Procedures

Engine & ancillaries - remove for access & refit
Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed.
Refer to Service Precautions.

Remove
1. Release bonnet support stays, raise and secure bonnet in upright position.
2. Disconnect battery earth lead.
3. Remove air intake plenum.
4. Depressurize fuel system.
5. Recover refrigerant from A/C system.
6. Remove MAF/IAT sensor.
7. Raise front of vehicle and support on stands.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

8. Drain cooling system.
9. Remove viscous coupling.





10. Release cover, remove nut and disconnect battery positive lead from stud.
11. Remove RH ignition coil cover.





12. Remove LH ignition coil cover.
13. Position differential breather pipe clear of engine.





14. Remove nut and disconnect earth lead from LH camshaft cover.
15. Remove nut and disconnect earth lead from RH camshaft cover.





16. Disconnect multiplugs from ignition coils.





17. Disconnect multiplugs from throttle body, thermostat heater, CMP sensor and ECT sensor.
18. Cut2 cable ties securing engine harness at throttle body and release harness.





19. Disconnect multiplug from RH VCC solenoid.
20. Release VCC multiplug harness from clip.





21. Disconnect multiplug from LH VCC solenoid.





22. Disconnect multiplug from alternator.
23. Release alternator harness from 4 clips.





24. Disconnect multiplugs from LH CMP sensor and LH knock sensor.





25. Remove 2 nuts securing LH fuel injector harness to fuel rail, release vacuum reservoir and mounting bracket from stud and position aside.





26. Release alternator harness from 2 clips on engine cover mounting brackets.





27. Disconnect multiplugs from LH fuel injectors.





28. Release engine harness from clips and move clear of camshaft cover.





29. Disconnect multiplug from SAI control valve.





30. Remove 2 nuts securing engine harness to induction manifold, remove washer and release SAI control valve from securing stud. Position valve aside.





31. Disconnect multiplug from RH KS.





32. Disconnect multiplugs from RH fuel injectors





33. Disconnect multiplug from charcoal canister purge control valve.
34. Position engine harness to RH bulkhead.





35. Disconnect pipe from charcoal canister purge control valve.

CAUTION: Always fit plugs to open connections to prevent contamination.





36. Remove charcoal canister purge valve pipe.
37. Release transmission breather pipes from clips at coolant manifold and position aside.
38. Release clips and disconnect heater hoses from coolant manifold.





39. Undo bolt securing gearbox multiplug bracket to gearbox bell housing and position aside.





40. Disconnect multiplug from starter motor lead.
41. Position absorbent cloth around fuel feed pipe connection to collect spillage.





42. Disconnect fuel feed hose from fuel rail.

CAUTION: Always fit plugs to open connections to prevent contamination.

43. Remove absorbent cloth.





44. Release hose clip and disconnect brake servo vacuum hose from 1 way valve.

CAUTION: Always fit plugs to open connections to prevent contamination.





45. Disconnect vacuum pipe from induction manifold.





46. Disconnect multiplug from radiator bottom hose.





47. Remove bolt securing radiator bottom hose to bracket, release clips and remove radiator bottom hose.
48. Release clip and disconnect radiator top hose from radiator.





49. Release clips and disconnect radiator top hose from coolant pump and alternator.





50. Release clip securing radiator top hose to coolant 'T' junction and remove radiator top hose.





51. Release clip and disconnect coolant hose from 'T' junction.





52. Disconnect multiplug from A/C compressor.





53. Remove Allen bolt securing A/C pipe to A/C compressor and disconnect A/C pipe. Discard 'O' ring.

CAUTION: Immediately cap all A/C pipes to prevent ingress of dirt and moisture into the system.





54. Remove Allen bolt securing A/C pipe to condenser and disconnect A/C pipe. Discard 'O' ring.

CAUTION: Immediately cap all A/C pipes to prevent ingress of dirt and moisture into the system.





55. Disconnect 2 hoses from the SAI control valve.

CAUTION: Always fit plugs to open connections to prevent contamination.





56. Disconnect multiplug from oil pressure switch.





57. Remove 2 nuts securing oil filter housing and release oil filter housing from mounting bracket.
58. Position oil filter housing and hoses aside and secure to engine with cable ties.
59. Position container to collect PAS fluid spillage.





60. Release clip and disconnect fluid inlet hose from PAS pump. Undo union nut and disconnect PAS outlet hose from PAS pump. Discard 'O' ring.

CAUTION: Always fit plugs to open connections to prevent contamination.

61. Remove container from below PAS pump.
62. Remove 4 bolts securing differential air flow panel to sub-frame and remove panel.





63. Remove 4 nuts securing front pipe flanges to exhaust manifolds and discard nuts.
64. Release exhaust front pipes from exhaust manifolds.
65. Remove front road wheels.
66. Remove RH front drive shaft.





67. Remove differential breather hose. Remove 4 differential securing bolts and release differential from engine sump.

NOTE: Securing bolt above pinion remains captive to differential.





68. Disconnect engine earth lead.
69. Remove CKP sensor.





70. Remove bolt securing transmission cooler pipes and release cooler pipes from bracket.





71. Remove grommet from bottom of bell housing to gain access to torque converter.





72. Remove grommet from bell housing to gain access to torque converter securing bolts.
73. Rotate crankshaft for access and remove 4 bolts securing torque converter to drive plate.
74. Position torque converter clear of drive plate.





75. Remove 2 bolts securing starter motor and release starter motor.

NOTE: Starter motor remains captive to engine.

76. Support gearbox.





77. Remove 8 Torx bolts securing gearbox to engine.





78. Fit LRT-12-216 to engine lifting eyes.





79. Remove nut securing RH engine mounting to engine mounting bracket.





80. Remove nut securing LH engine mounting to engine mounting bracket.
81. Connect chain to lifting bracket and take weight of engine.
82. Raise engine clear of mountings.





83. Remove 2 Torx bolts from top of bell housing.
84. Release engine from dowels, carefully raise and guide engine clear of vehicle.

CAUTION: To prevent damage to the radiator, do not allow engine to contact the radiator.





85. Discard differential 'O' ring.

Refit
1. Clean torque converter and drive plate mating faces.
2. Clean gearbox to engine mating faces, dowels and dowel holes.
3. Clean differential and engine sump mating faces.
4. Fit new 'O' ring to differential and lubricate with clean oil.
5. With assistance, carefully fit engine to gearbox. Ensure engagement of torque converter spigot and location onto dowels.

NOTE: When fitting engine guide the engine past differential making face.

6. Ensure torque converter is fully engaged with gearbox.
7. Fit 8 Torx bolts securing automatic gearbox to engine, tighten to 45 Nm (33 ft. lbs.).
8. Align starter motor to engine and tighten securing bolts to 45 Nm (33 ft. lbs.).
9. Fit 2 top bell housing Torx bolts and tighten to 25 Nm (18 ft. lbs.).
10. Remove support from gearbox.
11. Lower engine onto mountings.
12. Disconnect lifting chains.
13. Fit 2 nuts securing engine mountings to engine mounting brackets and tighten to 100 Nm (74 ft. lbs.).
14. Remove engine lifting bracket.
15. Fit bolts securing drive plate to torque converter and tighten to 45 Nm (33 ft. lbs.).
16. Fit grommets to bell housing.
17. Clean mating faces of exhaust front pipes and exhaust manifolds.
18. Align exhaust front pipes to exhaust manifolds.
19. Fit 4 new nuts securing exhaust front pipes to exhaust manifolds and tighten to 45 Nm (33 ft. lbs.).
20. Fit Differential to engine sump and tighten 4 securing bolts to 45 Nm (33 ft. lbs.).
21. Connect breather hose to differential.
22. Connect engine earth lead to engine and tighten securing nut and bolt.
23. Fit differential air flow panel to sub-frame and tighten bolts to 45 Nm (33 ft. lbs.).
24. Fit RH front drive shaft.
25. Fit new 'O' ring to PAS hose union, connect hose to pump and tighten nut to 25 Nm (18 ft. lbs.).
26. Connect supply hose to PAS pump and secure using new clip.
27. Fit oil filter housing to bracket and tighten securing nuts.
28. Connect multiplug to oil pressure switch.
29. Connect SAI control valve hoses.
30. Fit new 'O' rings to A/C pipes and lubricate with clean refrigerant oil.
31. Align A/C pipes to condenser and compressor. Fit Allen bolts securing A/C pipes to condenser and compressor and tighten to 25 Nm (18 ft. lbs.).
32. Connect multiplug to A/C compressor.
33. Connect coolant hose to 'T' junction and secure clip.
34. Fit radiator top hose and secure with clips.
35. Fit radiator bottom hose, secure with clips and tighten 'P' clip securing bolt.
36. Connect multiplug to radiator bottom hose.
37. Connect vacuum pipe to inlet manifold.
38. Connect brake vacuum servo hose to 1 way valve and secure using new clip.
39. Clean fuel hose connections.
40. Connect fuel feed hose to fuel rail.
41. Connect multiplug to starter motor lead.
42. Position gearbox multiplug and bracket to bell housing and tighten securing bolt.
43. Connect heater hoses to coolant manifold and secure with clips.
44. Fit transmission breather pipes into clips.
45. Fit charcoal canister purge valve pipe.
46. Position engine harness to engine.
47. Connect multiplug to charcoal canister purge control valve.
48. Fit washer to fuel injector harness securing stud.
49. Position and secure engine harness to brackets with clips.
50. Connect multiplugs to RH fuel injectors.
51. Connect multiplugs to LH fuel injectors.
52. Connect alternator harness to 2 clips on engine cover mounting brackets.
53. Fit fuel hose and mounting bracket to LH fuel injector harness securing stud.
54. Fit vacuum reservoir and mounting bracket to LH fuel injector harness securing stud.
55. Fit 2 nuts securing fuel injector harness to induction manifold and tighten nuts.
56. Connect multiplugs to knock sensors.
57. Connect multiplugs to CMP sensors.
58. Secure alternator harness into 4 securing clips.
59. Connect multiplug to alternator.
60. Connect multiplug to SAI control valve.
61. Connect multiplugs to VCC solenoids.
62. Connect multiplugs to throttle body, thermostat heater, ECT sensor, and RH CMP sensor.
63. Align engine harness to throttle body and secure using new cable ties.
64. Connect multiplugs to ignition coils.
65. Connect engine harness earth leads to LH and RH camshaft covers and tighten nuts.
66. Position differential breather pipe to LH engine camshaft cover.
67. Fit LH ignition coil cover.
68. Fit RH ignition coil cover.
69. Fit viscous coupling.
70. Fit front road wheels and tighten nuts to 140 Nm (103 ft. lbs.).
71. Remove stands and lower front end of vehicle.
72. Fit MAF/IAT sensor.
73. Recharge A/C system.
74. Fit air intake plenum.
75. Fit battery positive lead to stud, tighten nut to 18 Nm (13 ft. lbs.) and close cover.
76. Connect battery earth lead.
77. Fill cooling system.
78. Bleed PAS system.
79. Connect support stays and close bonnet.