Refit

Engine and Automatic Gearbox - up to 03MY

Service Repair No - 12.37.01.99

Refit
1. With assistance, raise engine and gearbox into engine compartment.
2. Position PAS pump to front mounting plate, fit and tighten bolts to 25 Nm (18 ft. lbs.).
3. Position PAS pump pulley, fit and tighten Torx screws to 9 Nm (7 ft. lbs.).
4. Position top arm to engine mounting bracket and RH hydramount, fit and tighten bolts to 100 Nm (74 ft. lbs.).
5. Position PAS pipe support bracket to RH hydramount, fit and tighten nut to 85 Nm (63 ft. lbs.).
6. Place a wooden block on jack, position jack under gearbox and raise jack sufficient to support weight of gearbox. Release lifting hook from lifting bracket on gearbox and connect to rear engine lifting bracket.
7. Lower and remove jack supporting gearbox.
8. Remove bolts securing LRT-44-026 lifting bracket to gearbox and remove bracket.
9. Position LH mounting bracket to gearbox, fit and tighten bolts to 85 Nm (63 ft. lbs.).
10. Position LH mounting to body, fit and tighten bolts to 48 Nm.
11. Align gearbox bracket to LH body mounting, fit and tighten through bolt to 100 Nm (74 ft. lbs.).
12. Position upper RH engine steady to top arm, fit and tighten bolt to 100 Nm (74 ft. lbs.).
13. Tighten bolt securing upper RH engine steady to body to 100 Nm (74 ft. lbs.).
14. Position PAS pipe to engine front mounting plate, fit and tighten bolt to 25 Nm (18 ft. lbs.).
15. Lower hoist, disconnect and remove lifting bracket, LRT-12-138.
16. Raise vehicle on ramp.
17. Position A/C compressor to front mounting plate and cylinder block, align heat shield, fit and tighten bolts to 25 Nm (18 ft. lbs.).
18. Connect multiplug to A/C compressor.
19. Using a 3/8 square drive socket bar, raise ancillary drive belt tensioner and fit drive belt to pulleys.
20. Position selector cable to gearbox bracket and secure with clip.
21. Position selector lever to selector shaft, fit and tighten nut to 25 Nm (18 ft. lbs.).
22. Clean splines and seal areas on each driveshaft and mating faces in front hubs.
23. Fit new circlips to RH and LH driveshaft inner joint splines.
24. Fit driveshafts to IRD and gearbox, ensuring that the circlip on each driveshaft is fully engaged.
25. Engage LH and RH driveshafts into front hubs.
26. Fit new driveshaft flange nuts but do not tighten at this stage.
27. Clean ball joint tapers and taper seats.
28. Position LH and RH track rod ends to steering arms, fit new nuts and tighten to 55 Nm (40 ft. lbs.).
29. Clean ABS sensors and mating faces.
30. Apply anti-seize grease to both ABS sensors and position sensors in front hubs.
Ensure ABS sensor is fully located into hub, so that sensor touches pole wheel teeth.
31. Position LH and RH brake hoses to front damper brackets and secure with clips.
32. Position LH and RH splash shields, fit and tighten bolts.
33. Ensure mating face of propeller shaft and IRD drive flange are clean.
34. Fit propeller shaft to IRD flange and align marks. Tighten nuts and bolts to 42 Nm (31 ft. lbs.).
35. Fit rear beam.
36. Fill IRD to correct level with fluid.
37. Fit exhaust front pipe.
38. With assistant depressing the brake pedal, tighten front hub nuts to 400 Nm (295 ft. lbs.).
39. Stake nut to shaft.
40. Fit front road wheels, fit and tighten nuts to 115 Nm (85 ft. lbs.).
41. Lower vehicle on ramp.
42. Connect brake servo vacuum hose to inlet manifold chamber.
43. Connect coolant hose to underside of expansion tank and secure with clip.
44. Connect expansion tank hose to inlet manifold and secure clip.
45. Connect top hose to radiator and secure with clip. Position hose in bracket.
46. Connect heater feed and return hoses and secure with clips.
47. Connect throttle inner cable to throttle cam and secure outer cable in abutment bracket, if fitted.
48. Secure throttle cable in clips on harness brackets, if fitted.
49. Adjust throttle cable, if fitted.
50. Connect hose to purge control valve.
51. Connect fuel hose to fuel rail pipe, fit rubber sleeve over hose connector.
52. Connect gearbox harness multiplugs and secure multiplugs in mounting bracket clips.
53. Connect Lucar connector to starter solenoid.
54. Position earth lead to gearbox housing, fit and tighten bolt to 25 Nm (18 ft. lbs.).
55. Position engine harness to 'E' box mounting bracket and secure with clips.
56. Connect earth header multiplug.
57. Connect multiplug to underbonnet fuse box.
58. Position battery and starter motor lead to underbonnet fuse box, fit and tighten bolts to 8 Nm (6 ft. lbs.).
59. Fit underbonnet fuse box cover.
60. Position 'E' box, secure in retaining clip, fit and tighten nut to 9 Nm (7 ft. lbs.).
61. Position carrier in 'E' box and secure with clips.
62. Position and secure air duct and harness rubber sleeve in 'E' box.
63. Connect multiplugs securing main harness to engine harness.
64. Position ECM harness and multiplug to 'E' box, align harness clamp and secure screws to 'E' box.
65. Fit engine ECM.
66. Fit battery carrier.
67. Fill cooling system.
68. Connect battery earth lead.
69. Fill gearbox with fluid.
70. Fit engine acoustic cover.