Engine and gearbox with air conditioning (page 11 of 12)

Refit

1. Using assistance, position engine and gearbox beneath vehicle.
2. Connect hoist to adjustable lifting bracket tool 18G 1598 .
3. Raise and manoeuvre engine and gearbox into position in vehicle.
4. Adjust lifting bracket tool so engine is horizontal in engine compartment.
5. Fit RH engine mounting to body and engine.
6. Fit through bolt securing RH engine mounting to body but do not tighten.
7. Fit 2 new nuts securing RH engine mounting to engine and tighten to 100 Nm.
8. Align engine and gearbox to gearbox mounting bracket, fit 2 bolts and tighten to 80 Nm.
9. Fit 2 bolts securing LH torque mounting to body and tighten to 45 Nm.
10. Fit 2 bolts securing RH torque mounting to body and tighten to 45 Nm.
11. Tighten through bolt, RH engine mounting to body, to 75 Nm.
12. Tighten through bolt, gearbox mounting to body, to 75 Nm.
13. Lower hoist and disconnect adjustable lifting bracket tool 18G 1598 from engine lifting bracket.
14. Remove bolt securing engine lifting bracket tool 18G 1572/2 to cylinder head and remove engine lift bracket.
15. Remove 2 bolts securing engine lifting bracket tool 18G 1572/1 to cylinder head and remove engine lifting bracket.
16. Clean camshaft rear cover plate.
17. Position camshaft rear cover plate to cylinder head, fit bolts and tighten to 25 Nm.
18. Secure coolant hose to clip on camshaft rear cover plate.
19. Fit rear engine mounting bracket to body and engine.
20. Position engine steady bar and fit through bolt securing rear engine mounting bracket to body, but do not tighten.
21. Align engine steady bar to engine, fit bolt and tighten to 45 Nm.
22. Fit 3 bolts securing rear engine mounting bracket to engine and tighten to 100 Nm.
23. Tighten through bolt, rear engine mounting to body, to 80 Nm.
24. Remove plugs from power steering pump and hose connections.
25. Lubricate new ’O’ ring with clean power steering fluid and fit to fluid outlet hose.
26. Connect fluid outlet hose to power steering pump and tighten union to 55 Nm.

CAUTION: To prevent damage to components, use two spanners when loosening or tightening unions.

27. Align fluid outlet hose clamp to bracket and secure with bolt.
28. Connect fluid inlet hose to power steering pump and secure with clip.
29. Connect coolant feed hose to coolant expansion tank and tighten clip.
30. Locate coolant expansion tank on body.
31. Fit 2 bolts securing coolant expansion tank to body and tighten to 9 Nm.
32. Secure coolant hose to clip on body.
33. Connect hose to heater and secure with clip.
34. Connect hose to heater control valve and secure with clip.
35. Connect expansion tank hose to inlet manifold and tighten clip.
36. Connect throttle cable to throttle cam.
37. Locate throttle cable adjusting nut in abutment bracket.
38. Ensure throttle cable is correctly routed and secure to clips on inlet manifold and hoses.
39. Connect brake servo vacuum hose to inlet manifold.
40. Connect hose to fuel return pipe and secure with clip.
41. Clean union of fuel filter and fuel filter outlet pipe.
42. Connect fuel outlet pipe to fuel filter and tighten union to 30 Nm.

CAUTION: To prevent damage to fuel system pipes and components use two spanners when loosening or tightening unions.