Engine and manual gearbox (page 9 of 9)

Refit

1. Raise engine assembly into position using assistance.
2. Fit engine RH mounting assembly.
3. Align engine mounting assembly.
4. Fit 3 bolts securing engine mounting to engine and tighten to 85 Nm.
5. Fit mounting restraint bar to mounting, fit and tighten 2 nuts to 45 Nm.
6. Align mounting tie bar to body bracket, fit and tighten bolt to 90 Nm.
7. Tighten bolt securing mounting tie bar to mounting to 90 Nm.
8. Align engine LH mounting to bracket.
9. Fit engine LH mounting, tighten M10 nuts to 45 Nm and M12 nut to 70 Nm.
10. Release lifting tool chains from engine.
11. Remove lifting tool 18G 1598.
12. Using assistance, fit front beam to vehicle, fit bolts and tighten to 69 Nm.
13. Attach lower tie bar to sump, tighten bolts to 85 Nm.
14. Fit LH and RH radius rod to lower arm bolts and tighten to 105 Nm.
15. Clean splines of LH drive shaft, fit NEW circlip to end of shaft.
16. Smear differential oil seal with clean engine oil.
17. Insert drive shaft in differential and push fully home until circlip locks into differential groove. Pull on inner housing to ensure circlip is fully engaged.

CAUTION: Keep drive shaft horizontal to avoid damaging differential oil seal.

18. Engage swivel pin in lower arm and tighten nut to 50 Nm, tighten to align hole and fit NEW split pin.

CAUTION: Bend split pin ends, against face of nut and along swivel pin.

19. Engage damper fork on damper so that tab is aligned with slot in damper fork.
20. Insert lower arm bolt and pinch bolt, tighten finger tight.

CAUTION: The bolt and nut should be tightened with the vehicle’s weight on the suspension.

21. Repeat operations to fit RH drive shaft and damper fork.
22. Position steady bar and gear selector rod.
23. Align holes in selector shaft and selector rod.
24. Fit selector rod roll pin, fit retaining clip.
25. Fit steady bar washers and bolt, tighten bolt to 60 Nm.
26. Fit exhaust front pipe. See MANIFOLD & EXHAUST SYSTEMS, Repairs.
27. Fit centre beam; fit bolts and tighten to 55 Nm.
28. Connect PAS pump feed hose to fluid reservoir and tighten clip.
29. Remove plugs from air conditioning pressure pipe union.
30. Clean union joint.
31. Lubricate NEW ’O’ ring with refrigerant oil.
32. Fit ’O’ ring to union.
33. Connect union and tighten to 17 Nm.

NOTE: Use 2 spanners when tightening or loosening unions.

34. Remove plugs from suction pipe union.
35. Clean union joint.
36. Lubricate NEW ’O’ ring with refrigerant oil.
37. Fit ’O’ ring to union.
38. Connect union and tighten to 17 Nm.

NOTE: Use 2 spanners when tightening or loosening unions.

39. Position suction pipe clip to bonnet locking panel, fit and tighten bolt.
40. Connect coolant heater feed hose to engine outlet pipe and tighten clip.
41. Connect boost pressure sensing pipe to turbocharger.
42. Connect vacuum pipe to vacuum pump pipe and secure clip.
43. Connect vacuum hose to EGR valve.
44. Secure fuel filter to mounting bracket and position coolant rail and engine harness.
45. Position coolant rail bracket to gearbox mounting plate bolt, tighten bolt.
46. Remove plugs from PAS pump pressure hose union.
47. Clean union joint.
48. Lubricate NEW ’O’ ring with PAS fluid, fit ’O’ ring to union and tighten union to 25 Nm.

NOTE: Use 2 spanners when tightening or loosening unions.

49. Connect coolant hose to engine oil cooler inlet pipe and tighten clip.
50. Connect coolant hose to radiator outlet pipe and tighten clip.
51. Fit coolant hose assembly.
52. Connect coolant hose to engine coolant rail and tighten clip.
53. Connect coolant hose to engine oil cooler inlet pipe and tighten clip.