Part 2

Note: The locking tang on the power steering reservoir bracket (1) must be released before removing the power steering reservoir (2).

95. Remove the power steering reservoir (2) from the power steering pump power steering reservoir bracket (1) and position the power steering reservoir (2) aside.




96. Remove the power steering pump (2) to power steering pump bracket retaining bolts (3) and position the power steering pump (2) away from the power steering pump bracket (1).




97. Position the J 41798 (1) on the cylinder head (3).

Caution: Refer to Fastener Caution (Fastener Caution).

98. Install the J 41798 to cylinder head retaining bolts (2) and tighten to 50 Nm (36 lb ft).
99. Attach a suitable lifting chain and hooks to the engine lifting brackets (1).




100. Remove the lower engine mount to front subframe retaining nut (1) from both engine mounts.
101. Using a suitable lifting crane, raise the engine to clear the engine mount stud.
102. Remove the engine from the subframe
If required mount the engine on a suitable engine stand.
103. Remove the left side spark plug leads. Refer to Spark Plug Wire Replacement (Service and Repair).
104. Remove the left side spark plugs from the cylinder head. Refer to Spark Plug Replacement (Service and Repair).




Warning: Refer to Exhaust Service Warning (Service Precautions).

Warning: Refer to Protective Goggles and Glove Warning (Protective Goggles and Glove Warning).

105. Remove the left side exhaust manifold heat shield to left side exhaust manifold retaining bolts (2).
106. Remove the left side exhaust manifold heat shield (1).





Note: The left side catalytic converter to exhaust manifold retaining nuts (1) are single use parts. They must be discarded after removal.

107. Remove the left side catalytic converter to exhaust manifold retaining nuts (1).
Discard the nuts.
108. Disconnect the left side catalytic converter (2) from the exhaust manifold (3).
Discard the gasket.
109. Remove the right side spark plug leads. Refer to Spark Plug Wire Replacement (Service and Repair).
110. Remove the right side spark plugs from the cylinder head. Refer to Spark Plug Replacement (Service and Repair).




111. Remove the right side exhaust manifold heat shield to right side exhaust manifold retaining bolts (2).
112. Remove the right side exhaust manifold heat shield (1).





Note: The right side catalytic converter to exhaust manifold retaining nuts (1) are single use parts. They must be discarded after removal.

113. Remove the right side catalytic converter to exhaust manifold retaining nuts (1).
Discard the nuts.
114. Disconnect the right side catalytic converter (3) from the exhaust manifold (2).
Discard the gasket.




115. Remove the power steering pump bracket to engine retaining bolts (1).
116. Remove the power steering pump bracket (2).




117. Remove the compressor to A/C compressor mounting bracket retaining bolts (1).
118. Remove the compressor (2) to the A/C compressor bracket (3).




119. Remove the A/C tensioner pulley to A/C tensioner retaining bolt (3).
120. Remove the A/C tensioner pulley (2).
121. Remove the A/C drive belt tensioner to A/C compressor bracket retaining bolt (4).
122. Remove the A/C drive belt tensioner (1).




123. Remove the A/C compressor bracket to cylinder head retaining bolts (1).
124. Remove the A/C compressor bracket (2).




125. Remove alternator to alternator bracket retaining bolts (1 and 2).
126. Remove the alternator (3) from the alternator bracket.




127. Remove the alternator bracket to engine block retaining bolt (1).
128. Remove the alternator bracket (2) from the engine.





Note: DO NOT bend or distort the left side engine mount heat shield (2).

129. Remove the left side engine mount to engine mount bracket retaining nut (1).





Note: DO NOT bend or distort the left side engine mount heat shield (2).

130. Remove the right side engine mount to engine mount bracket retaining nut (1).
131. Attach a suitable lifting chain and hooks to the 2 J 41798 , engine lifting brackets.
132. Using a suitable lifting crane, remove the engine from the subframe.
If required, mount engine to a suitable engine stand.
133. Remove the lifting equipment as required.

Installation Procedure





Caution: Refer to Fastener Caution (Fastener Caution).

Note: DO NOT bend or distort the left side engine mount heat shield (2).

1. Install the left side engine mount to engine mount bracket retaining nut (1) and tighten to 80 Nm (59 lb ft).





Note: DO NOT bend or distort the right side engine mount heat shield (2).

2. Install the right side engine mount to engine mount bracket retaining nut (1) and tighten to 80 Nm (59 lb ft).
3. Remove the lifting equipment as required and the J 41798 from the cylinder heads.




4. Install the alternator bracket (2) to the engine.
5. Install the alternator bracket to engine block retaining bolt (1) and tighten to 50 Nm (37 lb ft).




6. Install the alternator (3) to the alternator bracket.
7. Install alternator to alternator bracket retaining bolts (1 and 2) and tighten to 34 Nm (25 lb in).




8. Install the A/C compressor bracket (2) to the engine.
9. Install the A/C compressor bracket to the cylinder block retaining bolts (1) and tighten to 58 Nm(43 lb ft).




10. Install the A/C drive belt tensioner (1) to the engine.
11. Install the A/C drive belt tensioner to A/C compressor bracket retaining bolt (4) and tighten to 22 Nm (16 lb ft).
12. Install the A/C tensioner pulley (2) to the A/C tensioner.
13. Install the A/C tensioner pulley to A/C tensioner retaining bolt (3) and tighten to 50 Nm (37 lb ft).
14. If you are replacing the compressor, balance the compressor oil. Refer to Air Conditioning Compressor Oil Balancing (Service and Repair).




15. Install the A/C compressor (2) to the A/C compressor bracket (3).
16. Install the A/C compressor to A/C compressor bracket retaining bolts (1) and tighten to 22 Nm (16 lb ft).




17. Install the power steering pump bracket (2) to the engine.
18. Install the power steering pump bracket to engine retaining bolts (1) and tighten to 58 Nm (43 lb ft).





Note: Make sure that a new sealing ring is fitted prior to installation. If not the exhaust system may perform poorly.

19. Install a NEW sealing ring to the right side catalytic converter.
20. Connect the right side catalytic converter (3) to the right side exhaust manifold (2).
21. Install the right side catalytic converter to right side exhaust manifold retaining nuts (1) and tighten to 45 Nm (33 lb ft).




22. Install the right side exhaust manifold heat shield (1) to the right side exhaust manifold.
23. Install the right side exhaust manifold heat shield to right side exhaust manifold retaining bolts (2) and tighten to 10 Nm (89 lb in).
24. Install the right side spark plugs to the cylinder head. Refer to Spark Plug Replacement (Service and Repair).
25. Install the right side spark plug leads. Refer to Spark Plug Wire Replacement (Service and Repair).





Note: Make sure that a new sealing ring is fitted prior to installation. If not the exhaust system may perform poorly.

26. Install a NEW sealing ring to the left side catalytic converter.
27. Connect the left side catalytic converter (2) to the left side exhaust manifold (3).
28. Install the left side catalytic converter to left side exhaust manifold retaining nuts (1) and tighten to 45 Nm (33 lb ft).




29. Install the left side exhaust manifold heat shield (1) to the left side exhaust manifold.
30. Install the left side exhaust manifold heat shield to left side exhaust manifold retaining bolts (2) and tighten to 10 Nm (89 lb in).
31. Install the left side spark plugs to the cylinder head. Refer to Spark Plug Replacement (Service and Repair).
32. Install the left side spark plug leads. Refer to Spark Plug Wire Replacement (Service and Repair)




33. Position the J 41798 (1) on the cylinder heads (3).
34. Install the J 41798 to cylinder head retaining bolts (2) and tighten to 50 Nm (36 lb ft).
35. Using a suitable lifting crane and the J 41798 raise the engine slightly.
36. Remove the engine from the engine stand.
37. Lower the engine onto the front subframe.
38. Position the engine mounts to the front subframe.




39. Install the lower engine mount to front subframe retaining nuts (1) on both engine mounts and tighten to 80 Nm (59 lb ft).




40. Position the power steering pump (2) to the power steering pump bracket (1).
41. Install NEW power steering pump to power steering pump bracket retaining bolts (3) and tighten to 30 Nm (23 lb ft).





Note: Make sure the power steering reservoir (2) and the power steering reservoir bracket locking tang (1) are engaged to avoid an induced rattle condition.

42. Install the power steering reservoir (2) to the power steering pump power steering reservoir bracket (1).
43. Install the A/C drive belt. Refer to Air Conditioning Compressor Belt Replacement (Service and Repair).
44. Install the accessory drive belt. Refer to Drive Belt Replacement - Accessory (Service and Repair).
45. Install the engine flywheel. Refer to Engine Flywheel Installation (Overhaul).
46. Connect a suitable lifting crane to the engine lift brackets and raise the suitable lifting crane to support the engine.
47. Install the transmission. Refer to Transmission Replacement (Removal and Replacement).