Pulley - Crankshaft Land Rover Range Rover III

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

Removal

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Remove ancillary drive belt. See «ANCILLARY DRIVE BELT»(ref-139294-S29837205362004102900000).
4. Remove viscous fan. See «VISCOUS FAN»(ref-167168-S05613503662004101400000).
5. Remove compressor drive belt. See «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139295).
6. Remove 8 bolts securing crankshaft pulley to hub assembly. (Scheme 2)
7. Remove crankshaft pulley.

Scheme 2

Installation

1. Position crankshaft pulley to hub assembly, fit to locating dowel.
2. Fit 8 new bolts securing crankshaft pulley to hub assembly and tighten to 22 Nm (16 ft. lbs).
3. Fit compressor drive belt. See «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139295) .
4. Fit viscous fan. See «VISCOUS FAN»(ref-167168-S05613503662004101400000) .
5. Fit ancillary drive belt. See «ANCILLARY DRIVE BELT»(ref-139294-S29837205362004102900000) .
6. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000) .

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Remove crankshaft pulley. See «PULLEY - CRANKSHAFT»(ref-158804-S41624684182005013100000).
4. Fit LRT-12-229 to crankshaft pulley hub. (Scheme 3)
5. Position LRT-12-229 to rest on sub frame and remove crankshaft pulley bolt. (Scheme 4)
6. Remove LRT-12-229 from crankshaft pulley hub.
7. Remove crankshaft pulley hub.
8. Fit LRT-12-230/1 and LRT-12-230/2 to crankshaft seal and remove crankshaft oil seal. (Scheme 5)
9. Discard oil seal.

Scheme 3

Scheme 4

Scheme 5

1. Clean seal mating faces.
2. Fit new crankshaft oil seal to front cover using LRT-12-231. (Scheme 6) NOTE: Front crankshaft oil seal should be fitted flush to front timing cover.
3. Remove LRT-12-231.
4. Clean crankshaft pulley hub and mating faces, fit crankshaft pulley hub to crankshaft.
5. Fit new bolt to crankshaft, lock crankshaft using LRT-12-229 and initially tighten crankshaft bolt to 100 Nm (74 ft. lbs). Using an angle torque gauge tighten in the following sequence: Stage 1 60° Stage 2 60° Stage 3 30°
6. Remove LRT-12-229 from crankshaft pulley hub.
7. Fit crankshaft pulley. See «PULLEY - CRANKSHAFT»(ref-158804-S41624684182005013100000).
8. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).

Scheme 6

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Drain engine oil. See «FILTER - ENGINE OIL»(ref-158804-S13136612622005013100000).
4. Remove torque converter drive plate. See «TORQUE CONVERTER DRIVE PLATE»(ref-158804-S00746071092005013100000).
5. Remove 6 Torx bolts and 6 bolts securing crankshaft rear oil seal housing to cylinder block. (Scheme 7)
6. Remove crankshaft rear oil seal housing.
7. Discard gasket from crankshaft rear oil seal housing.
8. Remove crankshaft rear oil seal from housing.

Scheme 7

1. Clean crankshaft rear oil seal housing, locating dowels and mating faces on cylinder block and crankshaft oil seal running surface.
2. Fit LRT-12-217 and LRT-12-179 to new crankshaft rear oil seal and fit new seal to housing. (Scheme 8)
3. Check for correct fitment of dowels in cylinder block. (Scheme 9)
4. Fit new gasket to crankshaft rear oil seal housing.
5. Apply sealant, Part No. STC 50550 to upper oil sump gasket contact point. (Scheme 10)
6. Fit LRT-12-218 to crankshaft. Apply a thin coat of oil to inner lip of crankshaft rear oil seal, fit seal and housing over LRT-12-218, fit onto dowels and remove tool. (Scheme 11)
7. Fit new washers to 6 Torx bolts, fit 6 Torx bolts and 6 bolts securing crankshaft oil seal housing to cylinder block and tighten to 12 Nm (9 ft. lbs).
8. Fit torque converter drive plate. See «TORQUE CONVERTER DRIVE PLATE»(ref-158804-S00746071092005013100000).
9. Fill engine with oil. See «FILTER - ENGINE OIL»(ref-158804-S13136612622005013100000).
10. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000).
4. Drain engine oil and remove oil filter. See «FILTER - ENGINE OIL»(ref-158804-S13136612622005013100000).
5. Remove left exhaust manifold. See «GASKET(S) -- EXHAUST MANIFOLD -- LH»(ref-173241-S27519991532005031400000).
6. Remove coolant pump to coolant manifold pipes. See «PIPE(S) -- COOLANT PUMP TO COOLANT MANIFOLD»(ref-173343-S10492170012005031400000).
7. Remove left Variable Camshaft Control (VCC) unit. See «VARIABLE CAMSHAFT UNIT - VARIABLE CAMSHAFT CONTROL (VCC) - LEFT»(ref-158804-S04958445472005013100000).
8. Remove LRT-12-227 from timing tool access hole. (Scheme 12)
9. Rotate engine crankshaft pulley anti-clockwise to align the 45° mark before TDC timing mark. (Scheme 13) NOTE: Raise timing chain and hold under tension while turning crankshaft pulley.
10. Remove LRT-12-223/6, LRT-12-223/5, LRT-12-223/3 and LRT-12-223/4 from left cylinder head camshafts.
11. Remove bolt securing left timing chain guide rail to left cylinder head. (Scheme 14)
12. Working in the sequence shown, progressively loosen 10 cylinder head bolts. (Scheme 15)
13. Discard 10 cylinder head bolts and remove 10 cylinder head bolt washers.
14. With assistance, remove cylinder head assembly. (Scheme 16)
15. Discard cylinder head gasket.
16. Discard "O" ring from cylinder block. (Scheme 17)

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

1. Clean mating faces of cylinder head and cylinder block, dowels and dowel holes. If necessary remove all traces of sealing compound with hard wood scraper. Ensure remnants do not remain in oil ways cooling ducts or bolt holes. CAUTION: Make sure no oil or coolant is left in the cylinder head bolt holes as damage to the cylinder block may occur when tightening the cylinder head bolts.
2. Using a straight edge and feeler gauges, check cylinder head for distortion along lines in illustration. (Scheme 18)
3. Fit new "O" ring to cylinder block.
4. Apply sealant, Part No. STC 50550 to areas illustrated. (Scheme 19)
5. Fit new cylinder head gasket to locating dowels on cylinder block.
6. With assistance, fit cylinder head and carefully position cylinder head onto dowels.
7. Fit cylinder head bolt washers and new cylinder head bolts. Tighten cylinder head bolts in sequence shown to 30 Nm (22 ft. lbs). Using an angle torque gauge tighten all bolts in sequence by a further 80°, and then a final 80°. (Scheme 20) NOTE: DO NOT remove special coating from new cylinder head bolts.
8. Fit bolt securing left timing chain guide rail to left cylinder head and tighten.
9. Carefully rotate camshafts until letter and cylinder number markings located on rear of camshafts are in an upright position. (Scheme 21) NOTE: The twisting and apparent misalignment of the camshafts does not indicate incorrect engine timing.
10. Loosen bolt securing LRT-12-223/4 to LRT-12-223/3.
11. Fit LRT-12-223/4 and LRT-12-223/3 to rear of left camshafts and tighten bolt securing tools. (Scheme 22)
12. Fit LRT-12-223/5, LRT-12-223/6 to left cylinder head and tighten LRT-12-223/6 into spark plug thread. (Scheme 23)
13. Rotate engine crankshaft pulley clockwise to align TDC timing mark. (Scheme 24) NOTE: Raise timing chain and hold under tension while turning crankshaft pulley.
14. Position LRT-12-227 through timing tool access hole and secure flywheel in TDC position. (Scheme 12)
15. Fit left Variable Camshaft Control (VCC) unit. See «VARIABLE CAMSHAFT UNIT - VARIABLE CAMSHAFT CONTROL (VCC) - LEFT»(ref-158804-S04958445472005013100000).
16. Fit coolant pump to coolant manifold pipes. See «PIPE(S) -- COOLANT PUMP TO COOLANT MANIFOLD»(ref-173343-S10492170012005031400000).
17. Fit left exhaust manifold. See «GASKET(S) -- EXHAUST MANIFOLD -- LH»(ref-173241-S27519991532005031400000).
18. Fit new oil filter and fill engine with oil. See «FILTER - ENGINE OIL»(ref-158804-S13136612622005013100000).
19. Fill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000).
20. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000).
4. Drain engine oil and remove oil filter. See «FILTER - ENGINE OIL»(ref-158804-S13136612622005013100000).
5. Remove right exhaust manifold. See «GASKET(S) -- EXHAUST MANIFOLD -- RH»(ref-173241-S22743104602005031400000).
6. Remove coolant pump to coolant manifold pipes. See «PIPE(S) -- COOLANT PUMP TO COOLANT MANIFOLD»(ref-173343-S10492170012005031400000).
7. Remove right Variable Camshaft Control (VCC) unit. See «VARIABLE CAMSHAFT UNIT - VARIABLE CAMSHAFT CONTROL (VCC) - RIGHT»(ref-158804-S32020547622005013100000).
8. Fit LRT-12-226 to VCC solenoid and remove solenoid. (Scheme 25) CAUTION: DO NOT allow oil to come into contact with the drive belts while removing the solenoid.
9. Remove LRT-12-227 from timing tool access hole. (Scheme 12)
10. Rotate engine crankshaft pulley anti-clockwise to align the 45° mark before TDC timing mark. (Scheme 13) NOTE: Raise timing chain and hold under tension while turning crankshaft pulley.
11. Remove LRT-12-223/5, LRT-12-223/6, LRT-12-223/2 and LRT-12-223/1 from right cylinder head camshafts.
12. Working in the sequence shown, progressively loosen 10 cylinder head bolts. (Scheme 26)
13. Discard 10 cylinder head bolts and remove 10 cylinder head bolt washers.
14. With assistance, remove cylinder head assembly. (Scheme 27)
15. Discard cylinder head gasket.
16. Discard "O" ring from cylinder block. (Scheme 28)

Scheme 25

Scheme 26

Scheme 27

Scheme 28

1. Clean mating faces of cylinder head and cylinder block, dowels and dowel holes. If necessary remove all traces of sealing compound with hard wood scraper. Ensure remnants do not remain in oil ways cooling ducts or bolt holes. CAUTION: Make sure no oil or coolant is left in the cylinder head bolt holes as damage to the cylinder block may occur when tightening the cylinder head bolts.
2. Using a straight edge and feeler gauges, check cylinder head for distortion along lines in illustration. (Scheme 18)
3. Fit new "O" ring to cylinder block.
4. Apply sealant, Part No. STC 50550 to areas illustrated. (Scheme 29)
5. Fit new cylinder head gasket to locating dowels on cylinder block.
6. With assistance, fit cylinder head and carefully position cylinder head onto dowels.
7. Fit cylinder head bolt washers and new cylinder head bolts. Tighten cylinder head bolts in sequence shown to 30 Nm (22 ft. lbs). Using an angle torque gauge tighten all bolts in sequence by a further 80° and then a final 80°. (Scheme 30) NOTE: DO NOT remove special coating from new cylinder head bolts.
8. Carefully rotate camshafts until letter and cylinder number markings located on rear of camshafts are in an upright position. (Scheme 21) NOTE: The twisting and apparent misalignment of the camshafts does not indicate incorrect engine timing.
9. Loosen bolt securing LRT-12-223/2 to LRT-12-223/1.
10. Fit LRT-12-223/2 and LRT-12-223/1 to rear of right camshafts and tighten bolt securing tools. (Scheme 22)
11. Fit LRT-12-223/5, LRT-12-223/6 to right cylinder head and tighten LRT-12-223/6 into spark plug thread. (Scheme 23)
12. Rotate engine crankshaft pulley clockwise to align TDC timing mark. (Scheme 24) NOTE: Raise timing chain and hold under tension while turning crankshaft pulley.
13. Position LRT-12-227 through timing tool access hole and secure flywheel in TDC position.
14. Fit LRT-12-226 to Variable Camshaft Control (VCC) solenoid and fit solenoid. (Scheme 25)
15. Fit right VCC unit. See «VARIABLE CAMSHAFT UNIT - VARIABLE CAMSHAFT CONTROL (VCC) - RIGHT»(ref-158804-S32020547622005013100000).
16. Fit coolant pump to coolant manifold pipes. See «PIPE(S) -- COOLANT PUMP TO COOLANT MANIFOLD»(ref-173343-S10492170012005031400000).
17. Fit right exhaust manifold. See «GASKET(S) -- EXHAUST MANIFOLD -- RH»(ref-173241-S22743104602005031400000).
18. Fit new oil filter and fill engine with oil. See «FILTER - ENGINE OIL»(ref-158804-S13136612622005013100000).
19. Fill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000).
20. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).

Scheme 29

Scheme 30

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
2. Remove engine acoustic cover. See «ACOUSTIC COVER - ENGINE»(ref-158804-S20286524212005013100000).
3. Remove air intake plenum. See «80.15.62 PLENUM -- AIR INTAKE»(ref-208062-S24349779832005120200000).
4. Depressurize fuel system. See «FUEL SYSTEM -- DEPRESSURIZE»(ref-173410-S17809948792005031700000).
5. Disconnect fuel feed hose from fuel rail. (Scheme 31)
6. Release 2 clips securing battery cable to engine acoustic cover brackets. (Scheme 32)
7. Release heater pump from mounting rubbers and move aside. (Scheme 33)
8. Release clip and disconnect breather hose from camshaft cover.
9. Remove left ignition coil cover. See «COVER -- IGNITION COILS -- LH»(ref-172008-S29656128552005022200000).
10. Remove nut and disconnect earth lead from camshaft cover. (Scheme 34)
11. Disconnect multiplugs from ignition coils. (Scheme 35)
12. Remove 7 nuts securing ignition coils to camshaft cover. Remove 4 ignition coils. (Scheme 36)
13. Discard ignition coil cover gasket.
14. Remove 8 nuts and 3 bolts securing camshaft cover to cylinder head. Remove camshaft cover, discard 2 gaskets and 11 sealing washers. (Scheme 37)

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

1. Clean camshaft cover and mating face of cylinder head.
2. Apply sealant, Part No. STC 50550 to areas illustrated. (Scheme 38)
3. Fit 2 new gaskets and 11 new sealing washers to camshaft cover and fit to cylinder head.
4. Fit 8 nuts and 3 bolts securing camshaft cover and progressively tighten in sequence shown to 10 Nm (7 ft. lbs). see scheme 287
5. Fit 4 ignition coils.
6. Fit 7 nuts securing ignition coils to camshaft cover and tighten to 4 Nm (3 ft. lbs).
7. Connect multiplugs to ignition coils.
8. Connect earth lead to camshaft cover and tighten nut to 4 Nm (3 ft. lbs).
9. Fit new ignition coil cover gasket.
10. Fit left ignition coil cover. See «COVER -- IGNITION COILS -- LH»(ref-172008-S29656128552005022200000).
11. Connect breather hose to camshaft cover and secure with clip.
12. Secure heater pump to mounting rubbers.
13. Secure 2 clips on battery cable to engine acoustic cover brackets.
14. Connect quick release fuel hose to fuel rail.
15. Fit air intake plenum. See «80.15.62 PLENUM -- AIR INTAKE»(ref-208062-S24349779832005120200000).
16. Fit engine acoustic cover. See «ACOUSTIC COVER - ENGINE»(ref-158804-S20286524212005013100000).
17. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).

Scheme 38

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
2. Remove engine acoustic cover. See «ACOUSTIC COVER - ENGINE»(ref-158804-S20286524212005013100000).
3. Remove air intake plenum. See «80.15.62 PLENUM -- AIR INTAKE»(ref-208062-S24349779832005120200000).
4. Remove right ignition coil cover. See «COVER -- IGNITION COILS -- RH»(ref-172008-S10788591692005022200000).
5. Remove nut and disconnect earth lead from camshaft cover. (Scheme 34)
6. Disconnect multiplugs from ignition coils. (Scheme 35)
7. Remove 7 nuts securing ignition coils to camshaft cover. Remove 4 ignition coils. (Scheme 36)
8. Discard ignition coil cover gasket.
9. Remove dipstick tube. See «TUBE - DIPSTICK»(ref-158804-S20368223852005013100000).
10. Remove 6 nuts and 3 bolts securing camshaft cover to cylinder head. Remove camshaft cover, discard 2 gaskets and 11 sealing washers. (Scheme 37)

1. Clean camshaft cover and mating face of cylinder head.
2. Apply sealant, Part No. STC 50550 to areas illustrated. (Scheme 38)
3. Fit 2 new gaskets and 11 new sealing washers to camshaft cover and fit to cylinder head.
4. Fit dipstick tube. See «TUBE - DIPSTICK»(ref-158804-S20368223852005013100000).
5. Fit 6 nuts and 3 bolts securing camshaft cover and progressively tighten in sequence shown to 10 Nm (7 ft. lbs). see scheme 287
6. Fit 4 ignition coils.
7. Fit 7 nuts securing ignition coils to camshaft cover and tighten to 4 Nm (3 ft. lbs).
8. Fit new ignition coil cover gasket.
9. Connect multiplugs to ignition coils.
10. Connect earth lead to camshaft cover and tighten nut to 4 Nm (3 ft. lbs).
11. Fit right ignition coil cover. See «COVER -- IGNITION COILS -- RH»(ref-172008-S10788591692005022200000).
12. Fit air intake plenum. See «80.15.62 PLENUM -- AIR INTAKE»(ref-208062-S24349779832005120200000).
13. Fit engine acoustic cover. See «ACOUSTIC COVER - ENGINE»(ref-158804-S20286524212005013100000).
14. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
2. Release 4 Allen head turnbuckles and remove acoustic cover. (Scheme 39)

Scheme 39

1. Fit and secure engine acoustic cover.
2. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000) .

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000).
4. Release clip and disconnect coolant hose from coolant pump.
5. Disconnect multiplug from Variable Camshaft Control (VCC) solenoid.
6. Remove 2 bolts securing VCC solenoid seal and remove seal. (Scheme 42)
7. Fit LRT-12-226 to VCC solenoid and remove solenoid. (Scheme 43) CAUTION: DO NOT allow oil to come into contact with the drive belts while removing the solenoid.

Scheme 40

Scheme 41

Scheme 42

Scheme 43

1. Fit LRT-12-226 to Variable Camshaft Control (VCC) solenoid and fit solenoid.
2. Tighten VCC solenoid to 25 Nm (18 ft. lbs) and remove LRT-12-226.
3. Clean VCC solenoid, VCC solenoid seal and mating faces.
4. Lubricate inner mating face of VCC solenoid seal.
5. Fit VCC solenoid seal, fit bolts and tighten.
6. Connect multiplug to VCC solenoid.
7. Connect coolant hose to coolant pump and secure with clip.
8. Fill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000) .
9. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000) .

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
2. Remove air intake hose. See «HOSE -- AIR FLOW METER TO THROTTLE BODY»(ref-172008-S19384904682005022200000).
3. Disconnect multiplug from Variable Camshaft Control (VCC) solenoid. (Scheme 44)
4. Remove 2 bolts securing VCC solenoid seal and remove seal. (Scheme 45)
5. Fit LRT-12-226 to VCC solenoid and remove solenoid. (Scheme 46) CAUTION: DO NOT allow oil to come into contact with the drive belts while removing the solenoid.

Scheme 44

Scheme 45

Scheme 46

1. Fit LRT-12-226 to Variable Camshaft Control (VCC) solenoid and fit solenoid.
2. Tighten VCC solenoid to 25 Nm (18 ft. lbs) and remove LRT-12-226.
3. Clean VCC solenoid, VCC solenoid seal and mating faces.
4. Lubricate inner mating face of VCC solenoid seal.
5. Fit VCC solenoid seal, fit bolts and tighten.
6. Connect multiplug to VCC solenoid.
7. Connect air intake hose. See «HOSE -- AIR FLOW METER TO THROTTLE BODY»(ref-172008-S19384904682005022200000) .
8. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000) .

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000).
4. Remove fan cowl. See «VISCOUS FAN»(ref-167168-S05613503662004101400000).
5. Remove left camshaft cover. See «GASKET - CAMSHAFT COVER - LEFT»(ref-158804-S09318303122005013100000).
6. Remove right camshaft cover. See «GASKET - CAMSHAFT COVER - RIGHT»(ref-158804-S11807155832005013100000).
7. Remove 8 spark plugs.
8. Remove 2 bolts securing engine lifting eye to rear of right cylinder head and remove engine lifting eye. (Scheme 47)
9. Remove 20 nuts securing 4 camshaft oil lines to left and right cylinder heads and remove camshaft oil lines. (Scheme 48)
10. Rotate engine crankshaft pulley until cylinder one camshaft lobes are at TDC firing position. (Scheme 49)
11. The rear of the camshafts may appear twisted and out of alignment when cylinder one is in the TDC firing position. (Scheme 50) NOTE: The twisting and apparent misalignment of the camshafts does not indicate incorrect engine timing.
12. Position LRT-12-227 through timing tool access hole and secure flywheel in TDC position. (Scheme 51)
13. Remove left upper timing gear cover. See «COVER - TIMING GEAR - UPPER - LEFT»(ref-158804-S15316667622005013100000).
14. Remove right upper timing gear cover. See «COVER - TIMING GEAR - UPPER - RIGHT»(ref-158804-S17072079202005013100000).
15. Remove nut securing left CMP sensor ring and remove CMP sensor ring. (Scheme 52) NOTE: Thread is left handed.
16. Remove nut securing right CMP sensor ring and remove CMP sensor ring. (Scheme 53) NOTE: Thread is left handed.
17. Loosen 2 Torx bolts securing left VCC unit and left exhaust camshaft sprocket 1/2 a turn. (Scheme 54) NOTE: Thread is left handed.
18. Loosen 2 Torx bolts securing right VCC unit and right exhaust camshaft sprocket 1/2 a turn. (Scheme 55) NOTE: Thread is left handed.
19. Loosen bolt securing LRT-12-223/2 to LRT-12-223/1.
20. Fit LRT-12-223/2 and LRT-12-223/1 to rear of right camshafts and tighten bolt securing tools. (Scheme 56)
21. Fit LRT-12-223/5, LRT-12-223/6 to right cylinder head and tighten LRT-12-223/6 into spark plug thread. (Scheme 57)
22. Loosen bolt securing LRT-12-223/4 to LRT-12-223/3.
23. Fit LRT-12-223/4 and LRT-12-223/3 to rear of left camshafts and tighten bolt securing tools. (Scheme 58)
24. Fit LRT-12-223/5, LRT-12-223/6 to left cylinder head and tighten LRT-12-223/6 into spark plug thread. (Scheme 59)
25. Compress left exhaust timing chain tensioner, fit LRT-12-220 to chain tensioner and remove 2 Torx bolts securing left VCC unit and left exhaust camshaft sprocket. (Scheme 60) NOTE: Thread is left handed.
26. Remove left exhaust camshaft sprocket, left exhaust camshaft chain and left VCC unit. NOTE: Secure chain to cylinder head to prevent chain falling into lower timing gear cover.

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

1. Position left exhaust camshaft chain to left VCC unit and position left exhaust camshaft sprocket to left exhaust camshaft chain. NOTE: The Variable Camshaft Control (VCC) unit, exhaust camshaft chain and exhaust camshaft sprocket do not have timing marks on them. These parts may be freely fitted to the timing gear chain and camshafts in any position.
2. Secure chain to cylinder head to prevent chain falling into lower timing gear cover.
3. Compress left exhaust timing chain tensioner and remove LRT-12-220.
4. Fit LRT-12-221 to right cylinder head, fit LRT-12-222 to LRT-12-221 and hand tighten. (Scheme 61) NOTE: Only screw in adjustment bolt until slight resistance is present.
5. Fit LRT-12-224 to left VCC unit, connect multimeter between pin on left VCC unit and stud on left oil line. (Scheme 62)
6. Rotate left VCC unit using LRT-12-224 to 40 Nm (30 ft. lbs) and using the multimeter, check continuity is present. NOTE: Rotating the VCC unit using LRT-12-224 will remove the oil cushion and make sure the VCC unit is at the full left stop position. Continuity should be present when the VCC unit reaches this position.
7. Tighten Torx bolts securing left VCC unit and exhaust camshaft sprocket to 15 Nm (11 ft. lbs) and loosen one quarter of a turn. NOTE: Thread is left handed.
8. Fit LRT-12-224 to right VCC unit, connect multimeter between pin on right VCC unit and stud on right oil line. (Scheme 63)
9. Rotate right VCC unit using LRT-12-224 to 40 Nm (30 ft. lbs) and using the multimeter, check continuity is present. NOTE: Rotating the VCC unit using LRT-12-224 will remove the oil cushion and make sure the VCC unit is at the full left stop position. Continuity should be present when the VCC unit reaches this position.
10. Tighten Torx bolts securing right VCC unit and exhaust camshaft sprocket to 15 Nm (11 ft. lbs) and loosen one quarter of a turn. NOTE: Thread is left handed.
11. Adjust chain tension by tightening LRT-12-222 to 0.7 Nm (6.3 INCH lbs).
12. Fit LRT-12-224 to left VCC unit, connect multimeter between pin on left VCC unit and stud on left oil line. (Scheme 62) NOTE: When the chain tension is adjusted the VCC unit will move and require adjusting to the left stop.
13. Rotate left VCC unit using LRT-12-224 to 40 Nm (30 ft. lbs) and using the multimeter, check continuity is present. NOTE: Rotating the VCC unit using LRT-12-224 will remove the oil cushion and make sure the VCC unit is at the full left stop position. Continuity should be present when the VCC unit reaches this position.
14. Tighten left VCC unit Torx bolt to 110 Nm (81 ft. lbs) and left exhaust camshaft sprocket Torx bolt to 125 Nm (92 ft. lbs). NOTE: Thread is left handed.
15. Fit LRT-12-224 to right VCC unit, connect multimeter between pin on right VCC unit and stud on right oil line. (Scheme 63) NOTE: When the chain tension is adjusted the VCC unit will move and require adjusting to the left stop.
16. Rotate right VCC unit using LRT-12-224 to 40 Nm (30 ft. lbs) and using the multimeter, check continuity is present. NOTE: Rotating the VCC unit using LRT-12-224 will remove the oil cushion and make sure the VCC unit is at the full left stop position. Continuity should be present when the VCC unit reaches this position.
17. Tighten right VCC unit Torx bolt to 110 Nm (81 ft. lbs) and right exhaust camshaft sprocket Torx bolt to 125 Nm (92 ft. lbs). NOTE: Thread is left handed.
18. Fit right Camshaft (CMP) sensor ring, fit and hand tighten securing nut. NOTE: Thread is left handed.
19. Position LRT-12-228/1 locating dowel to right CMP sensor ring, fit 2 bolts securing tool to right cylinder head and tighten. (Scheme 64) NOTE: To ensure correct CMP sensor ring adjustment, make sure the tool is aligned flush with the cylinder head and lower timing gear cover before tightening the tool securing bolts.
20. Tighten nut securing CMP sensor ring to 40 Nm (30 ft. lbs) and remove LRT-12-228/1 from right cylinder head. NOTE: Thread is left handed.
21. Fit left CMP sensor ring, fit and hand tighten securing nut. NOTE: Thread is left handed.
22. Position LRT-12-228/2 locating dowel to left CMP sensor ring, fit 2 bolts securing tool to right cylinder head and tighten. (Scheme 65) NOTE: To ensure correct CMP sensor ring adjustment, make sure the tool is aligned flush with the cylinder head and lower timing gear cover before tightening the tool securing bolts.
23. Tighten nut securing CMP sensor ring to 40 Nm (30 ft. lbs) and remove LRT-12-228/2 from left cylinder head. NOTE: Thread is left handed.
24. Remove LRT-12-223/5, LRT-12-223/6, LRT-12-223/2 and LRT-12-223/1 from right cylinder head camshafts.
25. Remove LRT-12-223/6, LRT-12-223/5, LRT-12-223/3 and LRT-12-223/4 from left cylinder head camshafts.
26. Loosen LRT-12-222, remove 2 bolts securing LRT-12-221 to right cylinder head and remove LRT-12-221.
27. Fit right upper timing gear cover. See «COVER - TIMING GEAR - UPPER - RIGHT»(ref-158804-S17072079202005013100000).
28. Fit left upper timing gear cover. See «COVER - TIMING GEAR - UPPER - LEFT»(ref-158804-S15316667622005013100000).
29. Remove LRT-12-227 from timing tool access hole.
30. Fit 4 camshaft oil lines to left and right cylinder heads, fit and tighten 20 securing bolts.
31. Fit engine lifting eye to rear of right cylinder head and fit 2 bolts securing engine lifting eye and tighten.
32. Fit and tighten 8 spark plugs to 31 Nm (23 ft. lbs).
33. Fit right camshaft cover. See «GASKET - CAMSHAFT COVER - RIGHT»(ref-158804-S11807155832005013100000).
34. Fit left camshaft cover. See «GASKET - CAMSHAFT COVER - LEFT»(ref-158804-S09318303122005013100000).
35. Fit fan cowl. See «VISCOUS FAN»(ref-167168-S05613503662004101400000).
36. Fill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000).
37. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000).
4. Remove fan cowl. See «VISCOUS FAN»(ref-167168-S05613503662004101400000).
5. Remove left camshaft cover. See «GASKET - CAMSHAFT COVER - LEFT»(ref-158804-S09318303122005013100000).
6. Remove right camshaft cover. See «GASKET - CAMSHAFT COVER - RIGHT»(ref-158804-S11807155832005013100000).
7. Remove 8 spark plugs.
8. Remove 2 bolts securing engine lifting eye to rear of right cylinder head and remove engine lifting eye. (Scheme 66)
9. Remove 20 nuts securing 4 camshaft oil lines to left and right cylinder heads and remove camshaft oil lines. (Scheme 48)
10. Rotate engine crankshaft pulley until cylinder one camshaft lobes are at TDC firing position. (Scheme 49)
11. The rear of the camshafts may appear twisted and out of alignment when cylinder one is in the TDC firing position. (Scheme 50) NOTE: The twisting and apparent misalignment of the camshafts does not indicate incorrect engine timing.
12. Position LRT-12-227 through timing tool access hole and secure flywheel in TDC position. (Scheme 67)
13. Remove left upper timing gear cover. See «COVER - TIMING GEAR - UPPER - LEFT»(ref-158804-S15316667622005013100000).
14. Remove right upper timing gear cover. See «COVER - TIMING GEAR - UPPER - RIGHT»(ref-158804-S17072079202005013100000).
15. Remove nut securing right CMP sensor ring and remove CMP sensor ring. (Scheme 68) NOTE: Thread is left handed.
16. Remove nut securing left Camshaft (CMP) sensor ring and remove CMP sensor ring. NOTE: Thread is left handed.
17. Loosen 2 Torx bolts securing right Variable Camshaft Control (VCC) unit and right exhaust camshaft sprocket 1/2 a turn. (Scheme 55) NOTE: Thread is left handed.
18. Loosen 2 Torx bolts securing left VCC unit and left exhaust camshaft sprocket 1/2 a turn. (Scheme 54) NOTE: Thread is left handed.
19. Loosen bolt securing LRT-12-223/2 to LRT-12-223/1.
20. Fit LRT-12-223/2 and LRT-12-223/1 to rear of right camshafts and tighten bolt securing tools. (Scheme 56)
21. Fit LRT-12-223/5, LRT-12-223/6 to right cylinder head and tighten LRT-12-223/6 into spark plug thread. (Scheme 57)
22. Loosen bolt securing LRT-12-223/4 to LRT-12-223/3.
23. Fit LRT-12-223/4 and LRT-12-223/3 to rear of left camshafts and tighten bolt securing tools. (Scheme 58)
24. Fit LRT-12-223/5, LRT-12-223/6 to left cylinder head and tighten LRT-12-223/6 into spark plug thread. (Scheme 59)
25. Compress right exhaust timing chain tensioner, fit LRT-12-220 to chain tensioner and remove 2 Torx bolts securing right VCC unit and right exhaust camshaft sprocket. (Scheme 69) NOTE: Thread is left handed.
26. Remove right exhaust camshaft sprocket, right exhaust camshaft chain and right VCC unit. NOTE: Secure chain to cylinder head to prevent chain falling into lower timing gear cover.

Scheme 66

Scheme 67

Scheme 68

Scheme 69

1. Position right exhaust camshaft chain to right VCC unit and position right exhaust camshaft sprocket to right exhaust camshaft chain. NOTE: The Variable Crankshaft Control (VCC) unit, exhaust camshaft chain and exhaust camshaft sprocket do not have timing marks on them. These parts may be freely fitted to the timing gear chain and camshafts in any position.
2. Position right VCC unit to timing gear chain, fit VCC and exhaust camshaft sprocket to camshafts, fit and hand tighten 2 Torx bolts to eliminate play. NOTE: Thread is left handed.
3. Compress right exhaust timing chain tensioner and remove LRT-12-220. (Scheme 61) NOTE: Only screw in adjustment bolt until slight resistance is present.
4. Fit LRT-12-221 to right cylinder head, fit LRT-12-222 to LRT-12-221 and hand tighten.
5. Fit LRT-12-224 to left VCC unit, connect multimeter between pin on left VCC unit and stud on left oil line. (Scheme 62)
6. Rotate left VCC unit using LRT-12-224 to 40 Nm (30 ft. lbs) and using the multimeter, check continuity is present. NOTE: Rotating the VCC unit using LRT-12-224 will remove the oil cushion and make sure the VCC unit is at the full left stop position. Continuity should be present when the VCC unit reaches this position.
7. Tighten Torx bolts securing left VCC unit and exhaust camshaft sprocket to 15 Nm (11 ft. lbs) and loosen one quarter of a turn. NOTE: Thread is left handed.
8. Fit LRT-12-224 to right VCC unit, connect multimeter between pin on right VCC unit and stud on right oil line. (Scheme 63)
9. Rotate right VCC unit using LRT-12-224 to 40 Nm (30 ft. lbs) and using the multimeter, check continuity is present. NOTE: Rotating the VCC unit using LRT-12-224 will remove the oil cushion and make sure the VCC unit is at the full left stop position. Continuity should be present when the VCC unit reaches this position.
10. Tighten Torx bolts securing right VCC unit and exhaust camshaft sprocket to 15 Nm (11 ft. lbs) and loosen one quarter of a turn. NOTE: Thread is left handed.
11. Adjust chain tension by tightening LRT-12-222 to 0.7 Nm (6.3 INCH lbs).
12. Fit LRT-12-224 to left VCC unit, connect multimeter between pin on left VCC unit and stud on left oil line. (Scheme 62) NOTE: When the chain tension is adjusted the VCC unit will move and require adjusting to the left stop.
13. Rotate left VCC unit using LRT-12-224 to 40 Nm (30 ft. lbs) and using the multimeter, check continuity is present. NOTE: Rotating the VCC unit using LRT-12-224 will remove the oil cushion and make sure the VCC unit is at the full left stop position. Continuity should be present when the VCC unit reaches this position.
14. Tighten left VCC unit Torx bolt to 110 Nm (81 ft. lbs) and left exhaust camshaft sprocket Torx bolt to 125 Nm (92 ft. lbs). NOTE: Thread is left handed.
15. Fit LRT-12-224 to right VCC unit, connect multimeter between pin on right VCC unit and stud on right oil line. (Scheme 63) NOTE: When the chain tension is adjusted the VCC unit will move and require adjusting to the left stop.
16. Rotate right VCC unit using LRT-12-224 to 40 Nm (30 ft. lbs) and using the multimeter, check continuity is present. NOTE: Rotating the VCC unit using LRT-12-224 will remove the oil cushion and make sure the VCC unit is at the full left stop position. Continuity should be present when the VCC unit reaches this position.
17. Tighten right VCC unit Torx bolt to 110 Nm (81 ft. lbs) and right exhaust camshaft sprocket Torx bolt to 125 Nm (92 ft. lbs). NOTE: Thread is left handed.
18. Fit right CMP sensor ring, fit and hand tighten securing nut. NOTE: Thread is left handed.
19. Position LRT-12-228/1 locating dowel to right CMP sensor ring, fit 2 bolts securing tool to right cylinder head and tighten. (Scheme 64) NOTE: To ensure correct CMP sensor ring adjustment, make sure the tool is aligned flush with the cylinder head and lower timing gear cover before tightening the tool securing bolts.
20. Tighten nut securing CMP sensor ring to 40 Nm (30 ft. lbs) and remove LRT-12-228/1 from right cylinder head. NOTE: Thread is left handed.
21. Fit left CMP sensor ring, fit and hand tighten securing nut. NOTE: Thread is left handed.
22. Position LRT-12-228/2 locating dowel to left CMP sensor ring, fit 2 bolts securing tool to right cylinder head and tighten. (Scheme 65) NOTE: To ensure correct CMP sensor ring adjustment, make sure the tool is aligned flush with the cylinder head and lower timing gear cover before tightening the tool securing bolts.
23. Tighten nut securing CMP sensor ring to 40 Nm (30 ft. lbs) and remove LRT-12-228/2 from left cylinder head. NOTE: Thread is left handed.
24. Remove LRT-12-223/5, LRT-12-223/6, LRT-12-223/2 and LRT-12-223/1 from right cylinder head camshafts.
25. Remove LRT-12-223/6, LRT-12-223/5, LRT-12-223/3 and LRT-12-223/4 from left cylinder head camshafts.
26. Loosen LRT-12-222, remove 2 bolts securing LRT-12-221 to right cylinder head and remove LRT-12-221.
27. Fit right upper timing gear cover. See «COVER - TIMING GEAR - UPPER - RIGHT»(ref-158804-S17072079202005013100000).
28. Fit left upper timing gear cover. See «COVER - TIMING GEAR - UPPER - LEFT»(ref-158804-S15316667622005013100000).
29. Remove LRT-12-227 from timing tool access hole.
30. Fit 4 camshaft oil lines to left and right cylinder heads, fit and tighten 20 securing bolts.
31. Fit engine lifting eye to rear of right cylinder head and fit 2 bolts securing engine lifting eye and tighten.
32. Fit and tighten 8 spark plugs to 31 Nm (23 ft. lbs).
33. Fit right camshaft cover. See «GASKET - CAMSHAFT COVER - RIGHT»(ref-158804-S11807155832005013100000).
34. Fit left camshaft cover. See «GASKET - CAMSHAFT COVER - LEFT»(ref-158804-S09318303122005013100000).
35. Fit fan cowl. See «VISCOUS FAN»(ref-167168-S05613503662004101400000).
36. Fill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000).
37. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT . If fitting a replacement engine, a new dowel must be fitted, in the correct position, into the crankshaft boss. The procedure for this is detailed at the start of the installation section.

1. Release bonnet support stays, raise and secure bonnet in upright position.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Remove air intake plenum. See «80.15.62 PLENUM -- AIR INTAKE»(ref-208062-S24349779832005120200000).
4. Depressurize fuel system. See «FUEL SYSTEM -- DEPRESSURIZE»(ref-173410-S17809948792005031700000).
5. Recover refrigerant from A/C system. See «82.30.02 REFRIGERANT RECOVERY-RECYCLING AND RECHARGE»(ref-208063-S35423371232005120200000).
6. Remove Mass Air Flow (MAF)/Intake Air Temperature (IAT) sensor. See «SENSOR -- COMBINED MASS AIR FLOW (MAFS) & INTAKE AIR TEMPERATURE (IAT)»(ref-172008-S31989682142005022200000).
7. Raise front of vehicle and support on stands. WARNING: DO NOT work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
8. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000).
9. Remove viscous coupling. See «VISCOUS FAN»(ref-167168-S05613503662004101400000).
10. Release cover, remove nut and disconnect battery positive lead from stud. (Scheme 70)
11. Remove right ignition coil cover. See «COVER -- IGNITION COILS -- LH»(ref-172008-S29656128552005022200000).
12. Remove left ignition coil cover. See «COVER -- IGNITION COILS -- LH»(ref-172008-S29656128552005022200000).
13. Position differential breather pipe clear of engine. (Scheme 71)
14. Remove nut and disconnect earth lead from left camshaft cover. (Scheme 72)
15. Remove nut and disconnect earth lead from right camshaft cover. See «GASKET - CAMSHAFT COVER - RIGHT»(ref-158804-S11807155832005013100000).
16. Disconnect multiplugs from ignition coils. (Scheme 73)
17. Disconnect multiplugs from throttle body, thermostat heater, CMP sensor and ECT sensor. (Scheme 74)
18. Cut 2 cable ties securing engine harness at throttle body and release harness.
19. Disconnect multiplug from right Variable Camshaft Control (VCC) solenoid. (Scheme 75)
20. Release VCC multiplug harness from clip.
21. Disconnect multiplug from left VCC solenoid. (Scheme 76)
22. Disconnect multiplug from alternator. (Scheme 77)
23. Release alternator harness from 4 clips.
24. Disconnect multiplugs from left Camshaft (CMP) sensor and left knock sensor. (Scheme 78)
25. Remove 2 nuts securing left fuel injector harness to fuel rail, release vacuum reservoir and mounting bracket from stud and position aside. (Scheme 79)
26. Release alternator harness from 2 clips on engine cover mounting brackets. (Scheme 80)
27. Disconnect multiplugs from left fuel injectors. (Scheme 81)
28. Release engine harness from clips and move clear of camshaft cover. (Scheme 82)
29. If fitted: Disconnect multiplug from Secondary Air Injection (SAI) control valve. (Scheme 83)
30. Remove 2 nuts securing engine harness to induction manifold and, remove washer. (Scheme 84)
31. If fitted: SAI control valve from securing stud. Position valve aside.
32. Disconnect multiplug from right Knock Sensor (KS). (Scheme 85)
33. Disconnect multiplugs from right fuel injectors. (Scheme 86)
34. Disconnect multiplug from charcoal canister purge control valve. (Scheme 87)
35. Position engine harness to right bulkhead.
36. Disconnect pipe from charcoal canister purge control valve. (Scheme 88) CAUTION: Always fit plugs to open connections to prevent contamination.
37. Remove charcoal canister purge valve pipe. (Scheme 89)
38. Release transmission breather pipes from clips at coolant manifold and position aside.
39. Release clips and disconnect heater hoses from coolant manifold.
40. Undo bolt securing gearbox multiplug bracket to gearbox bell housing and position aside. (Scheme 90)
41. Disconnect multiplug from starter motor lead. (Scheme 91)
42. Position absorbent cloth around fuel feed pipe connection to collect spillage.
43. Disconnect fuel feed hose from fuel rail. (Scheme 92) CAUTION: Always fit plugs to open connections to prevent contamination.
44. Remove absorbent cloth.
45. Release hose clip and disconnect brake servo vacuum hose from one way valve. (Scheme 93) CAUTION: Always fit plugs to open connections to prevent contamination.
46. Disconnect vacuum pipe from induction manifold. (Scheme 94)
47. Disconnect multiplug from radiator bottom hose. (Scheme 95)
48. Remove bolt securing radiator bottom hose to bracket, release clips and remove radiator bottom hose. (Scheme 96)
49. Release clip and disconnect radiator top hose from radiator.
50. Release clips and disconnect radiator top hose from coolant pump and alternator. (Scheme 97)
51. Release clip securing radiator top hose to coolant "T" junction and remove radiator top hose. (Scheme 98)
52. Release clip and disconnect coolant hose from "T" junction. (Scheme 99)
53. Disconnect multiplug from A/C compressor. (Scheme 100)
54. Remove Allen bolt securing A/C pipe to A/C compressor and disconnect A/C pipe. Discard "O" ring. (Scheme 101) CAUTION: Immediately cap all A/C pipes to prevent ingress of dirt and moisture into the system.
55. Remove Allen bolt securing A/C pipe to condenser and disconnect A/C pipe. Discard "O" ring. (Scheme 102) CAUTION: Immediately cap all A/C pipes to prevent ingress of dirt and moisture into the system.
56. If fitted: Disconnect 2 hoses from the SAI control valve. (Scheme 103) CAUTION: Always fit plugs to open connections to prevent contamination.
57. Disconnect multiplug from oil pressure switch. (Scheme 104)
58. Remove 2 nuts securing oil filter housing and release oil filter housing from mounting bracket. (Scheme 105)
59. Position oil filter housing and hoses aside and secure to engine with cable ties.
60. Position container to collect Power Assisted Steering (PAS) fluid spillage.
61. Release clip and disconnect fluid inlet hose from PAS pump. Undo union nut and disconnect PAS outlet hose from PAS pump. Discard "O" ring. (Scheme 106) CAUTION: Always fit plugs to open connections to prevent contamination.
62. Remove container from below PAS pump.
63. Remove 4 bolts securing differential air flow panel to sub-frame and remove panel.
64. Remove 4 nuts securing front pipe flanges to exhaust manifolds and discard nuts. (Scheme 107)
65. Release exhaust front pipes from exhaust manifolds.
66. Remove front road wheels.
67. Remove right front drive shaft. See «FRONT DRIVE SHAFT»(ref-165633-S31254146512004061900000).
68. Remove differential breather hose. Remove 4 differential securing bolts and release differential from engine sump. (Scheme 108) NOTE: Securing bolt above pinion remains captive to differential.
69. Disconnect engine earth lead. (Scheme 109)
70. Remove Crankshaft (CKP) sensor. See «SENSOR -- CRANKSHAFT POSITION (CKP)»(ref-172008-S25395326432005022200000).
71. Remove bolt securing transmission cooler pipes and release cooler pipes from bracket. (Scheme 110)
72. Remove grommet from bottom of bell housing to gain access to torque converter. (Scheme 111)
73. Remove grommet from bell housing to gain access to torque converter securing bolts. (Scheme 112)
74. Rotate crankshaft for access and remove 4 bolts securing torque converter to drive plate.
75. Position torque converter clear of drive plate.
76. Remove 2 bolts securing starter motor and release starter motor. (Scheme 113) NOTE: Starter motor remains captive to engine.
77. Support gearbox.
78. Remove 8 Torx bolts securing gearbox to engine. (Scheme 114)
79. Fit LRT-12-216 to engine lifting eyes. (Scheme 115)
80. Remove nut securing right engine mounting to engine mounting bracket. (Scheme 116)
81. Remove nut securing left engine mounting to engine mounting bracket. (Scheme 117)
82. Connect chain to lifting bracket and take weight of engine.
83. Raise engine clear of mountings.
84. Remove 2 Torx bolts from top of bell housing. (Scheme 118)
85. Release engine from dowels, carefully raise and guide engine clear of vehicle. CAUTION: To prevent damage to the radiator, DO NOT allow engine to contact the radiator.
86. Discard differential "O" ring. (Scheme 119)

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Procedure for fitting crankshaft dowel to a replacement engine, steps 1 - 10 only

1. Remove right camshaft cover gasket. See «GASKET - CAMSHAFT COVER - RIGHT»(ref-158804-S11807155832005013100000).
2. Rotate engine crankshaft pulley clockwise until letter and cylinder number stampings, located on rear of camshafts, are in upright position. (Scheme 50)
3. If necessary, continue to rotate crankshaft slightly to align TDC timing marks. (Scheme 24)
4. Temporarily fit drive plate ensuring that hollow bush in drive plate securing bolt hole, is aligned with bolt hole "A" in crankshaft boss. (Scheme 120)
5. Fit and lightly tighten 8 drive plate securing bolts. Do not fit a bolt in drive plate hole with hollow bush.
6. Fit timing pin LRT-12-227, ensuring that it is inserted in hole in drive plate. If necessary, rotate crankshaft slightly to enable timing pin to be inserted. (Scheme 121)
7. Check that TDC timing marks are still aligned and that hole with hollow bush is still in position "A".
8. Remove timing pin LRT-12-227, and remove drive plate.
9. Fit crankshaft dowel into securing bolt hole at position "A".
10. Fit right camshaft cover gasket.
11. All engines: Clean torque converter and drive plate mating faces.
12. Clean gearbox to engine mating faces, dowels and dowel holes.
13. Clean differential and engine sump mating faces.
14. Fit new "O" ring to differential and lubricate with clean oil.
15. With assistance, carefully fit engine to gearbox. Ensure engagement of torque converter spigot and location onto dowels. NOTE: When fitting engine, guide the engine past differential mating face.
16. Ensure torque converter is fully engaged with gearbox.
17. Fit 8 Torx bolts securing automatic gearbox to engine, tighten to 45 Nm (33 ft. lbs)
18. Align starter motor to engine and tighten securing bolts to 45 Nm (33 ft. lbs).
19. Fit 2 top bell housing Torx bolts and tighten to 25 Nm (18 ft. lbs).
20. Remove support from gearbox.
21. Lower engine onto mountings.
22. Disconnect lifting chains.
23. Fit 2 nuts securing engine mountings to engine mounting brackets and tighten to 100 Nm (74 ft. lbs).
24. Remove engine lifting bracket.
25. Fit bolts securing drive plate to torque converter and tighten to 45 Nm (33 ft. lbs)
26. Fit grommets to bell housing.
27. Clean mating faces of exhaust front pipes and exhaust manifolds.
28. Align exhaust front pipes to exhaust manifolds.
29. Fit 4 new nuts securing exhaust front pipes to exhaust manifolds and tighten to 45 Nm (33 ft. lbs).
30. Carefully align differential to sump. Fit bolts, but DO NOT tighten at this stage.
31. Align differential to transfer box front output flange. See «FRONT DIFFERENTIAL ASSEMBLY ALIGNMENT»(ref-165010-S42383102462004052300000).
32. Tighten differential to engine sump securing bolts to 110 Nm (81 ft. lbs).
33. Connect breather hose to differential.
34. Connect engine earth lead to engine and tighten securing nut and bolt.
35. Fit differential air flow panel to sub-frame and tighten bolts to 45 Nm (33 ft. lbs).
36. Fit right front drive shaft. See «FRONT DRIVE SHAFT»(ref-165633-S31254146512004061900000).
37. Fit new "O" ring to Power Assisted Steering (PAS) hose union, connect hose to pump and tighten nut to 25 Nm (18 ft. lbs).
38. Connect supply hose to PAS pump and secure using new clip.
39. Fit oil filter housing to bracket and tighten securing nuts.
40. Connect multiplug to oil pressure switch.
41. If fitted: Connect Secondary Air Injection (SAI) control valve hoses.
42. Fit new "O" rings to A/C pipes and lubricate with clean refrigerant oil.
43. Align A/C pipes to condenser and compressor. Fit Allen bolts securing A/C pipes to condenser and compressor and tighten to 25 Nm (18 ft. lbs).
44. Connect multiplug to A/C compressor.
45. Connect coolant hose to "T" junction and secure clip.
46. Fit radiator top hose and secure with clips.
47. Fit radiator bottom hose, secure with clips and tighten "P" clip securing bolt.
48. Connect multiplug to radiator bottom hose.
49. Connect vacuum pipe to inlet manifold.
50. Connect brake vacuum servo hose to one way valve and secure using new clip.
51. Clean fuel hose connections.
52. Connect fuel feed hose to fuel rail.
53. Connect multiplug to starter motor lead.
54. Position gearbox multiplug and bracket to bell housing and tighten securing bolt.
55. Connect heater hoses to coolant manifold and secure with clips.
56. Fit transmission breather pipes into clips.
57. Fit charcoal canister purge valve pipe.
58. Position engine harness to engine.
59. Connect multiplug to charcoal canister purge control valve.
60. Fit washer to fuel injector harness securing stud.
61. Position and secure engine harness to brackets with clips.
62. Connect multiplugs to right fuel injectors.
63. Connect multiplugs to left fuel injectors.
64. Connect alternator harness to 2 clips on engine cover mounting brackets.
65. Fit fuel hose and mounting bracket to left fuel injector harness securing stud.
66. Fit vacuum reservoir and mounting bracket to left fuel injector harness securing stud.
67. Fit 2 nuts securing fuel injector harness to induction manifold and tighten nuts.
68. Connect multiplugs to knock sensors.
69. Connect multiplugs to Camshaft (CMP) sensors.
70. Secure alternator harness into 4 securing clips.
71. Connect multiplug to alternator.
72. If fitted: Connect multiplug to Secondary Air Injection (SAI) control valve.
73. Connect multiplugs to Variable Camshaft Control solenoids.
74. Connect multiplugs to throttle body, thermostat heater, Electronic Coolant Temperature (ECT) sensor, and right CMP sensor.
75. Align engine harness to throttle body and secure using new cable ties.
76. Connect multiplugs to ignition coils.
77. Connect engine harness earth leads to left and right camshaft covers and tighten nuts.
78. Position differential breather pipe to left engine camshaft cover.
79. Fit left ignition coil cover. See «COVER -- IGNITION COILS -- LH»(ref-172008-S29656128552005022200000).
80. Fit right ignition coil cover. See «COVER -- IGNITION COILS -- RH»(ref-172008-S10788591692005022200000).
81. Fit viscous coupling. See «VISCOUS FAN»(ref-167168-S05613503662004101400000).
82. Fit front road wheels and tighten nuts to 140 Nm (103 ft. lbs).
83. Remove stands and lower front end of vehicle.
84. Fit MAF/IAT sensor. See «SENSOR -- COMBINED MASS AIR FLOW (MAFS) & INTAKE AIR TEMPERATURE (IAT)»(ref-172008-S31989682142005022200000).
85. Recharge A/C system. See «82.30.02 REFRIGERANT RECOVERY-RECYCLING AND RECHARGE»(ref-208063-S35423371232005120200000).
86. Fit air intake plenum. See «80.15.62 PLENUM -- AIR INTAKE»(ref-208062-S24349779832005120200000).
87. Fit battery positive lead to stud, tighten nut to 18 Nm (13 ft. lbs) and close cover.
88. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
89. Fill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000).
90. Bleed PAS system. See «POWER ASSISTED STEERING (PAS) SYSTEM - BLEED»(ref-171799-S41948435342005021500000).
91. Connect support stays and close bonnet.

Scheme 120

Scheme 121

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Raise vehicle on lift.
4. Remove exhaust system. See «EXHAUST SYSTEM & MOUNTINGS»(ref-173241-S14190711022005031100000).
5. Remove 8 nuts securing center heat shield and remove shield. (Scheme 122)
6. Remove 5 nuts, release and remove right heat shield. (Scheme 123)
7. Remove 5 nuts, release and remove left heat shield. (Scheme 124)
8. Support gearbox on a jack.
9. Remove nut and bolt securing mounting to cross member.
10. Remove 6 bolts securing cross member and remove cross member. (Scheme 125)
11. Remove snubbers from mounting. (Scheme 126)
12. Lubricate center screw LRT-41-018/4 with Molybdenum Disulphide grease and assemble tool as shown to remove mounting from transfer gearbox. (Scheme 127) CAUTION: Ensure tool alignment indicator is at the 6 o'clock position. The tool alignment indicator is a machined flat, on LRT-41-018/1 and LRT-41-018/2.

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

1. Clean mounting and mating faces.
2. Lubricate new mounting and bore in transfer gearbox casing to aid assembly.
3. Position new mounting to rear face of transfer gearbox, and start entry. Mounting to be parallel, with timing marks aligned. (Scheme 128) NOTE: Transfer timing mark to side of mounting to assist with alignment.
4. Lubricate center screw LRT-41-018/4 with Molybdenum Disulphide grease and assemble tool as shown to fit mounting to transfer gearbox. Start with the center screw at full length and when the mounting is approximately 75 percent fitted, reduce the length of the center screw by screwing it fully into the base plate LRT-41-018/1. This will ensure the center screw LRT-41-018/4, does not foul on the gearbox fluid pan. CAUTION: Ensure tool alignment indicator is at the 6 o'clock position.
5. Ensure the mounting is fitted parallel. If necessary, use a mallet and tap the base plate to maintain a parallel fit.
6. Fit snubbers.
7. Fit cross member to mounting, fit nut and bolt but DO NOT tighten at this stage.
8. Raise gearbox on jack.
9. Align cross member, fit bolts and tighten to 68 Nm (50 ft. lbs).
10. Remove support from gearbox.
11. Tighten nut and bolt securing mounting to cross member to 100 Nm (74 ft. lbs).
12. Fit left heat shield and secure with nuts.
13. Fit right heat shield and secure with nuts.
14. Fit center heat shield and secure with nuts.
15. Fit exhaust system. See «EXHAUST SYSTEM & MOUNTINGS»(ref-173241-S14190711022005031100000).
16. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).

Scheme 128

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
2. Raise front of vehicle and support on stands.
3. Remove air intake plenum. See «80.15.62 PLENUM -- AIR INTAKE»(ref-208062-S24349779832005120200000).
4. Remove air intake hose. See «HOSE -- AIR FLOW METER TO THROTTLE BODY»(ref-172008-S19384904682005022200000).
5. Remove undertray. See «76.11.81 UNDERTRAY -- FRONT»(ref-208059-S32217400672005120200000).
6. Remove 4 bolts securing differential air flow panel and remove panel.
7. Remove screw securing fan cowl to radiator. (Scheme 129)
8. Release auxiliary cooling fan multiplug from fan cowl. (Scheme 130)
9. Remove scrivets securing fan cowl. (Scheme 131)
10. Release fan cowl from radiator. (Scheme 132)
11. Fit LRT-12-216 to engine lifting eyes. (Scheme 115)
12. Remove nut securing right engine mounting to engine mounting bracket. (Scheme 116)
13. Remove nut securing left engine mounting to engine mounting bracket. (Scheme 117)
14. Remove front road wheels.
15. Remove nut and disconnect link from left front suspension height sensor. (Scheme 133)
16. Remove nuts securing right and left track rod end ball joints to steering arms. Discard nuts. (Scheme 134)
17. Using LRT-57-036 release track rod ends from steering arms.
18. Disconnect multiplug from Power Assisted Steering (PAS) rack pinion sensor. (Scheme 135)
19. Note fitted position of intermediate steering column. Remove Torx bolt from intermediate steering column clamp and disconnect column from PAS rack. (Scheme 136)
20. Remove 2 Torx bolts and 2 nuts securing PAS rack, discard nuts and bolts. (Scheme 137)
21. Release PAS rack from front sub-frame and position rack forward for access.
22. Connect chain to engine lifting bracket and raise engine sufficiently only to clear mounting. CAUTION: To prevent damage to the radiator, guide the fan cowl clear of the radiator as it is raised with the engine.
23. Remove 2 bolts securing left engine mounting to sub-frame and remove engine mounting, discard bolts. (Scheme 138) NOTE: The left engine mounting is removed from under the left front wheel arch through the opening of the front sub-frame.

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

Scheme 138

1. Clean engine mountings and mating faces.
2. Fit left engine mounting to sub-frame and tighten new bolts to 56 Nm (41 ft. lbs).
3. Lower engine onto engine mountings. NOTE: Guide the fan cowl into position as the engine is lowered.
4. Position PAS rack into front sub-frame and using new Torx bolts and nuts tighten to 100 Nm (74 ft. lbs), then tighten a further 90°.
5. Connect intermediate steering column to PAS rack and tighten securing clamp Torx bolt to 24 Nm (18 ft. lbs). (Scheme 139) NOTE: Make sure that intermediate steering column is correctly aligned to PAS rack.
6. Connect multiplug to PAS rack pinion sensor.
7. Connect track rod ends to steering arms, using new nuts tighten to 55 Nm (41 ft. lbs).
8. Connect link to suspension height sensor and tighten nut.
9. Fit front road wheels and tighten nuts to 140 Nm (103 ft. lbs).
10. Fit 2 nuts securing engine mountings to engine mounting brackets and tighten to 100 Nm (74 ft. lbs).
11. Remove engine lifting chains.
12. Remove engine lifting bracket.
13. Fit fan cowl to radiator and fit securing scrivets.
14. Fit auxiliary cooling fan multiplug to fan cowl.
15. Fit screw securing fan cowl to radiator.
16. Fit undertray. See «76.11.81 UNDERTRAY -- FRONT»(ref-208059-S32217400672005120200000).
17. Fit differential air flow panel and tighten bolts to 45 Nm (33 ft. lbs).
18. Remove stands and lower front end of vehicle.
19. Connect air intake hose. See «HOSE -- AIR FLOW METER TO THROTTLE BODY»(ref-172008-S19384904682005022200000).
20. Fit air intake plenum. See «80.15.62 PLENUM -- AIR INTAKE»(ref-208062-S24349779832005120200000).
21. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).

Scheme 139

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

Scheme 140

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Remove air intake plenum. See «80.15.62 PLENUM -- AIR INTAKE»(ref-208062-S24349779832005120200000).
4. Remove air intake hose. See «HOSE -- AIR FLOW METER TO THROTTLE BODY»(ref-172008-S19384904682005022200000).
5. Remove undertray. See «76.11.81 UNDERTRAY -- FRONT»(ref-208059-S32217400672005120200000).
6. Remove screw securing fan cowl to radiator. (Scheme 129)
7. Release auxiliary cooling fan multiplug from fan cowl. (Scheme 130)
8. Remove scrivets securing fan cowl. (Scheme 131)
9. Release fan cowl from radiator. (Scheme 132)
10. Fit LRT-12-216 to engine lifting eyes. (Scheme 133)
11. Remove nut securing right engine mounting to engine mounting bracket. (Scheme 116)
12. Remove nut securing left engine mounting to engine mounting bracket. (Scheme 117)
13. Connect chain to engine lifting bracket and raise engine sufficiently only to clear mounting. CAUTION: To prevent damage to the radiator, guide the fan cowl clear of the radiator as it is raised with the engine.
14. Remove 2 bolts securing right engine mounting to sub-frame, discard bolts.
15. Remove right engine mounting. NOTE: The right engine mounting is removed from underneath the vehicle between the gearbox bell housing and the sub-frame.

1. Clean engine mountings and mating faces.
2. Fit right engine mounting to sub-frame and tighten new bolts to 56 Nm (41 ft. lbs).
3. Lower engine onto engine mountings. NOTE: Guide the fan cowl into position as the engine is lowered.
4. Remove engine lifting chains.
5. Fit 2 nuts securing engine mountings to engine mounting brackets and tighten to 100 Nm (74 ft. lbs).
6. Remove engine lifting bracket.
7. Fit fan cowl to radiator and fit securing scrivets.
8. Fit auxiliary cooling fan multiplug to fan cowl.
9. Fit screw securing fan cowl to radiator.
10. Fit undertray. See «76.11.81 UNDERTRAY -- FRONT»(ref-208059-S32217400672005120200000) .
11. Connect air intake hose. See «HOSE -- AIR FLOW METER TO THROTTLE BODY»(ref-172008-S19384904682005022200000) .
12. Fit air intake plenum. See «80.15.62 PLENUM -- AIR INTAKE»(ref-208062-S24349779832005120200000) .
13. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000) .

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT . New drive plates do not have the hollow bush fitted. It is supplied with a new drive plate separately.

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Remove gearbox and transfer gearbox assembly. See «TRANSFER BOX»(ref-171054-S22604711352005012600000).
4. Position LRT-12-219 to lock flywheel. (Scheme 141)
5. Reference mark the torque converter drive plate and crankshaft boss to aid fitment. One of the drive plate fixing holes has a hollow bush fitted.
6. Remove 9 bolts securing torque converter drive plate to crankshaft, discard the bolts. Note the fitted position of the hollow bush.
7. Remove torque converter drive plate and LRT-12-219.

Scheme 141

Scheme 142

1. If drive plate is to be replaced, ensure that the hollow bush, supplied with the replacement drive plate, is fitted into the same hole as on the original drive plate.
2. Clean crankshaft bolt holes and torque converter drive plate dowel.
3. Clean torque converter drive plate and mating face of crankshaft.
4. Align reference marks, position torque converter drive plate to crankshaft and LRT-12-219 to lock flywheel. Ensure that the bushed hole in the drive plate is located onto the dowel.
5. Fit new bolts securing torque converter drive plate to crankshaft and tighten progressively to 120 Nm (89 ft. lbs).
6. Remove LRT-12-219 from flywheel.
7. Refit gearbox and transfer gearbox assembly. See «TRANSFER BOX»(ref-171054-S22604711352005012600000) .
8. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000) .

1. Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
2. Position absorbent cloth beneath oil filter housing to collect spillage.
3. Remove oil filter cap and filter element from oil filter housing. Remove oil filter element from oil filter cap. Discard filter element and 2 "O" rings. (Scheme 143)

Scheme 143

1. Clean oil filter cap and housing.
2. Fit 2 new oil filter "O" rings and lubricate with clean engine oil.
3. Fit new oil filter element into oil filter cap.
4. Fit oil filter cap and tighten to 25 Nm (18 ft. lbs).
5. Remove absorbent cloth.
6. Clean oil filter cap and housing.
7. Remove engine oil dipstick.
8. Remove engine oil filler cap and fill engine to correct level.
9. Clean engine oil filler cap and mating face.
10. Fit engine oil filler cap.
11. Fit engine oil dipstick.
12. Start engine and run at idle speed until oil pressure warning light extinguishes.
13. Visually check oil filter cap for signs of leakage.
14. Stop engine, wait a few minutes, then check oil level. Top up if necessary.

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Remove dipstick.
4. Remove 2 nuts securing dipstick tube bracket to camshaft cover. (Scheme 144)
5. Remove nut and clamp securing dipstick tube to oil sump.
6. Remove dipstick tube, washer and "O" ring, discard "O" ring. (Scheme 145)

Scheme 144

Scheme 145

1. Clean dipstick tube and mating faces in engine oil sump.
2. Fit new "O" ring to oil sump and position dipstick tube and washer to oil sump.
3. Fit clamp securing dipstick tube to oil sump and tighten nut.
4. Fit and tighten 2 nuts securing dipstick tube bracket to camshaft cover.
5. Fit dipstick.
6. Check engine oil level, top-up if necessary.
7. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000) .

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Remove lower oil sump. See «GASKET - LOWER OIL SUMP»(ref-158804-S25051572372005013100000).
4. Remove 2 bolts securing oil pick-up strainer to oil pump, remove strainer and discard "O" ring. (Scheme 146)

Scheme 146

1. Clean oil pick up strainer and mating faces.
2. Fit new "O" ring to oil pump groove location, position oil pick-up strainer to oil pump.
3. Fit and tighten 2 bolts securing oil pick-up strainer to oil pump.
4. Fit lower oil sump. See «GASKET - LOWER OIL SUMP»(ref-158804-S25051572372005013100000) .
5. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000) .

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Remove engine upper oil sump. See «GASKET - OIL SUMP»(ref-158804-S18440914242005013100000).
4. Remove nut securing sprocket to oil pump and remove sprocket. (Scheme 147)
5. Remove 2 nuts and 1 bolt securing oil pump to engine and remove oil pump. (Scheme 148)
6. Discard "O" rings from oil pump and oil pipe.

Scheme 147

Scheme 148

1. Clean oil pipes to oil pump mating faces, fit new "O" ring seals and lubricate with clean engine oil.
2. Position oil pump to 2 oil pipes and engine, fit and tighten 2 nuts securing oil pump to engine.
3. Position sprocket to oil pump chain and fit sprocket to oil pump.
4. Fit and tighten nut securing sprocket to oil pump.
5. Adjust Allen bolt spacer to adjust oil pump chain deflection to between 8 mm (0.314 in) and 12 mm (0.470 in). (Scheme 149) NOTE: The oil pump chain is adjusted by turning the Allen bolt spacer which is accessed through the oil pump securing bolt hole.
6. Fit and tighten bolt securing oil pump to engine.
7. Fit engine upper oil sump. See «GASKET - OIL SUMP»(ref-158804-S18440914242005013100000).
8. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).

Scheme 149

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Drain engine oil. See «FILTER - ENGINE OIL»(ref-158804-S13136612622005013100000).
4. Remove 21 bolts securing lower oil sump to upper oil sump. Remove lower oil sump and discard gasket. (Scheme 150)

Scheme 150

1. Clean lower oil sump mating faces.
2. Fit new gasket to lower oil sump mating face.
3. Fit lower oil sump.
4. Fit 21 bolts securing lower oil sump and tighten to 10 Nm (7 ft. lbs).
5. Fill engine with oil. See «FILTER - ENGINE OIL»(ref-158804-S13136612622005013100000) .
6. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000) .

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Remove dipstick tube. See «TUBE - DIPSTICK»(ref-158804-S20368223852005013100000).
4. Remove Power Assisted Steering (PAS) pump. See «PUMP - POWER STEERING»(ref-171799-S24439289942005021500000).
5. Remove differential. See «FRONT DIFFERENTIAL ASSEMBLY»(ref-165010-S14111401982004061900000).
6. Remove oil pick-up strainer. See «STRAINER - OIL PICK UP»(ref-158804-S01434996222005013100000).
7. Remove banjo bolt securing engine oil return pipe to oil sump and discard 2 sealing washers. (Scheme 151)
8. Remove banjo bolt securing engine oil filter return pipe to oil sump and discard 2 sealing washers. (Scheme 152)
9. Remove 4 Torx bolts securing oil sump to bell housing. (Scheme 153)
10. Remove 31 bolts securing oil sump to engine cylinder block, note position of bolts as lengths vary. (Scheme 154) A = M8 x 60 mm B = M6 x 80 mm C = M6 x 40 mm All remaining bolts are M6 x 20 mm
11. Remove oil sump and discard gasket.

Scheme 151

Scheme 152

Scheme 153

Scheme 154

1. Clean oil sump and gasket mating faces.
2. Fit new gasket to sump, position sump to cylinder block, fit bolts but DO NOT tighten at this stage.
3. Tighten 31 bolts securing upper oil sump to cylinder block, M6 x 8.8 mm to 10 Nm (7 ft. lbs), M6 x 10.9 mm to 12 Nm (9 ft. lbs) and M8 x 8.8 mm to 22 Nm (16 ft. lbs). NOTE: Note position of 6 mm bolts as they are two different lengths.
4. Fit 4 Torx bolts securing oil sump to bell housing and tighten to 53 Nm (39 ft. lbs)
5. Fit 2 new sealing washers, fit banjo bolt securing engine oil filter return pipe to oil sump and tighten to 30 Nm (22 ft. lbs).
6. Fit differential. See «FRONT DIFFERENTIAL ASSEMBLY»(ref-165010-S14111401982004061900000) .
7. Fit oil pick-up strainer. See «STRAINER - OIL PICK UP»(ref-158804-S01434996222005013100000) .
8. Fit Power Assisted Steering (PAS) pump. See «PUMP - POWER STEERING»(ref-171799-S24439289942005021500000) .
9. Fit dipstick tube. See «TUBE - DIPSTICK»(ref-158804-S20368223852005013100000) .
10. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000) .

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Remove engine oil sump. See «GASKET - OIL SUMP»(ref-158804-S18440914242005013100000).
4. Remove 6 bolts securing baffle plate and remove plate. (Scheme 155)

Scheme 155

1. Fit baffle plate and tighten bolts to 10 Nm (7 ft. lbs).
2. Fit engine oil sump. See «GASKET - OIL SUMP»(ref-158804-S18440914242005013100000) .
3. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000) .

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
2. Disconnect multiplug from oil pressure switch. (Scheme 156)
3. Position absorbent cloth beneath oil filter housing to collect spillage.
4. Remove oil pressure switch from oil filter housing and discard sealing washer. (Scheme 157)

Scheme 156

Scheme 157

1. Clean oil pressure switch and oil filter housing mating faces.
2. Fit new sealing washer to oil pressure switch.
3. Fit oil pressure switch and tighten to 27 Nm (20 ft. lbs).
4. Connect multiplug to oil pressure switch.
5. Remove absorbent cloth.
6. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000) .
7. Connect exhaust extractor to tail pipes.
8. Start engine and run at idle speed until oil pressure warning light extinguishes.
9. Check for leaks from oil pressure switch.
10. Stop engine, wait a few minutes, then check oil level. Top up if necessary.
11. Disconnect exhaust extractor from tail pipes.

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000) .
3. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000) .
4. Remove left Variable Camshaft Control (VCC) unit. See «VARIABLE CAMSHAFT UNIT - VARIABLE CAMSHAFT CONTROL (VCC) - LEFT»(ref-158804-S04958445472005013100000) .
5. Remove lower timing gear cover. See «COVER - TIMING GEAR - LOWER»(ref-158804-S04166101802005013100000) .
6. Remove timing chain.

1. Clean timing chain guides and sprockets.
2. Check timing chain guides and sprockets for excessive wear.
3. Lubricate timing chain with clean engine oil.
4. Fit timing chain to crankshaft sprocket and right VCC unit. NOTE: The timing chain may be fitted in any position to the crankshaft sprocket and right Variable Camshaft Control (VCC) unit sprocket.
5. Secure timing chain to left cylinder head until left VCC unit is fitted.
6. Fit lower timing gear cover. See «COVER - TIMING GEAR - LOWER»(ref-158804-S04166101802005013100000) .
7. Fit left VCC unit. See «VARIABLE CAMSHAFT UNIT - VARIABLE CAMSHAFT CONTROL (VCC) - LEFT»(ref-158804-S04958445472005013100000) .
8. Fill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000) .
9. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000) .

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000).
4. Remove fan cowl. See «VISCOUS FAN»(ref-167168-S05613503662004101400000).
5. Release engine harness from bracket on right upper timing gear cover. (Scheme 158)
6. Remove 2 bolts securing engine harness bracket to right timing gear cover and remove bracket. (Scheme 159)
7. Cut 3 cable ties to release CMP sensor harness. (Scheme 160)
8. Disconnect multiplug from CMP sensor. (Scheme 161)
9. Disconnect multiplug from VCC solenoid. (Scheme 162)
10. Remove right camshaft cover. See «GASKET - CAMSHAFT COVER - RIGHT»(ref-158804-S11807155832005013100000).
11. Release clip and disconnect coolant hose from coolant pump. (Scheme 163)
12. Release clip, disconnect radiator bottom hose from thermostat housing and remove bolt securing "P" clip. (Scheme 164)
13. If fitted: Remove bolt securing Secondary Air Injection (SAI) pipe to left cylinder head. (Scheme 165)
14. If fitted: Remove bolt securing SAI pipe to right cylinder head. (Scheme 166)
15. If fitted: Remove Allen bolt securing SAI pipe clip to coolant pump. (Scheme 167)
16. If fitted: Release SAI pipe from cylinder heads and position aside. Discard "O" rings.
17. Remove 2 bolts securing VCC solenoid seal and remove seal. (Scheme 168)
18. Remove chain tensioner from timing gear cover and discard sealing washer. Separate oil tensioner body and allow oil to drain. (Scheme 169)
19. Remove 6 bolts securing timing gear cover to cylinder head and remove timing gear cover. (Scheme 170)
20. Discard timing gear cover gasket.
21. Discard timing chain tensioner "O" ring. (Scheme 171) NOTE: DO NOT carry out further dismantling if component is removed for access only.
22. Remove bolt securing CMP sensor and remove sensor.
23. Discard "O" ring.

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

Scheme 170

Scheme 171

1. Clean Camshaft (CMP) sensor and mating face.
2. Fit new "O" ring to CMP sensor.
3. Fit CMP sensor, fit bolt and tighten to 10 Nm (7 ft. lbs).
4. Clean timing gear cover and mating face, clean dowels and dowel holes.
5. Fit new timing gear cover gasket.
6. Fit new chain tensioner "O" ring and apply sealant, Part No. STC 50550 to areas illustrated. (Scheme 172)
7. Fit timing cover, fit and hand tighten 6 bolts.
8. Fit LRT-12-225/1 to right camshaft cover. (Scheme 173)
9. Fit camshaft cover and tool, fit 4 bolts and tighten to 10 Nm (7 ft. lbs). (Scheme 174)
10. Tighten bolts securing timing gear cover to 15 Nm (11 ft. lbs).
11. Remove 4 bolts securing camshaft cover, remove camshaft cover and LRT-12-225/1.
12. Fit new sealing washer, fit timing chain tensioner and tighten plug securing chain tensioner to 40 Nm (30 ft. lbs).
13. Clean Variable Camshaft Control (VCC) solenoid, seal and mating faces.
14. Lubricate inner mating face of VCC solenoid seal.
15. Fit VCC solenoid seal, fit bolts and tighten.
16. If fitted: Fit 2 new "O" rings to Secondary Air Injection (SAI) pipe and position SAI pipe to engine. Fit and tighten 3 bolts securing SAI pipe to engine.
17. Connect 2 coolant hoses to coolant pump and secure with clips.
18. Fit right camshaft cover. See «GASKET - CAMSHAFT COVER - RIGHT»(ref-158804-S11807155832005013100000).
19. Connect multiplug to VCC solenoid.
20. Connect multiplug to Camshaft (CMP) sensor.
21. Secure CMP sensor harness with 3 cable ties.
22. Fit engine harness bracket to engine harness, fit and tighten 2 bolts.
23. Fit fan cowl. See «VISCOUS FAN»(ref-167168-S05613503662004101400000).
24. Fill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000).
25. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).

Scheme 172

Scheme 173

Scheme 174

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Drain cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000).
4. Remove fan cowl. See «VISCOUS FAN»(ref-167168-S05613503662004101400000).
5. Remove charcoal canister purge solenoid valve. See «SOLENOID -- CANISTER PURGE»(ref-172008-S27057040852005022300000).
6. Release Camshaft (CMP) sensor harness from clip and release clip from timing gear cover.
7. Disconnect multiplug from CMP sensor. (Scheme 175)
8. Release fuel vapor pipe from bracket on timing gear cover.
9. Disconnect multiplug from alternator. (Scheme 176)
10. Release alternator harness from 3 clips.
11. Remove left camshaft cover. See «GASKET - CAMSHAFT COVER - LEFT»(ref-158804-S09318303122005013100000).
12. Remove left Variable Camshaft Control (VCC) solenoid valve. See «CONTROL SOLENOID - VARIABLE CAMSHAFT CONTROL (VCC) - LEFT»(ref-158804-S25524858582005013100000).
13. Release clip and disconnect coolant hose from alternator.
14. Release clip, disconnect radiator bottom hose from thermostat housing and remove bolt securing "P" clip. (Scheme 164)
15. If fitted: Remove bolt securing Secondary Air Injection (SAI) pipe to left cylinder head. (Scheme 165)
16. If fitted: Remove bolt securing SAI pipe to right cylinder head. (Scheme 166)
17. If fitted: Remove Allen bolt securing SAI pipe clip to coolant pump. (Scheme 167)
18. If fitted: Release SAI pipe from cylinder heads and position aside. Discard "O" rings.
19. Remove 6 bolts securing timing gear cover to cylinder head and remove timing gear cover. (Scheme 177)
20. Discard timing gear cover gasket. NOTE: DO NOT carry out further dismantling if component is removed for access only
21. Remove 2 bolts securing 2 brackets to upper timing gear cover and remove brackets.
22. Remove bolt securing CMP sensor and remove sensor.
23. Discard "O" ring.

Scheme 175

Scheme 176

Scheme 177

1. Clean Camshaft (CMP) sensor and mating face.
2. Fit new "O" ring to CMP sensor.
3. Fit CMP sensor, fit bolt and tighten to 10 Nm (7 ft. lbs).
4. Position 2 brackets to timing gear cover, fit bolts and tighten.
5. Clean timing gear cover and mating face, clean dowels and dowel holes.
6. Fit new timing gear cover gasket.
7. Apply sealant, Part No. STC 50550 to areas illustrated.
8. Fit right lower bolt to timing gear cover and position cover to cylinder head. NOTE: It is not possible to fit the right lower bolt after fitting the left upper timing gear cover.
9. Fit remaining 5 bolts and hand tighten 6 bolts securing timing cover.
10. Fit LRT-12-225/2 to left camshaft cover.
11. Fit camshaft cover and tool, fit 4 bolts and tighten to 10 Nm (7 ft. lbs).
12. Tighten bolts securing timing gear cover to 15 Nm (11 ft. lbs).
13. Remove 4 bolts securing camshaft cover, remove camshaft cover and LRT-12-225/2.
14. If fitted: Fit 2 new "O" rings to Secondary Air Injection (SAI) pipe and position SAI pipe to engine. Fit and tighten 3 bolts securing SAI pipe to engine.
15. Fit bolt securing radiator lower coolant hose "P" clip to bracket and tighten.
16. Connect coolant hose to alternator and secure with clip.
17. Fit left Variable Camshaft Control (VCC) solenoid valve. See «CONTROL SOLENOID - VARIABLE CAMSHAFT CONTROL (VCC) - LEFT»(ref-158804-S25524858582005013100000) .
18. Fit left camshaft cover. See «GASKET - CAMSHAFT COVER - LEFT»(ref-158804-S09318303122005013100000) .
19. Connect multiplug to alternator and secure alternator harness to 3 clips.
20. Secure fuel vapor pipe to bracket on timing gear cover.
21. Connect multiplug to Camshaft (CMP) sensor.
22. Secure CMP sensor harness to clip and secure clip to timing gear cover.
23. Fit fan cowl. See «VISCOUS FAN»(ref-167168-S05613503662004101400000) .
24. Fill cooling system. See «DRAINING & REFILLING COOLING SYSTEM»(ref-167168-S12097297872004100800000) .
25. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000) .

Scheme 178

Scheme 179

Scheme 180

Before disconnecting the battery, ensure all text and cautions in the battery disconnection section are observed. See BATTERY DISCONNECT & RECONNECT .

1. Position vehicle on lift.
2. Disconnect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000).
3. Remove coolant pump. See «GASKET -- COOLANT PUMP»(ref-173343-S14955489692005031500000).
4. Remove left upper timing gear cover. See «COVER - TIMING GEAR - UPPER - LEFT»(ref-158804-S15316667622005013100000).
5. Remove right upper timing gear cover. See «COVER - TIMING GEAR - UPPER - RIGHT»(ref-158804-S17072079202005013100000).
6. Remove crankshaft front oil seal. See «OIL SEAL - CRANKSHAFT - FRONT»(ref-158804-S33313730482005013100000).
7. Remove 2 bolts securing ancillary drive belt tensioner to lower timing gear cover. (Scheme 181)
8. Remove dust cap from ancillary drive belt tensioner idler pulley and remove Torx bolt securing ancillary drive belt tensioner idler pulley.
9. Remove ancillary drive belt tensioner assembly.
10. Remove nut and disconnect battery cable from alternator. (Scheme 182)
11. Release battery cable from lower timing gear cover.
12. Remove 6 alternator securing bolts and alternator harness securing clip. (Scheme 183)
13. Release and remove alternator from engine timing cover.
14. Discard alternator "O" ring.
15. Remove 2 Allen bolts and 1 nut securing Power Assisted Steering (PAS) pump and move aside. (Scheme 184)
16. Remove 6 bolts securing lower timing gear cover to upper sump. (Scheme 185)
17. Remove 15 bolts securing lower timing gear cover to cylinder block. (Scheme 186) A = M8 X 75 mm B = M6 X 40 mm C = M6 X 85 mm D = M6 X 80 mm E = M8 X 90 mm F = M6 X 60 mm NOTE: Note position of all securing bolts.
18. Remove lower timing gear cover.
19. Discard 3 lower timing gear cover gaskets.

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

1. Clean timing gear cover and mating faces, clean dowels and dowel holes.
2. Apply sealant, Part No. STC 50550 to areas illustrated.
3. Fit 3 new lower timing gear cover gaskets.
4. Fit lower timing gear cover.
5. Fit 15 bolts securing lower timing gear cover to cylinder block and initially tighten to 5 Nm (4 ft. lbs).
6. Tighten 6 mm bolts securing lower timing gear cover to 10 Nm (7 ft. lbs) and 8 mm bolts securing lower timing gear cover to 22 Nm (16 ft. lbs). CAUTION: Check torque of all bolts once they have been tightened down.
7. Fit 6 bolts securing lower timing gear cover to upper oil sump and tighten to 12 Nm (9 ft. lbs).
8. Position Power Assisted Steering (PAS) pump to mounting and fit Allen bolts and securing nut. Tighten Allen bolts to 10 Nm (7 ft. lbs) and securing nut to 25 Nm (18 ft. lbs).
9. Clean alternator and engine timing gear cover mating face.
10. Lubricate and fit new "O" ring to alternator.
11. Fit alternator and tighten securing bolts.
12. Secure battery cable to lower timing gear cover.
13. Connect battery lead to alternator and tighten nut securing battery lead to alternator to 13 Nm (10 ft. lbs).
14. Fit ancillary drive belt tensioner assembly, fit Torx bolt securing ancillary drive belt tensioner idler pulley and tighten Torx bolt.
15. Fit dust cap to ancillary drive belt tensioner idler pulley.
16. Fit 2 bolts securing ancillary drive belt tensioner to timing gear cover but DO NOT tighten at this stage.
17. Fit crankshaft front oil seal. See «OIL SEAL - CRANKSHAFT - FRONT»(ref-158804-S33313730482005013100000) .
18. Fit right upper timing gear cover. See «COVER - TIMING GEAR - UPPER - RIGHT»(ref-158804-S17072079202005013100000) .
19. Fit left upper timing gear cover. See «COVER - TIMING GEAR - UPPER - LEFT»(ref-158804-S15316667622005013100000) .
20. Fit coolant pump. See «GASKET -- COOLANT PUMP»(ref-173343-S14955489692005031500000) .
21. Connect battery earth lead. See «BATTERY DISCONNECT & RECONNECT»(ref-139294-S17401612682004102900000) .

Scheme 187

1. Remove cylinder head gaskets.
2. Remove connecting rod bearings. See «BEARINGS - CONNECTING RODS - ENGINE SET»(ref-158804-S26420747892005013100000).
3. With a socket and bar fitted to crankshaft pulley bolt, rotate crankshaft for access to the lubrication jets. (Scheme 188)
4. Remove Allen screws securing lubrication jets and remove the jets.

Scheme 188

Disassembly

1. Mark connecting rod relative to its fitted position to aid reassembly. (Scheme 189)
2. Mark piston relative to its fitted position to aid reassembly. (Scheme 190)
3. Fit guides LRT-12-176 to connecting rod to protect cylinder bore and crankshaft journals. (Scheme 191)
4. Remove ridge of carbon from top of cylinder bore.
5. Carefully push piston assembly from cylinder bore.
6. Remove guides LRT-12-176 from connecting rod.
7. Hold connecting rods in a soft jawed vice.
8. Carefully remove and discard 2 retaining rings securing the gudgeon pin in the piston. (Scheme 192)
9. Push the gudgeon pin out of the piston and connecting rod, remove the piston.
10. Repeat for the 7 remaining pistons.

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Inspect

1. Clean cylinder bores, pistons, piston rings connecting rods and gudgeon pins.
2. Pistons and cylinder bores: check and record cylinder bore diameters at bottom, center and top of bore ensuring that measurements are taken at the angle shown. (Scheme 193)
3. Repeat procedure at angle shown and from the 2 sets of measurements obtained, calculate cylinder bore ovality and taper.
4. Starting with No 1 piston, measure and record piston diameter at right angles to gudgeon pin holes, and 12 mm from bottom of piston skirt. (Scheme 194)
5. Compare piston diameter with cylinder bore size and determine piston to bore clearance.
6. Using an expander, remove piston rings from piston.
7. Check new ring fitted gap 30 mm from top of bore. Ensure rings are fitted square to bore when checking gap. (Scheme 195)
8. Fit oil control ring rails and expander, ensuring ends butt and do not overlap. (Scheme 196)
9. Fit 2nd compression ring with TOP marking upwards.
10. Check piston to groove clearance. (Scheme 197)
11. Fit 1st compression ring with TOP marking upwards.
12. Check fit of gudgeon pin in piston, pin must be a tight, sliding fit with no perceptible side play.
13. Check small-end bushes for wear, check that gudgeon pin is a sliding fit in the bush with no perceptible side play. Small end bushes cannot be replaced, a NEW connecting rod must be fitted.
14. Check parallelism of connecting rods on both sides taking the measurement approximately 150 mm from the center line of the connecting rod. (Scheme 198)
15. Check for distortion on both sides of connecting rod.

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198