Transferring Engine Accessories

1. Disconnect the "A" bank V.V.T. solenoid harness multiplug. Move the clips of the mounting bracket of the fuel injection harness on the generator mounting bracket. Disconnect the engine oil pressure sensor multiplug and the generator harness multiplug. Reroute the fuel injection harness from behind the link lead connecting the generator to the starter motor and release the clips securing the fuel injection harness to the front cover and "A" bank cam cover.

2. Disconnect the multiplugs of the coolant temperature sensor and the "A" bank knock sensor and fuel injectors and withdraw the harness rearwards.

3. Remove the screws and remove the "A" bank on-plug coil cover; disconnect the multiplugs from the on-plug ignition coils.

4. Disconnect the "B" bank V.V.T. solenoid harness multiplug. Move the securing clips of the harness to the "B" bank cam cover and PAS pump, disconnect the multiplugs to the Air Conditioning compressor clutch and lock sensor and disconnect the crankshaft angle sensor multiplug.

5. Disconnect the part-load breather hose from the "B" bank cam cover, remove the screws and remove the on-plug coil cover; disconnect the multiplugs from the ignition coils.

6. Release the clips retaining the fuel injection harness to the rear of the "B" bank cam over, and disconnect the multiplugs from:

^ throttle body motor/clutch

^ throttle position sensor

^ throttle pedal demand sensor

^ PAS pressure switch.

thus allowing the fuel injection harness to be released and removed from the engine.

7. Remove the securing bolts, allowing the multiplug bracket for the Engine Management harness to be removed.

8. Disconnect the coolant feed hose and heater pipe from the throttle body. Remove the bolt from the fuel return pipe bracket.

9. Disconnect the EGR valve coolant feed hose from the throttle body, remove the 2 bolts from each end of the EGR pipe and disconnect it from the valve. Discard the EGR pipe and EGR valve body gaskets and clean the gasket faces of the valve.

10. Remove the retaining bolts, disconnect the coolant return hose and remove the EGR valve. Release the clip and remove the coolant return hose.

11. Remove the 10 bolts securing the intake manifold and 2 bolts securing the throttle body intake elbow. Release the camshaft position sensor multiplug and remove the intake manifold. Remove and discard the seals in each intake port.

Seal the intake port using adhesive tape to prevent the possible entry of foreign matter.

12. Disconnect both knock sensor multiplugs from their mounting bracket and use a 24 mm "crowfoot" wrench to remove both knock sensors.

13. Remove the 4 bolts securing the coolant outlet pipe, 4 bolts securing the thermostat housing and remove the thermostat housing; discard the housing seal and the coolant outlet pipe seal. Release the clip and remove the heat feed hose.

14. From both banks, remove the on-plug coils; disconnect and remove the full load breather hose.

15. From both banks remove the securing bolts and spacers, supporting the manifold during their removal; remove the manifolds and gaskets.

16. Remove the 4 bolts from each engine mounting bracket and remove the brackets.

17. Remove the 2 bolts, release and remove the muffler pipe from the compressor, discarding the O-ring seal and inserting plugs in the pipe and port. Remove the 2 bolts, release and remove the air conditioning compressor discharge pipe; discard the O-ring seal; insert suitable blanking plugs in the pipe and in the compressor outlet port.

18. Apply a wrench to the drive belt tensioner pulley securing bolt, release the belt tension and disconnect the belt from the generator pulley before allowing the tensioner to relax.

Suitable wrench: Special Tool JD-230 or Snap-on Tools XDHM 1415

Release this drive belt from the remaining pulleys and remove the belt.

19. Prevent the water pump pulley from rotating, using a suitable strap-type oil filter wrench, while the three bolts are removed allowing the pulley to be withdrawn.

Suitable wrench: Snap-on Tools A91 B

20. Remove the 5 securing bolts and remove the water pump, discarding the gasket and O-ring seal.

21. Remove the rear lower securing bolt of the A/C compressor, and release the bracket of the crank sensor multiplug. Remove the 3 additional bolts and remove the compressor.

22. Remove the 3 bolts from the PAS pump pulley, holding the pulley with a strap-type oil filter wrench. Remove the pulley.

23. Remove the bolt and relocate the bracket of the oil level dipstick tube. Loosen the PAS pump upper securing bolt. Turn the drive belt tensioner pulley bolt against spring pressure to obtain clearance to allow removal of the bolt. Remove the 2 lower securing bolts and remove the pump.

24. Remove the 2 bolts and remove the compressor/pump/belt tensioner bracket assembly.

25. Release the clips, remove the securing bolt and remove the crankshaft sensor.

26. At the generator, move the protective boot and disconnect the link lead to the starter motor.

27. Remove the generator upper securing bolt. Support the generator, allowing the lower bolt to be removed along with the fuel injection harness mounting bracket, allowing removal of the generator.

28. After removing the 4 bolts, remove the generator bracket/idler pulley assembly.

29. After removing the 2 bolts, remove the starter motor. Remove the bolt and remove the engine grounding strap.

30. With a suitable container positioned to collect oil, remove the oil filter and clean up the spillage. Insert a plug in the oil filter boss.

31. From the banjo connector remove the bolt, allowing removal of the throttle body coolant pipe. Remove and discard the "Dowty" washers.

32. After removing the 2 bolts securing each Variable Valve Timing actuating solenoid; remove the solenoids, discarding the O-ring seals. Insert suitable plugs in the openings in the timing cover.

33. Using a hoist with chain hooks attached to the engine lifting eyes, lift the engine from the workbench. In the case of replacement engines, lower the engine into its transit container before disconnecting the hoist. Remove the bolts together with the engine lifting eyes.

34. Install the lifting eyes and raise the replacement engine to a convenient workbench.

35. Reinstall all accessory components in the reverse order of the removal procedure, observing the following:

Clean all mating faces where gaskets or seals are fitted, before reinstalling components. Use NEW gaskets or seals.

36. Observe Torque Data on following page.

37. When installing the engine oil filter, lubricate the rubber seal and tighten 3/4 turn only after initial contact of the seal with the mounting base.

38. When installing the exhaust manifolds, first finger-tighten only the central pair of bolts to retain the manifold and gasket in position. Insert and finger tighten the remaining bolts and spacers. Then fully tighten the bolts to the torque wrench setting in pairs, upper and lower, beginning with the FRONT pair.

39. When fitting the intake manifold, first finger-tighten the bolts. Tighten the bolts to the torque wrench setting in pairs, beginning from the center.





TORQUE DATA