Work Instructions
No. 207aGRP. 83
Date: May 1988
SUBJECT:
INSTALLING SPLASH GUARDS TO PREVENT BELT SLIPPAGE
MODEL 124 WITH ENGINE 103
1. Cut out sound absorbing material from inner side of right splash guard (Figure 1).
2. Measure and cut a hole (35 mm) with a circular saw cutter as specified, for coolant hose, on outer side of right splash guard (Figure 2).
3. Cut and work work out an opening for the reinforcement tube (arrow, r=15) and torsion bar (5/6) on left and right splash guards (Figure 3).
4. Install rubber grommet (5) in right splash guard (Figure 4).
5. Saw off upper part (b) of thermocouple element (a) on left splash guard (Figure 5).
6. Unscrew six sheet metal screws (arrows). Remove and discard encapsulation panel and bracket below engine compartment.
7. loosen left and right torsion bar mounts from body rail, pull torsion bar down (Figure 7).
8. Drain coolant, and disconnect coolant hose (arrow, Figure 8).
9. Fasten right splash guard to body rail with two sheet metal screws (6), and to the lower control arm mounting bracket with one sheet metal screw (6, Figure 9).
10. Guide coolant hose through right splash guard and reconnect (Figure 10).
11. Loosen high pressure line (29, Figure 11) on power steering pump and turn it so that it lays level and points towards the back. Tighten high pressure line.
12. Fasten left splash guard to body rail with two sheet metal screws (6), and to the lower control arm mounting bracket with one sheet screw (6, Figure 12).
13. Reinstall torsion bar mounts to body rail (use new bolts).
14. Attach expandible fastening clip (4), to left and right radiator bracket (Figure 13).
15. Engage recess of encapsulation panel to lip of splash guard (arrow, Figure 14). From below the engine compartment push the encapsulation panel up so that the edges of the left and right splash guards and panel snap together.
16. Fasten encapsulation panel (1) using existing sheet metal screws (arrows Figure 15).
17. Refill coolant system, check for leaks.