Fitting the rear suspension assembly
Fitting the fuel lines
Position and secure the fuel lines to their mountings in the same order as they were removed.
Install
- the fuel line attachments between the fuel pump and fuel filter
- the fuel lines from the fuel pump and ejector pump.
Fitting the fuel lines into the clips
Fit the return line from the ejector pump (LH side).
Fitting the hand brake cable
Raise the rear suspension about 10 cm.
Remove the cable tie (A).
Fit the hand brake cable with clips; use a pop rivet (ø 4 mm) (B).
Raising the rear suspension
Raise the rear suspension with fuel tank.
Make sure the filler pipe does not foul the wheel arch liner. Make sure the fuel line is clear of the body and that the fuel gauge line does not get caught in the fuel strap brackets.
Lift up the tank fitting lines and fuel pump lines through the body (hatch).
| CAUTION | Secure the front part of the differential to the lift table. This prevents the rear suspension from tipping backward when lifted. |
Note. Check also that the fuel line between the fuel level sensor and the ejector pump does not foul the body when the rear suspension is lifted.
Adjust and secure the filler pipe's crash guard bracket.
Scheme 6
Fitting the retaining bolts for the rear axle member
Apply a couple of drops of threadlock, part number 1161351-0, to each bolt.
Fit all the retaining bolts for the rear axle member.
Note. Before fitting the rear axle to the body, measure the distance between the rear axle member guide ø 16. 5 mm holes (A) outside the rear retaining bolts, and the ø 16 mm holes furthest to the rear on the side members. The distance between the holes should be 595 mm +/- 2 mm.
Tighten the outer bolts to 80 Nm and the center bolts to 50 Nm .
Tightening the tank strap attachments
Tighten the tank strap attachments on both sides.
Remove the lift table.
Fitting the fuel tank EVAP lines
Install
- the brake pipe in the 4 clips
- the fuel and EVAP lines
- the lines to the protective cover
- the protective cover, use new nuts and washers
- protective covers.
Scheme 7
Fitting the propeller shaft and driver
Fit the propeller shaft to the driver.
Note. Fit the propeller shaft as marked earlier. Refit the bolts in their original positions.
Check that the contact surfaces of the viscous coupling and propeller shaft driver are clean.
Tighten opposite bolts to 8 Nm . Then tighten opposite bolts to 30 Nm . Use holder 9995561 . Start by tightening the same bolt both times.
Scheme 8
Fitting the longitudinal stay mountings and jack attachments
Fit the front longitudinal stay mountings and the jack attachments to the body.
Press up the link arms to their normal position.
See XXX (tension yoke) and XXX (normal position).
Connect the LH three-way branching to the LH jack attachment.
Fit the longitudinal stay brackets and the jack attachments using new bolts.
Tighten the 3 bolts for the longitudinal stay bracket to 65 Nm + 60° .
Tighten the bolt through the jack attachment to 105 Nm + 90° .
Fitting the exhaust pipe
Install
- the rear exhaust pipe
- the silencers.
Note. Check that there is clearance to the heat shields.
Fitting the filler pipe
Fit the fuel filler pipe to the body with the rubber bellows and lock ring.
Fitting the hatches and connections to the tank fitting
Install
- the front and rear hatch in the body and the connector holder. Make sure the rubber seal around the wiring is properly fitted when the rear hatch is fitted.
- the connectors to the tank fitting, fuel pump and ABS system.
Positioning the luggage compartment floor mountings
Position
- the mounting at front edge of the luggage compartment floor. Fit the screws along the rear edge.
- the hatch with the rear floor hatch.
Tighten the bolts.
Fitting the rear wheels
Install
- the wheel arch liner and mud flap on rear edge on right-hand side.
- the rear wheels.
Refill the fuel tank.
Test drive and perform functional checks.