Engine: Service and Repair

ENGINE AND ANCILLIARIES
Service repair no - 12.41.01.99

Remove
1. Drain engine oil and remove oil filter.
2. Remove radiator.
3. Remove ignition coils.





4. Position absorbent material to catch any fuel spillage and disconnect fuel pipe from rail.

CAUTION: Plug the connections.





5. Disconnect MAP sensor multiplug.





6. Release clip and remove top hose from adapter on inlet manifold.
7. Remove 2 bolts securing auxiliary drive belt cover, remove cover and collect spacers.





8. Using a 15 mm spanner, release auxiliary drive belt tension and remove drive belt.





9. Disconnect A/C compressor multiplug.
10. Remove 4 bolts securing A/C compressor, release compressor and tie aside.





11. Remove 2 bolts securing PAS pump to mounting bracket, release pump and tie pump aside.





12. Release clip and disconnect coolant hose from water pump.





13. Release 2 clips securing coolant hoses to coolant rails, release hoses and remove hoses and thermostat housing.





14. Release 2 clips securing heater hoses to coolant rails and disconnect hoses from rails.
15. Disconnect multiplug from purge valve and position EVAP pipe aside.





16. Remove bolt securing engine oil cooler return pipe to alternator mounting bracket.





17. Loosen engine oil cooler feed and return pipe unions from oil pump.
18. Release feed and return pipes, remove and discard O-rings.

CAUTION: Plug the connections.





19. Remove bolt securing gearbox fluid cooler pipes clamp to engine LH mounting bracket and remove clamp and spacer.
20. Disconnect multiplug from LH KS.
21. Remove bolt securing harness P-clip to cylinder block.





22. Disconnect multiplug from RH KS.
23. Remove nut securing battery lead to starter solenoid, release lead and disconnect lucar from solenoid.
24. Release clip securing harness to engine RH mounting bracket.





25. Disconnect multiplug from CMP sensor.
26. Disconnect Lucar from oil pressure switch.





27. Release clip securing harness to coolant rail.
28. Remove bolt securing engine earth lead and position lead aside.
29. Release cover from battery positive terminal.
30. Remove nut securing positive lead to battery terminal, release fuse box feed lead, and disconnect positive lead from battery terminal.
31. Release positive lead from battery carrier.
32. Remove 2 screws and remove harness clamp from battery carrier.





33. Remove 3 bolts securing under bonnet fuse box.





34. Disconnect engine harness multiplug from fuse box.
35. Remove nut and disconnect 2 earth leads from RH wing valance.





36. Disconnect engine harness multiplug from main harness.
37. Disconnect multiplug from Canister Vent Solenoid (CVS) unit.
38. Release clip securing harness to RH wing valance.





39. Release harness clips from fuel rail and heater coolant pipe.
40. Disconnect multiplug from ECT sensor.
41. Disconnect multiplugs from fuel injectors.





42. Disconnect multiplug from CKP sensor.





43. Remove 2 nuts securing engine harness to alternator.





44. Remove bolt securing engine harness P-clip to rear of LH cylinder head.





45. Remove cable tie securing purge pipe to engine rear lifting eye.
46. Move harness clear of engine.
47. Raise vehicle on ramp.





48. Remove 6 nuts securing exhaust front pipes to exhaust manifolds and collect gaskets.





49. Remove 2 nuts securing exhaust front pipe to intermediate pipe.
50. Release exhaust front pipe from intermediate pipe.





51. Remove access plug and remove 4 bolts securing torque converter to drive plate.





52. Using hoist and LRT-12-138 connected to engine lifting eyes provided, support engine weight.





53. Remove 8 nuts securing engine mountings, raise engine and remove engine mountings.
54. Remove bolt securing earth strap to RH cylinder head.





55. Release 3 breather hoses from RH lifting eye.





56. Remove 12 bolts securing engine to gearbox and remove crash bracket.
57. Support gearbox on a jack.
58. Remove 2 remaining bolts securing engine to gearbox and with assistance, remove engine from gearbox dowels and remove engine from engine bay.
59. Care must be taken when releasing engine from dowels to ensure torque converter remains fully engaged with gearbox.


Refit
60. Clean mating faces of engine and gearbox, dowel and dowel holes.
61. Ensure drive plate and converter mating faces are clean.
62. With assistance position engine in engine bay, align to gearbox and locate on dowels.
63. Fit crash bracket to gearbox flange and fit and tighten engine to gearbox bolts to 45 Nm (33 ft. lbs.).
64. Lower and remove support from gearbox.
65. Fit breather hoses to clip on engine RH lifting eye.
66. Position earth strap to RH cylinder head and secure with bolt.
67. Fit engine mountings, lower engine onto mountings and tighten nuts to 45 Nm (33 ft. lbs.).
68. Lower lifting equipment and remove from engine.
69. Align torque converter and drive plate. Fit bolts and tighten to 50 Nm (37 ft. lbs.).
70. Fit access plug.
71. Ensure mating face of exhaust front pipe, intermediate pipe and exhaust manifolds are clean.
72. Use new gaskets, fit front pipe to exhaust manifolds and tighten nuts to 30 Nm (22 ft. lbs.).
73. Fit intermediate pipe to front pipe, align clamp and tighten nuts to 25 Nm (18 ft. lbs.).
74. Secure purge pipe to rear engine lift eye with cable tie.
75. Fit bolt to secure harness P-clip to LH cylinder head.
76. Connect harness to alternator and tighten B + terminal nut to 18 Nm (13 ft. lbs.) and D + terminal nut to 5 Nm (3.5 ft. lbs.).
77. Connect multiplug to CKP sensor.
78. Connect multiplugs to fuel injectors and ECT sensor.
79. Fit harness clips to fuel rail and heater coolant pipe.
80. Connect multiplug to Canister Vent Solenoid (CVS) unit.
81. Connect engine harness multiplug to main harness.
82. Connect earth leads to stud on RH wing valance and tighten nut to 10 Nm (7 ft. lbs.).
83. Connect engine harness multiplug to fuse box.
84. Secure harness clip to RH wing valance.
85. Fit bolts to secure fuse box.
86. Fit harness clamp to battery carrier and secure with screws.
87. Fit battery positive lead to battery carrier and connect cable to battery terminal. Connect fuse box positive feed to terminal clamp bolt and secure with nut. Fit terminal cover.
88. Fit engine earth lead to alternator bracket and tighten bolt to 20 Nm (15 ft. lbs.).
89. Secure harness to coolant rail.
90. Connect Lucar to oil pressure switch.
91. Connect multiplug to CMP sensor.
92. Connect battery lead to starter solenoid and tighten nut to 18 Nm (13 ft. lbs.).
93. Connect Lucar to starter solenoid.
94. Connect multiplug to RH KS and secure harness clip to engine RH mounting bracket.
95. Connect multiplug to LH KS, align harness P-clip to cylinder block and tighten bolt to 20 Nm (15 ft. lbs.).
96. Align gearbox oil cooler pipes, fit spacer and clamp and tighten bolt to 18 Nm (13 ft. lbs.).
97. Ensure engine oil cooler pipe unions are clean. Fit new O-rings, connect pipes to oil pump and tighten unions to 15 Nm (11 ft. lbs.).
98. Align engine oil cooler return pipe to alternator mounting bracket and secure with bolt.
99. Align EVAP pipe and connect multiplug to purge valve.
100. Connect and secure heater hoses to coolant rails.
101. Fit thermostat housing and hose assembly. Connect and secure hoses to coolant rails.
102. Connect and secure coolant hose to water pump.
103. Ensure PAS pump and mating face is clean. Fit PAS pump to mounting bracket and tighten bolts to 22 Nm (16 ft. lbs.).
104. Ensure compressor and mating face is clean. Fit compressor to mounting bracket and tighten bolts to 22 Nm (16 ft. lbs.).
105. Connect multiplug to compressor.
106. Ensure auxiliary drive belt pulley grooves are clean and free from damage.
107. Fit new drive belt to pulleys, and ensure belt is correctly aligned in pulley grooves.
108. With assistance, hold tensioner fully clockwise and fit drive belt to remaining pulley.
109. Fit auxiliary drive belt cover and spacers and tighten bolts to 18 Nm (13 ft. lbs.).
110. Connect and secure coolant top hose to adapter on inlet manifold.
111. Connect multiplug to MAF sensor.
112. Ensure connection is clean and connect fuel pipe to fuel rail.
113. Fit ignition coils.
114. Fit radiator.
115. Fit engine oil filter and fill engine with engine oil.
116. Check and if necessary top up gearbox oil.