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Power unit, fitting

Power unit, fitting

To remove

Warning

A large number of hoses, cables, etc., are secured with cable ties. After tightening, the ties are cut off and leave more or less sharp edges at the fastening point. Watch out for the risk of cuts due to these sharp ends on the cable ties!



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. Raise the train until the inner drive shaft universal joints are level with the wheel hubs and insert the hub nuts. Make sure that nothing catches or gets damaged.

3. 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.

4. Move the subframe stays back into position. Position and insert the bolts through the subframe to the body.

5. Raise the engine all the way and tighten the subframe bolts and the rear bolts of the stays.

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

Tightening torque, stay: 90 Nm + 45° (66 lbf ft +45°)

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


7. Tighten the bolts on the lower swivel joints.

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.


8. 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)

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

10. Man: Fit the quick coupling to the clutch slave cylinder. Remove the hose pinch-off pliers.


11. Aut: Attach the breather hose of the automatic transmission.


12. Remove the straps and attach the gear cables to the gearbox.

13. Fit the left engine mounting.

Tightening torque: 70 Nm +45° (52 lbf ft +45°)

14. Fit the right-hand engine mounting.

Tightening torque: 70 Nm +60° (52 lbf ft +60°)


15. Fit the quick coupling to the breather line.


16. Remove the plugs and connect the fuel line to the fuel rail.

17. Connect the brake servo vacuum pipe.

18. Attach the coolant hose and secure it in the holder on the engine.


19. Raise the car.

20. Plug in the angle sensor connector and secure the cable to the subframe.

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


22. Fit the power steering pipes to the radiator assembly.


23. Connect the steering shaft to the steering gear. Use thread lock.

Tightening torque 30 Nm (22 lbf ft)


24. Lower the car.

25. Plug in the two connectors on the structural member.


26. Attach the ground cables and the clamp for the engine harness to the body.

27. Tighten the retaining screw on the engine harness connector in the main fuse box.


28. Attach the positive cable to the positive terminal of the battery.

29. Fit the two retaining bolts and the fuse box cover.

30. Attach the breather hoses to the coolant reservoir.


31. Fit the charge air pipe between the throttle body and charge air cooler.


32. Plug in the boost pressure sensor connector (688).

33. Attach the lower radiator hose. Aut: Remove the plugs and attach the oil pipes to the radiator.


34. Attach the upper radiator hose to the engine.


35. Fit the cover over the radiator core.

36. Fit the air cleaner casing, air filter and air filter cover.


37. Fit Fan cowling .

38. Fit the upper engine cover.

39. Raise the car and fit the coolant connection.


40. Install the rear catalytic converter.


41. Attach the oil cooler's coolant hose to the radiator.


42. Fit the dryer filter bolts on the radiator.

43. Attach the hose to the charge air cooler.

44. Fit the cover on the right-hand side.

45. Fit the lower charge air pipe to the fan cowling.


46. Attach the charge air hose between the charge air pipe and the charge air cooler.

47. Fit the cover on the left-hand side.

48. Fit the Upper radiator member .

49. Relieve the load on the belt tensioner. Use a 1/4 " puller handle and fit the driver belt to the A/C compressor pulley.


50. Fit the front part of the left wing liner and fit the right wing liner.


51. Remove the plug and attach the headlight washer hose.

52. Plug in the connector and fit the lower spoiler shield.

53. Lower the car slightly and fit the front wheels. See Wheels .

54. Connect the negative cable and fit the battery cover.

55. Remove the wing covers.

56. Check oil level and top up as necessary. Fill with coolant to approx. 20 mm above the mark on the expansion tank. If a new engine is fitted, follow the instructions given in Venting and filling the cooling system .

57. Close the expansion tank cap.

58. Aut: If the gearbox was drained, check the automatic transmission fluid level as described in Checking oil level .

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

60. Fit the upper engine cover.