With Automatic Transmission

1. Raise power unit. Guide into engine bay.
2. Position transmission jack beneath transmission brake drum.
3. With assistance, raise transmission and lower engine until engine mountings can be installed.

CAUTION: Ensure all under body wax is removed from mating surfaces of fixings before installing.





4. Attach mountings to chassis with new flange nuts. Do not tighten at this stage. [88]

CAUTION: Engine mountings must be installed with center bolt head facing outboard as shown.

5. Lower and guide engine onto mounting studs.
6. Attach engine to mountings with new flange nuts. Do not tighten at this stage.
7. Release lifting bracket from engine lifting eyes. Remove hoist.
8. Route gearbox harness. Secure with clips.
9. Connect multiplug to engine harness.
10. Connect multiplugs to High/Low motor and output shaft speed sensor.
11. Connect multiplugs to gear selection position switch and gearbox speed sensor.
12. Position selector cable abutment bracket to gearbox. Secure with bolts.
13. Adjust gear selector cable.
14. Connect connectors to transfer box fluid temperature sensor.
15. Raise gearbox on transmission jack.
16. Align harness bracket to gearbox.
17. Raise one wheel on each axle to allow rotation of propeller shafts.
18. Position shafts to transfer box flanges. Align marks.
19. Secure propeller shaft flanges with nuts and bolts. Tighten to 48 Nm (35 ft. lbs.).
20. Install propeller shaft guard. Tighten bolts.
21. Guide hand brake cable through grommet in transmission tunnel.
22. Install exhaust front pipe and chassis cross member.
23. Remove support from under transmission.
24. Tighten engine mounting nuts to 45 Nm (33 ft. lbs.).
25. Lower lift.
26. Connect hand-brake cable to lever, secure with clevis pin and clip.
27. Install window switch pack.
28. With assistance, position radiator/condenser/oil cooler assembly.
29. Connect multiplugs to condenser cooling fans.
30. Engage radiator in lower mounting rubbers. Secure with nuts and bolts.
31. Remove plugs from air conditioning compressor and pipes.
32. Install new O-rings to compressor pipes. Lubricate O-rings with compressor oil. Connect to compressor.
33. Install compressor connection bolts. Tighten to 23 Nm (17 ft. lbs.).
34. Remove plugs from air conditioning condenser and pipes.
35. Install new O-rings to condenser pipes. Lubricate O-rings with compressor oil. Secure pipes to condenser. Tighten to 15 Nm (11 ft. lbs.).
36. Connect gearbox oil temperature multiplug.
37. Remove plugs from power steering pump and pipes.
38. Install new O-rings to power steering pipes. Lubricate O-rings with power steering fluid. Secure to power steering pump. Tighten to 16 Nm (12 ft. lbs.).
39. Untie power steering reservoir from engine. Remove plugs. Connect return pipe. Secure return pipe to reservoir with clip.
40. Position reservoir to radiator. Secure with bolts.
41. Secure fog lamp breather hoses to clips on either side of radiator.
42. Route plenum chamber hose along front of engine. Secure in clips.
43. Connect hose to plenum chamber water jacket. Secure with clip.
44. Connect coolant hoses to radiator, thermostat housing and inlet manifold. Secure hoses with clips.
45. Remove plugs from oil coolers and pipes.
46. Lubricate pipes with clean fluid. Install new O-rings. Connect to oil coolers. Tighten to 30 Nm (22 ft. lbs.).
47. Install washer bottle filler neck. Secure with bolt and screw.
48. Install radiator deflector panels. Secure with studs.
49. Position hood platform. Secure hood release cable to platform with clips.
50. Secure hood platform with bolts.
51. Install front grille.
52. Install cooling fan and viscous coupling.
53. Evacuate and recharge air conditioning system.
54. Refill cooling system.
55. Refill transmission fluids.
56. Refill engine oil.
57. Install oil filler cap.
58. Route engine harness along valance. Secure clip.
59. Connect engine harness multiplugs to main harness. Secure earth terminal to valance stud.
60. Connect engine harness multiplug to base of fuse box.
61. Position fuse box. Secure with bolts.
62. Position earth lead to alternator bracket. Secure with bolt.
63. Install battery tray. Secure with bolts.
64. Install starter feed wire to battery positive terminal clamp. Secure with nut.
65. Position engine harness to battery tray. Secure harness grommets.
66. Secure harness clamp to battery tray with screws.
67. Install ECM.
68. Install throttle and cruise control cables to abutment bracket. Secure cruise control cable with 'C' clip.
69. Position cable trunnions to throttle linkage. Secure with clevis and split pins.
70. Adjust throttle cable free-play.
71. Adjust cruise control cable.
72. Install intake hose and air flow meter assembly to plenum chamber. Secure with clip. Connect multiplug to air flow meter.
73. Connect multiplug to purge valve.
74. Position purge valve on shock absorber turret. Secure with bolt.
75. Connect purge hose to ram pipe housing.
76. Secure harness to clip on intake hose.
77. Install air cleaner.
78. Remove plugs from fuel hoses and fuel rail connections.
79. Connect fuel feed pipe to fuel rail. Tighten to 16 Nm (12 ft. lbs.).
80. Connect return hose to pressure regulator pipe. Secure with clip.
81. Install battery.





82. With assistance, release hood stay clips. Engage hood struts. [176]

CAUTION: Ensure hood stay clips are returned to their original positions as shown.

83. Start engine. Check for fuel, coolant and oil leaks.