Removal and installation of the Cummins ISF2.8 engine GAZelle NEXT

Removal and installation of the Cummins ISF2.8 engine (GAZelle Next)

The engine on the GAZelle Next vehicle must be removed without the gearbox, withdrawing it forwards out of the engine compartment. A hoist or crane must be used for this.

The following tools are required for the work: 7, 10, 13 and 14 mm sockets; 7, 8, 10, 13, 15 and 16 mm spanners; a 6 mm hex key; pliers; a flat-blade screwdriver.

Place the vehicle over an inspection pit.

Disconnect the negative battery terminal.

Drain the coolant.

Remove the engine mudflap.

Press the retainer of the camshaft position sensor wiring connector and disconnect the connector.

Disconnecting the camshaft position sensor connector — Fig. 1. Disconnecting the camshaft position sensor wiring connector.

Slacken the clamp of the radiator inlet hose and disconnect the hose from the upper radiator connection.

Fig. 2. Disconnecting the radiator inlet hose from the upper radiator connection.

Slacken the clamp securing the hose to the thermostat cover and remove the hose.

Fig. 3. Removing the hose from the thermostat cover.

Remove the bumper.

Removing the front bumper — Fig. 4. Removing the bumper.

Unscrew two securing bolts on the left and on the right and remove the bumper reinforcement.

Bumper reinforcement fixing on the left — Fig. 5. Bumper reinforcement securing bolts on the left.

Bumper reinforcement fixing on the right — Fig. 6. Bumper reinforcement securing bolts on the right.

Remove the air filter.

Removing the air filter housing — Fig. 7. Removing the air filter.

Remove the air intake hose.

Remove the headlamp unit.

Remove the cooling system radiator.

Fig. 10. Removing the cooling system radiator.

Remove the charge-air cooler (intercooler).

Removing the charge-air cooler — Fig. 11. Removing the intercooler.

Remove the bonnet.

Squeeze the retainers and disconnect the wiring connectors from the horns.

Disconnecting the horn wiring connectors — Fig. 13. Disconnecting the wiring connectors from the horns.

Unscrew two securing bolts on the left and on the right and remove the power steering heat exchanger.

Fig. 14. Power steering heat exchanger fixing on the left.

Fig. 15. Power steering heat exchanger fixing on the right.

Unscrew the screws securing the radiator frame base to the cab side members on the left-hand side of the front end.

Screws securing the radiator frame base to the side member — Fig. 16. Screws securing the radiator frame base to the cab side members.

Unscrew the screw to the front wing holder.

Unscrew the screw to the upper front panel reinforcement.

Also unscrew the securing screws on the right-hand side and remove the plastic base of the radiator frame.

Disconnect the wiring connector from the crankshaft position sensor.

Disconnecting the crankshaft position sensor connector — Fig. 19. Disconnecting the wiring connector from the crankshaft position sensor.

Unscrew the nut securing the wire terminal to terminal “30” of the alternator and disconnect the wire from the terminal.

Alternator terminal 30 — Fig. 20. Disconnecting the wire from terminal “30” of the alternator.

Also disconnect the wire from the alternator power terminal.

Slacken the clamp securing the pipe to the turbocharger adapter and disconnect the pipe.

Fig. 22. Disconnecting the pipe from the turbocharger adapter.

Unscrew the nut securing the power steering pressure pipe and disconnect the pipe from the pump.

Fig. 23. Disconnecting the power steering pressure pipe from the pump.

Drain the fluid from the pipe into a suitable container.

Slacken the clamp of the power steering return pipe and disconnect the pipe from the power steering pump.

Disconnecting the power steering return pipe — Fig. 24. Disconnecting the return pipe from the power steering pump.

Drain the fluid from the pipe into a suitable container.

Slacken the clamp securing the air supply hose to the air flap connection and disconnect the hose.

Fig. 25. Disconnecting the air supply hose from the air flap connection.

Slacken the clamp securing the inlet hose to the water pump connection and remove the hose.

Fig. 26. Removing the inlet hose from the water pump connection.

Remove the control wire connector from the starter relay terminal.

Slide the protective cover off the starter power terminal and unscrew the nut securing the wire terminal to the power terminal.

Starter power terminal under the protective cover — Fig. 28. Starter power terminal.

Remove the spring washer and disconnect the wire terminal from the terminal.

Fig. 29. Disconnecting the wire terminal from the starter terminal.

Slacken the clamp securing the hose to the intermediate pipe by squeezing its bent lugs and disconnect the hose from the water pump connection.

Fig. 30. Disconnecting the hose from the water pump connection.

Squeeze the retainers of the fuel supply pipe end fitting at the high-pressure fuel pump.

Disconnect the pipe.

Fig. 32. Disconnecting the fuel supply pipe.

On the left-hand side of the engine, unscrew the two bolts securing the hose bracket and disconnect the bracket together with the hoses from the engine cylinder block.

Fig. 33. Hose bracket on the left-hand side of the engine.

Also on the right-hand side of the engine, unscrew the two bolts securing the hose bracket and disconnect the bracket together with the hose.

Fig. 34. Hose bracket on the right-hand side of the engine.

Squeeze the clamp, slide it along the hose and disconnect the heater supply hose from the pipe.

Fig. 35. Disconnecting the heater supply hose.

Also disconnect the second hose of the intermediate pipe to the heater radiator.

Slacken the clamp securing the hose to the vacuum pump connection.

Clamp on the vacuum pump connection — Fig. 36. Clamp securing the hose to the vacuum pump connection.

Disconnect the hose from the pump.

Fig. 37. Disconnecting the hose from the vacuum pump.

Slide the protective cap off the terminal of the intake air heater in the intake pipe.

Fig. 38. Intake air heater terminal in the intake pipe.

Unscrew the nut securing the power wire terminal while holding the terminal nut with a second spanner, and disconnect the terminal from the terminal post.

Unscrew the nut of the clamp securing the catalytic converter inlet pipe to the turbocharger connection adapter and slide the clamp along the pipe.

Clamp of the catalytic converter inlet pipe — Fig. 39. Clamp securing the catalytic converter inlet pipe to the turbocharger connection adapter.

The nut of the clamp securing the catalytic converter inlet pipe to the turbocharger connection adapter is easier to unscrew from the engine compartment side.

Remove the fan impeller so that it is not damaged when the engine is removed.

Attach the lifting slings to the engine lifting eyes.

Lifting slings on the engine lifting eyes — Fig. 41. Attaching the lifting slings to the engine lifting eyes.

Remove the propeller shaft.

Remove the gearbox.

From underneath the vehicle, unscrew the two bolts securing the clutch release actuator slave cylinder bracket to the clutch housing and move the bracket with the cylinder aside without disconnecting the hose.

Unscrew the bolt securing the left-hand engine bracket to the powertrain mounting support cushion.

Left-hand engine bracket securing bolt — Fig. 43. Bolt securing the left-hand engine bracket to the mounting support cushion.

Unscrew and withdraw the bolt securing the right-hand engine bracket to the powertrain mounting support cushion.

Right-hand engine bracket securing bolt — Fig. 44. Bolt securing the right-hand engine bracket to the mounting support cushion.

Withdraw the engine from the engine compartment.

Install the engine in the reverse order.

Before installation, clean the threaded holes for securing its brackets in the support cushions.

When connecting the wires and pipes, make sure they are routed correctly.

After installing the engine, fill the engine with oil, fill with coolant and fill the power steering system with fluid.

Start the engine and check all connections for leaks.

Check the oil pressure.

Listen to the engine running.

Bleed the air from the steering hydraulic system.

Materials used and recommendations

Slings — textile or steel with hooks, load capacity at least 500 kg; hoist or crane — load capacity at least 1 t; coolant — ethylene glycol-based antifreeze; engine oil — API CI-4 (Cummins); power steering fluid — ATF or a specialised fluid to the manufacturer's specification; sealant — anaerobic sealant for threaded connections. Before removing the engine, it is recommended to label the wires and hoses to facilitate assembly.