B - Work Instructions

B. Subsequent Installation of Engine Mount Cooling Tube

When Engine Mounts are Replaced

Model 201.024/028 (Except Model 201.024, Model Year 1984)

When engine mounts have to be replaced, an engine mount cooling tube has to be installed in all model 201.024/.028 (except 201.024 model Year 1984).
IN 201.024 MODEL YEAR 1984, INSTALL NEW HEAT SHIELD ONLY.

Procedure

Note:
- ON VEHICLES WITHOUT TIE-DOWN BRACKET, DISREGARD STEP 13.

- APPLY ZINC DUST PAINT TO ANY CUTS AND HOLES DRILLED AND JOINING SURFACES TO PREVENT CORROSION.

1. Disconnect battery.
2. Disconnect alternator rear cover.
3. Remove air cleaner.
4. Loosen fan shroud.
5. Remove the upper bolt on the left and right engine mount.
6. Raise the vehicle.
7. Remove the right front wheel.
8. Remove the lower engine compartment cover.
9. Remove the right engine compartment side-cover.




10. Cut out the template (sketch) along lines A and B (Figure 6).




11. Place template (C) as shown in Figure 2 on the right engine compartment side-cover and mark the section to be cut out along line B.
12. Cut out marked section and remove any burrs.




13. Cut off the right tie-down bracket at the side member (dashed line, Figure 3) and apply zinc dust paint to cuts.
14. Unscrew the Allen bolts for the right and left engine mounts at the front frame cross member.
15. Lift the engine, support and secure engine between oil pan and front frame cross member.
16. Remove the left and right engine mounts and the heat shield. Position the left engine mount on the frame cross member with an Allen bolt.
17. Lower the vehicle.




18. Measure diameter of hole D in the front frame cross member and scribe a mark at distance A on the front axle cross-member. Measure from the edge of the hole D.

If D = 13 mm then A = 48.5 mm
If D = 20 mm then A = 45.0 mm

Extend the center line of hole D straight forward in the direction of vehicle travel and mark the position to be drilled with a center punch.

19. Drill a 4.4 mm hole in the front frame cross member.
20. With the hex bolt, position the new right engine mount and new heat shield on the engine mount bracket.
21. Lift the vehicle.
22. Remove support between oil pan and front frame cross-member. Lower the engine and insert the Allen bolt on the right engine mount.
23. Install modified right engine compartment side-cover.




24. Position the cooling tube and mark the hole in the side member (Figure 5). Remove the cooling tube and drill 4.4 hole into side member.
25. Install two-piece cooling tube and fasten to side member.
26. Exchange towing hook flap in front bumper.
27. Tighten the Allen bolts for the engine mount at the front frame cross member from underneath (torque 40 Mm.).
28. Install the lower engine compartment cover.
29. Mount the right front wheel.
30. Lower the vehicle.
31. Insert the hex. bolt on the left engine mount. Tighten both hex bolts on the left and right engine mount (torque 55 Nm).

Note:
The heat shield should not make side contact with the engine mount bracket and both engine mounts must be tightened tension free.

32. Attach the air cleaner.
33. Attach the fan shroud.
34. Reconnect the alternator rear cover.
35. Connect the battery.




Parts Information

In Case of Warranty:
Time Allowance

02-2213 Engine mount cooling kit, install
with replacement of engine mount 2.2 hrs. | 41/47

Damage Code

24 900 04 Installation of engine mount cooling tube and replacement of front engine mounts