Installation
ENGINE INSTALLATIONSpecial Tools Needed: 2810, 5006, 5033, 5115; 5244, 5428, 5429, 5972.
Attach Lifting Equipment
- Attach lifting lug 5429 to rear of engine.
- Use lifting yoke 5428.
NOTE: Position wiring harnesses so as to avoid damage when lifting.
CAUTION: Since work is carried out with engine freely suspended ensure that lifting equipment is securely attached and is in perfect condition.
Lower Engine and Transmission Into Position
- Use lifting tool 2810.
- Adjust lifting yoke to ensure engine is evenly balanced.
- Adjust angle of lift throughout operation.
NOTE: Carefully check that drive unit is free of body and accessories (if any).
Guide Engine Mountings Into Position
- Tighten mounting top nuts. Torque: 50 Nm (37 ft.lb).
Support Transmission on Jack
- Remove lifting yoke 2810 from engine.
Support Engine at Rear
- Use two support rails 5033, lifting beam 5006 and lifting hook 5115.
- Remove Jack Under Transmission.
Install Transmission Support Member
- Use transmission lifting fixture 5972.
- Raise transmission.
- Tighten bolted joints between support member and side members.
- Tighten transmission bump stop nut. Torque: 50 Nm (37 ft.lb).
Install Gear Selector Lever
- Attach control rod and reaction arm to lever mounting.
- Install locking clip.
- Connect and secure oxygen sensor lead.
Reconnect Propeller Shaft
- Use socket 5244.
- Tighten front and rear couplings (note markings).
Install Air Preheater Pipe
- Inspect 0-ring and connect pipe to exhaust pipe.
- Tighten sump bolts.
Install AC Compressor
- Bolt compressor to mounting.
- Reconnect hoses to oil cooler. Torque: 30 Nm (22 ft.lb).
NOTE: Ensure that compressor pipes are not jammed.
Remove Lifting Tools
- Remove tools 5006, 5033, 5115, 5428 and 5429.
Install / Reconnect:
- Coolant hoses (two) to branches on bulkhead.
- Timing pick-up and camshaft position sensor connectors.
Reconnect Engine Connector
- Reconnect engine connector at left wheel housing.
- Reconnect relay and refit wiring duct mounting nuts.
- Install cover.
Install:
- Fuel hoses.
- Cruise control vacuum hose.
- ECC vacuum hoses.
- Brake servo vacuum hose.
- Throttle cable.
- Throttle pulley cover.
Install Air Mass Meter and Intake Hose
- Install air preheater hose.
- Reconnect air mass meter and connector.
- Reconnect idling valve hose and connector.
- Reconnect oil trap hoses.
- Reconnect EVAP vacuum hoses (two).
Install Servo Pump
- Mount pump on auxiliaries mounting bracket (five bolts).
- First tighten three front bolts in servo pump to ensure correct location.
- Install auxiliaries drive belt.
Install / Reconnect:
- Battery leads in holders.
- Radiator and radiator hoses.
- Expansion vessel hoses.
- Transmission oil pipes. Torque: 35 Nm (26 ft.lb.).
- Cooling fan.
Install Battery and Reconnect Leads
- Reconnect cooling fan leads.
- Install battery.
- Reconnect battery positive lead.
- Reconnect lead from right wheel housing to positive terminal.
- Reconnect ground lead to right-hand front member.
Jack Up Car
- Reconnect fluid pipes to transmission. Torque: 35 Nm (26 ft.lb.).
Install Exhaust Pipe
- Torque M10 bolts to: 60 Nm (44 ft.lb.).
- Torque M8 bolts and heat shield to: 40 Nm (30 ft.lb.).
Undo Bolted Joint After Catalytic Converter
- Retighten to 25 Nm (18 ft.lb.).
- This is necessary to prevent stresses in the system.
Install:
- Radiator mounting bolts.
- Air baffle under radiator.
- Splashguard under engine.
Top Up Coolant and Engine Oil
- Coolant capacity: 10.7 liters.
- Oil capacity without oil filter 5.25 L (5.5 qts.).
- Oil capacity with oil filter 5.75 L (6.0 qts.).
Check Operation
- Reconnect battery ground lead.
- START and RUN engine until thermostat opens.
- Inspect for leaks.
- Check and top up engine oil and coolant levels as required.
- Check transmission fluid level.