Fitting the Power Train
Fitting the power trainTo fit
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 centering tool, engine and subframe.
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 degrees (55 ft. lbs. + 135 degrees)
Tightening torque, stay: 90 Nm + 45 degrees (66 ft. lbs. + 45 degrees)
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 ft. lbs.)
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 ft. lbs.)
9. Position the outboard steering links and tighten them.
Tightening torque 35 Nm (26 ft. lbs.)
10. Plug in the angle sensor connector (option).
11. Fit the left engine mounting.
Tightening torque: 70 Nm + 45 degrees (52 ft. lbs. + 45 degrees)
12. Fit the right engine mounting.
Tightening torque: 70 Nm + 60 degrees (52 ft. lbs. + 60 degrees)
13. Raise the car.
14. Secure the power steering pipe to the subframe with the clips.
15. Install the exhaust system assembly with nuts and rubber mountings.
Tightening torque 25 Nm (18 ft. lbs.)
16. Fit the A/C compressor retaining bolts and plug in the A/C compressor connector.
Tightening torque 20 Nm (15 ft. lbs.).
17. Unload and fit the multi groove belt as previously marked. Use 83 96 095 Unloading tool, belt circuit, B207.
18. Fit the steering shaft to the steering gear.
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.
19. Engage the quick coupling for the ventilation line and secure the fuel lines and breather lines at the camshaft cover.
20. Remove the plug and attach the two fuel lines to the fuel rail. Counterhold at the lower nut.
21. Fit the quick coupling to the clutch slave cylinder. Remove the hose pinch-off pliers.
22. Attach the gear cables to the gearbox.
23. Connect the coolant hose quick couplings.
24. Connect the coolant hose to the thermostat housing.
25. Attach the engine harness to the body.
26. Plug the engine harness connector into the main fuse box.
27. Attach the positive cable to the positive terminal of the battery.
28. Fit the two retaining bolts and the main fuse box.
29. Aut: Attach the oil pipes to the radiator.
30. Plug in the connector on the left structural member.
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.
31. Fit the air cleaner casing and connect the intake hose. Fit the air filter and the air cleaner casing cover.
32. Fit the mass air flow sensor connector.
33. Plug in the connector for the A/C pressure sensor.
34. Fit the upper radiator hose.
35. Fit the battery tray, plug in the bonnet switch connector and attach the cable clip.
36. Install the main fuse box in front of the battery tray.
37. Aut: Plug in the connector beneath the control module. Fit the cover with the control module and plug in the connectors of the TCM control module.
38. Connect the vacuum hose quick-release coupling to the vacuum pump.
39. Connect the ventilation hose to the engine.
40. Fit the battery.
41. Attach the charge air hose to the throttle body and charge air pipe.
42. Plug in the connector to the pressure/temperature sensor and attach the bypass valve hose.
43. Fit the battery cover.
44. Fit the dipstick and the upper engine cover.
45. Fit the hose between the charge air cooler and the charge air pipe and fit the cover on the right-hand side.
46. Attach the lower coolant hose to the radiator and fit the cover on the left side.
47. Raise the car slightly and fit Front bumper shell.
48. Remove the plug and attach the headlight washer hose.
49. Fit the front part of the left wing liner. Fit the right wing liner.
50. Plug in the headlight washer connector and attach the hose. Fit the lower spoiler shield.
51. Lower the car slightly and fit the front wheels.
52. 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 Bleeding the cooling system when working on the oil cooler.
53. If necessary, bleed the clutch as described in Bleeding the clutch hydraulic system in situ.
54. Check the oil level in the automatic transmission.
55. Remove the wing covers and restore car electrical functions, see Procedure after reconnecting the battery