Installation

Installation





1. Position the engine into the engine compartment.
Traverse the engine/transmission assembly to the vehicle and lower the assembly into the engine compartment and onto front mounting locations.





2. Align the engine front mountings.
Align the engine front mountings and install the securing nuts. Tighten to 60-80 Nm.
3. Operate the crane controls and the ramp simultaneously (with assistance) to raise the vehicle to a convenient working height.





4. Position the transmission jack and raise it to take the weight of the transmission. Install and adjust the chains to secure the transmission to the jack.





5. Install the engine rear mounting bracket.
Install the four bolts which secure the crossmember to the body.
Install the bolt which secures the engine rear mounting rubber to the transmission.





6. Tighten the rear mounting bolts to 30-40 Nm.





7. Tighten the rear mounting bolts to the stated torque figure. Tighten to 22-28 Nm.
8. Release and remove the transmission jack.
9. Operate the crane controls and the ramp simultaneously (with assistance) to lower the vehicle to a convenient working height.





10. Lower the crane and remove the chain assembly and lifting eyes.
Remove the engine rear lifting eyes.
11. Move the crane away from the vehicle.
12. Raise the vehicle on the ramp.





13. Connect the transmission selector cable.
Install the selector lever to the cross shaft.
Install the nut which secures the selector lever to the transmission cross shaft. Tighten to 7-10 Nm.
Reposition the selector cable abutment bracket to the transmission and install the securing bolts. Tighten to 7-10 Nm.





14. Connect the transmission harness connector.
Connect the transmission harness connector.
Secure the lever lock mechanism.





15. Reposition the ground lead to the transmission casing and install the securing bolt.





16. Install the brackets which support the downpipe catalytic converters to the bell housing.
Position the mounting bracket and install the two bolts which secure it to the bell housing. Tighten to 43-57 Nm.
Repeat the above procedure for the other side.





17. Align any marks made when removing and install the driveshaft (propshaft) to the transmission output flange.
Install the three bolts which secure the flange. Tighten to 75-88 Nm.





18. Install the downpipe catalytic converters.
Install a new gasket to the downpipe flange and install the downpipe assembly. to the manifold.
Install the bolts which secure the downpipe to the lower mounting bracket.
Repeat the above operations for the other downpipe catalytic converter.





19. From above the vehicle, tighten the manifold flange nuts, Bank 1 and Bank 2 flanges, to 15-20 Nm.
20. Install the front muffler assembly.
Locate the front muffler into the down pipe catalytic converters.





21. Move the front muffler forward to allow the intermediate mufflers to be connected.
Connect the front muffler to the intermediate mufflers, noting the alignment of the indicator rings. With the front muffler positioned correctly, tighten the clamps (left-hand and right-hand sides) to the catalytic converter, to 60-80 Nm (97 MY) or 50-60 Nm (98 MY).





22. Tighten the clamps (left-hand and right-hand sides), intermediate mufflers to front muffler, to 60-80 Nm (97 MY) or 50-60 Nm (98 MY).





23. Tighten the downpipe bracket securing bolts to 42-52 Nm.





24. Connect the oil cooler pipes (where installed) to the engine.
Remove the blanking plugs from the pipes and from the mating unions on the engine.
Install new O-ring seals to the pipes and lubricate with new engine oil.
Connect the pipes to the engine and install the clamping plate and bolt. Tighten the bolt 18-24 Nm.
25. Adjust the handbrake cable.
26. Lower the vehicle on the ramp.





27. Connect the heater and brake servo hoses.
Connect the heater return hose.
Connect the heater feed hose and secure the locking lever.
Connect the brake servo hose.





28. Connect the P.I. harness to the engine management harness.
Reposition the engine management harness connector to the bracket.
Install the nut which secures the engine management harness connector to the mounting bracket.
Connect the connectors.
Install the bolt which secures the P.I. harness connector to the engine management harness.





29. Connect the transmission rotary switch harness connector.
Reposition and connect the harness.





30. Connect the Oxygen sensor multiplugs to the mounting bracket and connect the plugs.





31. Connect the throttle cable.
Install the outer cable abutment to the bracket. Tighten the screws to 4-6 Nm.
Rotate the butterfly actuator cam and connect the cable. Reposition the cable into the cam.
Remove any tape or plastic strap which was installed when disconnecting the cable abutment.





32. Connect the pipes to the purge valve (where installed).
Connect the part load breather hose.
Install the clip which secures the part load breather hose to the purge valve.
Connect the vacuum hose to the purge valve.





33. WARNING: BEFORE PROCEEDING, IT IS ESSENTIAL THAT THE WARNING NOTES ARE READ AND UNDERSTOOD.

Connect the fuel feed and return hoses.
Remove the blanking plugs from the mating pipes.
Connect the hoses at the Quick Fit connectors.
Install the return hose into the feed hose clip.





34. Connect the starter motor power cable.
Reposition and connect the power cable to the power stud. Install the securing nut to the stud.
Reposition the protective boot over the starter motor power stud.
Connect the harness connector, engine management harness to starter motor. Install the connector to the mounting bracket.
Renew the tie strap which secures the power cable to the right hand enclosure.





35. Connect the generator suppression module (where installed) harness.
Reposition the harness under the suppression module and connect the harness connector.





36. Connect the hoses to the power steering pump.
Remove the blanking plugs from the pipes and unions. Install a new sealing washer to the high pressure hose joint.
Connect the high pressure hose union.
Connect the feed hose to the pump.
Tighten the hose unions to 22-28 Nm.





37. Connect the engine oil pressure transmitter.





38. With assistance, reposition the radiator to the vehicle. Check that the lower mounting rubbers are located correctly.





39. Connect the radiator coolant top hose.
Reposition and connect the top hose to the radiator.
Install and tighten the hose clip.





40. Connect the pipe to the receiver/drier.
Remove the blanking plugs from the pipe and from the receiver/drier.
Install a new O-ring seal to the pipe.
Reconnect the pipe to the receiver/drier and install the securing bolt. Tighten to 8-10 Nm.





41. Connect the pipe to the compressor.
Remove the blanking plugs from the pipe.
Install a new O-ring seal to the pipe.
Reconnect the pipe to the compressor/condenser joint and install the securing nut. Tighten to 8-10 Nm.





42. Connect the radiator coolant bottom hose.
Reposition and connect the bottom hose to the radiator.
Install and tighten the hose clip.





43. Connect the transmission oil cooler upper pipe.
Remove the blanking plugs and install a new O-ring seal to the pipe.
Reposition the pipe and the union nut to the radiator.
Connect and tighten the union nut.





44. Install the radiator top securing panel.
Position and align the top securing panel.
Install the five securing bolts to the panel. Tighten to 8-10 Nm.





45. From below the vehicle, connect the transmission lower cooler pipe to the radiator.
Remove the blanking plugs and install a new O-ring seal to the cooler pipe.
Reposition the pipe and the union nut to the radiator.
Connect and tighten the union nut.
Reposition and install the climate control pipe to the clips on the fan cowl.





46. Connect the harness multiplug to the cooling fans.
Connect the multiplug to the high speed fan and reposition the harness into the retaining clip.





47. Connect the harness multiplug to the cooling fans.
Connect the multiplug to the low speed fan and reposition the harness into the retaining clip.





48. Install the expansion tank to the vehicle.
Connect the hose to the expansion tank.
Reposition and secure the pipe clip.
Position the expansion tank to the left side enclosure panel.





49. Install the expansion tank.
Connect the coolant level sensor connector.
Locate the tank to the dowels and install the bolt which secures the tank.





50. Connect the hoses to the expansion tank.
Remove all blanking plugs from the pipes and the expansion tank.
Connect the hose, expansion tank to thermostat housing.
Connect the hose, expansion tank to recovery tank.
Connect the hose. expansion tank to radiator





51. Install the intake tube/air flow meter/air cleaner cover assembly.
Position the intake tube/air flow meter/air cleaner cover assembly.
Install a new rubber seal and position the air intake tube to the throttle body.





52. Connect the intake tube to the throttle body.
Install a new seal and connect the intake tube to the throttle body.
Install the two bolts which secure the intake tube to the throttle body. Tighten to 4-5 Nm.





53. Connect the air cleaner cover.
Install the five clips which secure the air cleaner cover.





54. Reconnect the breather pipe to Bank 1 camshaft cover.
Install a new O-ring seal to the breather pipe.
Connect the breather pipe to the stub pipe.
55. Connect the air flow meter connector.
56. Install a new ty-strap to secures the vacuum pipe to the induction elbow.
57. Perform the Battery Reconnection Procedure.
58. Refill the cooling system.

59. NOTE: When the engine is started from cold and run for a short period only, before being switched off, a quantity of oil will be 'hung up' within the engine because it is not up to operating temperature.

Should the oil level subsequently be topped-up, the level could become too high, causing oil burning.
Typically, 0.875L is hung up.
Refill the engine with the correct specification engine oil.
60. Refill the automatic transmission.
61. Refill and bleed the power steering system.
62. Repressurize the air conditioning system.





63. Install the engine covers.





64. With assistance reposition the engine compartment cover (bonnet) and install the six bolts reconnect the ground lead to the original location on the left hand hinge. Tighten to 22-28 Nm.
Reconnect the gas struts.
Remove the masking tape from the front edge.
65. Remove the paintwork protection sheets and close the engine compartment cover.