Refit

63. Disconnect oxygen sensor multiplug.
64. Raise hoist, tilt engine with gearbox as low as possible and using assistance, manoeuvre and lift engine and gearbox from vehicle.

Refit

1. Raise hoist, tilt engine with gearbox as low as possible and using assistance, manoeuvre engine and gearbox into vehicle. Set engine horizontal.

Power steering

2. Connect return hose to power steering pump, tighten clip.
3. Lubricate and fit new 'O' ring to union and connect hose union to power steering pump. Align bracket to pump, fit and tighten bolts.

All models

4. Fit R.H. engine mounting to engine, tighten nuts to 100 Nm.
5. Raise engine, fit and lightly tighten R.H. mounting bolt to body.
6. Fit mounting bracket to gearbox, tighten bolts to 100 Nm
7. Position L.H. engine mounting bracket to body, fit and tighten bolts to 45 Nm.
8. Raise engine, align gearbox bracket to L.H. engine mounting, fit bolts and tighten to 60 Nm.
9. Remove adjustable lifting bracket 18G 1598.
10. Remove lifting brackets tool 18G 1572 from cylinder head.
11. Tighten dipstick tube bolt to 9 Nm.
12. Tighten R.H. engine mounting through bolt to 82 Nm.
13. K16: Fit camshaft rear cover plate to cylinder head, tighten bolts to 9 Nm.
14. Power steering: Secure power steering pipes to body.
15. Fit expansion tank and tighten bolts to 9 Nm, secure hose in clip.
16. Connect clutch cable to release lever, see CLUTCH – Repairs.
17. Connect throttle cable and adjust, see MODULAR ENGINE MANAGEMENT SYSTEM – Adjustments.
18. Connect fuel return hose to pipe, secure clip.
19. Connect fuel feed hose union to pipe.
20. Alloy inlet manifold: Connect brake servo hose to manifold, use new sealing washers and tighten banjo bolt to 50 Nm.

Plastic inlet manifold

21. Connect brake servo vacuum hose to inlet manifold.
22. Secure throttle cable in clip on inlet manifold.

Alloy and plastic inlet manifold

23. Connect expansion tank hose to manifold, tighten clip.
24. Connect heater inlet and outlet hoses, tighten clips.
25. Connect top and bottom coolant hoses to engine, tighten hose clips.

Air conditioning

26. Fit compressor to engine, tighten bolts to 45 Nm.
27. Secure air conditioning pipe to engine bracket.
28. Connect compressor multiplug and position compressor heat shield.
29. Connect multiplug and fit alternator to engine bracket, tighten bolts to 25 Nm.
30. Fit compressor heat shield.
31. If fitted: Fit alternator heat shield.
32. Fit and adjust alternator drive belt, see MAINTENANCE.
33. Power steering: Fit and adjust power steering drive belt, see MAINTENANCE.
34. Fit starter motor see ELECTRICAL – Repairs.
35. Fit battery tray support bracket, tighten bolts to 9 Nm.
36. Connect vacuum hose and engine harness multiplug to E.C.U.
37. Connect engine harness multiplugs to fusebox.
38. Fit fusebox mounting bracket to body, tighten bolts to 9 Nm.
39. Fit battery tray and tighten bolts to 9 Nm, secure harness clip.
40. Connect intake hose to intake elbow and resonator.
41. Connect ht lead to distributor and coil, fit cover to coil.
42. Fit battery, connect '+' lead.
43. Fit air cleaner assembly, see MODULAR ENGINE MANAGEMENT SYSTEM – Repairs.
44. Connect oxygen sensor multiplug.