With Manual Transmission
1. Position vehicle on four post lift.
2. Remove battery.
3. Remove ECM.
4. Remove 2 screws securing engine harness clamp to battery tray. Collect clamp. [4]
5. Release starter feed wire from battery terminal clamp. [5]
6. Release earth lead from alternator bracket. [6]
7. Release fuel return hose clip. Release fuel return hose from regulator connecting pipe. [7]
8. Release fuel feed pipe from fuel rail. [8]
9. Disconnect multiplug from purge valve. [9]
10. Release purge hose from ram pipe housing.
11. Remove purge valve securing bolt from shock absorber turret. Place valve aside. [11]
12. Disconnect multiplug from air flow meter.
13. Release harness from intake hose. [13]
14. Slacken clip securing intake hose to plenum chamber. [14]
15. Remove intake hose/air flow meter assembly. [15]
16. Position harness across engine.
17. Disconnect throttle and cruise control cables from throttle linkage. [17]
18. Release cables from abutment bracket. [18]
19. Disconnect top hose from inlet manifold. [19]
20. Disconnect heater hose from inlet manifold. Release hose from clip. Place hose aside. [20]
21. Disconnect coolant hose from plenum chamber water jacket. Release hose from 2 clips. Place hose aside on valance. [21]
22. Remove 4 bolts securing battery tray. Remove battery tray.
23. Remove 2 bolts securing fuse box. Pivot fuse box for access. [23]
24. Disconnect engine harness multiplug from base of fuse box. [24]
25. Release earth wire from valance stud. [25]
26. Disconnect 2 engine harness multiplugs from main harness. [26]
27. Release engine harness clip from valance. Tie harness aside over engine. [27]
28. With assistance, release bonnet struts from body locations. Retain bonnet in vertical position using stay clips. [28]
WARNING: Only open the bonnet to the vertical position with the vehicle on a horizontal surface in the workshop. This position is not intended to be used outdoors where the bonnet could be affected by winds.
29. Depressurize fuel system.
30. Remove air cleaner.
31. Drain cooling system.
32. Discharge air conditioning system.
33. Remove cooling fan and viscous coupling.
34. Remove front grille.
35. Remove 4 bolts securing bonnet platform. [35]
36. Release straps securing bonnet release cable to platform. Remove platform. [36]
37. Remove 2 studs securing each radiator air deflector. Remove both deflectors. [37]
38. Remove bolt and screw securing washer bottle filler neck. Remove filler neck.
CAUTION: Where pipes are disconnected, plug pipes and ports to prevent entrance of dirt.
39. Disconnect engine and gearbox oil coolers. Remove O-rings and discard. Tie pipes aside on engine. [39]
40. Disconnect coolant bleed hose from radiator. [40]
41. Release 2 fog lamp breather hoses from clips on either side of radiator. [41]
42. Disconnect 3 coolant hoses from thermostat housing.
43. Remove 2 bolts securing power steering fluid reservoir to radiator. [43]
NOTE: Position container beneath power steering reservoir to catch spillage.
44. Disconnect return pipe from reservoir. Tie reservoir aside to engine. [44]
45. Disconnect feed pipe from power steering pump. Remove O-rings and discard. [45]
46. Release feed pipe clip from bracket. Place pipe aside.
47. Disconnect multiplug from gearbox oil temperature sensor. [47]
48. Disconnect 2 pipes from air conditioning condenser. Remove O-rings and discard.
49. Disconnect 2 pipes from air conditioning compressor. Remove O-rings and discard. Place pipes aside. [49]
50. Remove 2 nuts and bolts securing radiator mountings to chassis. [50]
51. With assistance, raise radiator assembly for access to condenser cooling fan connections.
52. Disconnect 2 condenser cooling fan multiplugs. [52]
53. With assistance, remove radiator/condenser/oil cooler assembly.
54. Clamp clutch flexible hose using an approved brake hose clamp.
55. Remove clip securing flexible hose to gearbox bracket.
56. Disconnect clutch flexible hose at gearbox pipe. Position hose aside.
57. Remove centre console.
58. Remove 6 nuts securing boot ring. Remove ring and boot. [59]
59. Remove 2 bolts securing gear lever. Remove lever. [60]
60. Release hand-brake. Release hand-brake cable clevis pin. [61]
61. Raise lift. Drain gearbox, transfer box and engine fluids.
62. Using a transmission jack, support transmission under brake drum.
63. Remove exhaust front pipe.
64. Release hand brake cable from grommet in tunnel. [65]
65. Remove 4 bolts securing rear propeller shaft award. Remove Guard. [66]
66. Mark transfer box and propeller shaft flanges to aid reassembly.
67. Raise one wheel on each axle to allow rotation of propeller shafts.
68. Remove 4 nuts and bolts from each flange. Disconnect propeller shafts. Tie aside. [69]
69. Lower gearbox for access.
70. Disconnect 2 connectors from transfer box fluid temperature sensor.
71. Disconnect multiplugs from High/Low motor and output shaft speed sensor. [73]
72. Disconnect multiplugs from reverse and neutral switches. Remove bolt securing harness bracket to gearbox. Release harness from clips on gearbox brackets. [75]
73. Disconnect engine harness to gearbox harness multiplug. Position harness aside.
74. Remove 4 nuts securing each engine mount to chassis and engine brackets. Discard nuts. [77]
75. Remove oil filler cap. [78]
76. Place cloth over plenum chamber to protect from damage during lifting.
77. Shorten front chain of lifting bracket to 2 links as shown. [80]
78. Install lifting bracket to engine lifting eyes. Attach suitable hoist. [81]
79. Raise engine slightly. Ensure that lifting bracket does not foul bulkhead. Remove both engine mountings.
NOTE: It may be necessary to lower gearbox support slightly during above operation.
80. Raise power unit and draw forward. Lower support from transmission.
NOTE: Power unit must be tilted at an angle of approximately 45 degrees before it can be withdrawn from engine compartment.
81. Remove engine/transmission assembly.