Page 904 of 2490
41. Raise the vehicle on the ramp.
42. Drain the engine oil.
1. Position the waste oil bowser.
2. Remove the sump drain pl ug and drain the engine oil.
Wipe the drain plug and refit it to the sump to prevent oil
dripping.
Move the oil bowser away from the vehicle.
43. Move the front muffler forwar d to allow the intermediate
mufflers to be displaced.
Slacken the clamps (left-hand and right-hand sides),
catalytic converter to front muffler.
44. Slacken the clamps (left-han d and right-hand sides),
intermediate mufflers to front muffler.
45. Remove the front muffler.
Disconnect the front muffler from the intermediate
mufflers and then from the downpipe catalytic converters.
46. Remove the downpipe catalytic converters.
Page 905 of 2490
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.
47. Remove the two bolts which secure each mounting bracket to
the bell housing and remove the brackets.
48. Disconnect the driveshaft (propshaft) flange from the
transmission output flange.
Remove the three bolts which secure the flange. Rotate
the shaft for access to each bolt.
Disconnect the shaft and reposition it to the side.
49. Remove the securing bolt and disconnect the ground lead
from the transmission casing.
50. Disconnect the oil cooler pi pes (where fitted) from the
engine.
1. Remove the bolt which secures the pipe clamping
plate. Remove the clamping plate.
2. Place a drain tray beneat h the pipes and disconnect
Page 906 of 2490

the pipes. Allow the oil to drain.
3. Remove the O-ring seals and fit blanking plugs to the
pipes and to the mating unions on the engine.
51. Lower the ramp.
52. Disconnect the generator suppres sion module (where fitted)
harness.
Disconnect the harness multi-plug and reposition the
harness from under the suppression module.
53. Disconnect the starter motor power cable, at the right hand
side engine compartment enclosure.
1. Disconnect the multi-plug, engine management harness to starter motor.
2. Reposition the protective boot from the starter motor
power stud.
3. Remove the nut and disc onnect the power cable.
Cut the tie strap which secures the power cable to the
enclosure and route the cable into the engine bay.
54. Disconnect the P.I. harness from the engine management
harness.
1. Release the bolt which secures the P.I. harness multi-plug to the engine management harness.
2. Disconnect the multi-plug.
3. Remove the nut which secures the engine management harness multi-plug to the mounting
bracket.
4. Reposition the multi-plug from the bracket.
55. Disconnect the transmission rota ry switch harness connector.
Reposition and disconnect the harness multi-plug.
Page 915 of 2490
Connect
the front muffler to
the intermediate muffler,
noting the alignment of the indicator rings.
W
ith the front muffler positioned correctly, tighten the
clamps (left-hand and right-hand sides) to the catalytic
converter.
21
.
Tighten the clamps (left-hand and right-hand sides),
intermediate mufflers to front muffler.
22
.
Tighten the downpipe bracket se curing bolts to the correct
torque
23
.
Connect the oil cooler pipes (w here fitted) to the engine.
1. Remove the blanking plugs from the pipes and from the mating unions on the engine.
2. Fit new O-ring seals to the pipes and lubricate with new engine oil.
3. Connect the pipes to the engine and fit the clamping
plate and bolt.
24. Lower the vehicle on the ramp.
25. Connect the heater and brake servo hoses.
1. Connect the heat er return hose.
2. Connect the heater feed hose and secure the locking
lever.
Page 918 of 2490
1.
Remove the blanking plugs from the pipes and
unions. Fit a new sealing washer to the high pressure
hose joint.
2. Connect the high pressure hose union.
3. Connect the feed hose to the pump.
34 . Conne
ct the engine oil
pressure transmitter.
35 .
Fit the radiator and
condense
r assembly. Check that the
lower mounting rubbers are located correctly.
36 . Fit the radiator top
retaining panel.
1. Fit the panel.
2. Check that the radiator top mounting bushes are
located correctly.
37. Fit the radiator top retaining panel.
Fit
the ten bolts which secure the panel.
Page 919 of 2490
38
.
Connect the radiator top hose.
1. Connect the hose to the radiator.
2. Reposition and secure the hose retaining clip.
39
.
Connect the radiator bottom hose.
1. Connect the hose to the radiator.
2. Reposition and secure the hose retaining clip.
40
.
Connect the discharge hose to the condenser.
1. Remove the blanking plugs from the hose and condenser.
2. Fit and fully seat a new O-ring seal to the hose.
Lubricate the seal with clean compressor oil
3. Fit the hose to the condenser and tighten the securing bolt.
41. Connect the jump hose to the receiver/drier.
1. Remove the blanking plugs from the hose and receiver/drier.
2. Fit and fully seat a new O-ring seal to the hose.
Lubricate the seal with clean compressor oil
Page 920 of 2490
3.
Fit the hose and tighten the securing bolt.
42 . Conne
ct the transmission
oil cooler upper pipe.
1. Remove the blanking plugs from the pipe and the radiator.
Fit and
fully seat a new O-ring
seal to the pipe. Lubricate
the seal with clean transmission oil
2. Reposition and connect the union nut, upper cooler pipe to radiator.
43 . Conne
ct the transmission oil cooler lower pipe.
1. Remove the blanking plugs from the pipe and the radiator.
Fit and
fully seat a new O-ring
seal to the pipe. Lubricate
the seal with clean transmission oil
2. Reposition and connect the union nut, lower cooler
pipe to radiator.
44. Fit the twin fan and motor assembly. Refer to Operation
26.25.12.
45 . Connect
the radiator breather hose.
Re
po
sition the Quick-Fit hose (radiator to expansion tank)
and connect the hose to the radiator.
46. Fit the expansion tank to the vehicle.
1. Remove the pipe clamp if still in place and connect
the hose to the expansion tank.
Page 922 of 2490
to th
e throttle body.
51 . Co
nnect the intake tube to the throttle body.
1. Fit a new seal and connect the intake tube to the throttle body.
2. Fit the two bolts which secure the intake tube to the throttle body.
52 . Conne
ct the air cleaner cover.
F
it
the five clips which secu
re the air cleaner cover.
53 . Re
connect the breather pipe to the A-Bank camshaft cover.
1. Fit a new O-ring seal to the breather pipe.
2. Connect the breather pipe to the stub pipe.
54. Connect the air flow meter connector.
55. Fit a new Ty-strap to secures the vacuum pipe to the
induction elbow.
56. Refill the cooling system. Refer to Operation 26.10.01.
57. NOTE: When the engine is star ted from cold and run for a
short period only, before being swit ched off, a quantity of oil will