30 - 3
Removal and Replacement
Removal (continued)
25 If fitted, loosen and disconnect the ether cold start fuel
line from the engine. Plug and cap open orifices to
prevent ingress of dirt and loss of fluid.
26 If fitted, loosen and remove the ether cold start canister
retaining bolts, lift off the canister and retaining bracket
assembly.
27 Disconnect the throttle linkage L from the arm on the
fuel injection pump. Leave at least one of the locking
nuts in position, this will ensure that the engine revs are
set correctly when reassembling.
28 Loosen and remove the rear propshaft to gearbox
retaining bolts M.
29 On 4WD machines, loosen and remove the front
propshaft to gearbox retaining bolts N.
30 Remove the access bung located at the base of the
gearbox. Through the access hole, loosen and remove
the torque converter to engine flywheel retaining bolts
P (turn the flywheel to align bolts with access hole).
31 If manual gearbox fitted, disconnect the gearshift lever
from the top of the gearbox.
32 Use a suitable trolley jack and support the weight of the
gearbox.
Note: Attach a ‘cradle’ to the trolley jack that will evenly
support the weight of the gearbox. Refer to Service Tools.
33 Use a suitable stand and support the weight of the
engine.
34 Loosen and remove the gearbox mounting bolts Q.
35 Remove the gearbox to engine retaining bolts R, pull
the transmission and converter clear of the engine,
make sure that the converter stays mounted on the
gearbox shaft.
36 Attach suitable lifting chains to the engine (see Lifting
Wire Assembly, service tool 892/00836 in Service
Tools). Take the weight of the engine on the hoist.
37 Loosen and remove the engine mounting bolts S (both
sides).
38 Lift the engine clear of the machine.
39 Put the engine on a suitable stand, the correct
dismantling and assembly procedures are detailed in
the Engine Service Manual, publication number
9806/0100.
Replacement
Replacement is a reversal of the removal procedure.
1 When mating the gearbox/torque converter to engine,
ensure that the drive tangs are correctly located in the
gearbox pump. See Section F Gearbox Replacement
for a detailed procedure.
Note: It is vitally important that the torque converter is
fitted at the gearbox and engine flywheel correctly.
Failure to locate the converter correctly will result in damage
to the gearbox oil pump on engine start up.
2 When you are satisfied that the torque converter is
located correctly, use the access hole in the bottom of
the gearbox to fit and tighten the flexi-plate to engine
flywheel retaining bolts. Rotate the flywheel to align the
next bolt hole, fit and tighten all retaining bolts.
3 When fitting the radiator sub-assembly, including
radiator, cooler and shroud take care not to damage
the engine fan, align the shroud using alignment mark
made at step 13 in Removal.
4 Make sure that the front nose guard and the engine
cover are correctly aligned.
5 Refill cooling system using correct mixture of
water/anti-freeze.
6 Check engine, coolant and brake oil levels.
7 When connecting the battery, connect the earth (black)
lead last.
Make sure that the engine idle speed is correct, adjust as
required, refer to Technical Data.
Torque Figures
Item Nm Kgf m lbf ft Description
M 118 12 87 Rear propshaft bolts
N 79 8 58 Front propshaft bolts
P 44 4.5 32 Flexi-plate to flywheel bolts
Q 237 24 175 Gearbox mounting bolts
R 98 10 72 Gearbox to engine bolts
S 85 8.7 63 Engine mounting bolts
Note: The engine oil pressure switch, water temperature
switch and water temperature sensor torque figure varies
depending on the material it is screwed into.
Nm Kgf m lbf ft
Plastic 4 0.4 3.0
Aluminium 30 3.0 22
Section K Engine
9803/3280
Section K
30 - 3
Issue 1
Engine
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