remove the tensioner cap (1) and loosen the
3. Disconnect the intake hose (1.) Loosen and tensioner bolt (2).
remove the Air filter mounting bolts (2 and 3)
and remove the Air filter with Air reservoir.

41
ENGINE
2. Reduce the belt tension by rotating the tensioner A C AND ALTERNATOR BELT ADJUSTMENT
screw (3) in clockwise direction (Tightening direc-
tion of a RH threaded screw) and remove the
belt.
INSPECTION
Inspect the belt for wear, cracks and signs of fail-
ures. Replace if necessary.
FITMENT
1. For fitment, first place the belt, and then tighten
the tensioner screw (3) by rotating it in the anti-
clockwise direction (Loosening direction of a RH
threaded screw).
2. Tighten the tensioner bolt (2) to a torque of 4
Kgm and fit the cap.
3. Adjust the belt tension.
1. Remove the tensioner cap (1) and loosen the
tensioner bolt (2).
2. Adjust the belt tension as follows:
a. To reduce the tension rotate the tensioner screw
(3) in clockwise direction (Tightening direction of
a RH threaded screw)
b. To increase the tension rotate the screw (3) in
anti clockwise direction (Loosening direction of a
RH threaded screw).
Keep belt tension in given range .which is as follows.
For new Belt
Tension for new belt = 268 ± 10 Hz
Then run the engine for 15 mins. Now the belt has to
be retensioned to 244 ± 10 Hz.
For reusing same belt
In case of reusing the same belt, it should be ten-
sioned to 244 ± 10 Hz.

42
 ENGINE
D. INJECTOR REMOVAL 4. Remove the HP pipes connecting injector to
common rail and cover the injector opening with
1. Remove the engine cover by pulling it upwards
suitable caps.
firmly.

5. Loosen and remove the bolt (1) along with

2. Disconnect the injector electrical connecters (1)
washer and remove the injector claw (2).

3. Disconnect the injector back leak tube (Overflow

pipe) and cover the injector side opening with
suitable caps.

43
ENGINE
6. Extract the injector using injector removal tool (1)
(Part no. 2868 5890 07 04). Remove the injector
with the sealing washer.
E. TIMING BELT REMOVAL:
REMOVAL
1. Remove the engine cover.
2. Remove power steering belt. Then remove alter-
nator and AC compressor belt. (Refer alternator
and AC compressor belt removal procedure)

3. Loosen & remove the front timing cover bolts and

take out the front timing cover.

NOTE
Injector should be tagged as soon as it is removed to
avoid chances of it being interchanged. Since the
I2C code of each injector is calibrated to the EMS,
whenever an injector is replaced it I2C codes of the
respective injectors should be fed in the EMS ECU
using diagnostic tool.
FITMENT:
x Follow the reverse order of removal procedure.
NOTE
x Do not reuse the bolt and washer removed in
step 5, use new ones.
x Replace the injector sealing washer while refit-
ting the injector.
x Vacuum clean the injectors.

44
 ENGINE
4. Disconnect electrical connection from cam phase 7. Lock the flywheel using locking pin (Part no. 2653
sensor and loosen and remove the bolt of cam 5890 06 04) to bring the piston of No.1 cylinder to
phase sensor. TDC position.

8. Align hole on the HP mounting bracket & lock the

5. Remove the cam phase sensor and insert the gear with the help of locking pin (Part no. 2653
locking pin (Part no. 2653 5890 06 09) for on ve- 5890 06 07).
hicle ease for locking the camshaft

6. Lift the vehicle and remove the stone guard and

noise shield.

45
ENGINE
9. Loosen the camshaft gear. INSPECTION
Inspect the Timing belt for wear, cracks and signs
of failures. Replace if necessary.
FITMENT OF TIMING BELT
1. Slightly tighten the camshaft gear. Keep the cam-
shaft bolt loose so that the gear is free to rotate.

10.Release the timing belt tension by loosening the

auto tensioner mounting bolt.
11.Remove the timing cover lower.

2. Tighten the auto tensioner bolt finger tight or 0.3

- 0.6 kgm torque through the fixing bore hole
during setting.
3. Position the timing belt first on the camshaft gear
& last on the auto tensioner as per the routing
shown.

12.Take out the timing belt.

NOTE
Do not remove the special tools.

46

4. Rotate the auto tensioner using allen key in anti-
clockwise direction so that the tensioner locator
crosses the cylindrical pin by approx 15º-20º.
5. Now rotate the allen key in clockwise direction to
align tensioner locator with the cylindrical pin.
ENGINE
12. If belt tension is not proper, then loosen the
camshaft and auto tensioner bolt and repeat the
steps 5 - 8.
13. Reconfirm the engine timing.
NOTE
Do not crimp or use sharp tool on timing belt.
14. Fix the bottom timing cover.

15. Assemble the timing cover front.

6. Adjust the allen key on the auto tensioner so that
the locator remains aligned to the cylindrical pin.
(Maximum permissible misalignment + 5º).

16. Fit the Cam angle sensor and electrical connec-

tions.
7. Tighten auto tensioner mounting fastener to 17. Refit the power steering belt and alternator com-
specified torque. pressor belt.
8. Tighten the camshaft gear bolt to specified
torque.
9. Remove all the special tools from engine.
10. Rotate engine for two revolutions.
11. Check for the timing belt tension. Belt tension
should be within 250 ± 15 Hz by CLAVIS gauge
(measure belt tension at the span between touch
idler and camshaft gear)

47