Engine: Service and Repair
ENGINE AND GEARBOX
Service repair no -12.37.01/99
REMOVE
1. Position vehicle on four post lift.
2. Remove battery.
3. Remove ECM.
4. Remove 2 screws securing engine harness clamp to battery tray. Collect clamp.
5. Release starter feed wire from battery terminal clamp.
6. Release earth lead from alternator bracket.
7. Release fuel return hose clip. Release fuel return hose from regulator connecting pipe.
8. Release fuel feed pipe from fuel rail.
9. Disconnect multiplug from purge valve.
10. Release purge hose from ram pipe housing.
11. Remove purge valve securing bolt from shock absorber turret. Place valve aside.
12. Disconnect multiplug from air flow meter.
13. Release harness from intake hose.
14. Slacken clip securing intake hose to plenum chamber.
15. Remove intake hose/air flow meter assembly.
16. Position harness across engine.
17. Disconnect throttle and cruise control cables from throttle linkage.
18. Release cables from abutment bracket.
19. Disconnect top hose from inlet manifold.
20. Disconnect heater hose from inlet manifold. Release hose from clip. Place hose aside.
21. Disconnect coolant hose from plenum chamber water jacket. Release hose from 2 clips. Place hose aside on valance.
22. Remove 4 bolts securing battery tray. Remove battery tray.
23. Remove 2 bolts securing fuse box. Pivot fuse box for access.
24. Disconnect engine harness multiplug from base of fuse box.
25. Release earth wire from valance stud.
26. Disconnect 2 engine harness multiplugs from main harness.
27. Release engine harness clip from valance. Tie harness aside over engine.
28. With assistance, release bonnet struts from body locations. Retain bonnet in vertical position using stay clips.
WARNING: Only open the bonnet to the vertical position with the vehicle on a horizontal surface in the workshop. This position is not intended to be used outdoors where the bonnet could be affected by winds.
29. Depressurize fuel system.
30. Remove air cleaner.
31. Drain cooling system.
32. Discharge air conditioning system.
33. Remove cooling fan and viscous coupling.
34. Remove front grille.
35. Remove 4 bolts securing bonnet platform.
36. Release straps securing bonnet release cable to platform. Remove platform.
37. Remove 2 studs securing each radiator air deflector. Remove both deflectors.
38. Remove bolt and screw securing washer bottle filler neck. Remove filler neck.
CAUTION: Where pipes are disconnected, plug pipes and ports to prevent ingress of dirt.
39. Disconnect engine and gearbox oil coolers. Remove O-rings and discard. Tie pipes aside on engine.
40. Disconnect coolant bleed hose from radiator.
41. Release 2 fog lamp breather hoses from clips on either side of radiator.
42. Disconnect 3 coolant hoses from thermostat housing.
43. Remove 2 bolts securing power steering fluid reservoir to radiator.
NOTE: Position container beneath power steering reservoir to catch spillage.
44. Disconnect return pipe from reservoir. Tie reservoir aside to engine.
45. Disconnect feed pipe from power steering pump. Remove O-rings and discard.
46. Release feed pipe clip from bracket. Place pipe aside.
47. Disconnect multiplug from gearbox oil temperature sensor.
48. Disconnect 2 pipes from air conditioning condenser. Remove O-rings and discard.
49. Disconnect 2 pipes from air conditioning compressor. Remove O-rings and discard. Place pipes aside.
50. Remove 2 nuts and bolts securing radiator mountings to chassis.
51. With assistance, raise radiator assembly for access to condenser cooling fan connections.
52. Disconnect 2 condenser cooling fan multiplugs.
53. With assistance, remove radiator/condenser/oil cooler assembly.
Manual Vehicles:
54. Clamp clutch flexible hose using an approved brake hose clamp.
55. Remove clip securing flexible hose to gearbox bracket.
56. Disconnect clutch flexible hose at gearbox pipe. Position hose aside.
Automatic Vehicles:
57. Remove window switch pack.
Manual Vehicles:
58. Remove center console.
59. Remove 6 nuts securing gaiter ring. Remove ring and gaiter.
60. Remove 2 bolts securing gear lever. Remove lever.
All Vehicles:
61. Release handbrake. Release handbrake cable clevis pin.
62. Raise lift. Drain gearbox, transfer box and engine fluids.
63. Using a transmission jack, support transmission under brake drum.
64. Remove exhaust front pipe.
65. Release hand brake cable from grommet in tunnel.
66. Remove 4 bolts securing rear propeller shaft guard. Remove guard.
67. Mark transfer box and propeller shaft flanges to aid reassembly.
68. Raise one wheel on each axle to allow rotation of propeller shafts.
69. Remove 4 nuts and bolts from each flange. Disconnect propeller shafts. Tie aside.
70. Automatic Vehicles: Disconnect gear selector cable trunnion from gearbox lever. Remove 2 bolts securing selector cable abutment bracket to gearbox. Place selector cable aside.
71. Lower gearbox for access.
72. Disconnect 2 Lucars from transfer box fluid temperature sensor.
73. Disconnect multiplugs from High/Low motor and output shaft speed sensor.
74. Automatic Vehicles: Disconnect multiplugs from gear selection position switch and gearbox speed sensor.
75. Manual Vehicles: Disconnect multiplugs from reverse and neutral switches. Remove bolt securing harness bracket to gearbox. Release harness from clips on gearbox brackets.
76. Disconnect engine harness to gearbox harness multiplug. Position harness aside.
77. Remove 4 nuts securing each engine mount to chassis and engine brackets. Discard nuts.
78. Remove oil filler cap.
79. Place cloth over plenum chamber to protect from damage during lifting.
80. Shorten front chain of lifting bracket to 2 links as shown.
81. Fit lifting bracket to engine lifting eyes. Attach suitable hoist.
82. Raise engine slightly. Ensure that lifting bracket does not foul bulkhead. Remove both engine mountings.
NOTE: It may be necessary to lower gearbox support slightly during above operation.
83. Raise power unit and draw forward. Lower support from transmission.
NOTE: Power unit must be tilted at an angle of approximately 45 degrees before it can be withdrawn from engine compartment.
84. Remove engine/transmission assembly.
REFIT
85. Raise power unit. Guide into engine bay.
86. Position transmission jack beneath transmission brake drum.
87. With assistance, raise transmission and lower engine until engine mountings can be fitted.
CAUTION: Ensure all under body wax is removed from mating surfaces of fixings before fitting.
88. Attach mountings to chassis with new flange nuts. Do not tighten at this stage.
CAUTION: Engine mountings must be fitted with center bolt head facing outboard as shown.
89. Lower and guide engine onto mounting studs.
90. Attach engine to mountings with new flange nuts. Do not tighten at this stage.
91. Release lifting bracket from engine lifting eyes. Remove hoist.
92. Route gearbox harness. Secure with clips.
93. Connect multiplug to engine harness.
94. Connect multiplugs to High/Low motor and output shaft speed sensor.
Manual Vehicles:
95. Secure gearbox harness bracket with bolt. Tighten to 6 Nm (4 ft. lbs.).
96. Connect multiplugs to reverse and neutral switches.
97. Secure harness to gearbox bracket with clips.
Automatic Vehicles:
98. Connect multiplugs to gear selection position switch and gearbox speed sensor.
99. Position selector cable abutment bracket to gearbox. Secure with bolts.
100. Adjust gear selector cable.
All Vehicles:
101. Connect Lucars to transfer box fluid temperature sensor.
102. Raise gearbox on transmission jack.
103. Align harness bracket to gearbox.
104. Raise one wheel on each axle to allow rotation of propeller shafts.
105. Position shafts to transfer box flanges. Align marks.
106. Secure propeller shaft flanges with nuts and bolts. Tighten to 48 Nm (35 ft. lbs.)
107. Fit propeller shaft guard. Tighten bolts.
108. Guide hand brake cable through grommet in transmission tunnel.
109. Fit exhaust front pipe and chassis cross member.
110. Remove support from under transmission.
111. Tighten engine mounting nuts to 45 Nm (33 ft. lbs.)
112. Lower lift.
113. Connect hand brake cable to lever, secure with clevis pin and clip.
Manual Vehicles:
114. Fit seal around gearbox remote housing to transmission tunnel aperture.
115. Position gear lever. Secure with bolts. Tighten to 25 Nm (18 ft. lbs.)
116. Fit gaiter and ring. Secure with bolts.
117. Fit center console.
118. Connect clutch flexible hose. Remove hose clamp.
119. Secure flexible hose union to gearbox bracket with clip.
120. Bleed clutch hydraulic system.
Automatic Vehicles:
121. Fit window switch pack.
All Vehicles:
122. With assistance, position radiator/condenser/oil cooler assembly.
123. Connect multiplugs to condenser cooling fans.
124. Engage radiator in lower mounting rubbers. Secure with nuts and bolts.
125. Remove plugs from air conditioning compressor and pipes.
126. Fit new O-rings to compressor pipes. Lubricate O-rings with compressor oil. Connect to compressor.
127. Fit compressor connection bolts. Tighten to 23 Nm (17 ft. lbs.)
128. Remove plugs from air conditioning condenser and pipes.
129. Fit new O-rings to condenser pipes. Lubricate O-rings with compressor oil. Secure pipes to condenser. Tighten to 15 Nm (11 ft. lbs.)
130. Connect gearbox oil temperature multiplug.
131. Remove plugs from power steering pump and pipes.
132. Fit new O-rings to power steering pipes. Lubricate O-rings with power steering fluid. Secure to power steering pump. Tighten to 16 Nm (12 ft. lbs.)
133. Untie power steering reservoir from engine. Remove plugs. Connect return pipe. Secure return pipe to reservoir with clip.
134. Position reservoir to radiator. Secure with bolts.
135. Secure fog lamp breather hoses to clips on either side of radiator.
136. Route plenum chamber hose along front of engine. Secure in clips.
137. Connect hose to plenum chamber water jacket. Secure with clip.
138. Connect coolant hoses to radiator, thermostat housing and inlet manifold. Secure hoses with clips.
139. Remove plugs from oil coolers and pipes.
140. Lubricate pipes with clean fluid. Fit new O-rings. Connect to oil coolers. Tighten to 30 Nm (22 ft. lbs.)
141. Fit washer bottle filler neck. Secure with bolt and screw.
142. Fit radiator deflector panels. Secure with studs.
143. Position bonnet platform. Secure bonnet release cable to platform with clips.
144. Secure bonnet platform with bolts.
145. Fit front grille.
146. Fit cooling fan and viscous coupling.
147. Evacuate and recharge air conditioning system.
148. Refill cooling system.
149. Replenish transmission fluids.
150. Replenish engine oil.
151. Fit oil filler cap.
152. Route engine harness along valance. Secure clip.
153. Connect engine harness multiplugs to main harness. Secure earth terminal to valance stud.
154. Connect engine harness multiplug to base of fuse box.
155. Position fuse box. Secure with bolts.
156. Position earth lead to alternator bracket. Secure with bolt.
157. Fit battery tray. Secure with bolts.
158. Fit starter feed wire to battery positive terminal clamp. Secure with nut.
159. Position engine harness to battery tray. Secure harness grommets.
160. Secure harness clamp to battery tray with screws.
161. Fit ECM.
162. Fit throttle and cruise control cables to abutment bracket. Secure cruise control cable with 'C' clip.
163. Position cable trunnions to throttle linkage. Secure with clevis and split pins.
164. Adjust throttle cable free-play.
165. Adjust cruise control cable.
166. Fit intake hose and air flow meter assembly to plenum chamber. Secure with clip. Connect multiplug to air flow meter.
167. Connect multiplug to purge valve.
168. Position purge valve on shock absorber turret. Secure with bolt.
169. Connect purge hose to ram pipe housing.
170. Secure harness to clip on intake hose.
171. Fit air cleaner.
172. Remove plugs from fuel hoses and fuel rail connections.
173. Connect fuel feed pipe to fuel rail. Tighten to 16 Nm (12 ft. lbs.)
174. Connect return hose to pressure regulator pipe. Secure with clip.
175. Refit battery.
176. With assistance, release bonnet stay clips. Engage bonnet struts.
CAUTION: Ensure bonnet stay clips are returned to their original positions as shown.
177. Start engine. Check for fuel, coolant and oil leaks.