Refit

Engine and Automatic Gearbox - From 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.
3. Position PAS pump pulley, fit and tighten Torx screws to 9 Nm.
4. Position top arm to engine mounting bracket and RH hydramount, fit and tighten bolts to 100 Nm.
5. Position PAS pipe support bracket to RH hydramount, fit and tighten nut to 85 Nm.
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 44-026 lifting bracket to gearbox and remove bracket.
9. Position LH mounting bracket to gearbox, fit and tighten bolts to 85 Nm.
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.
12. Position upper RH engine steady to top arm, fit and tighten bolt to 100 Nm.
13. Tighten bolt securing upper RH engine steady to body to 100 Nm.
14. Position PAS pipe to engine front mounting plate, fit and tighten bolt to 25 Nm.
15. Lower hoist, disconnect and remove lifting bracket, LRT-12-138.
16. Raise vehicle on lift.
17. Position A/C compressor to front mounting plate and cylinder block, align heat shield, fit and tighten bolts to 25 Nm.
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 dip.
21. Position selector lever to selector shaft, fit and tighten nut to 25 Nm.
22. Clean splines and seal areas on each drive shaft and mating faces in front hubs.
23. Fit new circlips to RH and LH drive shaft inner joint splines.
24. Fit drive shafts to IRD and gearbox, ensuring that the circlip on each drive shaft is fully engaged.
25. Engage LH and RH drive shafts into front hubs.
26. Fit new drive shaft 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.
29. Clean ABS sensors and mating faces.
30. Apply anti-seize grease to both ABS sensors and position sensors in front hubs.

CAUTION: Ensure ABS sensor is fully located into hub, so that sensor touches pole wheel tooth.

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.
39. Stake nuts to drive shafts
40. Fit front road wheels.
41. Lower vehicle on lift.
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 dip.
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.
48. Connect hose to purge valve.
49. Fit purge hose into clip.
50. Connect fuel hose to fuel rail pipe, fit rubber sleeve over hose connector.
51. Connect gearbox harness multiplugs and secure multiplugs in mounting bracket clips.
52. Connect Lucar connector to starter solenoid.
53. Position earth lead to gearbox housing, fit and tighten bolt to 25 Nm.
54. Position engine harness to 'E' box mounting bracket and secure with clips.
55. Connect earth header multiplug.
56. Connect multiplug to under bonnet fuse box.
57. Position battery and starter motor lead to under bonnet fuse box, fit and tighten bolts to 8 Nm.
58. Fit under bonnet fuse box cover.
59. Position 'E' box, secure in retaining clip, fit and tighten nut to 9 Nm.
60. Fit carrier to 'E' box.
61. Fit air ducting to 'E' box.
62. Fit body harness to 'E' box, secure grommet and harness clip.
63. Connect 'E' box cooling fan multiplug.
64. Connect multiplug to 'E' box temperature sensor.
65. Connect multiplug to gearbox ECU.
66. Position engine harness to 'E' box and secure grommet.
67. Fit engine harness clamp and secure with screws.
68. Connect engine harness multiplug to body harness multiplug and fit multiplug to 'E' box,
69. Fit heated front screen harness to battery positive cable and tighten bolt to 15 Nm (11 ft. lbs.).
70. Fit engine ECM.
71. Fit battery carrier.
72. Fill cooling system.
73. Connect the battery earth lead.
74. Fill gearbox with fluid.
75. Fit the engine acoustic cover.
76. Untie and close bonnet.