Engine and gearbox - models with air conditioning (page 7 of 8)

66. Remove 2 bolts securing engine LH mounting to bracket.
67. Lower engine on hoist.
68. Remove 2 bolts securing bracket to gearbox.
69. Remove bracket from gearbox.
70. Remove 4 bolts securing engine LH mounting to body.
71. Remove engine LH mounting.
72. Using assistance, raise and remove engine and gearbox, tilt engine and manoeuvre during lifting to clear engine compartment.

Refit

1. Using assistance, lower and manoeuvre engine and gearbox into position in vehicle.
2. Adjust lifting bracket tool so engine is horizontal in engine compartment.
3. Position engine LH mounting to body, fit bolts and tighten to 45 Nm.
4. Position mounting bracket to gearbox, fit bolts and tighten to 45 Nm.
5. Raise engine on hoist and align mounting to bracket.
6. Fit bolts securing engine LH mounting and tighten to 45 Nm.
7. Fit engine RH mounting to engine, fit bolts and tighten to 105 Nm.
8. Lower engine.
9. Align engine mounting to body.
10. Fit engine mounting restraint bar, fit bolts and tighten to 45 Nm.
11. Align tie bar to engine RH mounting, fit bolt but DO NOT tighten.
12. Remove bolts securing lifting bracket to engine and remove bracket.
13. Fit bolts securing h.t. lead clip plate to cylinder head and tighten to 10 Nm.
14. Fit spark plug cover, fit screws and tighten to 2 Nm.
15. Connect hose to PAS fluid reservoir and secure clip with clip.
16. Connect expansion tank return hose to thermostat housing and secure with clip.
17. Connect radiator top hose to thermostat housing and secure with clip.
18. Connect bottom coolant hose to radiator and coolant rail, secure with clips.
19. Secure coolant hose to clip on engine LH mounting bracket.
20. Clean 2 ends of clutch hydraulic pipe.
21. Connect 2 halves of clutch hydraulic pipe, ensure 2 halves of pipe are correctly engaged by trying to pull hydraulic pipes away from connector.
22. Secure clutch hydraulic pipe to clip on harness.
23. Remove plugs from end of air conditioning pipes.
24. Clean air conditioning pipe unions.
25. Lubricate 2 new ’O’ rings with refrigerant oil and fit to air conditioning pipe unions.
26. Connect compressor pipe to condenser pipe and tighten union to 22 Nm.

CAUTION: To prevent damage to air conditioning pipes or components, use 2 spanners when loosening or tightening unions.

27. Connect compressor pipe to evaporator pipe and tighten union to 22 Nm.
28. Replace receiver/drier. See AIR CONDITIONING, Repairs.
29. Remove plugs from PAS pipe unions, connect union and tighten to 37 Nm.

CAUTION: To prevent damage to PAS pipes, use 2 spanners when tightening unions.