Engine and gearbox assembly - sequential auto (EM-CVT) (page 9 of 9)

Refit

1. Connect hoist to 18G 1598 and raise engine assembly.
2. Position subframe assembly under engine.
3. Lower engine assembly onto subframe, align RH buttress and LH engine mounting.
4. Fit RH buttress bolts and tighten to 45 Nm.
5. Fit nut and bolt securing gearbox mounting to RH buttress and tighten to 82 Nm.
6. Position rear engine steady to bracket on sump and tighten bolt to 85 Nm.
7. Lower hoist and remove 18G 1598, remove lifting brackets 18G 1572/1 and 18G 1572/2.
8. Using a new gasket, position exhaust front pipe, engage front pipe to support rubber, fit exhaust manifold to front pipe flange nuts and tighten to 70 Nm.
9. Clean end of both drive shafts.
10. Lubricate differential oil seals.
11. Wipe taper joints of both hub ball joints and upper arms.
12. Fit both hub assemblies to upper arms and engage both drive shafts to differential.
13. Fit lock washers to upper ball joint pins and tighten nuts to 54 Nm.
14. Bend lock washers upward to lock nuts.

NOTE: Pull outwards on drive shaft inboard joints to check for full engagement.

15. Align both hubs to lower arms and tighten bolts to 100 Nm.
16. Wipe tapers and seats of track control arms and hubs.
17. Fit track control arms to hubs and tighten nuts to 30 Nm.
18. Fit inhibitor/reverse switch and tighten to 12 Nm.
19. Connect multiplug to inhibitor/reverse switch and secure lead to clip.
20. Position engine table under body, and carefully lower onto engine and gearbox assembly.
21. Align subframe to body and loosely fit bolts.

NOTE: Fit rear anti-roll bar mounting brackets to subframe rear mounting bolts.

22. Carefully lower body remaining distance onto subframe and tighten bolts to; Subframe front bolts = 30 Nm. Subframe rear bolts = 45 Nm.
23. Raise vehicle and remove engine table.
24. Fit bolts securing anti-roll bar to mounting brackets and tighten to 22 Nm.
25. Fit rear anti-roll bar to anti-roll bar links, fit bolts and tighten to 35 Nm.
26. Connect dampers to upper arms, fit bolts and tighten to 45 Nm.
27. Clean brake caliper mating faces.
28. Fit rear RH brake caliper to hub, fit bolts and tighten to 85 Nm.
29. Fit rear LH brake caliper to hub, fit bolts and tighten to 85 Nm.
30. Clean ABS sensors and mating faces.
31. Fit ABS sensors and spacers, fit bolts and tighten to 10 Nm.
32. Secure ABS leads in clips.
33. Fit tail pipe heat shield. See MANIFOLD & EXHAUST SYSTEMS, Repairs.
34. Clean oil cooler pipe ends and mating faces.
35. Connect and tighten oil cooler pipe unions.
36. Fit selector cables to gearbox abutment brackets and secure with spring clips.
37. Clean hydragas pipe unions.
38. Fit new ’O’ ring seals to hydragas pipe unions.
39. Connect hydragas pipes to hydragas units and tighten to 20 Nm.
40. Models with A/C: Connect A/C pipes and tighten unions.
41. Fit hoses to coolant rail on underside of vehicle and secure with clips.
42. Connect heater hoses and secure with clips.
43. Fit road wheel(s) and tighten nuts to correct torque. See INFORMATION, Torque wrench settings.
44. Lower vehicle.
45. Fit road speed transducer multiplug.
46. Position engine harness earth leads to body, fit and tighten earth lead bolt.
47. Connect fuel return hose.
48. Connect EVAP cannister purge valve multiplug.
49. Connect engine harness and relay unit multiplugs.
50. Fit ECM bracket and tighten bolts to 8 Nm.