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Power unit fitting, 4WD

Power unit fitting, 4WD


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 unit and adjust it into position against the body.

2. Lift up the power train until the inboard drive shaft universal joints are level with the wheel hubs and insert the drive shafts into the hubs. Make sure nothing gets caught or 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. Position the bolts and screw them through the subframe into the body.

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

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. Fit the bolts with new nuts for the lower swivel joints (C).

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 (B) and tighten them while gripping the flats with a thin spanner.

Tightening torque 64 Nm (47 lbf ft)

9. Position the outboard steering links and tighten them (A).

Tightening torque 35 Nm (26 lbf ft)

10. Fit the connector (D) and cable tie to the angle sensor (option).

11. Adjust the supports on KM-6313 Centring tool, subframe-engine approximately 10 mm upwards; see Centring tool, engine and subframe, 4WD, KM-6313-300 no higher than the groove on the thread of the support.

12. Lower the car.

13. Fit the left engine mounting (A).

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


14. Fit the right engine mounting (A).

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

Tightening torque to body 40 Nm +60° (30 lbf ft +60°)


15. Raise the car.

16. Remove KM 6313 Centring fixture, subframe - engine.

17. Secure the power steering pipe to the subframe with the clips (A).


18. Fit the A/C compressor retaining bolts (B) and plug in the A/C compressor connector (A).

Tightening torque 20 Nm (15 lbf ft)


19. Relieve the load on the multigroove belt (A) and fit it as previously marked. Use 83 96 095 Relieving tool, belt circuit, B207E/L .


20. Connect the steering shaft (A) to the steering gear. Use thread locking adhesive.

Tightening torque 30 Nm (22 lbf ft)

Use thread locking adhesive on the threads.


21. Fit the hose (B) between the charge air cooler and the charge air pipe and fit the cover (A) on the right-hand side.


22. Fit the propeller shaft .

23. Lower the car.

Warning

The work involved in removing the fuel pipe requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures:

• Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.

• Absolutely No Smoking!

• Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used.

• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.

• Wear protective goggles.


24. Connect the quick coupling (B) of the breather line.


25. Remove the plugs and connect the two fuel lines (A) to the fuel rail, gripping the lower nut. Secure (C) the fuel lines and bleeder line at the camshaft cover.

26. Attach the upper radiator hose (A) to the engine and attach the turbocharger hose (B).


27. Plug in the A/C pressure sensor connector (C).

28. Connect the intake hose (B), fit the air cleaner casing and the air cleaner (A).


29. Fit the air cleaner cover (B) and plug in the mass air flow sensor connector (A).


30. Man: Fit the quick coupling (B) on the clutch slave cylinder. Remove the hose pinch-off pliers.


31. Attach the gear cables (A) to the gearbox.

Aut: one cable only.

32. Man: If necessary, bleed the clutch as described in Bleeding the clutch hydraulic system in situ.

33. Man: Fill the gearbox with oil. See Filling/changing gearbox oil.

34. Connect the coolant hose quick couplings (B).


35. Connect the coolant hose (A) to the thermostat housing.

36. Attach the engine harness (E) to the body and plug in the 2-pin connector.


37. Plug in the engine harness connector in the main fuse box and tighten the bolt (D).

38. Attach the positive cable (C) to the positive terminal of the battery.

39. Fit the two retaining bolts (B) of the main fuse box.

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

41. Plug in the connector (A) on the left structural member.

42. Man: Attach the electrical connection of the reversing light switch.

43. Attach the lower radiator hose (A) to the thermostat housing and fit a cable tie to the engine wiring harness.


44. Fit the battery tray (A), plug in the bonnet switch connector and attach the cable clip.


45. Install the main fuse box in front of the battery tray.

46. Aut: Plug in the connector (B) beneath the control module. Fit the cover with the control module and plug in the connectors (A) of the TCM control module.

47. Connect the vacuum hose quick coupling (B) to the vacuum pump.


48. Connect the ventilation hose (A) to the engine.

49. Fit the battery (D).


50. Attach the charge air hose (C) to the throttle body and charge air pipe.

Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.


51. Plug in the connector (A) to the pressure/temperature sensor and attach the bypass valve hose (B).

52. Fit the battery cover (C).


53. Fit the dipstick (A) and the upper engine cover (B).

54. Detach the straps from the radiator assembly.

55. Fit the Front bumper shell .

56. Fit the front part of the wing liner on the right and left sides.

57. Fit new nuts on the drive shafts.

58. Fit the front wheels without protective washers. See Wheels .

59. Lower the car and tighten the hub nuts.

Tightening torque 230 Nm (170 lbf ft).

60. Press the protective washers on the rims.

61. Check the engine oil level. Top up as necessary.

62. 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 Bleeding the cooling system when working on the oil cooler .

63. Checking/adjusting oil level in the automatic transmission.

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