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Fitting

Fitting


Warning

Numerous electrical leads, hoses, cables, etc. are secured by plastic cable ties.

After pulling these ties tight, cut the ends off as short as possible.

Help to avoid the risk of people cutting and scratching their hands on the sharp edges of cable ties.



1. Fit the sub-frame and position the lifting table with power train under the raised car.

2. Carefully lower the car and raise the lifting table. Fit the drive shafts and end pieces.


3. Hang the A/C compressor in position and fit the bolts but do not tighten them. Then tighten the lower bolt.

4. Lift up the engine and fit the front engine mountings.


Tightening torque: 73 Nm (54 lbf ft).

5. Tighten the sub-frame retaining bolts.

Tightening torques

front: 115 Nm (85 lbf ft)

middle: 190 Nm (140.6 lbf ft)

- rear: 110 Nm + 75° (81.4 lbf ft + 75°).

Use angle gauge 82 93 128

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


Tightening torque: 18 Nm (13.3 lbf ft).

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

8. Reconnect the gearbox oil hoses (automatic transmission).

Tightening torque 25 Nm (18.5 lbf ft).

9. Clean the exhaust pipe joints.


10. Fit the bolt securing the catalytic converter to the bracket on the engine but do not tighten it. Screw the front exhaust pipe to the exhaust manifold or turbocharger. Before assembly, apply Molycote 1000 to the threaded studs on the turbocharger.

11. Tighten the bolt securing the catalytic converter to the bracket or rubber mounting on the engine and tighten the joint under the car.

12. Fit the spoiler sections and the covers in the wheel housings.


13. Fit the nuts for the end pieces.

Tightening torque: 75 Nm (55.5 lbf ft).

14. Refit the brake calipers.


Tightening torque: 105 Nm (77.7 lbf ft).

15. Fit the hub nuts loosely and put the wheels back on the car.

Tightening torque 110 Nm (81 lbf ft).

16. Lower the car and tighten the hub nuts. Use new hub nuts.

Tightening torque: 290 Nm (214.6 lbf ft).

Warning

Do not forget to tighten the hub nuts.


17. Feed the wiring through the grommet in the bulkhead and check the seal. Run the wiring to the boost pressure control valve (BPC) (turbo).


18. Connect the engine wiring under the instrument panel, put back the control module for the central locking system, fit the glove box or the lower part of the panel, and fold down the carpet.

19. Hook the clutch cable in place (manual gearbox) or assemble the clutch pipe and bleed the clutch system (SENSONIC).


20. Fit the selector lever cable (automatic transmission) or assemble the selector rod (manual gearbox/SENSONIC). Check the gear positions.

Tightening torque 21 ± 2 Nm (15.5 ± 1.5 lbf ft).

21. Reconnect the breather hose to the gearbox (automatic transmission).


22. Connect the oxygen (Lambda) sensor lead and (in certain markets) the catalytic converter temperature warning lead.

23. Plug in the gearbox connectors.

24. Reconnect the ground cable to the gearbox and connect the positive lead to the positive terminal block.


25. Tighten the upper bolts securing the A/C compressor and plug in the connector.

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

27. Reconnect the coolant hoses.

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


29. Mount the servo pump, fit the belt and check its position on all belt pulleys.

30. Relieve the belt tensioner of strain, using a ratchet handle extension, and remove the drill.

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


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


33. Remove the plugs, attach the tank breather hose and fit the fuel hoses.

34. Fit the Cruise Control unit with cable, plug in the connector, and hook the Cruise Control cable to the throttle body. Hook on the throttle cable.

35. Make sure that the radiator drain plug is tight, fill up with coolant and check the system for leaks.

36. Check the coolant and oil levels and top up as necessary.

37. Fit the cover or the resonator, take the protective covers off the wings and make sure that the engine bay presents a neat and clean appearance.

38. Start the engine, bleed the cooling system and check all functions.