Installing

Installing housing for coolant guide - GT3




Tools

Installation overview:




Components 1 - 8




Components 9 - 16

Overview:
1 Position housing for coolant
2 Install engine carrier
3 Tighten engine mount
4 Tighten oil return line
5 Push hose connections onto coolant pump
6 Install bracket for generator
7 Push on connecting hose
8 Install air-conditioning compressor
9 Install hydraulic pump
10 Install generator
11 Install catalytic converters and connecting sleeves
12 Install holder for oil filter
13 Install drive belt
14 Fasten belt pulley for hydraulic pump
15 Install air cleaner assembly
16 Bleed coolant circuit

Numbered procedures and instructions





1.
Position housing for coolant guide.
Replace the four O-rings on the two connection fittings, grease lightly and insert. Position the housing for coolant and fit the three upper hoses on the coolant pump. Then fit the engine carrier again. To do this, insert the engine carrier in the studs of the engine mounts and then swivel towards the engine.





2.
Tighten engine carrier.
Screw on the four fastening screws and tighten to 65 Nm (48 ft. lbs.).
Tighten the engine mounts on the left and right to 85 Nm (63 ft. lbs.).





3.
Remove engine support.
Carefully remove special tool 9111/3.





4.
Tighten oil return lines.
Tighten the oil return lines on the oil extraction pumps. Make sure to stop with an open-ended wrench when doing this.





5.
Push hose connections onto coolant pump.
Push the three upper hoses securely on the coolant pump. Fit the three hose clamps as shown in the figure. The hose clamps must be aligned so that the bracket for the generator is not pressing on top of them. Tighten the eight hose clamps. Push the lower hose onto the coolant pump and fit the spring band clamp again using special tool No. 72 or 73.





6.
Install bracket for the generator.
Place the bracket for the generator back into the engine compartment. Insert the front right screw with Loctite 574. Tighten the four screws to 65 Nm (48 ft. lbs.). Insert the connection fittings for the coolant with new O-rings which have been greased lightly, and tighten the connection fittings to 9.7 Nm (7.0 ft. lbs.)





7.
Push on connecting hose.
Push on the connecting hose between the bracket for the generator and the bracket for the oil cooler. Tighten the hose clamp. Tighten the lower hose holder to 9.7 Nm (7.0 ft. lbs.).





8.
Install air-conditioning compressor.
Place the air-conditioning compressor onto the bracket for the generator again. Connect electrical connections again. Screw in the three fastening screws and tighten to 23 Nm (17 ft. lbs.).





9.
Install hydraulic pump.
Place the hydraulic pump with connected wires onto the bracket for the generator again.
Tighten the four fastening screws. M8 screw to 23 Nm (17 ft. lbs.) M6 screw to 9.7 Nm (7.0 ft. lbs.) Push on belt pulley and position the three fastening screws.





10.
Install generator.
Place the generator onto the bracket for the generator again. Position the rear left fastening screw and the front right screw.
Tighten the two screws to 46 Nm (34 ft. lbs.). Connect the B+ terminal again and tighten the nut to 15 Nm (11 ft. lbs.)





11.
Install catalytic converters.
Push on the connecting sleeves again. Align the connecting sleeves so that the slot in the sleeve directly covers the arrow on the connector tube of the end muffler. First fit the catalytic converter of cylinder bank 1-3. Fit the catalytic converters with new gaskets.
Tighten the three nuts on the exhaust manifold to 30 Nm (22 ft. lbs.) Insert oxygen sensors and clip in the cable again.





12.
Install holder for oil filter.
Push in the holder in downward direction. Position the four fastening screws and tighten to 9.7 Nm (7.0 ft. lbs.).





13.
Installing drive belt.
Fit the drive belt on all pulleys. Put on the servo pump pulley with the drive belt and position the three fastening screws. Tension the drive belt on the tensioning roller. It is absolutely necessary to check that the drive belt is correctly seated on all belt pulleys.





14.
Tighten belt pulley on the hydraulic pump.
Tighten the three fastening screws on the belt pulley of the hydraulic pump to 23 Nm (17 ft. lbs.).





15.
Install air cleaner assembly.
Place the air cleaner assembly in the engine compartment. Align the throttle body and tighten the clamps on the left and right of the throttle body again.
Tighten the clamp on the connecting sleeve. Push on the plug of the hot film mass air flow meter and tighten the M6 x 34 hexagon-head bolt to 9.7 Nm (7.0 ft. lbs.).





16.
Bleed coolant circuit
Lift bow on bleeder valve. Allow engine to warm up and carry out brief accelerations. Top up missing coolant. Set antifreeze protection to - 37°C.