Scribd Logo
Upload

Welcome to Scribd!

  • Motor

    Uploaded by

    Peter Dostoe Nemin
    4 views26 pages

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Report this Document

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    4 views26 pages

    Motor

    Uploaded by

    Peter Dostoe Nemin

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 26
    2De1 Chapter 2 Part D: Engine removal and overhaul procedures Contents Bane aft housing (OW? Giese engin) ~ removal, ingpecton and Engine and manual ransmission~ removal, separation anérefting 4 ret 10. Engine oval domanting soquence 8 Carthat inspection [IIIS Engine evemhul~gonoralefonation 2 Garishat=refting and main 13 Engine crorouloussorty sequence " Carshat removal 12 _Enginestransmission removal - methods and precautions 3 jinderblock/erankcase ~ ening and inspecten 1113 General information 2 finder head ~ dismantling 7 Main and big-end bearings ~ ins 16 finder nead ~ reassembly - © 9 Piston rings ~ refitting eee 18 finder head and valves - cleaning and inspection 8 Piston/connecting rod assembly — inspection 14 Engine ~ inital start-up after overhaul... 2-22-22 coos ees 21 Pistor/connecting rod assembly ~ removal 1" Exgne and automatic transmission ~ removal, Separation and Pistons/connecting rods ~ refitting and big-end bearing running reiting 5 clearance check 20 Degrees of difficulty Easjcutablefor | Folly easy, suitable rece wit ite forbeginer wth suitable for expert DY ‘experience 8 ‘some experience: oF professional Specifications Note: At the time of writing, some specifications for certain engines were not available Where the relevant specifications are not given here, refer teyour Peugeot dealer for furthor information Oylinder head Maximum gasket face distortion: wWengne (LEY). sana O08 til EW engines (6F2, RFR and REN) 0.05 mm DW engines (RHY, AHZ and 44K) 000000000 0.63 mm (¥inder ead height: WU engine (LEY): Nominal . 197.00 = 0.05 mm Minimum (ater grinding) 136.80 mm EW engines (6F2, RFR and AN Nominal... seeeeeeeeeteretereseneses 197,002 0.05 mm Minimum (ater grinding) 136.70 = 0.05 mm OW engines (RHY, RHZ and 44x} Nominal... 133.0 = 0.05 mm ‘Minimum (after grinding) 192.8 mm 2De2 Engine removal and overhaul procedures Valves Valve hoad diameter: Inet Exhaust XU engine mimmnnnaerenrasns (70,202 297 +0.0,-02mm EW? engine : 2980.1 mm 27.2201 mm EW10 engine 33.3 2 0.1 mm 29.02 0.1 mm Diesel engines: 2.0 tre engine - coceeceeeeecess Not avaliable Not available 22 litre engine nee SLL) 29.92 0.1 mm 25.0201 mm Valve stom diameter: XU engine « 6.98 +0.0, -0.015 mm 6.96 +0.0, 0.015 mm EW engines 5.985 +000, 0.015 mm 5.975 +0.0,-0.015 mm Diesel engines: 2.0 litre engine ern Not available Not avaiable 22 tre engine 5.968 = 0.05 mm 5.968 + 0.05 mm Overaltength: XU engine ... veceeeeess 10488 404, +00 1029 +0.4, 40.0 EW7enging 00S EET 10447204 mm 104.10 = 0.1 mm EW10 engine 108.182 03 mm 108.68 + 0.1 mm Diesel engines: 20 tre engine 2 Not available Not available 22 ire engine .- 102.55 = 0.15 mm 102.48 = 0.15 mm Valve head recess below cylinder head surace (maximum): DW12 diesel engine 0510 1.0mm 0.910 1.4mm Balance shafts (212 cllesel engine) Endfioat....... : seve 0.03 10 0.20 mm Backlash clearance between shafts... 0.01 1007 mm Backlash clearance between driver shaft and crankshaft gear 0.01 100.26 mm Cylinder block Cylinder bore diameter: KU engine Category A... error 83,00 +0.010, +0.0, Gatogory 8 a 83.01 +0.010. +00 Category C 83.02 +0.010. +0.0, EW7 engine: Nominal cos 82.7 40.018, 40.0 mm Oversize : 83.3 +0.016, +0.0mm EW1C engine: ‘Nominal ame 85.0 +0.018, +0.0mm Oversize. 85.6 +0.018, +0.0mm Diese! engines: 20 ire engine: ‘Standard £85,000 to 85.018 mm Oversize A1 85,090 to 85.048 mm ‘Oversize Ri 85.250 10 85.268 mm Oversize R2 85.600 to 85.618 mm. 22 litre engine: Standard 85,0000 85.018 mm Oversize Ri 85,600 10 85.618 mm Liner protrusion above block mating surface — XU7 aluminium biock engine only: Standard 0.03 10 0.10. mm Maximum citference between any two liners - 0.05 mm Piston rings End gaps: Petrol engines: Top compression ring XU engine ee Not available Ewengines isn enianarieni 0.2 +0.26, +0.0 mm ‘Second compression rng XU engine : cites Not available EW engines 0.2 40.25, +0.0. mm Diese! engines: Top compression ring vd 0.20 100.38 mm Second compression ring o.oo 2 0.80 to 1.00. mm Oi eontrot ring . 0.25 10 0.50.mm Engine removal and overhaul procedures 2D*3 Pistons ston diameter: U7 (LFY) engine: Category A: PDC type 82.970 + 0.007 mm ‘SMM type exe 82.912 = 0.005 mm Fe type SLL $2,982 2 0.008 mm Category 8: POC type ceseeeseeses 82,990 4 0.007 mm ‘SMM type 182.922 + 0.005 mm Futtype vee 82.972 + 0.005 mm Category ¢: POC type - ‘SMM type £82,982 = 0.005 mm Fettypo ‘i “ ENT engine: Nominal 82.857 mm Oversize cuenta 83.257 mm BW10 engine: Nominal ceceeere 84,948 mm. Oversiza 85.5483 mm WI0 engine: Standard £84,210 to 84.228 mm Maximum difference in weight between any twoppistons =. 4.09) W12 engine: Standard £84,931 + 0.008 mm Istoversize 85.531 + 0.009 mm ston weight class: Dw2 engine: Pt From 605 to 600 Fe PIII From 610 0 614 ro nu 1 From 616 to 610, Pa From 620 to 625 Weta: A 4 pistons must be of the same weight class. Crankshaft oat sees 0.07 to 0.82 mm ain bearing joumal diameter” Wengine ss ee 60.0 +0,-0.019 mm EWengines: ‘Nominal . : 60.0 +0, -0.025 mm Undersizo 59,7 40, -0.019 mm Desel engines: Standaré oseaeet socteeeeeesesesss 60.040, 0.025 mm. Undersizo 59.7 +0, -0.025 mm ‘Bg-end bearing journal diameter: WU engin Nominal... .esecseeee : 45.0 -0.025, -0.009 mm Undersize 447 -0.028, -0.008 mm EW engines: Nominal ravrereeeere seosewere 60.0 +0, -0.025 mm Undersiza 220000200 : 597 +0,-0.019 mm Bisel engines: Standard .. : coseeceeses $0.0 40,0016 mm Undersize DEIN 49.7 49,-0.016 mm Maximum bearing journal out-oF-round (all models) 0.007 mm Main bearing running clearance: Wergine 0.025 to 0.062 mm EW engines pauecaeceaa ce seeamteerte 0.020 to 0.054 mm Dosel engines” 0.025 t0 0.050 mm ‘Bg-end bearing running clearance ~ all models” -.... 0.025 t0 0.050 mm “These are suggested figures, typical for this type of engine ~ no exact values are stated by Peugeot Torque wrench settings Rlseries (petro) engine 2 Refer to Chapter 2A Specifications EW series (petrol) engine Refer to Chapter 28 Specifications DW series (diesel) engine Fer to Chapter 26 Specifications 2De4 Engine removal and overhaul procedures 1. General information Included in this Part of Chapter 2 are details ‘of removing the engine/transmission from the ‘car and general overhaul procedures for the cylinder head, cylinder block/erankcase and all other engine internal components. The information given ranges from advice cconceming preparation for an overhaul and the purchase of parts, to detailed step-by- step procedures ‘covering removal, Inspection, renovation and refiting of engine {nteral components. ‘tar Section 6, all instructions are based on the assumption that the engine has been removed from the car. For information ‘conceming in-car engine repair, as well asthe smoval_and refitting of those external components necessary for full overhaul, refer to Part A, Bor C of this Chapter (as applicable) ‘and to Section 6. Ignore any preliminary dismantling operations described in Part A. B for C that are no longer relevant once the {engine has been removed trom the car. Apart from torque wrench settings, which are given atthe beginning of Part A, B or (as applicable), all specifications relating to fengine overhaul are at the beginning of this art of Chaptor 2. 2 Engine overhaul -* femalnaor Tea It isnot always easy to determine when, or if, an engine should be completely overhauled, {a8 a number of factors must be considered. High mileage is not necessarily ‘an indication that an overhaul is needed, while low mileage does not preclude the need for an overhaul. Frequency of servicing is probably the most important consideration. An engine Which has had regular and frequent oil and filter changes, as well as other required ‘maintenance, should give many thousands of miles of reliable service. Conversely, neglected engine may require an overhaul very early in its it. Excessive oil consumption is an indication that piston rings, valve seals and/or valve uidas are in need of attention. Make sure that oil leaks are not responsible before deciding that the rings and/or guides are worn, Perform a compression test, as described in Part A or B (petro! engines) or C (diesel engine) of this Chapter, to determi the likely cause of the problem. Check the oil pressure with a gauge fitted in place of the oll prassure switch, and compare it with that spectid. It itis extremely low, the ‘main and big-end bearings, and/or the oil pump, are probably worn out Lass of power, fough running, knocking or metalic engine noises, excessive valve gear noise, and high fuel consumption may also ppoint to the nead for an overhaul, especialy i! they are all present at the same time. If a complete service does not cure the situation, ‘major mechanical work isthe only solution, ‘An engine overhaul involves restoring all Internal parts to the specification of a new engine, During an overnaul, the cylinder lines (XU7 engine), the pistons and the piston rings fare renewed. New main and big-end bearings are generally fitted: if necessary, the Crankshaft may be renewed to restore the Journals. The valves are also serviced es wel, since they are usually in lass-than-perfect condition at this point. While the engine is ‘being overhauled, other components, such os the distributor, starter and alternator, can be overhauled as well. The end result should be {an as-new engine that will give many trouble free mies. Note: Critical cooling system components such as the hoses, thermostat and coolant pump should be renewed when an engine is overhauled. The radiator should be checked Carefully, to ensure that itis not clogged or leaking. Also, itis a good idea to renew the oil pump whenever the engine is overhauled. Belore beginning the engine overhaul, read through the entire procedure, to familiarise yourself with the scope and requirements of the job. Overhauling an engine is not dificult it you follow carefully all of the instructions, have the necessary tools and equipment, and pay close attention to all specications. It can, however, be time-consuming, Plan on the car being off the road for a minimum of two wooks, especially if parts must be taken to an engineering works for repair or reconditioning. Check on the availabilty of parts and make sure that any necessary special tools and equipment are obtained in advance. Most work can be done with typical hand tools, although a number of precision measuring tools are required for inspecting parts to determine it they must be renewed. Otten the engineering works will handle the inspection of parts and offer advice concerning Feconditioning and renewal ‘Always wait until the engine has been completely dismantied. and until all components (especially the cylinder block/erankcase and the crankshaft) have ‘been inspected, before deciding what service and repair operations must be performed by {an engineering works. The condition of these components will be the major factor to consider when determining whether to overhaul the original engine, or to buy a reconditioned unit. Do not, therefore, purchase parts or have overhaul work done fon other components until they have been thoroughly inspected, As a general rule, time Is the primary cost of an overhaul, so it does ot pay to ft worn or sub-standard parts. ‘As final note, to ensure maximum ite and ‘minimum trouble from a reconditioned engine, everything must be assembled with care, in a spotlessly-clean environment. 3. Engine/transmission removal - ‘methods and precautions Ityou nave decided that the engine mustte removed for overhaul or major repair werk, ‘Several preliminary steps should be taken. Locating a suitable place to work ‘extremely important. Adequate work space, ‘along with storage space for the car, wile needed. It a workshop or garage is nat avaiable, atthe very least, a fat, level, len work surface is required. Cleaning the engine compartment and fengine/transmission before beginning th removal procedure wil help keep tools clan ‘and organised. ‘An engine hoist or A-frame will also be necessary. Make sure the equipment is aed in excess of the combined weight of the ‘engine and transmission. Safety is of pimay ‘importance, considering the potential hazards involved in liting the enginetransmission ot of the car. It this is the frst time you have removed a ‘engine, an assistant should ideally be available. Advice and aid from someone mor ‘experienced would also be helpful. There a ‘many instances when one person cannat ‘simultaneously pertorm all of the operations required when removing the engine trom the venice. Pan the operation ahead of time. Before starting work, arange forthe hire of or obtain all of the toois and equipment you wil need. ‘Some of the equipment necessary to perfom fengine/transmission removal and instalabon safely and with relative ease (in adaition toan ‘engine hoist is as follows: a heavy duty trolay jack, complete sets of spanners and sockets wooden blocks, and plenty of rags and cleaning solvent for mopping-up spilled ol ‘coolant and fuel, If the hoist must be hire, ‘make sure that you arrange for it in advance, ‘and perform all of the operations possible without it beforehand. This will save you ‘money and time. Plan for the car to be out of use for qutea while. An engineering works will be requred to pertorm some of the work which the do‘ yyourselfer cannot accomplish without speci ‘equipment. These places often have a busy ‘schedule, $0 it would be a good idea 0 ‘consult them before removing the engine, in ‘order to accurately estimate the amount of time roquired to rebuild or repair components that may need work. During the engine removal procedure, it advisable to make notes of the locations of al brackets, cable ties, earthing points, etc, = well as how the wiring harnesses, hoses ard alectrical connections are attached and routed around the engine and engine ‘compartment. An effective way of doing ths 10 take a series of photographs of the varovs ‘components before they are disconnected ar removed. A simple inexpensive disposab Engine removal and overhaul procedures 2D*5 amera is ideal for this and the resulting Bhotographs will prove invaluable when the lege is reited. ‘Aways be extremely careful when removing 1nd reftting the engine/transmission. Serious Inuy can result from careless actions. Plan ‘head and take your time, and a job of this ‘le, though major, can be accomplished ssccessuly Note 1: All manual transmission petrol ergnes and the DWWI0 diese! engine are removed upwards from the car as a complete tnt together with the transmission, then the tansmission is separated from the engine on the bench, The DW/12 diesel engine and all egines with automatic transmission are best ‘moved by lowering them from the engine ‘axmpartment ater removing the subframe. Note 2: Such is the complexity of the power init arrangement on these vehicles, and the \afiaions that may be encountered according {model and optional equipment fitted, that the folowing should be regarded as a guide to the work involved, rather than @ step-by-step procedure, Where differences. are ‘ecouniered, or additional component ‘dsconnection or removal is necessary, make ‘oes ofthe work involved as an aid to reiting. Engine and manual & transmission - removal, 3S procenevivmng oe Removal 1 Dsconnect the battery negative lead (refer twDisconnecting the battery at the end of this manu. 22 Apply the handbrake, then jack up the front df the vehicle and suppor it on axle stands (bee Jacking and vehicle support). Remove both front roadwheels. Also remove the Undertay from beneath the engine and tarsmission where fitted {Remove the engine top cover. if necessary for use of the lifting hoist, disconnect the bornet support struts as described in Chap- lw 11, Section 8, and tle oF support the tome! in the vertical position. Alternatively, famove the bonnet completely. 4 Drain the cooling system with reference to Chapter 1A or 1B. '§ Drain the transmission oil as described in Chapter 7A (see illustration). Refit tho drain 126 filer plugs, and tighten them to their speciied torque settings. 6 {the engine isto be dismantled, drain the exgjina oil and remove the oil filter as escribed in Chapter 1A or 1B (see Mustrations). Clean and refit the drain plug titening it securely, ‘Tele to Chapter 11, Section 24, and remove the from wineolarch liners trom both sides, '8 Reler to Chapter B and remove both front (iveshatts (see illustration). {ele to Chapter 1A or 1B and remove the alr crivebot, 4.5 Manual transmission oll drain plug 4.6 Engine oll filter on the EW10 engine ... 40 On diesel engines with an intercooler, remove the air duct leading trom the turbocharger tothe intercooler 11 Remove the exhaust referonce to Chapter 4A or 48, 12 From underneath the vehicle, stacken and remove the nuts and bolts securing the rear engine mounting connecting link to the ‘mounting assembly and subframe, and remove the connecting link. Refer to Chapter 2A, 2B, or20. 13. On mode's with air conditioning, refer to Chapter 9 and unbolt the compressor from the engine. On the DW12 diasel engine, it wil be necessary to unbott the auxiliary drivebelt idler for access to the upper compressor mounting bolt (see illustration). Do not cisconnect the rerigerant lines. Support or tio. the compressor to one side. 114. Unclip the power steering fuid pipe trom beneath the transmission. On models where system with 4.8 Removing the driveshatv/hub nuts 4.6a Unscrewing the sump drain plug (EW10 engine) the DW10 engine) the engino/transmission assembly is lowered trom the engine compartment, caretuly tie the pipe to the right-hand side of the engine ‘compartment. 45 On diesel engines with an intercooler, remove the air duct leading from the intercooler to the ait leaner. 46 Refer to Chapter 4A or 48 and remove the sir cleaner and its bracket, and all air inlet ucts, 17 Refer to Chapter 5A and remove the battery and battery tray. 18 Refer to Chapter 3 and remove the radiator. Although not essential, this will fensure ine radiator is not damaged as the fengine/transmission assembly is being removed. Alternatively, a piece of wood or card may be placed over the radiator as protection. If the radiator is lettin position, ‘emove the bottom hose from the thermostat housing and radiator. 4.18 Air conditioning compressor on the DW12 engine - auxiliary drivebelt idler has boon removed for access to the upper bolt 2D*6 Engine removal and overhaul procedures 4.29 Unbbolting the power steering pump from its bracket 19 On diesel engines, remove the preheating control unit cover, then remove the preheating Control unit housing, 20 Refer to Chapter 4A or 48 and remove the tengine management ECU and housing 21 Where applicable, disconnect the two ‘engine/transmission wiring connectors at the left-hand front of the engine/transmission. If rrecessary, trace the wiring hares back from the engine to the main hamess connectors at the fuse/relay box, and/or at the bulkhead ‘connection behind the battery tray location. Release the locking rings by twisting them ‘anti-clockwise and disconnect’ the ‘connectors. Also trace the wiring connectors: back to the transmission and disconnect all ‘engine related wiring and. earth leads in this ‘area. Check that all the relevant connectors have been disconnected, and thatthe harness is released from all the clips or ties, so that it is free to be removed with the angine/ transmission. On some models it may be necessary to disconnect all the relevant wiring from the engine, then unbolt the harness ‘conduit and move it to one side, 22 Remove the battery support bracket. 23 Unbolt tho accelerator control_and bracket from the let-hand side of the engine ‘compartment. 24 Disconnect the gear linkage cable end fittings from the levers on the top of the ‘transmission then unelip the outer cables from their supports and tie them to one side. 25 On models with a clutch release cable, disconnect the cable from the transmission release lever and support it to one side. On models with a hydraulic clutch, remove the 4.38 Lowering the engine/transmission assembly to the ground (DW12 engine) slave cylinder from the transmission with reference to Chapter 6, Section 4; this will necessitate disconnecting the hydraulic pipe first, as there is insufficient movement with the Pipe in position. 28 On diesel models disconnect the brake ‘vacuum pipe from the vacuum pump on the left-hand end of the cylinder head. Also disconnect the vacuum pipes from throttle bodies and swirl-contrel unit 27 On diesel models, disconnect the wiring {rom the EGR vale, 28 At the bulkhead, disconnect the coolant hoses from the heater matrix 129 Refer to Chapter 10 and unbolt the power steering pump from the engine, without ‘disconnecting the hydraulic hoses - access to the front bolls is through the pulley (see ilustration). Tie it to one side. Note on ‘models where the engine is lowered from the ‘engine compartment, it will be necessary to pull the power steering fluid pipe from under the transmission tothe right-hand side before lowering the engine. Take care not to damage the pipe at its connection tothe steering gear. ‘Atematively, disconnect the fluid pipe either {rom the steering gear or pump. 30 Disconnect the fuel supply and raturn hoses with reference to the appropriate part Cf Chapter 4. Tape over or plug the holes in the fuel rail and the ends of the hoses, to prevent entry of dust and dit. 31 On the DWI2 diesel engine and all ‘automatic transmission models, remove the front suspension subframe with reference to Chapter 10, 32 Using a hoist attached to the iting eyes fon the cylinder head, take the weight of the ‘engine and transmission. 38 Refer to Chapter 2A, 28 or 2C and unbolt the right-hand engine mounting. torque reaction link and the mounting itslt ‘34 Unscrew and remove the left-hand engine ‘mounting centre nut and washer, then unblt the rubber mounting from the body support bracket. 35 Romovo tho spacer, then unscrew the left-hand engine mounting centre stud trom the transmission and remove its washer. On the MLST transmission, unbolt the bracket together with tho stud. 38 Make a final check that any components which would prevent the removal of the ‘engine/transmission from the car have been removed or disconnected. Ensure that ‘components such as the gearchange selector Cables are secured so that they cannot be damaged on removal 37 On models where the engine is lifted ‘upwards from the engine compartment (see note in Section 3), raise the engine hoist and Carefully lit the engine’transmission upwards, Clear of the mountings, ensuring that nothing 's trapped or damaged. Enlist the help of an assistant during this procedure, as it will be necessary to tilt and twist the assembly shghtl to clear the body panels and adjacent ‘components. Once the engine/transmission assembly is high enough to clear the fot crossmember, withdraw the unit forward and ‘out of the engine compartment. Move the unt clear of the car and lower ito the ground. 38 On models where the engine is lowered from the engine compartment, carctuly love the assembly to the ground, making sutet clears the surrounding engine compartent ‘components (see illustration). On the DWIt engine, make sure that the power steering fluid pipe Is tied to the right-hand side of te engine compartment, so that it will clear ke engine ‘Separation 39 With the engine/transmission assembly removed, support the assembly on suitable blocks of wood on a workbench (or faling that, on a clean area of the workshop floor, 40 Undo the retaining bolts, and remove tw flywheel lower cover plate(s) from the trans 41 Slacken and remove the retaining bol, ‘and remove the starter motor from tw transmission 42 Undo the bolts and release the coolant heating housing from the transmission, naing the location of the earth leads and cable cigs also secured by the housing retaining bots, 43 Disconnect any remaining wiring com ectors at the transmission, then move te main engine wiring hamess to one side, ‘are adequately supported, then slacken ard remove the remaining bolts securing th transmission housing to the engin. Note tm correct fited positions of each bolt (and tw relevant brackets) as they are removed, ous ‘as a reference on reiting, 45. Carefully withdraw the transmission fam the engine, ensuring that the weight oft transmission is not allowed to hang on tw input shaft while itis engaged with the cuca friction disc. On models with the ‘pull-tyoe clutch, make sure that tho release fon ‘disengages fully from the release beanng, 46 If they are loose, romove the locating {dowels from the engine or transmission, ard keop thom in a safe place. Refitting 47 Ifthe engine and transmission have rat been separated, perform the operations described below from paragraph 58 onwards 48 Apply a smear of high-melting-pomt ‘grease (Peugeot recommend the use o Molykota BR2 plus ~ available from yor Peugeot dealer) to the splines of the transmission input shaft. Do not apply tor ‘uch, otherwise there is a possibilty of tm ‘grease contaminating the clutch friction ase. 49 On models with the ‘pull-type' clute, ft the release bearing to the release fork win feference to Chapter 6, ensuring that the ‘snap-ring is correctly in position in its groove 50 Ensure that the locating dowels art correctly positioned in the engine @ transmission Engine removal and overhaul procedures 2D*7 51 Carefully ofter the transmission to the ‘egre, uni the locating dowels are engaged. Engure that the weight of the transmission is ttalowed to hang on the input shaft as itis ‘egaged with tho clutch triction disc {& Feit the transmission housing-to-engine ‘bs, ensuring that all the necessary brackets: ‘ue correctly positioned, and tighten them securely ‘3 On models with the ‘pulltype' clutch, use the special too! described in Chapter 6 to pull the lease fork in order to force the release ‘baaing through the friction disc {4 Locate the main engine wiring hamess on the transmission and reconnect the relevant ‘wang connectors. On the OW'2 engine in tho oject car, the wiring connectors are ‘lowed as foliows: Foal tar Green High-pressure fuel pump White Gilpressure switch Grey Gilevel sensor Green Fuel at Red Coolant temperature sensor Green Gow pugs Grey Airconditioning compressor Grey {5 Refit tne coolant heating housing to the tarsmission, ensuring that the earth leads and cable clips are correctly attached, Refit the starter motor, and securely Jghten ts retaining bolts 17 Raft the lower fywheet cover plates) tothe actission, and securely tiie the bolts, Reconnect the hoist and lifting tackle to Be engine iting brackets. With the aid of an ‘sistant, lift the assembly into the engine ‘compartment, taking care not to damage surouncing components. Reft tne right-hand engine mounting and torque reaction link, but leave the link bolts feger-tgnt at this stage. {© Working on the left-hand mounting, refit the Iet-nand engine mounting stud to the tansmission together with its washer, then inl the epacer and coat it with grease. Raft tte rubber mounting to the body and tighten ‘eboits, thon refit the centre nut and washer td finger-tighten. On models with the MLST tarsmission, refit the bracket to the trans- ‘ission and tighten the bolts, {1 Postion the engine and transmission on the rountings, and refit the mounting nuts/bolts handstight at this stage. Remove the hoist {@ From underneath the vehicle, refit the rear ‘Rounting connecting link and fingor-tighten Be bolts. © Rock the engine to settle it on its rurtings, then go around and tighten all the ‘mounting nuts and bolts to their specified rave settings. 1H The remainder of the refitting procedure is rect reversal of the removal sequence, [wit relecence to the relevant chapters and [taing the following points: 4 Ensure thatthe wiring loom is correctly ‘outed and retained by all the relevant ‘taining clips; all connectors should be ‘corectly and securely reconnected. 1) Prior to refting the driveshatts to the transmission, ronow the driveshaft oil ‘seals as described in Chapter 7A «) Rafer to Chapter 10 whan refting the power stoering pump; the rear mounting bolt must be tightened las (see ‘tustration. ©) Ensure that all coolant hoses are correctly ‘reconnected, ant securely retained by their retaining clips. €) Refi! the engine and transmission with the correct quantity and type of lubricant, as

    You might also like