Page 908 of 2490
3. Disconnect the brake servo hose.
60. Fit engine rear lifting eyes (303 - 536).
61. Traverse the hoist to the engine compartment and lower it to
working height.
62. Fit 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 wh en removing from the vehicle.
63. Remove the engine front mounting nuts.
64. Raise the ramp.
65. Disconnect the transmission connector.
1. Release the lever lock on the transmission harness
multi-plug.
2. Disconnect the connector.
66. Disconnect the transmission selector cable.
Page 909 of 2490
1. Remove the nut which secures the selector lever to
the transmission cross shaft.
2. Remove the selector cable abutment bolts.
3. Disconnect the selector arm from the cross shaft.
67. Loosen the bolt which secures the engine rear mounting
rubber to the transmission.
68. Position a transmission jack e.g. Epco V100 and raise the
support bed of the jack to take the weight of the transmission.
Fit and adjust the chains to secure the transmission to the jack.
69. Remove the engine rear mounting assembly.
Remove the mounting centre bolt.
Remove the four bolts which secure the crossmember to
the body.
Remove the crossmember and mounting assembly.
70. Release the engine and tran smission assembly from the
engine compartment.
Take the weight of the engine / transmission with the
hoist and move it towards th e front of the vehicle.
Lower the transmission jack slightly to release the
securing chains. Remove the ja ck from below the vehicle.
Page 910 of 2490
Remove the engine and transmission assembly, upwards
and forwards, from the vehicle.
71. Remove the engine and tran smission 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.
Page 911 of 2490
Engine - Engine
Installation
Installation
Special Tool(s)
Engine Lifting Brackets
303-536
Quick Fit Connector Release Tool
310-044
Quick Fit Connector Release Tool
310-054
Quick Fit Connector Release Tool
303-623
Fuel Injection Pressure Test Equipment
310-058
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.
Page 912 of 2490
Align th
e engine front mountings and fit the securing nuts.
Tighte
n to the stated torque value.
3. Operate the crane controls and the ramp simultaneously (with
assistance) to raise the vehicle to a convenient working height.
4. Po
sition the transmission jack and raise it to take the weight of
the transmission. Fit and adjust the chains to secure the
transmission to the jack.
5. Fit th
e engine rear mounting bracket.
Fi
t the four bolts which secu
re the crossmember to the
body.
Fi t t
he bolt which secures the
engine rear mounting rubber
to the transmission.
6. Tigh ten th
e rear mounting bolts
to the stated torque figure.
7. Release and remove the transmission jack.
8. Operate the crane controls and the ramp simultaneously (with
assistance) to lower the vehicle to a convenient working height.
9. Lower th e cran
e and remove th
e chain assembly and lifting
eyes.
Page 914 of 2490
Repeat
the above procedure for the other side.
16 . Connect
the driveshaft (propshaft
) flange to the transmission
output flange.
F i
t the three bolts which secure the flange.
17 . F
it the downpipe catalytic converters.
1. Fit a new gasket to the downpipe flange and fit the
downpipe assembly. to the manifold.
F i
t the bolts which secure
the downpipe to the lower
mounting bracket.
Repeat the above operation
s
for the other downpipe
catalytic converter.
18 . F
rom above the vehicle, tighte
n the manifold flange nuts, A-
Bank and B-Bank flanges, to the correct torque.
19. Fit the front muffler assembly.
Locate the front muf fler into the
downpipe catalytic
converters.
20. Move the front muffler forwar d to allow the intermediate
mufflers to be connected.
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.