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

43. Clean gear selector linkage and gear change linkage ball joints.
44. Position gear selector linkage through rear engine mounting bracket and using tool 18G 1594 connect ball joints to gear selector and gear selector lever.
45. Using tool 18G 1594 connect gear change linkage ball joint to gear change lever.
46. Connect 3 engine harness multiplugs to main harness.
47. Secure multiplugs to mounting bracket.
48. Secure engine harness to mounting brackets.
49. Connect positive lead to engine compartment fusebox and secure with screw.
50. Fit engine compartment fusebox cover.
51. Secure air conditioning relay module to mounting bracket.
52. Fit evaporative emission canister to mounting bracket.
53. Secure evaporative emission canister breather hose to clips on fuel pipe.
54. Connect hose to fuel tank vent pipe.
55. Connect purge hose to throttle housing and secure with clip.
56. Connect multiplug to evaporative emission canister purge valve.
57. Secure fuel trap to engine control module mounting bracket.
58. Position relay module and connect 2 multiplugs.
59. Fit relay module to mounting bracket.
60. Fit 2 bolts securing mounting bracket to body and tighten to 9 Nm.
61. Secure engine harness clip to mounting bracket.
62. Fit engine control module. See ENGINE MANAGEMENT SYSTEM - MEMS, Repairs.
63. Clean 2 ends of clutch hydraulic pipe.
64. Connect 2 halves of clutch hydraulic pipe, ensure 2 halves are correctly engaged by trying to pull hydraulic pipes away from connector.
65. Secure clutch hydraulic pipe to clip on harness.
66. Connect 2 earth leads to starter motor upper bolt.
67. Fit upper bolt securing starter motor to engine and tighten to 45 Nm.
68. Connect battery cable to starter solenoid and secure with nut.
69. Fit plastic cap to nut securing battery cable to starter solenoid.
70. Remove caps from air conditioning pipes and compressor.
71. Clean mating face of compressor and air conditioning pipe union.
72. Lubricate 2 new ’O’ rings with refrigerant oil and fit to compressor.
73. Position air conditioning pipe union to compressor, fit bolt and tighten to 45 Nm.
74. Clean condenser pipe and compressor pipe unions.
75. Lubricate new ’O’ ring with refrigerant oil and fit to condenser pipe.
76. Connect condenser pipe to compressor pipe and tighten union to 25 Nm.

CAUTION: To prevent damage to air conditioning pipes or components use two backing spanners when loosening or tightening unions.

77. Clean compressor pipe and evaporator unions.
78. Lubricate new ’O’ ring with refrigerant oil and fit to evaporator pipe.
79. Connect compressor pipe to evaporator pipe and tighten union to 45 Nm.
80. Align air conditioning pipe to bracket on flywheel housing, fit bolt and tighten to 9 Nm.
81. Replace receiver drier. See AIR CONDITIONING, Adjustments.