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Power unit, fitting

Power unit, fitting


1. Position the trolley lift with power train and adjust its position in relation to the body. Use 82 93 102 Extension, 500 mm, 3/8 square through the holes in the subframe to the attachments in the body. See Centring tool, engine and subframe.

2. Lift a little higher and position the lower swivel joints to the steering swivel members. If necessary, adjust the trolley lift screws to provide even contact with the body. Check that the guide pins are positioned correctly relative the reference holes in the body.

3. Position the bolts and screw them through the subframe into the body.

4. Raise the engine completely and tighten the subframe bolts.

Tightening torque 75 Nm + 135° (55 lbf ft +135°)


5. Lower the trolley lift and move it out of the way.

6. Lower the car.

7. Fit the left and right-hand engine mountings.

Tightening torque, right 50 Nm (37 lbf ft)

Tightening torque, left 50 Nm (37 lbf ft)

Tightening torque, right-hand engine pad to body: 40 Nm + 60° (30 lbf ft+ 60°)


8. Remove 83 95 212 Strap from the radiator member and A/C compressor.


9. Lift off the radiator member.

10. Raise the car.

11. Remove 83 96 145 Centring fixture, subframe - engine from the subframe.


12. Option: Fit the bracket for the headlamp angle sensor and the connector. Secure the cable to the subframe.

13. Fit the front exhaust pipe.


14. Up to and including Vehicle Identification Number 71107671: Fit the oil sump's insulation.


15. Fit the intermediate shaft bracket and the intermediate shaft.


16. Fit the right-hand drive shaft.


17. Fit the lower swivel joints to the steering swivel members.

Tightening torque 50 Nm (37 lbf ft)

Important

Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.



18. Position the lower anti-roll bar links and tighten them while gripping the flats with a thin spanner.

Tightening torque 64 Nm (47 lbf ft)


19. Position the outboard steering links and tighten them.

Tightening torque 35 Nm (26 lbf ft)

20. Fit the drive shafts and mount the centre nuts.

21. Fit the A/C compressor retaining bolts and A/C compressor connector.

Tightening torque 20 Nm (15 lbf ft)


22. Fit the multigroove belt in the direction of rotation noted earlier.

CV : Fit Chassis reinforcement, front subframe, CV, diesel


23. Fit the steering shaft onto the steering gear. Clean the threads and apply 74 96 268 Thread locking adhesive to the threads.

Tightening torque 30 Nm (22 lbf ft)


24. Lower the car. Option: Fit the parking heater coolant hose to the thermostat housing.

25. Connect the coolant hose quick couplings.


26. Remove the plugs and connect both fuel lines to the pipes on the engine.


27. Remove the hose pinch-off pliers from the clutch hose and connect the quick coupling to the clutch slave cylinder.


28. Fit the gear wires to the gearbox.

29. Fit the expansion tank on the body and connect the coolant lever sensor connector.


30. Fit the engine harness to the right structural member.


31. Fit the ground cables.


32. Fit the clamp for the engine harness.

33. Fit the screw securing the engine wiring harness connector in the electrical centre.

34. Fit the positive cable to the battery's positive terminal.

35. Fit the cover on the electrical centre and undo the two retaining bolts.

36. Fit the windscreen washer fluid filler pipe.

37. Attach the connector to the left structural member.

38. Connect the hose with quick coupling to the vacuum pump.


39. Fit the fan cowling.


40. Fit the connector to the fan cowling.

41. Attach the lower radiator hose to the engine.


42. Fit the turbocharger intake manifold and the lower radiator hose.

43. Fit the air cleaner casing and connect the inlet hose.


44. Fit the air filter, air cleaner casing cover and connect the mass air flow sensor connector.

45. Fit the turbocharger inlet hose.

46. Fit the upper radiator mountings.


47. Fit the hose from the manifold, the two mountings and the coolant pipe to the reservoir on the engine.

48. Aut: Attach the oil pipes to the radiator.


Aut, Man: Attach the bleeder hose to the radiator and cylinder head.


49. Fit the upper radiator hose.

50. Fit the hose to the turbocharger outlet and the turbocharger delivery pipe.

51. Fit the turbocharger delivery pipe to the throttle body and mount the upper retaining bolts.

52. Plug in the connectors of the particle filter pressure sensor and temperature sensor.

53. Fit the upper radiator member and plug in the connector for the horn.


54. Fit the turbocharger solenoid valve.


55. Fit the A/C pipe mounting on the upper radiator member.

56. Fit the bonnet wire quick coupling.

57. Fit the right-hand headlight.

58. Raise the car.

59. Fit the bracket and secure the wiring harness.


60. Plug in engine control module connectors and fit the right cover.


61. Fit the lower charge air pipe mounting to the fan cowling.


62. Fit the charge air hose between the charge air pipe and the charge air cooler and fit the cover on the left-hand side.

63. Lower the car slightly and fit the bumper.


64. Plug in the headlight washer hose.


65. Fit the wing liners in both front wheel housings.


66. Raise the car and fit the front spoiler shield and the lower engine cover. Fit the connector.


67. Lower the car somewhat and fit the front wheels.

68. Lower the car completely and tighten the hub nuts.

Tightening torque 230 Nm (170 lbf ft).

69. Fill oil in the gearbox.

70. Fit the battery tray and plug in the bonnet switch connector.


71. Fit the fuse holder to the battery tray and the glow plug control module.

72. Fit the battery.

73. Fit the battery cable.

74. Fit the battery cover.

Note

The cooling system should be test pressurised before filling. See Cooling system, pressure testing .



75. Fill with 40 - 400 131 389 Coolant to approx. 30 mm above the mark on the expansion tank.

76. Open the air vent cock on the coolant pipe and release the air.

77. Close the air vent cock and fit the coolant reservoir cap.

78. Top up the washer fluid.

79. Bleed the clutch as described under Bleeding the clutch hydraulic system in situ .

80. Check the automatic transmission fluid level. See Checking oil level.

81. Remove the wing covers and restore car electrical functions, see Procedure after reconnecting the battery .

82. Fit the insulation and the upper engine cover.

83. Connect Tech2 and run the "Add" program. Select ECM. Answer YES when asked whether the control module has been changed.