Engine and automatic gearbox - models with air conditioning (page 10 of 11)

Refit

1. Connect hoist to adjustable lifting bracket tool 18G 1598.
2. Using assistance, raise engine and manoeuvre into position in vehicle.
3. Adjust lifting bracket tool so engine is horizontal in engine compartment.
4. Locate gearbox mounting bracket on engine LH mounting.
5. Fit new Nyloc nut securing bracket to engine mounting and tighten to 160 Nm.
6. Fit engine RH mounting bracket to engine mounting, steady bar and engine.
7. Align mounting bracket to engine, fit bolts and tighten to 160 Nm.
8. Fit nut securing mounting bracket to engine mounting and tighten to 85 Nm.
9. Tighten nuts securing engine mounting to body, to 45 Nm.
10. Fit bolt securing RH steady bar to mounting bracket and tighten to 80 Nm.
11. Lower hoist and disconnect lifting bracket tool 18G 1598 from lifting brackets.
12. Remove bolt securing lifting bracket tool 18G 1572/2 to cylinder head and remove lifting bracket.
13. Remove 2 bolts securing lifting bracket tool 18G 1572/1 to cylinder head and remove lifting bracket.
14. Clean camshaft rear cover plate.
15. Position camshaft rear cover plate to cylinder head, fit bolts and tighten to 25 Nm.
16. Connect engine steady bar to bracket on sump, fit through bolt and tighten to 80 Nm.
17. Tighten through bolt, engine steady bar to subframe, to 80 Nm.
18. Remove plugs from fluid cooler hose unions, lubricate new ’O’ rings with gearbox and fit to unions.
19. Connect fluid cooler hoses to gearbox and tighten unions to 37 Nm.
20. Fit selector cable to abutment bracket and push anti-vibration rubbers into position.
21. Tighten selector cable lock nut to abutment bracket.
22. Slide selector cable rod sleeving into position.
23. Connect selector cable rod to selector rod, DO NOT tighten nut.
24. Remove caps from air conditioning pipes and compressor.
25. Clean mating faces of air conditioning pipe union and compressor.
26. Lubricate 2 new ’O’ rings with refrigerant oil and fit to compressor.
27. Position air conditioning pipe union to compressor, fit bolt and tighten to 35 Nm.
28. Clean condenser pipe and compressor pipe unions.
29. Lubricate new ’O’ ring with refrigerant oil and fit to condenser pipe.
30. Connect condenser pipe to compressor pipe, fit bolt and tighten to 6 Nm.
31. Clean compressor pipe and evaporator pipe unions.
32. Lubricate new ’O’ ring with refrigerant oil and fit to compressor pipe.
33. Connect evaporator pipe to compressor pipe and tighten union to 45 Nm.

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

34. Align air conditioning pipe to bracket on flywheel housing, fit bolt and tighten to 6 Nm.
35. Remove plugs from power steering pump and hose connections.
36. Lubricate new ’O’ ring with clean power steering fluid and fit to fluid outlet hose.
37. 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.

38. Align fluid outlet hose clamp to bracket and secure with bolt.
39. Connect fluid inlet hose to power steering pump and tighten clip.