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Fitting the power train

Fitting the power train

Warning

A large number of hoses, electrical leads, etc., are secured with cable ties of rigid plastic.

When these ties have been pulled tight, cut off any excess so that the ends remaining at the fixing points are as short as possible.

Help to prevent cuts and scratches caused by the sharp ends of cable ties!




1. Fit the subframe and place the lifting trolley with power train under the raised car.

2. Carefully lower the car and raise the lifting trolley. Position the drive shafts and end pieces.


3. Hang the A/C compressor in place and tighten the bolts loosely. Then tighten the bottom bolt.

4. Lift the engine and fit the front mountings.


5. Tighten the bolts on the subframe.

Tightening torques:

Front: 115 Nm (85 lbf ft)

Centre: 190 Nm (140.6 lbf ft)

Rear: 110 Nm + 75° (81.4 lbf ft + 75°)

6. Fit the oil hoses for the oil cooler (turbo).


Tightening torque 8 Nm (6 lbf ft)

Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressures, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 30 15 815 Cleaning agent to wipe clean inside the ends of the hoses. Clean also the connecting pieces. If hose clips are rusty or damaged, they must be replaced with new ones to maintain the correct clamping force.


7. Fit the pipe between the turbocharger and the charge air cooler (turbo).

8. Fit the gearbox oil hoses (aut.).

Tightening torque: 25 Nm (18.5 lbf ft)

9. Clean the area for the joint in the exhaust pipe.


10. Fit the front exhaust pipe to the exhaust manifold or, alternatively, the turbocharger. Lubricate the studs on the turbocharger with Molycote 1000 before fitting. Hang up the three way catalytic converter.

11. Screw together the joint between the front and intermediate exhaust pipes.

12. Fit the air shields and covers in the wheel housings.


13. Fit and tighten the nuts on the end pieces.

Tightening torque: 75 Nm (55.5 lbf ft)

14. Replace the brake caliper.


Tightening torque: 105 Nm (77.7 lbf ft)

15. Fit the hub centre-nuts loosely and put on the wheels.

Tightening torque: 110 Nm (81 lbf ft)

16. Lower the car and tighten the hub centre-nuts.

Tightening torque: 290 Nm (214.6 lbf ft)

Tightening torque, nuts with top groove: 170 Nm + 45° (126 lbf ft + 45°)

Warning

Do not forget to tighten the hub centre-nuts.


17. Insert the wiring harness through the bulkhead. Check the seal. Lay the cable to the boost pressure control valve (turbo).


18. Connect the engine wiring harness under the dashboard, replace the control module for the central locking system, fit the glove box or, alternatively, the lower section of the dashboard and replace the mat. Make sure the rubber grommet is positioned correctly.

19. Connect the clutch pressure pipe to the gearbox and fit the locking clip. Bleed the system.


20. Fit the gear selector cable (aut.) or alternatively assemble the gear selector rod (man). Check the gear positions.

Tightening torque: 21 Nm (15.5 lbf ft)

21. Connect the gearbox ventilation hose (aut.).

22. Connect the oxygen sensor cable.


23. Connect the electrical connections on the gearbox.

24. Connect the ground cable to the gearbox and the positive cable to the plus terminal.


25. Tighten the top bolt to the A/C compressor and reconnect the electric connection.

26. Fit the hose for the secondary air injection (certain cars).

27. Connect the coolant hoses.

28. Fit the pressure pipe between the charge air cooler and the throttle body (turbo).

29. Fit the power steering pump, mount the belt and check the position of all the belt pulleys.

30. Relieve the belt tensioner with a ratchet handle extension and remove the drill.

31. Fit the boost pressure control valve (turbo) and vacuum hose for the secondary air injection (certain cars). Fit the heat shield (turbo).


32. Fit the pressure sensor (turbo) and replace the vacuum hose for the brake servo.


33. Connect the tank ventilation hose and fuel hoses.

34. Fit the cruise control unit with cable, reconnect the electric connection and hook the cruise control cable onto the throttle body. Hook on the accelerator cable.

35. Check that the radiator drain plug is securely tightened and fill with coolant. Check for leaks.

36.
Note

AC/ACC should be OFF.


Fill the cooling system to MAX level. Close the cap on the expansion tank, start the engine and warm it up at various engine speeds until the radiator fan starts. Carefully open the cap and top up to MAX.

37. Check the oil level. Fit the engine cover or, alternatively, the resonator, remove the wing protectors and make sure the engine bay is clean.

38. Start the engine and check all functions. Conduct a road test. Set the clock and radio code if applicable.