Remove air mass meter connector
Remove air filter box mounts
Remove air filter box assembly
Removed power train control module mounts
Remove power train control module
Remove all connections to intake manifold
Remove intake manifold mount bolts
Remove intake manifold
Remove oil filer tube
Remove pcv pipe from rocker cover
Remove rocker cover mount bolts
Slice sealant from rocker cover
Remove rocker cover
Clean sealing surfaces
Apply new film of sealant to sealing surfaces
Fit rocker cover and let surfaces settle
Tension rocker cover mount bolts
Reassemble all of the above
Wash oil from engine
Road test
Inspect for leak

Raised vehicle
Removed stone guard
Remove serpentine belt
Support engine
Remove front engine mount
Removed top timing cover
Removed camshaft position sensor
Set engine to top dead centre number 1
Insert cam locking tool
Remove crank pulley bolt
Remove crank pulley
Remove timing covers
Remove timing belt tensioner
Remove timing belt
Remove water pump
Clean sealing surfaces
Replace water pump
Replace modified rollers
Replace timing belt
Replace timing belt tensioner , modified with mount bolt
Tensioned belt
Turned engine over by hand and inspected valve timing and belt tension
Fitted air lift to cooling system
Pulled cooling system down to vacuum
Locked off
Tested for leaks under vacuum
Recharged system with fresh glycol\inhibitor
Reassembled all of the above
Replace torque to yield crank pulley bolt
Test

Remove exhaust manifold cover bolts
Remove exhaust flange to engine pipe
Remove manifold to cylinder head bolts
Remove exhaust manifold
Remove timing case cover
Fit special tool to locate timing chain and sprocket when removing water pump
Remove connections to thermostat housing
Removed thermostat housing from engine block
Remove bypass pipe from thermostat housing
Remove by-pass pipe from rear water pump housing
Remove water pump housing
Remove water pump
Clean sealing surfaces
Replace water pump
Replace By-pass pipe seals
Replace thermostat seals
Fitted air lift to cooling system
Pulled cooling system down to vacuum
Locked off
Tested for leaks under vacuum
Recharged system with fresh glycol\inhibitor
Reassembled all of the above
Test

Remove engine cover
Raise vehicle
Remove stone covers
Remove pollen filter cover
Remove wiring to access plenum covers
Remove plenum cover mount bolts
Remove plenum cover to access engine in service mode
Remove wiring to ignition system
Remove wiring to eccentric shaft motor
Remove engine ignition coils
Remove eccentric seal mount bolts
Removed eccentric seal
Remove rocker cover mount bolts
Remove rocker cover
Remove gaskets
Clean sealing surfaces
Replace rocker cover gasket
Replace eccentric shaft seal
Reassemble

Remove engine cover
Remove tension on driver belt
Insert retainer pin in tensioner to keep tension off belt
Remove serpentine belt
Disconect wiring from alternator and secure wiring
Remove serpentine belt roller
Remove serpentine belt tensioner
Remove oil filter top cover
Removed steering reservoir
Remove steering pump
Remove alternator mount olts
Remove alternator
Remove oil filter housing mount bolts
Remove oil filter housing
Wash engine block and lower section of engine
Replace oil filter housing seal
Reassemble all of the above
Answer

Remove inner door trim
Remove inner weather shield
Remove window glass from regulator clamps
Raise window in frame and secure
Remove electrical connectors to regulator
Remove regulator and motor assembly from door frame
Remove motor from regulator
Inspect motor and gear condition
Fit motor to new regulator
Replace regulator
Attach window glass to regulator
Adjust window operation
Reassemble
Test

Pressure test cooling system
Located leak at expansion tank
Remove engine covers
Raise vehicle
Remove splash tray
Drain coolant
Remove lower connection to expansion tank
Remove sensor wirng
Remove lower mount
Lower vehicle
Remove upper mount
Remove expansion tank
Remove thermostat
Replace thermostat and expansion tank
Refit sensor
Reassemeble
Refill cooling system
Add glycol/ inhibitor coolant
Run electric water pump
Bleed cooling system and bleed ports
Run engine till operating temperature
Cool engine
Reinspect and top up coolant

Remove engine cover
Raise vehicle
Remove stone covers
Remove pollen filter cover
Remove wiring to access plenum covers
Remove plenum cover mount bolts
Remove plenum cover to access engine in service mode
Remove wiring to ignition system
Remove wiring to eccentric shaft motor
Remove engine ignition coils
Remove eccentric seal mount bolts
Removed eccentric seal
Remove rocker cover mount bolts
Remove rocker cover
Remove gaskets
Clean sealing surfaces
Replace rocker cover gasket
Replace eccentric shaft seal
Reassemble

Raise vehicle
Remove front wheels
Support engine
Remove front cross member bolts
Remove front cross-member
Remmove dipstick
Remove dipstic tube
Remove sump pan switch
Remove sump pan mount bolts
Prize sump pan from engine block
Clean sealing surfaces
Replace sump pan gasket
Replace dipstick seals
Raessemble all of the above
Raise vehicle
Remove front wheels
Support engine
Remove front cross member bolts
Remove front cross-member
Remmove dipstick
Remove dipstic tube
Remove sump pan switch
Remove sump pan mount bolts
Prise sump pan from engine block
Clean sealing surfaces
Replace sump pan gasket
Replace dipstick seals
Reassemble all of the above

Remove engine cover
Raise vehicle
Remove stone covers
Remove pollen filter cover
Remove wiring to access plenum covers
Remove plenum cover mount bolts
Remove plenum cover to access engine in service mode
Remove intake pipe from air filter to manifold
Remove engine breather pipe to valve
Remove connections to intake manifold
Remove intake manifold mount bolts
Remove intake manifold
Remove engine breather valve mount bracket
Remove valve
Remove pipes to engine
Replace valve
Replace pipes
Reassemble all of the above

Connect computer and inspect faults
Remove engine cover
Remove pollen filter cover
Remove wiring to access plenum covers
Remove plenum cover mount bolts
Remove plenum cover to access engine in service mode
Remove wiring to ignition system
Move faulty and failing coils to different cylinders
Run engine and test
Replace ignition coils
Reassemble
Conect computer and clear faults
Inspect rough running parameters
Road test
Connect computer no reported faults and rough running within normal parameters

Raise vehicle
Inspect drive train
Remove both rear wheels
Remove exhaust front to rear
Remove prop shaft covers
Remove prop shaft mount bolts from transmission
Remove propshaft spline lock nut from final drive
Support propshaft
Remove center bearing mount bolts
Remove propshaft assembly
Access interior fuse box
Remove air pump fuse
Connect diagnostic tool to data link conector
Comand air suspension to release air from suspension cushions on both sides
Remove driveshaft nuts at hubs
Remove lower control arm mount bolts
Remove lower cushion bolts
Lower rear suspension
Remove driver side driveshaft
Passenger side driveshaft was seized in crown wheel
Support final drive
Drain remaining fluid from final drive
Remove final drive mount bolts
Remove final drive and driveshaft complete
Remove drive shaft from final drive , had to press shaft inner from final drive
Replace final drive
Replace passenger side driveshaft
Replace lock nut
Reassemble all of the above
Refit fuse to air pump
Comand air cushion controller to refill cushions
Carried out wheel alignment
Test

Transmission leaking from harness connectors
Remove splash trays
Drain fluid into clean container
Remove sump pan mount bolts
Remove valve body mount bolts to access harness release
Release harness
Remove harness seal plug connector
Replaced seal connector
Reassemble
Set bolt toque as specified
Using oil pump refill transmission sump
Using helper start engine
Continue refilling transmission until correct level reached before transmission temperature reached 48deg ,adding fluid as necessary
Test driven
Raised inspect for leak
Refit splash tray

Drain coolant from system at lower radiator hose and/or radiator drain cock
Remove heater hose at fire wall or heater tap
Block bottom radiator hose
Flow clear water into heater until clear water exits from cylinder head outlet
Reverse process feeding clean water into cylinder head outlet until clear water exits
Unblock bottom radiator hose. Block off heater hose and flush
Refit heater hose cylinder head outlet
Flow clear water through radiator
Reconnect bottom hose to radiator
Fit air lift evacuation tool to radiator
Fit air lift evacuation tool to filler hole
Evacuate air from cooling system to create a vacuum
Lock off and test for leaks with vacuum guage
Remove expansion reservoir where possible and clean out algae and deposits
Refit reservoir and fill with coolant mix to correct level
If no leaks present fill premix coolant / water to cooling system
Run engine to check operation of thermostat
Continue running until fan operates
Allow system to cool, remove cap for final top up and refit cap

(All cars are different this is to give a general idea of the procedure involved.)
Road test vehicle
Raise vehicle on hoist
Remove front and rear wheels
Lift bonnet
Inspect brake fluid and condition of fluid in master cylinder reservoir
Inspect brake booster connection to manifold
Inspect brake booster vacuum hose
Inspect check valve
Inspect brake pipes under bonnet
Inspect brake pipes to wheels
Inspect front callipers
Inspect front pads
Inspect front rotors
Inspect front wheel bearing play
Remove rear lock hub nuts
Remove rear drums / rotors
Inspect rear brake drum / rotor surfaces
Inspect rear brake linings
Compare actual measurements with specifications.

(All cars are different this is to give a general idea of the
procedure involved.)
Remove alternator belt
Remove power steering belt
Remove air conditioning belt
Set engine to top dead centre number 1
Remove crank pulley bolt
Remove crank pulley
Remove timing covers
Remove timing belt tensioners
Remove and replace timing belt
Tension belt
Turn engine over by hand and inspected valve timing and belt tension
Reassemble all of the above
Reset ignition timing
Test

Remove lower floor carpet
Remove floor grommet in fire wall to access engine bay from cabin
Rotate steering to expose Cotter pin in steering column
Press cotter pin from column shaft to enable shaft to be released from steering rack spindle shaft
Centralise steering
Lock steering
Raise vehicle
Remove front wheels
Remove front outer track rod lock bolts
Release interference clamp on each track rod to steering knuckle joint
Remove track rods from steering knuckles
Release lock nut at steering track rods
Remove track rods from steering rack
Remove spalsh tray
Remove mount bolts for support/ protector tray
Remove protector tray
Access anti lock brake module
Release module mounts and support module
Release heat exchanger mounts
Release heat exchanger and support
Support engine and transmission
Remove lower sub frame mount bolts
Remove catalytic convertor to engine pipe exhaust mount bolts
Bolts were seized
Bolts and nuts broke when removed
Lower, lower section of sub frame exposing lower control arm rear bushes
Loosen high pressure pipe nuts to spool valve
Remove pipe tube nuts from spool valve
Remove steering rack mount bolts
Remove steering rack from mounts
Release steering rack , snake out of engine bay , twisting and turning like doing a jigsaw puzzle
Replace steering rack
Remove front lower control arm mount bolts
Remove lower ball joint lock nuts
Remove interference clamp on lower ball joints
Remove control arm from vehicle
Replace both front control arms
Reassemble

Remove clutch pedal link pin
Remove pedal from master cylinder under dash
Remove fluid from master cylinder
Remove master cylinder mount bolts
Remove pipe from master cylinder
Remove master cylinder assembly
Fit new master cylinder
Remove air filter box
Remove flex hose
Remove slave cylinder pipe fitting
Remove slave cylinder mount bolts
Remove slave cylinder
Replace slave cylinder
Replace flex hose
Fill reservoir
Bleed fluid through master pipes, hose and slave cylinder
Road test
Inspect for leaks

Raise vehicle
Remove gear lever console
Remove gear lever insulation boot
Remove gear knob
Remove gear lever retainer at top of gear box
Remove gear lever
Remove tail shaft bolts at differential flange
Remove tail shaft from rear extension housing
Plug extension housing
Support engine
Remove rear cross member
Remove starter motor bolts
Remove clutch slave cylinder
Remove all bell housing bolts to engine
Remove reverse light switch wires
Remove speedometer drive cable
Remove gearbox from engine
Remove clutch pressure plate and clutch plate
Remove clutch flywheel bearing by pressing bearing out of crankshaft
Inspect and replace flywheel bearing
Inspect flywheel surface for discolouration and deterioration
Remove and machine flywheel
Refit flywheel
Remove clutch release bearing
Inspect fork and bearing locating shaft
Replace release bearing
Replace clutch friction plate and clutch pressure plate
Aligne plates
Refitte gearbox and assembled
Inspect gear oil level and adjusted as necessary
Road tested vehicle

Raise vehicle
Remove gear lever console
Remove gear lever insulation boot
Remove gear knob
Remove gear lever retainer at top of gear box
Remove gear lever
Remove tail shaft bolts at differential flange
Remove tail shaft from rear extension housing
Plug extension housing
Support engine
Remove rear cross member
Remove starter motor bolts
Remove clutch slave cylinder
Remove all bell housing bolts to engine
Remove reverse light switch wires
Remove speedometer drive cable
Remove gearbox from engine
Remove clutch pressure plate and clutch plate
Remove clutch flywheel bearing by pressing bearing out of crankshaft
Inspect and replace flywheel bearing
Inspect flywheel surface for discolouration and deterioration
Remove and machine flywheel
Refit flywheel
Remove clutch release bearing
Inspect fork and bearing locating shaft
Replace release bearing
Replace clutch friction plate and clutch pressure plate
Aligne plates
Refitte gearbox and assembled
Inspect gear oil level and adjusted as necessary
Road tested vehicle

(All cars are different this is to give a general
idea of the procedure involved.)
Road test vehicle
Adjust clutch free play
Re-test
Disconnect battery
Raise vehicle onto hoist
Drain gearbox oil
Remove front wheels
Remove lower control arms and stub axles
Remove track rod ends from stub axles
Remove drive shafts from gear box
Remove all upper connections to gearbox
Support engine
Remove front and rear cross member
Remove engine / gearbox mounts
Remove all lower connections to gearbox
Remove gearbox
Remove clutch release bearing from bell housing extension
Lubricate extension
Replace release bearing
Remove clutch plate and pressure plate
Inspect flywheel face for discolouration and deterioration
Remove flywheel
Machine flywheel surface
Inspect clutch spigot bearing
Press spigot bearing from crankshaft
Replace spigot bearing pressing into crankshaft
Refit flywheel
Replace clutch plate and pressure plate
Aligned plates
Refit gearbox
Reassemble

Remove wheel
Remove drive shaft retaining Bolt
Remove stub axle connection to lower control arm
Remove stub axle connection to track rod end
Remove drive shaft from axle Knuckle
Remove drive shaft from transmission
Press driveshaft seal from output housing in differential
Inspect sealing surfaces
Clean sealing surfaces
Press new seal into output shaft housing
Refit shaft to transmission and axle knuckle
Reassemble
Road test vehicle

Raise vehicle
Remove cable from transmission
Remove cable mount clips from front transmission
Remove cable support at fire wall
Disconnect battery
Remove both front seats
Remove centre console trims
Remove gear lever trim
Remove all contents of centre consol
Remove centre console assembly
Remove gear selector box
Disconnect cable from selector box
Remove firewall grommet with cable
Fed new cable into firewall
Fit firewall grommet
Fit cable ties to transmission
Fit cable to inhibitor selector
Fit cable to gear lever box
Fit cable clips to gear lever box and under dash mounts
Reassemble
Test

Raise vehicle
Remove tail shaft from rear differential
Remove rear wheels
Remove rear brake callipers from calliper retainers
Remove handbrake cable connections to front
Support rear sub frame
Remove rear shock absorbers lower bolts
Remove sub frame mount bolts
Lower complete sub frame
Remove differential from sub frame
Press bushes from frame
Replace passenger side driveshaft seal
Reassemble
Reset adjustments
Road test

Removed front wheels
Removed strut tower retaining nuts
Removed strut bottom bolts
Tilted front suspension out to remove shock assemblies
Fit each strut to hydraulic spring compressor
Compressed springs
Removed spring retainer plate nut
Removed tower bearing and bush
Replaced tower bushes and bearing
Reassembled
Road tested vehicle

Inspect battery operation ok
Locate and inspect fuses for open circuit ok
Inspect spark at lead ends , more than 30kv good
Access intake added small parcel of fuel attempt to start , engine fires and stalls when fuel was use
Remove rear seat
Access fuel pump wiring , test for power when commanded
Fuel pump not commanded
Provide external power and ground and run fuel pump , engine dosnt run
Inspect power supply at injectors , OK
I injector command was not actioned
Loacated fuel pump/PCM relays
Test relay operation off vehicle if OK
Test power supply and command to relays
Test component power supply at relay
Fuel pump relay had open circuit on component power supply
PCM relay had open circuit at command ground
Trace wiring to external immobiliser
Research immobiliser wiring diagram
By-pass immobiliser
Started engine

aise vehicle
Remove stone tray
Remove cooling drain plug
Drain coolant from system
Remove front bumper mount clips
Remove front bumper
Remove lower radiator hose clamp
Remove hose from radiator
Remove transmission cooler lines from radiator
Remove upper hose clamp
Remove upper hose from radiator
Remove fan wiring
Remove fan mount bolts
Remove thermo fans
Remove radiator mount bolts
Remove radiator assembly
Remove intake pipe cover
Remove side mount bolt for by-pass pipe
Remove by-pass pipe clamps[ very awkward ]
Remove By-pass y hose
Replace hose and clamps
Flush fresh water through cooling system until no old coolant remained
Replace radiator
Reassemble all of the above
Fit air lift tool to expansion tank
Evacuate system until 24hg vacuum
Locke off and tested for leaks under vacuum
If no leaks
Charge system with fresh batch

Pressure test cooling system
Coolant leak at radiator
Raise vehicle
Remove splash tray
Remove top covers
Drain cooling system
Remove radiator mount bolts
Remove top and bottom hoses from radiator
Remove transmission cooler lines from Radiator
Remove radiator
Replace radiator
Fitted air lift to cooling system
Pulled cooling system down to vacuum
Locked off
Tested for leaks under vacuum
Recharged system with fresh glycol\inhibitor
Inspected transmission fluid level
Ran engine tested

Raise vehicle
Remove stone guard
Remove serpentine belt
Support engine
Remove front engine mount
Remove top timing cover
Remove camshaft position sensor
Set engine to top dead centre number 1
Insert cam locking tool
Remove crank pulley bolt
Remove crank pulley
Remove timing covers
Remove timing belt tensioner
Remove timing belt
Remove water pump
Clean sealing surfaces
Replace water pump
Replace modified rollers
Replace timing belt
Replace timing belt tensioner , modified with mount bolt
Tensioned belt
Turne engine over by hand and inspected valve timing and belt tension
Fitt air lift to cooling system
Pull cooling system down to vacuum
Lock off
Test for leaks under vacuum
Recharge system with fresh glycol\inhibitor
Reassemble all of the above
Replace torque to yield crank pulley bolt
Test

aise vehicle
Remove stone tray
Remove cooling drain plug
Drain coolant from system
Remove front bumper mount clips
Remove front bumper
Remove lower radiator hose clamp
Remove hose from radiator
Remove transmission cooler lines from radiator
Remove upper hose clamp
Remove upper hose from radiator
Remove fan wiring
Remove fan mount bolts
Remove thermo fans
Remove raditor mount bolts
Remove radiator assembly
Remove intake pipe cover
Remove side mount bolt for by-pass pipe
Remove by-pass pipe clamps[ very awkward ]
Remove By-pass y hose
Replace hose and clamps
Flush fresh water through cooling system until no old coolant remains
Replace radiator
Reassemble all of the above
Fit air lift tool to expansion tank
Evacuate system until 24hg vacuum
Lock off and test for leaks under vacuum
No leaks
Charge system with fresh batch of premix glycol\inhibitor
Run system until thermostat opens
Test drive
Inspect thermo fan operation

Raise vehicle
Drain cooling system
Remove engine covers
Remove engine ground connections
Remove alternator belt
Remove air intake tube to throttle body
Remove connections to throttle body
Remove electrical connections to intake manifold
Remove alternator mount bolts
Remove alternator
Remove coolant bypass pipes
Remove plenum chamber mount bolts
Remove plenum chamber from engine
Clean manifold sealing surfaces
Remove rocker cover mount bolts
Remove rocker covers
Clean sealing surfaces
Replace rocker cover gaskets
Replace manifold gaskets
Fit sealing strips
Apply Room temperature vulcanising sealant
Fit plenum chamber with manifold
Secure and let Sealant set
Reassemble all of the above
Fitted coolant vacuum pump to cooling system
Pulled cooling system down to vacuum
Locked off system and tested for leaks under vacuum
No leaks
Recharged cooling system adding correct quantity of coolant
Reassembled

Disconnect battery
Remove battery hold down clamps
Remove battery clamps
Remove battery
Remove air box mount bolts
Remove air box cover
Remove air filter housing assembly
Remove air intake tube to throttle body
Remove all connections to throttle body
Remove throttle body mount bolts
Remove bonnet catch mount bolts
Remove bonnet catch
Remove bolts to intake manifold
Remove all connections to intake manifold
Remove manifold assembly
Remove wiring to starter motor
Remove starter mount bolts
Remove starter motor
Replace starter motor
Reassemble all of the above
Reconnect battery
Set code in radio
Test starter

Raise vehicle
Remove splash tray
Support engine with eagle crane
Remove front engine mount
Remove serpentine drive belt
Remove covers to access engine fans
Disconnect fan motors
Remove fan motors
Remove lower radiator hose retainer clip
Remove hose
Drain cooling system
Remove battery connections , wiring from alternator was very close to rear pipe access
Access rear pipe and remove mounts
Remove water pump by-pass pipe
Remove water pump mount bolts
Remove water pump
Clean sealing surfaces
Replace water pump and gasket
Reassemble

Fit air lift tool to cooling system

Evacuate cooling system

Hold under vacuum and test for leak

Charge system with fresh batch of Glycol\inhibitor

Road Test

Remove rear wheels
Remove rear wheel hub covers
Remove rear wheel ABS sensor mount bolts
Remove ABS sensor from backing plate
Remove rear wheel hub retainer nut
Remove rear brake drum
Fit press tool to hub
Press bearing hub from stub axle
Clean sub shaft
Fit new bearing and hub assembly
Refit lock nut
Torque lock nut to specified tension
Pein lock nut shroud into stub keyway
Refit hub dust cover
Reassemble
Test drive

Remove gear lever cover
Remove all retainers to centre console
Remove centre console assembly
Remove handbrake tension
Remove handbrake lever mount bolts
Remove hand brake lever
Store lever behind front seats
Remove wiring to chassis cover
Remove chassis cover plate mount screws
Pry chassis cover from chassis was glued to floor
Remove connecting plug to fuel sender unit
Disconnect fuel lines to sender cover
Fit special tool to sender cover retainer ring
Release retainer ring
Remove ring and sender unit complete with fuel pump assembly
Drain fuel from swirl pot
Separate fuel pump from sender
Replace fuel filter
Fit retainer
Reassemble Fuel pump
Refit sender to tank
Refit retainer ring
Torque ring to specified tension
Run fuel pump to test for leaks
Reassemble all of the above

Remove engine covers
Support engine with crane
Remove front engine mount bolts from engine
Remove front engine mount bolts from chassis
Remove front engine mount
Replace mount
Reassemble
Test

Carried out to both front
Removed front wheels
Removed strut tower retaining nuts
Remove pinch bolt clamp
Insert pinch bolt clamp spreader
Tilted front suspension out to remove strut assembly
Remove Strut assembly
Fit each strut to hydraulic spring compressor
Compressed springs
Removed spring retainer plate nut
Removed tower bearing and bush
Remove spring
Remove strut from compressor
Fit new strut to compressor
Refit spring
Refit bearing plate and bush
Replace retainer nut
Reassembled
Road tested vehicle

Raise vehicle
Remove splash tray
Remove exhaust engine pipe bolts
Bolts were seized
Supported exhaust
Remove engine sump pan lower support mount bolts
Remove engine sump pan bolts
Sump pan was glued to engine block
Inserted knife into sealant and cut sump pan from engine block
Resurfaced sump pan
Remove gaskets
Clean sealant from engine block and prepare surface to be resealed
Clean sump pan and prepare surface to be resealed
Fit gaskets
Reseal sump pan
Reassemble
Let sump pan rtv sealant cure
Refill engine
Road test
Raise and inspect for leak

Removed lock hub nut
Moved driveshaft in splines
Lubricated shaft in hub
Re-tensioned drive shaft lock nut
Noise was still present
Remove front lower axle knuckle from lower ball joint
Remove axle knuckle from track rod end
Remove brake pad calliper bracket
Remove brake calliper mount bracket
Remove axle knuckle from vehicle
Set axle knuckle in hub press
Press hub from axle knuckle
Remove wheel bolts from hub
Set wheel hub in C clamps to press wheel bearing outer race from hub
Press outer race
Clean race inner diameter surface where it has and interference fit on wheel hub
Lubricate inner race surface and refit to bearing
Reassemble axle knuckle to vehicle
Fit wheel hub
Press hub into bearing outer race
Fit driveshaft to splines
Press hub into inner race
Torque driveshaft wheel hub nut
Pein over lock on nut
Reassembled
Road test

Remove lower dash trim
Remove lower fuse box mount bolts
Move fuse box to release from rear support
Move fuse box to access fan housing
Remove fan housing cover screws
Remove fan housing side cover
Remove pollen filter
Clean leaves and contamination from fan housing and floor
Replace pollen filter
Reassembled

Remove battery connection
Remove covers at engine bay to access bell housing
Place drain tray below transmission
Open Fluid cooler lines
Remove cooler lines from transmission
Mark tail shaft positions
Remove tail shaft uni bolts
Remove tail shaft
Remove connections to transmission
Fit transmission jack to support transmission
Remove drive plate cover
Remove drive plate bolts from Torque convertor
Remove all bell housing bolts and connections
Remove transmission from engine
Store transmission secured
Removed drive plate
Inspect rear engine
Remove rear main oil seal housing
Remove gasket from engine
Gasket pieces collected in engine sump pan
Drained engine sump pan oil
Flushed out all gasket parts from engine sump pan
Replaced rear main oil seal
Replaced cover plate gasket
Refit transmission
Reassembled
Refilled transmission fluid
Refilled engine
Washed engine lower and transmission front
Road tested
Raised to inspect for leaks

Raise vehicle
Remove wheel
Remove anti lock brake wheel speed sensor bolt
Remove wheel speed sensor and tie out of harm’s way
Clamp brakes to stop driveshaft moving
Remove wheel driveshaft retaining nut
Remove lower ball joint clamp nut
Remove brake calliper mount bolts
Remove brake calliper and secure to not stress brake hose
Remove pad carrier mount bolts
Remove brake pads and carrier
Remove upper ball joint clamp bolt
Remove track rod end clamp bolt
Remove interference fit shafts on lower ball joint
Upper ball joint and track rods
Remove axle knuckle assembly
Remove stone cover
Fit knuckle assembly to press
Press out hub from knuckle
Remove large circlip from knuckle
Fit knuckle into press
Force bearing assembly from knuckle
Cleaning bearing space
Press new bearing into knuckle with anti lock brake reluctor pick up in correct position
Fit circlip
Press hub into bearing
Reassemble all of the above

Raise vehicle
Remove front wheels
Fit dial gauge to lower control arm
Test free play at ball joint
Ball joint free play was excessive
Remove driveshaft retaining nut
Remove ABS wheel speed sensor and secure in safe area
Remove lower ball joint clamp nut
Remove upper ball joint clamp nut
Remove steering track rod clamp nut
Remove brake calliper mount bolts
Remove brake calliper from axle knuckle
Remove calliper mount bracket
Remove brake disc rotor from drive hub
Using percussion tool loosen interference fit on ball joint
Press joints from lower arm
Remove driveshaft from axle knuckle
Fit axle knuckle to press
Force interference fit ball joint from axle knuckle
Fit new ball joint to axle knuckle
Using special tool to secure ball joint tension joint clamp to 330nm
Reassemble
Replace driveshaft retaining nut

Carried out to both sides of engine
Removed all upper connections to air intake to access rocker covers
Removed ignition coil connections
Removed ignition coil mount bolts
Removed ignition coils
Removed wiring harness connector above rocker covers
Removed Engine breather hoses to rocker covers
Removed rocker cover mount bolts
Removed rocker cover assemblies
Separated breather box from rocker cover
Removed sealant from breather box cover and top of rocker cover
Applied RTV sealant to rocker cover seated breather box fitted bolts and lamped very lightly
Removed rocker cover gaskets from covers
Cleaned sealing surfaces on rocker covers
Replaced rocker cover gaskets
Cleaned sealing surfaces on cylinder head
Refit rocker covers
Replaced engine breather hoses
Clamped breather box bolt to specific tension as RTV had set
Tensioned rocker cover bolts to specified tension
Reassembled
Washed excess oil from top of engine

Disarm air bag system
Remove driver rear door trim panel
Remove driver rear door weather shield
Remove Brocken window glass connector from inside door
Press out old connector from regulator
Replace complete modified connector kit
Adjusted glass to regulator , aligned and tested
Carried out window system relearn to allow auto function to operate
Carried out relearn to set sensitivity of pressure sensor
Reassemble
Test

Remove exhaust manifold cover
Remove exhaust manifold mount bolts
Move exhaust manifold to access oil filter housing
Raise vehicle
Remove driver side inner wheel arch
Remove heat exchanger mount bolts
Remove oil filter cap
Remove oil filter
Remove housing from engine block
Remove seals front and rear
Clean sealing surfaces
Replace housing to block seal
Replace heat exchanger seals
Replace oil filter
Reassemble
Wash area
Test

Inspect and record belt layout
Fit tensioner release tool to tensioner
Load spring and insert retainer pin
Remove serpentine belt
Inspect pulleys
Replace serpentine belt
Hold spring tension and release pin
Tension belt
Test

Remove bolts holding intercooler clamps
Remove intercooler mount brackets
Remove intercooler
Remove high tension leads
Remove rocker cover bolts
Remove rocker cover
Clean rocker cover
Clean sealing surfaces
Replace gasket
Reassemble all of the above

Raised vehicle
Removed driver front wheel
Removed passenger front wheel
Remove battery connection to disarm air bag system
Lock steering in straight ahead position
Released tension from steering tie rod lock nut from thread both sides
Using percussion tool freed interference fit between joint and steering arm both sides
Remove power steering pipes to rack spindle
Remove pinch bolt from rack uni-joint spindle
Remove lower control joint arm at wheel end both sides
Fit cradle to support engine
Remove engine mount bolts
Remove sway bar link mounts both sides
Remove sub frame assembly bolts
Release uni-joint from rack
Lower sub frame with rack
Remove rack mount bolts
Remove steering rack assembly
Released lock nut on steering arm
Removed tie rod from Steering track arm thread , noting the position to return to on reassemble
Fit track rods to new rack
Reassembled
Filled steering with fresh fluid
Cycled steering from lock to lock before starting engine to bleed air from steering rack
Tested
Carried out wheel alignment

Remove engine covers
Remove high tension leads from spark plugs
Remove engine breather pipes to access rocker covers
Remove ignition coils from rocker covers
Remove rocker cover mount bolts
Remove rocker covers from cylinder head
Separate rocker cover top baffle cover from rocker cover
Clean sealing surfaces
Remove rocker cover gasket from rocker cover
Clean sealing surfaces
Clean engine breather ports in rocker covers
Seal top baffle cover with RTV
Replace rocker cover gaskets
Reassemble
Wash engine
Road test
Reinspect for leak

Remove battery connection
Raise vehicle on hoist
Remove front wheelsRemove all upper connections to transmission
Fit eagle support to hold engine and transmission
Remove lower front suspension arm mount bolts from chassis frame
Remove steering track rod end ball joint from axle knuckles
Remove driveshaft inner bearing mount support bolts
Remove drive shafts from transaxle
Remove exhaust at engine pipe flange
Support exhaust system
Remove exhaust front to rear
Remove tail shaft mount bolts
Mark tail shaft position on transfer
Remove tail shaft assembly
Support sub frame
Remove sub frame mount bolts
Removed complete front sub frame
Drain transmission fluid
Drain transfer case fluid
Remove transfer case side mount
Remove transfer case mount bolts
Remove transfer case from transaxle to access bolt between transmission and transfer case
Remove all bell housing bolts
Remove transmission mount bolts
Remove transmission assembly
Remove clutch plate
Remove clutch fork arm
Remove release bearing
Inspect transmission nose cone
Inspect clutch fork arm
Inspect clutch for arm pivot ball
Lubcricate pivot ball and fork arm
Replace release bearing
Remove clutch pressure plate
Remove clutch plate
Remove flywheel mount bolts
Remove flywheel
Replace dual mass flywheel
Replace clutch plate
Replace pressure plate
Reassemble
Refill transmission fluid
Refill transfer case fluid
Carry out wheel alignment
Tested

Raise vehicle
Remove splash tray
Remove engine cover
Inspect and note serpentine belt path
Fit special tool to belt tensioner
Release belt tension
Remove serpentine belt
Remove hoses above alternator
Remove wiring to alternator and insulate wiring
Remove alternator lower mount bolts
Remove alternator upper mount bolt
Remove alternator out of engine bay
Remove Overrun Pulley from Alternator
Fit new overrun pulley to alternator
Reassemble
Test

Raised vehicle
Removed stone guard splash tray
Remove front wheels
Remove driver side inner wheel arch splash cover trim
Remove serpentine belt
Support engine
Remove front engine mount
Removed top timing cover
Set engine to top dead centre number 1
Insert cam locking tool
Insert crankshaft locking tool
Remove crank pulley bolt
Remove crank pulley
Remove timing covers
Remove timing belt tensioner
Remove timing belt
Remove crank pulley driver gear
Remove crank drive oil seal
Clean sealing surfaces
Press new seal into engine block
Remove water pump
Clean sealing surfaces
Replace water pump
Replace idler roller
Replace timing belt
Replace timing belt tensioner
Tensioned belt
Turned engine over by hand and inspected valve timing and belt tension
Fitted air lift to cooling system
Pulled cooling system down to vacuum
Locked off
Tested for leaks under vacuum
Recharged system with fresh glycol\inhibitor
Reassembled all of the above

Raise vehicle
Remove stone tray
Connect diagnostic tool and interrogate
Camshaft and Crankshaft alignment was incoherent
Remove engine cover
Remove air intake pipe to turbo
Remove wiring to coils
Remove coils from engine
Remove spark plugs
Remove rocker cover mount bolts
Remove rocker cover
Remove rocker cover gaskets from cover
Clean sealing surfaces
Release tension on water pump drive pulley
Remove drive pulley mount bolts
Remove drive pulley
Fit belt tensioner tool
Release belt tension
Remove drive belt
Set engine to timing lock position
Insert crankshaft lock tool
Test camshaft
Avance mechanism
Fit camshaft lock tools
Remove crank shaft pulley bolts
Remove crankshaft gear bolt
Remove crankshaft oil seal
Release camshaft gear bolts
Remove timing chain tensioner
Remove chain guide pivot bolts
Remove guides
Remove camshaft sprockets
Remove chain
Replace chain
Replace sprockets
Replace guides
Replace guide torque to yield bolts
Replace crank shaft seal
Replace sprocket torque to yield bolts
Replace crankshaft torque to yield bolt
Reassemble
Replace rocker cover gaskets
Test
Interrogate with diagnostic tool
Crankshaft camshaft relationship coherent

Remove engine covers
Remove air tube from turbo to air filter
Remove heat shield
Remove inlet and outlet banjo fittings on turbo oil cooler
Remove turbo mount bolts
Remove exhaust clamps to turbo
Remove engine pipe to turbo
Move turbo to access inlet pipe
Access outlet to sump
Replace pipes and banjo fittings
Replace gaskets
Reassemble
Wash oil from turbo both inlet and exhaust areas
Road test
Raise and inspect for leaks

Lift vehicle
Remove splash tray
Moved both seats forward
Remove rear firewall carpet
Remove access cover to engine bay
Remove heat shield to access engine
Remove coolant from lower hoses
Remove serpentine drive belt
Remove water pump mount bolts
Remove water pump
Replace water pump
Reassemble
Fit air lift tool to cooling system expansion tank
Pull system to vacuum and lock off to inspect for leaks
Refilled cooling system with Porsche coolant
Bled system
Ran engine until cooling system at operating temperature
Test driven
Raised and inspected for leak
Reassembled
After cooling system cooled reinspected coolant level in expansion tank

Pressure test cooling system
Radiator top tank had bad leak
Filled system and inspected for pressure from engine in cooling system
Raise vehicle
Remove coolant hoses
Drain cooling system
Remove thermo fans
Remove radiator
Replace radiator
Reassemble
Pressure test cooling system
System held pressure
Flushed fresh water through system
Fit air lift tool to cooling system
Pull system to vacuum
Lock off to test for leak
No leak detected
Charged system with fresh coolant\ inhibitor
Ran engine till operating temperature
Inspected fan operation
Cooled
Test and top off coolant level

Remove top engine cover
Pressure test cooling system
Located leak at junction box above fuel cooler
Drain cooling system to below junction
Remove air intake pipe
Remove both Exhaust gas recirculation outlet pipes to throttle
Remove both EGR pipe support brackets
Move pipes to access Y intake duct
Remove intake duct
Clean carbon from duct ports
Remove top hose from junction
Remove by-pass pipe from junction
Remove junction mount bolts from head riser
Remove junction box from fuel cooler
Replace junction box assembly and seals
Reassemble cooling pipes
Wash area to remove pink coolant
Pressure test system
No leaks
Using vacuum unit remove coolant and water from valley in engine
Reassemble
Fit Air lift unit to cooling system
Evacuate system and lock off at -24hg
Inspect for leaks under vacuum
Recharge system with Coolant\ inhibitor

Raised vehicle
Removed driver front wheel
Removed passenger front wheel
Remove battery connection to disarm air bag system
Lock steering in straight ahead position
Released tension from steering tie rod lock nut from thread both sides
Using percussion tool freed interference fit between joint and steering arm both sides
Remove pinch bolt from rack universal spindle
Release universal joint from rack
Remove rack mount bolts
Remove power steering pipes to rack spindle
Remove steering rack assembly
Released lock nut on steering arm
Removed tie rod from Steering track arm thread , noting the position to return to on reassemble
Fit track rods to new rack
Reassembled
Filled steering with fresh fluid
Cycled steering from lock to lock before starting engine to bleed air from steering rack
Tested
Carried out wheel alignment

Raised vehicle
Removed driver\passenger front wheel
Released tension from steering tie rod lock nut from thread
Using percussion tool freed interference fit between joint and steering and arm
Released lock nut on steering arm
Removed tie rod from Steering track arm thread , noting the position to return to on reassemble
Removed steering rack boot clamps
Removed old rack boot
Replaced rack boot
Replaced rack boot mount clamps
Reassembled
Tested

Raised vehicle onto hoist
Remove splash trays
Disconnect battery
Drained gearbox oil
Removed front wheels
Removed lower control arms and stub axles
Removed track rod ends from stub axles
Removed drive shafts from gear box
Remove all upper connections to gearbox
Support engine
Removed Exhaust manifold bolts
Remove complete exhaust system
Remove tail shaft mount bolts at differential
Remove centre bearing bolts
Removed gearbox mounts
Removed all lower connections to gearbox
Removed gearbox
Removed clutch release bearing from bell housing extension
Lubricated extension
Replaced release bearing
Removed clutch plate and pressure plate
Inspected flywheel face for discolouration and deterioration
Removed flywheel
Machined flywheel surface
Press spigot bearing from flywheel
Press new spigot into flywheel
Refitted flywheel
Replaced clutch plate and pressure plate
Aligned plates
Refitted gearbox
Reassembled
Road tested OK

Remove wheel
Remove drive shaft retaining Nut
Remove stub axle connection to lower control arm
Remove stub axle connection to track rod end
Remove drive shaft from axle Knuckle
Remove drive shaft from transmission
Remove constant velocity inner joint from drive shaft
Cleaned dirt and grease from joint
Repacked joint with fresh molybdem disulphide grease
Replaced flex boot
Replaced flex boot clamps
Refitted joint to shaft
Tied boot to shaft and joint
Refitted shaft to transmission and axle knuckle
Reassembled
Road tested vehicle

Raise vehicle
Remove wheel
Remove drive shaft retaining nut
Remove brake calliper mount bolts
Remove brake calliper assembly
Hang brake calliper assembly on support hanger to preserve flex able brake hose
Remove rear brake disc rotor
Remove axle knuckle lower mount bolts
Remove strut lower mount bolts
Remove control arm bolts to axle knuckle
Remove rear handbrake shoes
Remove rear backing plate
Remove axle knuckle with hub
Fit press to knuckle press wheel hub from knuckle
Remove extra large circlip from knuckle
Fit knuckle to press
The bearing cage is and interference fit in the knuckle
Forced bearing cage from knuckle
Cleaned knuckle surfaces
Pack new bearing with fresh lubricant
Press new bearing into knuckle
Press hub into bearing
Reassemble
Road test

Remove air intake tube
Removed belt cover
Removed alternator belt
Removed air conditioning belt
Remove radiator cooling fan wiring connector
Remove radiator fan mount bolts
Remove fans
Remove power steering reservoir from mount and rest on engine guard
Raised vehicle
Remove stone trays
Set engine in timing belt removal position, not top dead centre as with most other makes
Hold engine
Remove front crank pulley bolt
Remove crank pulley
Remove radiator drain plug
Drain coolant from radiator
Dispose of coolant
Remove bottom radiator hose from thermostat housing
Remove thermostat housing bolts
Remove thermostat and housing
Inspect housing for seal damage and housing deterioration
Replace thermostat
Replace thermostat seal
Remove camshaft timing belt tensioner tension
Remove camshaft timing belt
Remove tensioner mount bolts
Remove tensioner and roller
Inspect roller for bearing noise, bearing free play and loss of lubricant
Inspect hydraulic tensioner operation
Remove tooth idler
Remove lip idler no 1
Remove idler no2
Inspect idlers for bearing noise, bearing free play and loss of lubricant
Remove oil pump
Remove oil seal front
Remove oil seal rear
Remove RTV
Retention oil pump backing plate screws
Inspect sealing surfaces
Replace rear oil pump seal
Apply RTV to rear oil pump
Press oil pump front seal into housing
Refit oil pump
Remove water pump
Clean sealing surfaces
Inspect sealing surfaces
Replace water pump gasket
Replace water pump
Replace camshaft timing belt idler no 1
Replace camshaft timing belt idler no 2
Replace camshaft timing belt idler toothed
Replace camshaft timing tensioner and roller
Replace camshaft timing belt
Release tension pin
Inspect tensioner operation
Rotate engine 2 rotations and realign timing marks
Inspect alignment
Fit belt tension gauge to belt
Inspect belt tension, compare to specification
Reassemble all of the above
Refit crankshaft pulley bolt
Tension bolt to specified torque
Fit air evacuation tool to cooling system
Pulled cooling system down to neg 24 in vacuum
Lock of f valve
Hold at vacuum to inspect for leaks
No leaks
Charged system with glycol\inhibitor
Reassembled
Tested
OK

Remove washer bottle
Remove air filter assembly
Remove oil filler tube
Remove spark plug high tension leads from plugs
Remove rocker cover mount bolts
Remove rocker covers
Remove spark plug tube seals
Remove rocker cover gaskets
Cleaned both rocker covers
Cleaned sealing surfaces
Replaced rocker cover gaskets
Replaced spark plug tube seals
Reassembled
Replaced rocker cover bolt seals
Tensioned bolt to manufacturers specified tension
Replaced oil filler tube seal
Refit oil filler tube
Washed engine both side
Washed cross-member below rocker covers
Tested

Remove rear seat cushion
Remove carpet covering body
Remove body cover
Remove fuel lines to sender \ pump unit
Remove electrical connector to sender \ pump unit
Fit fuel retainer cap special tool
Release fuel retainer from tank
Remove to sender \ pump unit
Remove petrol pump from to sender \ pump unit
Remove sender from suction unit
Replace suction unit
Refit fuel sender
Refit pump to suction unit
Reassemble
Test

Remove engine bay plenum cover bolts
Remove plenum cover to access top engine manifold
Remove connections to throttle body
Remove air intake tube to throttle body
Remove connections to inlet manifold
Remove inlet manifold mount bolts
Remove inlet manifold
Access fire wall side of engine
Remove connectors to ignition coils
Remove ignition coil clamp bolts
Remove ignition coils
Remove spark plugs
Replace spark plugs
Reassemble all of the above
Test

Remove rear brake calliper
Remove calliper mount bracket
Remove rear brake disc rotor
Remove floating rear axle mount nuts
Using percussion tool release tension on conical sleeves holding shaft to differential
Remove axle shaft
Inspect axle shaft seal
Remove taper bearing lock ring adjuster
Remove outer wheel bearing
Remove anti lock brake sensor mount bolt
Move sensor away from bearing housing
Remove bearing housing
Press axle shaft seal into axle housing
Clean bearing mount shaft
Inspect bearing grease hub sealing surface
Press hub seal from bearing case
Clean bearing case
Press bearing race inner and outer from bearing case
Press new race into inner and outer
Pack bearings
Replace bearings
Press seal into bearing case
Reassemble beaing to axle shaft
Set bearing preload and lock adjusters
Replace axle gasket
Refit axle shaft
Refit axle shaft nuts and tension to specified torque
Reassemble

Removed top engine cover
Removed battery
Removed battery tray
Supported engine with cross strut Tower Bridge
Removed transmission mount
Removed transmission fluid
Removed lower ball joint from stub axles
Remove steering track rod ends from stub axles
Remove drive shafts from transmission
Removed sub frame mount bolts
Removed sub frame assembly
Removed cover from bell housing
Removed all connections to transmission
Removed flex plate bolts to Torque convertor
Removed selector assembly
Removed starter motor mount bolts
Removed starter motor and supported
Removed all bell housing bolts
Removed transmission assembly
Remove flex plate
Inspect rear engine for leak
Remove rear main oil seal
Clean rear engine block
Clean sealing surfaces
Inspect surfaces
Press new seal into engine block
Refit flex plate
Tensioned flex plate mount bolts with torque wrench
Reassembled all of the above
Tested

Raised vehicle
Removed driver front wheel
Removed passenger front wheel
Remove battery connection to disarm air bag system
Lock steering in straight ahead position
Released tension from steering tie rod lock nut from thread both sides
Using percussion tool freed interference fit between joint and steering arm both sides
Remove pinch bolt from rack universal joint spindle
Release universal joint from rack
Support engine and transmission
Remove lower sub frame mount bolts
Remove catalytic convertor to engine pipe exhaust mount bolts
Lower lower section of sub frame exposing lower control arm rear bushes
Loosen high pressure pipe nuts to spool valve
Remove pipe tube nuts from spool valve
Remove rack mount bolts
Remove steering rack assembly
Released lock nut on steering arm
Removed tie rod from Steering track arm thread , noting the position to Return to on reassemble
Mount Rack assembly on bench
Press rack mount bushes from rack
Clean rack mount bush holes
Press new bushes into rack assembly
Reassembled
Filled steering with fresh fluid
Cycled steering from lock to lock before starting engine to bleed air from steering rack
Tested
Carried out wheel alignment

Remove stone guard
Removed driver front wheel
Drain cooling system
Remove serpentine belt tension
Remove drive belt
Removed water pump drive pulley
Remove water pump mount bolts
Remove ater pump from engine
Clean sealing surfaces
Seal water pump to engine
Reassembled
Fit air lift to cooling system
Evacuate cooling system and lock off under vacuum
Inspect for leaks under vacuum
Charged system with fresh glycol/inhibitor
Ran engine until thermostat opened
Road test

Raised vehicle
Remove spark plug wires from rocker cover
Remove rocker cover mount bolts
Removed stone guard
Remove Alternator belt
Remove rocker cover bolts
Remove rocker cover
Remove air conditioning belt
Support engine
Remove front engine mount
Removed top timing cover
Set engine to top dead centre number 1
Remove crank pulley bolt
Remove crank pulley
Remove timing covers
Remove timing belt tensioner
Remove timing belt
Remove water pump
Clean sealing surfaces
Replace water pump
Replace timing belt
Replace timing belt tensioner
Tensioned belt
Turned engine over by hand and inspected valve timing and belt tension
Reassembled all of the above
Replace rocker cover gasket
Fitted air lift to cooling system
Pulled cooling system down to vacuum
Locked off
Tested for leaks under vacuum
Recharged system with fresh glycol\inhibitor
Ran engine tested
OK

Raise Vehicle
Carry out to both sides
Support rear lower control arm
Remove lower control arm bolt from axle knuckle
Lower control arm to access lower shock absorber bolt
Remove lower shock absorber bolt
Remove upper shock absorber bolt from chassis
Remove shock absorber
Replace shock absorber
Reassemble
Road test

Raise vehicle
Remove splash tray
Remove tension on serpentine belt
Drain cooling system
Remove Battery connections
Remove alternator mount bolts
Remove alternator connections
Remove alternator
Remove water pump pulley bolts
Remove water pump mount bolts
Remove water pump assembly
Remove sealant from engine
Clean sealing surfaces
Inspect surfaces
Replace water pump
Fitted air lift to cooling system
Pulled cooling system down to vacuum
Locked off
Tested for leaks under vacuum
Recharged system with fresh glycol\inhibitor
Reassembled all of the above
Road test
Cooled and inspected\ adjusted coolant level

Removed top engine cover
Removed battery
Removed battery tray
Supported engine with cross strut Tower Bridge
Removed transmission mount
Removed power steering rack from sub frame assembly
Removed driveshaft bolts to differential
Removed lower ball joint from stub axles
Removed sub frame
Removed clutch slave cylinder from bell housing
Removed slave cylinder connection to flexible hose
Removed gear lever cable locks to free selectors from cables
Removed selector assembly
Removed starter motor mount bolts
Removed starter motor and supported
Removed all bell housing bolts
Removed transmission assembly
Cleaned burnt out clutch wool from inside bell housing
Removed clutch pressure plate bolts
Removed pressure plate and burnt out clutch plate
Removed flywheel mount bolts
Removed flywheel
Machine flywheel surface
Removed release bearing
Removed release bearing lever
Lubricated lever pivot point
Refitted lever
Replaced clutch release bearing
Refitted flywheel
Tensioned fly wheel bolts with torque wrench and compass wrench
Replace clutch plate and pressure plate
Tensioned clutch plate mount bolts with torque wrench
Reassembled all of the above
Tested

Remove engine cover
Remove air filter box cover clips
Remove air mass meter connection
Remove clamp holding air intake tube to throttle body
Remove throttle connections
Remove air intake manifold connections
Remove air intake manifold mount bolts
Remove air intake manifold
Remove rocker cover mount bolts
Remove rocker cover
Remove gasket
Clean sealing surfaces
Replace gasket
Reassemble all of the above
Wash engine
Road test
Reinspect for leak

Raise vehicle
Remove stone tray
Remove engine cover
Remove throttle body connections
Remove pipes to intake manifold
Remove connections to intake manifold
Remove intake manifold
Remove rocker cover mount bolts
Remove rocker cover
Clean sealing surfaces
Replace rocker cover gasket
Reassemble all of the above
Clean oil from rear engine and exhaust

Road tested vehicle
Adjusted clutch free play
Retested
Disconnect battery
Removed battery
Raised vehicle onto hoist
Drained gearbox oil
Removed front wheels
Removed lower control arms and stub axles
Removed track rod ends from stub axles
Removed drive shafts from gear box
Remove all upper connections to gearbox
Support engine
Removed sub frame assembly
Removed engine / gearbox mounts
Removed all lower connections to gearbox
Removed gearbox
Removed clutch release bearing from bell housing extension
Lubricated extension
Replaced release bearing
Removed clutch plate and pressure plate
Inspected flywheel face for discolouration and deterioration
Removed flywheel
Machined flywheel surface
Refitted flywheel
Replaced clutch plate and pressure plate
Aligned plates
Refitted gearbox
Reassembled
Reconnected battery
Road tested OK

Raise vehicle
Pressure test cooling system
Located leak at radiator
Remove stone tray
Remove lower hose and drain coolant from system
Remove front bump support bolts
Support front bumper
Remove bumper from brackets
Store bumper securely
Remove bumper rear cushions
Remove front cradle support bolts
Insert service tool to enable service mode
Remove front frame supports
Remove hoses from radiator
Remove thermo fan mount bolts
Remove thermo fan
Remove radiator support mounts
Remove radiator assembly
Replace radiator assembly
Reassembled
Fit air lift tool to cooling system expansion tank
Evacuate air from system
Locked off system under vacuum and tested for leaks
Charged system with fresh coolant glycol\inhibitor G12 plus plus

Carried out to both sides
Removed front wheels
Removed strut tower retaining nuts
Removed strut Clamp pinch bolt
Insert pinch clamp spreader
Tilted front suspension out to remove shock assemblies from pinch clamp
Fit each strut to hydraulic spring compressor
Compressed springs
Removed spring retainer plate nut
Removed tower bearing and bush
Release spring tension
Remove spring from strut
Replace strut
Fit spring and compress
Replace bump stops and dust boots
Reassembled shock in compressor
Reassembled on vehicle
Road tested vehicle .

Remove door inner trim
Remove door motor
Inspect motor and gear box ok
Inspect regulator
Remove outer door skin
Raise window and support
Remove window from regulator
Remove regulator assembly
Replace window regulator
Refit motor
Reassemble all of the above
Test

Removed top window weather shield
Remove door switches
Remove top trim cover
Remove inner door trim
Remove inner door skin mounts
Remove door skin complete with handle and speaker
Access window clamps
Remove clamps from regulator
Remove window glass
Remove window regulator guides
Removed window regulator
Remove motor from regulator
Replace window regulator
Refit window motor
Reassemble

Raise vehicle
Remove stone tray
Remove lower hose and drain coolant from system
Remove front bump support bolts
Support front bumper
Remove bumper from brackets
Store bumper securely
Remove bumper rear cushions
Remove front cradle support bolts
Insert service tool to enable service mode
Remove front frame supports
Remove fuel pipe connectors
Remove front engine mount
Removed top timing cover
Set engine to top dead centre number 1
Remove crank pulley bolt
Remove crank pulley
Remove timing covers
Fit crank gear locking tool
Remove timing belt tensioner
Removed large idler
Remove small idler
Remove timing belt
Remove water pump
Remove wiring to Ignition coils
Remove ignition coils
Remove rocker cover mount bolts
Remove rocker cover assembly
Fit special tool to rear camshaft chain tensioner
Release chain tension
Remove camshaft bearing clamp bolts
Remove camshaft bearing journals
Remove camshafts from engine
Remove rear tensioner assembly
Remove gasket
Clean sealing surfaces
Replace gasket and half moon
Refit tensioner
Refit camshafts
Refit cam journal clamps
Tension bolts to specified torque
Replace rocker cover gasket
Clean sealing surfaces
Replace water pump
Replace large roller
Replace large roller mount bolt
Replace small roller
Replace timing belt
Replace timing belt tensioner
Tensioned belt
Turned engine over by hand and inspected valve timing and belt tension
Fitted air lift to cooling system
Pulled cooling system down to vacuum
Locked off
Tested for leaks under vacuum
Recharged system with fresh glycol\inhibitor
Reassembled all of the above
Test

Raised vehicle
Removed stone guard
Remove serpentine belt
Support engine
Remove expansion tank
Remove fuel pipe connectors
Remove front engine mount
Removed top timing cover
Set engine to top dead centre number 1
Insert camshaft locking tools
Remove crank pulley bolt
Remove crank pulley
Remove timing covers
Fit crank gear locking tool
Remove timing belt tensioner
Removed large idler
Remove small idler
Remove timing belt
Remove water pump
Clean sealing surfaces
Replace water pump
Replace large roller
Replace large roller mount bolt
Replace small roller
Replace timing belt
Replace timing belt tensioner
Tensioned belt
Turned engine over by hand and inspected valve timing and belt tension
Fitted air lift to cooling system
Pulled cooling system down to vacuum
Locked off
Tested for leaks under vacuum
Recharged system with fresh glycol\inhibitor
Reassembled all of the above
Test

Remove front bump support bolts
Support front bumper
Remove bumper from brackets
Store bumper securely
Remove bumper rear cushions
Remove front cradle support bolts
Insert service tool to enable service mode
Remove front frame supports
Remove thermo fan mount bolts
Remove thermo fans
Replace thermo fans
Reassemble
Test

Remove engine cover
Remove engine intake tube clamps
Remove pipes to throttle body
Remove connections to throttle body
Connect diagnostic tool
Released fuel pressure
Remove high pressure fuel line
Remove fuel rail mount bolts
Remove connections to injectors
Remove all manifold connections
Remove manifold mount bolts
Remove manifold assembly
Separate throttle body from manifold
Separate fuel rail from manifold
Remove injectors from engine
Remove injector seals with special tool
Fit injector seals with special tool
Tool enable the Teflon seal to be fit and take the correct shape when re - inserted into engine
Refit injectors
Replace intake manifold assembly
Reassemble all of the above
Connect diagnostic tool
Re-enable fuel system
Ran engine
Set adaptions and basic settings
Road tested
Cleared faults
Road tested

Remove intake air tube
Remove intake air filter assembly
Disconnect throttle body wiring
Remove intake tube clamps
Remove connections to intake manifold
Remove intake manifold assembly
Remove intake manifold
Remove engine breather pipe from oil filter housing to rocker cover
Remove oil dipstick
Remove oil dipstick tube
Remove oil cooler mount bolts
Remove oil cooler assembly
Remove oil filter housing bracket mount bolts
Remove oil filter housing assembly
Clean oil from engine block and sump
Replace oil filter housing assembly
Replace oil dip stick
Replace engine breather pipe
Reassemble
Refilled engine oil
Ran engine
Tested for leaks
Washed under engine
Road tested
Raised vehicle inspected for leaks
Refit splash tray

Remove wheel
Remove drive shaft retaining Bolt
Remove stub axle connection to lower control arm
Remove stub axle connection to track rod end
Remove drive shaft from axle Knuckle
Remove drive shaft from transmission
Remove constat velocity outer joint from drive shaft
Cleaned dirt and grease from joint
Repacked joint with fresh molybdem disulphide grease
Replaced flex boot
Refitted joint to shaft
Tied boot to shaft and joint
Refitted shaft to transmission and axle knuckle
Reassembled
Road tested vehicle

Remove door trim
Reconnect door switch connections
Back probe power and grounds to motor
Back probe and inspect command from BCM to window module
Remove window motor/ module from inner door skin
Replace motor\ module
Reassemble
Test