Power unit fitting, A20NFT/LHU
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Power unit fitting, A20NFT/LHU
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Warning
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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!
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1.
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Position the trolley lift with power unit and adjust its position in relation to the body.
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2.
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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.
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3.
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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.
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4.
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Position the bolts and screw them through the subframe into the body.
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5.
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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°)
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6.
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Lower the trolley lift and move it out of the way.
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7.
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Fit the bolts with new nuts for the lower swivel joints (C).
Tightening torque 50 Nm (37 lbf ft)
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Important
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Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.
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8.
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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)
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9.
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Position the outboard steering links and tighten them (A).
Tightening torque 35 Nm (26 lbf ft)
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10.
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Attach the connector (D) and fit the cable tie for the angle sensor (option).
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13.
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Fit the left-hand engine mounting (A).
Tightening torque 53 Nm (39 lbf ft)
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14.
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Fit the right engine mounting (A).
Tightening torque to bracket: 45 Nm +90° (33 lbf ft +90°)
Tightening torque to body 50 Nm +180° (37 lbf ft +180°).
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16.
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Remove KM 6313 Centring fixture, subframe - engine.
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17.
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Secure the power steering pipe to the subframe with the clips (A).
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18.
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Fit the A/C compressor retaining bolts (B) and plug in the A/C compressor connector (A).
Tightening torque 24 Nm (18 lbf ft).
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20.
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Connect the steering shaft (A) to the steering gear. Use thread locking adhesive.
Tightening torque 26 Nm (19 lbf ft)
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21.
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Fit the hose (B) between the charge air cooler and the charge air pipe and fit the cover (A) on the right-hand side.
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23.
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Lower the car.
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Warning
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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:
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• 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.
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• Absolutely No Smoking!
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• Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used.
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• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.
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• Wear protective goggles.
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24.
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Connect the quick coupling (B) for the breather line.
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25.
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Remove the plugs and connect both fuel lines (A) to the high pressure pump, and fix (C) the fuel line and discharge line at the camshaft cover.
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26.
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Fit the lower coolant hose (A) to the thermostat housing, fit a new cable tie.
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27.
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Fit the hose to the oil cooler and thermostat housing (B).
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28.
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Fit the upper radiator hose (C) to the engine and the hose (D) to the turbo.
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29.
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Plug in the connector (E) for the A/C pressure sensor.
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31.
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Man:
Fit the quick coupling (B) on the clutch slave cylinder. Remove the hose pinch-off pliers.
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32.
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Attach the gear cables (A) to the gearbox.
Aut:
only one cable.
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35.
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Connect the coolant hoses' quick couplings (B).
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36.
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Connect the coolant hose (A) to the thermostat housing.
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37.
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Fit the engine harness (E) to the body and the 2-pin connector housing.
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38.
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Fit the engine harness connector in the electrical centre and tighten the screw (D).
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39.
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Attach the positive cable (C) to the positive terminal of the battery.
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40.
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Fit the two retaining bolts (B) for the electrical centre.
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41.
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Aut:
Attach the oil pipes to the radiator.
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42.
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Plug in the connector (A) on the left structural member.
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43.
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Man:
Fit the electrical connection for the reversing light switch.
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44.
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Fit the battery tray (C), plug in the bonnet switch connector and attach the cable clip.
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45.
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Install the electrical centre (B) in front of the battery tray.
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46.
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Fit the ECM (A) to the battery tray.
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47.
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Fit the vacuum hose quick coupling (D) to the vacuum pump and intake manifold.
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48.
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Attach the bleeder hose for the engine (C).
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49.
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Fit the charge air pipe (B).
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50.
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Fit the charge air pipe screws (A).
Tightening torque 22 Nm (16 lbf ft)
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52.
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Fit the battery cover.
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53.
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Fit the dipstick and upper engine cover.
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55.
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Fit the cover (A) on the right-hand side and the hose (B) between the charge air cooler and the charge air pipe.
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56.
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Fit the left and right wing liner.
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57.
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Detach the straps from the radiator unit.
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59.
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Fit the wing liner front section, right and left-hand sides.
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60.
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Fit new nuts for the drive shafts.
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61.
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Fit the front wheels without protective washers. See
Wheels
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62.
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Lower the car and tighten the hub centre nuts.
Tightening torque 230 Nm (170 lbf ft).
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63.
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Press the protective washers into the wheel rim.
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64.
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Check engine oil level, top up as necessary.
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