Remove
1. Prop the hood open, disconnect the screen washer hose from the reservoir and electrical leads to the engine compartment illumination lamp. Remove the fasteners, hinges to hood and lift the hood clear.2. Set the vehicle on level ground and apply the transmission brake.
3. De-pressurize the fuel system. Service and Repair
4. Disconnect the battery terminals and remove the battery from the vehicle.
5. Release the hose clamp and remove the radiator bottom hose to enable the cooling system to be drained.
6. Release the hose clamps and remove the radiator top hose and expansion tank hose.
7. Remove the fan cowl, drive belt and viscous unit/fan assembly.
8. Release the fasteners and remove the radiator.
9. Place an absorbent cloth around the fuel feed hose at the fuel rail and release the compression nut, remove the feed hose from the rail, seal the end of the pipes with masking tape to prevent ingress of dirt.
10. Release the hose clamp and remove the fuel return hose from the pressure regulator, seal both openings with masking tape to prevent ingress of dirt. Remove the vacuum hose from the rear of the regulator.
11. Detach the throttle lever return springs, remove the fasteners securing the kickdown cable anchor bracket to the plenum chamber bracketry and lay the assembly to one side. DO NOT DISTURB THE KICK DOWN CABLE SETTING.
12. Disconnect the multi-plug from the air bypass valve (stepper motor).
13. Release the hose clamp securing the hose to the inlet neck of the plenum chamber.
14. Disconnect the multi-plug from the air flow sensor, release the two clips securing the air cleaner to the air flow sensor, remove the sensor complete with hose from the engine compartment.
15. Release the fasteners and remove the air cleaner assembly from the engine compartment.
16. Release the alternator pivot bolts and remove the drive belt, remove the alternator fasteners and withdraw the alternator.
17. Release the idler pulley between the crankshaft pulley and compressor pulley and remove the drive belt.
18. Release the compressor from its mounting and lay to one side. DO NOT discharge the air conditioning system.
NOTE: Release the bolts securing the compressor mounting bracket to the engine and remove the bracket to enable a temporary lifting eye ETC 5964 to be fitted. Secure the lifting eye to the mounting bracket points with suitable bolts of equivalent size, pitch and thread. Leave the lifting eye attached to the engine until the engine has been reinstalled in the vehicle.
19. Place a drain tray underneath the vehicle to catch any power steering fluid which may seep from the steering fluid reservoir when the hose is disconnected from the steering pump.
20. Disconnect the hose and secure the end of it above the level of the fluid reservoir to avoid the loss of any more fluid than necessary. Seal the power steering pump and pipe opening with masking tape to prevent ingress of dirt.
21. Disconnect the power steering pump to power steering box hose, seal the hose and pump opening with masking tape to prevent ingress of dirt. Wipe away any fluid that may have come into contact with the chassis or steering box.
22. Remove the two coolant hoses and one crankcase breather hose from the potentiometer side of the plenum chamber.
23. Disconnect the potentiometer multi-plug.
24. Remove the distributor vacuum hose from the top of the plenum chamber and disconnect the vacuum supply hose to the cruise control actuator.
25. Remove the six bolts and maneuver the plenum chamber off the ram housing.
26. Disconnect the hoses from around the outside of the ram housing and remove the six bolts securing the ram housing to the intake manifold.
27. Lift the ram housing clear of the intake manifold and remove it from the engine compartment. Place a protective cover over the intake manifold openings to prevent ingress of dirt.
28. Disconnect the fuel temperature and coolant temperature sensor multi-plugs.
29. Disconnect the High tension and Low tension leads from the coil.
30. Identify each injector multi-plug for re-assembly and disconnect the plugs from the injectors.
31. Maneuver the harnesses from behind the fuel rails and place aside , clear of the engine assembly.
32. Remove the two clamps securing the automatic gearbox oil cooler pipes to the bottom left hand side of the engine block.
33. Remove the top and bottom nuts securing the engine mountings at either side of the cylinder block.
Engine Lifting Chain:
KEY TO CHAIN LENGTHS
1. L/H Front chain 356mm(14 in.) total overall length.
2. R/H Front chain 330mm(13 in.) total overall length.
3. R/H Rear chain 457mm(18 in.) total overall length.
NOTE: All chain dimensions are measured from the end of the lifting hook to the end of the last link in the chain.
34. Fit suitable lifting chains to the engine lifting eyes located at the front of both cylinder heads and the rear of the right hand cylinder head.
35. Fit the chain lifting eye to a suitable hydraulic hoist. Raise the hoist sufficiently high enough to enable the engine mounting rubbers to be removed, and withdraw the rubber mountings.
36. Lower the hoist until the engine rests securely on the engine mounting brackets. Remove the lifting chains and hoist.
37. Disconnect the two heater hoses located on the top of the right hand rocker cover.
38. Remove the ground strap from the rear of the left hand cylinder head.
39. Remove the cylinder block to hood ground strap from the retaining clip at the engine compartment closure panel.
40. Remove all electrical harnesses from the retaining clips on and around the rear of the engine.
41. Remove the gearbox breather pipe from the retaining clip at the rear right hand lifting eye.
42. Remove the top two bolts securing the bell housing to cylinder block.
43. Position a suitable hydraulic floor jack under the front differential casing, raise the front of the vehicle sufficiently to enable two axle stands to be positioned under the front axle, lower the vehicle on to the axle stands.
44. Remove the bolts securing the bell housing bottom cover, detach the cover from the bell housing and remove the gasket from the bell housing face.
45. Remove the transfer box to engine block tie bar.
46. Remove the nuts securing the exhaust downpipes to the manifolds, remove the heat shield from the right hand side downpipe.
47. Remove the electrical leads from the rear of the starter motor solenoid, and disconnect the multi-plug from the oil level sensor on the side of the oil pan.
Torque Convertor Bolt Access Holes:
48. With the assistance of a second person to rotate the engine at the crankshaft pulley, rotate the crankshaft until two of the access holes in the drive plate/ring gear assembly are visible through the bellhousing bottom cover opening.
49. Remove the two bolts that are visible through the access holes, which secure the flexible drive plate to the torque converter. Mark one of the access holes and one of the bolt holes with some means of identification to enable the unit to be fitted in the same position on re-assembly to maintain the original build setting.
50. Rotate the crankshaft 180° until the two remaining access holes are visible, and remove the two bolts.
51. Remove the remaining bell housing to cylinder block bolts.
52. Raise the vehicle off the axle stands using a suitable hydraulic floor jack under the front axle, remove the stands and lower the vehicle to rest on its road wheels.
53. Fit the engine lifting eyes, locate the chain lifting eye into the floor crane.
54. Remove the starter motor ground strap from the chassis.
55. Place a hydraulic floor jack under the gearbox bell housing to support the gearbox when the engine and gearbox are separated.
56. Carefully raise the crane a little, ease the engine to gearbox joint faces apart, steady the engine on the crane.
57. Ensure there are no restricting electrical harnesses, hoses, pipes, or components that will prevent the engine being raised clear of the engine compartment.
58. Slowly raise the engine clear of the engine compartment, move the engine away from vehicle and place on a suitable engine stand.