Remove
Engine and Automatic Gearbox - From 03MY
Service Repair No - 12.37.01.99
Remove
1. Disconnect battery earth lead.
2. Tie bonnet back in upright position.
3. Drain cooling system.
4. Remove the engine acoustic cover.
5. Remove battery carrier.
6. Remove engine ECM.
7. Remove bolt securing heated front screen harness to battery positive cable.
8. Remove 2 screws securing harness clamp and remove clamp.
9. Release multiplug from 'E' box and disconnect body harness from engine harness
10. Move engine harness aside.
11. Disconnect multiplug from 'E' box temperature sensor.
12. Disconnect multiplug from automatic gearbox ECU.
13. Disconnect 'E' box cooling fan multiplug.
14. Release body harness clip from 'E' box.
15. Move body harness aside.
16. Release air duct from 'E' box.
17. Rotate heated front screen relay anti-clockwise and release it from 'E' box bracket.
18. Release 4 clips and remove carrier from 'E' box.
19. Remove nut, release retainer and remove 'E' box.
20. Remove engine compartment fuse box cover.
21. Remove 2 bolts securing battery and starter lead to fuse box.
22. Disconnect multiplug from fuse box.
23. Disconnect earth header multiplug.
24. Release 3 clips securing engine harness to 'E' box mounting bracket, lay harness over engine.
25. Remove bolt securing engine earth lead.
26. Disconnect Lucar from starter solenoid.
27. Release 2 gearbox harness multiplugs from mounting bracket clips and disconnect multiplugs.
28. Position absorbent cloth around fuel feed pipe connection to collect spillage.
WARNING: The spilling of fuel is unavoidable during this operation. Ensure that all necessary precautions are taken to prevent fire and explosion.
29. Pullback rubber sleeve on fuel pipe connector, release connector and disconnect fuel pipe from fuel rail pipe.
CAUTION: Always fit plugs to open connections to prevent contamination.
30. Release purge hose from clip.
31. Release and disconnect hose from purge control valve.
CAUTION: Always fit plugs to open connections to prevent contamination.
32. Release clips and disconnect heater feed and return hoses from matrix
33. Release top hose from support bracket, release clip and disconnect top hose from radiator.
34. Release clip and disconnect expansion tank hose from inlet manifold.
35. Release clip and disconnect hose from underside of expansion tank.
36. Depress locking collar and disconnect brake servo hose from inlet manifold chamber.
CAUTION: Always fit Plugs to open connections to prevent contamination.
37. Raise vehicle on lift.
38. Remove front road wheels.
39. Release stake in drive shaft nuts.
40. With assistant depressing the brake pedal, remove and discard LH and RH drive shaft nuts.
41. Remove rear beam.
42. Remove exhaust front pipe.
43. Raise one rear wheel for rotation of propeller shaft to access bolts.
44. Reference mark position of viscous coupling flange to IRD unit flange to aid reassembly.
45. Remove 6 nuts and bolts securing propeller shaft to IRD drive flange.
46. Release propeller shaft from IRD drive flange and fie shaft aside.
CAUTION: Care must be taken to support the Tripode joint when removed from the IRD unit. To avoid damage to gaiter or steel can, the joint should not be allowed to fully extend or be dropped.
47. Drain gearbox fluid.
48. Drain fluid from IRD.
49. Remove 6 bolts securing RH and LH front splash shields and remove shields.
50. Remove clips securing brake hoses to RH and LH damper brackets.
51. Release ABS sensor leads from bracket.
52. Release ABS sensors from RH and LH front hubs.
53. Remove nuts securing RH and LH track rod end ball joints.
54. Fit an M12 nut to each ball pin, flush with end of each pin.
55. Using 57-043, separate ball pins from RH and LH steering arms. Remove M12 nuts and release ball pins from steering arms.
56. Pull RH and LH hubs outwards and release drive shafts from hubs.
57. Using 54-026, release drive shafts from IRD unit and gearbox.
58. Remove nut securing selector lever to selector shaft on gearbox and release lever from selector shaft.
59. Release dip securing selector cable to gearbox bracket, remove cable and tie aside.
60. Using a 3/8 square drive socket bar, raise ancillary drive belt tensioner and release drive belt from A/C compressor pulley.
61. Disconnect multiplug from A/C compressor.
62. Note fitted position of heat shield on A/C compressor and remove 3 bolts securing A/C compressor to front mounting plate and cylinder block. Release A/C compressor and heat shield and position aside.
63. Lower vehicle on lift.
64. Using a hoist, connect adjustable lifting bracket, LRT-12-138 to engine.
65. Raise hoist to take weight without exerting any load on the engine mountings.
66. Remove through bolt securing LH engine mounting to gearbox bracket.
67. Remove 4 bolts securing LH mounting to body and remove mounting.
68. Remove 4 bolts securing LH mounting bracket to gearbox and remove bracket.
69. Using gearbox bracket bolts, secure LRT-44-026 lifting bracket to gearbox.
70. Place a wooden block on jack, position jack under gearbox and raise jack sufficient to support weight of gearbox. Release lifting hook from rear engine lifting bracket and connect to lifting bracket on gearbox.
71. Remove bolt securing upper RH engine steady to top arm.
72. Loosen bolt securing upper RH engine steady to body, pivot engine steady away from top arm.
73. Remove bolt securing PAS pipe to engine front mounting plate.
74. Remove nut and 4 bolts securing engine top arm bracket to RH hydramount and to engine front mounting bracket.
75. Release PAS pipe support bracket from hydramount and position pipe aside.
76. Remove bolt securing PAS pipe to engine front mounting plate.
77. Remove top arm.
78. Remove 3 Torx screws securing PAS pump pulley and remove pulley.
79. Remove 3 bolts securing PAS pump to front mounting plate and tie pump aside.
80. With assistance, maneuver and lower engine and gearbox to floor.