Removal

Removal
1. Park the vehicle on a four post ramp, over which, an overhead lifting crane is available, and set the gear selector to 'N'.
The crane should be rated at a minimum of 500 kg Safe Working Load and have sufficient fore and aft movement to traverse the engine assembly clear of the vehicle.
Do not apply the handbrake, but use wedges to chock one wheel to prevent movement of the vehicle.
2. Open the engine compartment and fit paintwork protection sheets.
3. Open the driver's door, or both doors if necessary, to allow the side windows to drop. Ensure that the doors remain open until after the battery has been disconnected.





4. Disconnect the battery ground cable.
Remove the battery cover.





5. Remove the engine compartment cover (bonnet).
Apply masking tape to the front edge of the engine compartment cover to protect the paintwork during removal and storage.
With assistance, support the cover and release the gas struts.





6. With assistance, release the six bolts which retain the cover (bonnet) and lift the cover clear.
Disconnect the ground lead from the left hand hinge.





7. Remove the engine covers
8. Drain the cooling system. Conserve as much of the coolant as possible to refill the system.

9. WARNING: ENSURE THAT ALL FIRE PREVENTION PROCEDURES ARE ACTIVE.

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

Depressurize the air conditioning system.





10. Depressurize the fuel system.
Ensure that the ignition is switched off and remove the valve cap from the fuel cross-over pipe.
Place a cloth under the valve to collect any spillage.
Place a closed container, suitable for collecting fuel, adjacent to the vehicle. Remove the lid.





11. Connect the fuel injection pressure test equipment 310-058 (or other suitable type).
Insert the drain/bleed tube into the fuel container. Follow the manufacturer's instructions and depressurize the fuel system.
12. Store the drained fuel safely and ensure that the lid is closed securely.
Remove the equipment and discard the cloth from beneath the valve. Install the valve cap.





13. Disconnect the breather pipe from Bank 1 camshaft cover.
Disconnect the breather pipe from the stub pipe.
Remove and discard the O-ring seal from the breather pipe.
14. Disconnect the air flow meter multi-plug.
15. Cut and remove the strap which secures the vacuum pipe to the induction elbow.





16. Disconnect the intake tube from the throttle body.
Remove the two bolts which secure the intake tube to the throttle body.
Disconnect the intake tube from the throttle body.





17. Disconnect the air cleaner cover.
Remove the five clips which secure the air cleaner cover.





18. Remove the intake tube/air flow meter/air cleaner cover assembly.
Remove the intake tube/air flow meter/air cleaner cover assembly.
Remove and discard the rubber seal; air intake tube to throttle body.
19. Place a cloth under the expansion tank to absorb any spillage caused by disconnecting the hoses.





20. Release the hoses from the expansion tank.
Release the hose clip (expansion tank to thermostat housing hose).
Disconnect the hose from the expansion tank and remove the clip.
Release the hose clip (expansion tank to radiator, air bleed hose).
Disconnect the hose from the expansion tank and remove the clip.
21. Install blanking plugs to the pipes and the tank.





22. Remove the expansion tank from the mounting.
Remove the bolt which secures the tank.
Remove the tank from the rear mounting grommets.
Disconnect the coolant level sensor connector.





23. Remove the expansion tank from the vehicle.
Use a pipe clamp to clamp the bottom hose branch.
Release the pipe clip and move it along the pipe.
Disconnect the tank from the bottom hose and remove it from the vehicle.
24. Empty any surplus coolant from the expansion tank into a drain tray.
25. Remove the cloth from the engine and clean any spillage from the engine bay.





26. Disconnect harness multiplug from the cooling fan (working from under the vehicle).
Disconnect the multiplug from the high speed fan and reposition the harness from the retaining clip.





27. Disconnect harness multiplug from the cooling fan (working from under the vehicle).
Disconnect the multiplug from the low speed fan and reposition the harness from the retaining clip.





28. Disconnect the transmission oil cooler lower pipe.
Disconnect and reposition the union nut, lower cooler pipe to radiator. Disconnect the pipe.
Remove and discard the O-ring seal from the pipe and install blanking plugs to the pipe and to the union on the radiator.
29. Reposition the climate control pipe from the clip on the fan cowl.





30. From above the vehicle, disconnect the transmission oil cooler upper pipe.
Disconnect and reposition the union nut, upper cooler pipe to radiator. Disconnect the pipe.
Remove and discard the O-ring seal from the pipe and install blanking plugs to the pipe and to the union on the radiator.





31. Disconnect the radiator bottom hose.
Slacken the hose retaining clip and reposition the clip along the hose.
Disconnect the hose from the radiator.





32. Remove the radiator top retaining panel.
Remove the five bolts which secure the panel.
Remove the panel.
Remove the radiator top mounting rubbers.





33. Disconnect the radiator top hose.
Slacken the hose retaining clip and reposition the clip along the hose.
Disconnect the hose from the radiator.





34. Disconnect the radiator breather hose.
Slacken the hose (radiator to expansion tank) retaining clip and reposition the clip along the hose.
Disconnect the hose from the radiator.





35. Disconnect the pipe from the climate control receiver/drier.
Remove the bolt which secures the pipe to the receiver/drier and disconnect the pipe.
Remove and discard the O-ring.
Install blanking plugs to the pipe and the receiver drier.





36. Disconnect the pipe from the climate control condenser joint (condenser to compressor).
Remove the nut which secures the pipe to the condenser and disconnect the pipe.
Remove and discard the O-ring.
Install blanking plugs to the pipe and the condenser.





37. Remove the radiator.
With assistance, remove the radiator assembly.
Clean coolant spillage from the radiator lower carrier panel.





38. Disconnect the engine oil pressure transmitter.
39. Remove the filler cap from the power steering reservoir.
40. Remove the engine oil dipstick, for access.





41. Disconnect the hoses from the power steering pump.
Position a drain tray under the pump.
Release the high pressure hose union nut and drain the fluid.
Discard the O-ring seal and install blanking plugs to the pipe and union.
Release the feed hose from the pump and install blanking plugs to the pipe and union.
Discard the fluid.





42. Release the Oxygen sensor multiplugs from the mounting bracket and disconnect the plugs.





43. Remove the four nuts, each side, which secure the downpipe catalytic converters to the exhaust manifold.
44. Raise the vehicle on the ramp.





45. Drain the engine oil.
Position the waste oil container.
Remove the sump drain plug and drain the engine oil.
Wipe the drain plug and install it to prevent oil dripping.
Move the oil container away from the vehicle.





46. Move the front muffler forward to allow the intermediate mufflers to be displaced.
Slacken the clamps (left-hand and right-hand sides), catalytic converter to front muffler.





47. Slacken the clamps (left-hand and right-hand sides), intermediate mufflers to front muffler.
48. Remove the front muffler.
Disconnect the front muffler from the intermediate mufflers and then from the downpipe catalytic converters.





49. Remove the downpipe catalytic converters.
Remove the bolts which secure the downpipe to the lower mounting bracket.
Remove the downpipe assembly.
Repeat the above operations for the other downpipe catalytic converter.





50. Remove the two bolts which secure each mounting bracket to the bell housing and remove the brackets.
51. Remove the driveshaft (propshaft).





52. Remove the securing bolt and disconnect the ground lead from the transmission casing.





53. Disconnect the oil cooler pipes (where installed) from the engine.
Remove the bolt which secures the pipe clamping plate. Remove the clamping plate.
Place a drain tray beneath the pipes and disconnect the pipes. Allow the oil to drain.
Remove the O-ring seals and install blanking plugs to the pipes and to the mating unions on the engine.
54. Lower the ramp.





55. Disconnect the generator suppression module (where installed) harness.
Disconnect the harness multiplug and reposition the harness from under the suppression module.





56. Disconnect the starter motor power cable, at the right hand side engine compartment enclosure.
Disconnect the multiplug, engine management harness to starter motor.
Reposition the protective boot from the starter motor power stud.
Remove the nut and disconnect the power cable.
Cut the tie strap which secures the power cable to the enclosure and route the cable through the heatshield into the engine bay.





57. Disconnect the P.I. harness from the engine management harness.
Release the bolt which secures the P.I. harness multiplug to the engine management harness.
Disconnect the multiplug.
Remove the nut which secures the engine management harness multiplug to the mounting bracket.
Reposition the multiplug from the bracket.





58. Disconnect the transmission rotary switch harness connector.
Reposition and disconnect the harness multiplug.





59. Disconnect the fuel feed and return hoses.
Disconnect the fuel hoses at the Quick Fit connectors, using special tool 310-044 for the feed hose and 310-54 for the return hose.
Disconnect the return hose from the feed hose clip.
Install blanking plugs to the pipes.





60. Disconnect the pipes from the purge valve (where installed).
Remove the clip which secures the part load breather hose to the purge valve.
Disconnect the part load breather hose.
Disconnect the vacuum hose from the purge valve and reposition the hose.





61. Disconnect the throttle cable.
Secure the cable abutment to the bracket with tape or a ratchet strap if necessary (to save subsequent adjustment procedure). Remove the bolts which secure the abutment bracket to the throttle body.
Rotate the butterfly actuator cam and disconnect the cable. Reposition the cable.





62. Disconnect the heater and brake servo hoses.
Disconnect the heater return hose.
Release the heater feed hose locking lever and disconnect the hose.
Disconnect the brake servo hose.





63. Install engine rear lifting eyes (303-536).
64. Traverse the hoist to the engine compartment and lower it to working height.
65. Install lifting chains to the hoist and connect to each engine lifting eye. Use longer chains to the rear lifting eyes to allow the engine to tilt rearwards when removing from the vehicle.





66. Remove the engine front mounting nuts.
67. Raise the ramp.





68. Disconnect the transmission connector.
Release the lever lock on the transmission harness multiplug.
Disconnect the connector.





69. Disconnect the transmission selector cable.
Remove the nut which secures the selector lever to the transmission cross shaft.
Remove the selector cable abutment bolts.
Disconnect the selector arm from the cross shaft.





70. Remove the bolt which secures the engine rear mounting rubber to the transmission.





71. Position a transmission jack e.g. Epco V100 and raise the support bed of the jack to take the weight of the transmission. Install and adjust the chains to secure the transmission to the jack.





72. Remove the engine rear mounting assembly.
Remove the four bolts which secure the crossmember to the body.
Remove the crossmember and mounting assembly.





73. Release the engine and transmission assembly from the engine compartment.
Take the weight of the engine/transmission with the hoist and move it towards the front of the vehicle.
Lower the transmission jack slightly to release the securing chains. Remove the jack from below the vehicle.
Remove the engine and transmission assembly, upwards and forwards, from the vehicle.





74. Remove the engine and transmission assembly from the vehicle.
Operate the crane controls and the ramp simultaneously (with assistance) to lower the vehicle to a convenient working height.
Traverse the crane clear until the assembly can be lowered.