Converting Reconditioned Engine

Information 

• All components listed must be removed from the old engine and installed on the new engine. 
• Seals and O-rings must be replaced. 
• Aluminium screws and torque angle-tightened screws must be replaced. 
• All stoppers must be removed from the new engine. 

1. Convert bracket for torque support -1-  .

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   Torque support bracket

   1. 1.1  Unscrew screws -2-  .
   2. 1.2  Remove bracket for torsion mounting support -1-  and move it into installation position on the reconditioned engine.
   3. 1.3  Tighten screws -2-  .

      Tightening torque: > Tightening torque 23 Nm (17 ftlb.)  .

2. -1-  Convert vacuum sensors.

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   Vacuum sensor

   1. 2.1  Press retaining lugs -2-  outwards and pull off vacuum sensor.
   2. 2.2  Replace O-ring.
   3. 2.3  Fit vacuum sensor -1-  on the reconditioned engine.
3. Install vacuum line -1-  .

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   Vacuum lines

   1. 3.1  Release and disconnect connection -2-  .
   2. 3.2  Loosen holder -3-  .
   3. 3.3  Loosen connection -4-  .
   4. 3.4  Remove vacuum line -1-  and fit it on the reconditioned engine in reverse order.
4. Convert air-conditioning compressor bracket -1-  .

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   Air-conditioning compressor support

   1. 4.1  Unscrew the screws of the air conditioning compressor support -2-  .
   2. 4.2  Remove air-conditioning compressor support -1-  .
   3. 4.3  Refit air-conditioning compressor bracket -1-  on the reconditioned engine in reverse order. Pay particular attention to the following:
      1. 4.3.1 Tighten new  screws for the air-conditioning compressor bracket -2-  .

         > Tightening torque 23 Nm (17 ftlb.) 

5. Convert generator bracket -1-  .

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   Generator support

   1. 5.1  Unscrew screws -2-  .
   2. 5.2  Remove generator support -1-  .
   3. 5.3  Refit generator bracket -1-  on the reconditioned engine in reverse order. Pay particular attention to the following:
      1. 5.3.1  Tighten screws -2-  .

         > Tightening torque 23 Nm (17 ftlb.) 

6. Convert coolant hoses -1-  .

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   Coolant hoses

   1. 6.1  Unscrew screws -2-  .
   2. 6.2  Loosen spring band clamps -3-  using > VAS 6890 - spring band clamp pliers  .
   3. 6.3  Remove coolant hoses -1-  .
   4. 6.4  Refit coolant hoses -1-  on the reconditioned engine in reverse order. Pay particular attention to the following:
   5. 6.5  Tighten screws -2-  .

      > Tightening torque 9 Nm (6.5 ftlb.)