Lifting Engine In
Lifting engine in
Special tools:
999 2810 LIFTING YOKE 999 2810 Lifting Yoke
999 5428 LIFTING YOKE 999 5428 Lifting Yoke
999 5462 Jimmy tool 999 5462 Jimmy Tool
999 5474 RADIATOR PROTECTION 999 5474 Radiator Protection
999 5488 PLUGS 999 5488 Plugs
999 5533 Holder 999 5533 Holder
Note! From autumn 93 onwards lifting arm 998 9734 is included in the kit for tool 999 2810. The lifting arm is required for removing and installing the turbo motor.
Lift in engine with transmission
Use lifting yoke 999 2810 LIFTING YOKE 999 2810 Lifting Yoke (in version with lifting arm 999 5428 LIFTING YOKE 999 5428 Lifting Yoke.
Locate lifting yoke so that the engine is balanced.
Adjust lift angle during the lift.
Caution! Check that the driveline is clear of the bodywork and other equipment.
Tighten the front engine mounting nut.
Install:
- A/C compressor
- power steering pump and collision protection system
Install the engine cable harness
Install cable duct bracket. Connect all connectors as marked earlier.
1. Thermostat
2. Generator (GEN)
3. Air conditioning (A/C) if installed
4. Ground terminal
5. Oil pressure switch
6. Oil level sensor
7. Starter motor (all)
8. Knock sensor (KS)
9. Ground terminal
10. Ground terminal
11. Throttle housing switch
12. Idle air trim
13. Flywheel sensor
14. Injectors
15. Camshaft position (CMP) sensor
16. Back-up (reversing) lamp switch
17. Mass air flow (MAF) sensor
18. Vehicle speed sensor (VSS)
19. Heated oxygen sensor (HO2S) (automatics x 2)
20. PTC element
Install fuel rail
Grease O-rings for injectors.
Tighten fuel rail.
Remove holder 999 5533 Holder 999 5533 Holder.
Install:
- the protective cover over the fuel rail
- fuel line clip (upper/lower)
- auxiliaries belt
- expansion tank with radiator pipes
- upper and lower oil cooling hoses
Install:
- starter motor bracket and its splash guard
- cold air hose
- radiator hoses to the cowl panel
- fresh air intake hose to the turbocharger (TC)
Install:
- negative lead to the engine, and install the clamp on the frame member
- lower radiator hose
- clutch slave cylinder to the gearbox
Note! (Take care that the piston does not slide out)
- slave cylinder snap ring
- the rubber air filter mountings and tighten bracket.
- idle air trim, connect connector
Install the engine cooling fan (FC)
Remove shroud ( 999 5474 RADIATOR PROTECTION 999 5474 Radiator Protection ) from radiator.
Lift out the engine cooling fan (FC) with the cover. Connect the connector, clamp the wiring.
Install the upper charge air pipe, between charge air cooler and turbocharger (TC).
Install the fresh air intake.
Install the upper fan shroud. Tighten the fan shroud to the radiator (ensure that the clip is in place.
Connect the pressure pipe (to the turbo instruments).
USA: Connect the vacuum hoses to the EGR-regulator.
Install the EVAP canister shut-off valve in the bracket and connect the canister vacuum hose.
Install:
- the air duct for cooling the control module box.
- both relays on the fan shroud and connect connectors. Clamp the wiring
- idle air trim
Install:
- cable to the PTC-element and heated oxygen sensor (HO2S)
Car with manual transmission:
- back-up (reversing) light switch cable
- the gear selector cables rubber mounting.
- gear selector cables to their mounting on the transmission.
Note! Color marking mounting/cable.
Cars with automatic transmission:
Connect connector to the transmission.
Install gear selector cable (as marked earlier)
Install two transmission oil cooler hoses and negative lead to the transmission.
Install:
- upper torque rod from the engine with new screws. Tighten to 50 Nm and 90° angle
- both ground strips
- throttle cable to the throttle pulley and cover
- charge air pipe to the turbocharger (TC) (adjust the distance to 15 mm )
Install air cleaner (ACL) housing
Connect the connector and vacuum hoses to the idle air control (IAC) valve.
Ignition cable between distributor/ignition coil.
Note! Yellow marking first rib on cleaner cover.
Install the air hose and the air cleaner (ACL) housing. Connect mass air flow (MAF) sensor connector.
Connect fresh air intake.
Install the bracket for the turbocharger control valve (TCV) on the air cleaner (ACL) housing.
Install:
- the battery shelf and battery with the cables
Caution! If the car is equipped with a cruise control connect the vacuum hose and vacuum motor wiring before the battery shelf is screwed into place.
Install:
- two upper exhaust pipe nuts (do not tighten them), raise the car
- exhaust pipe lower nut (do not tighten them)
- screw for exhaust pipe bracket. Torque to 30 Nm .
- speedometer connector.
- front and rear engine mounting screws. Torque to 50 Nm .
- torque arm screw in the transmission, use a new screw and nut. Tighten to 35 Nm + 90° .
Install:
- the two screws for the right engine mounting (bend the right fender liner to one side slightly first)
- right drive shaft and pilot bearing
Install:
- left drive shaft, this should be easily installed with hand pressure ( the snap ring is easy to damage )
- ABS cable/brake pipe bracket screw
Reinstall on both sides:
- control arm to ball joint. Use new nuts.
- wheels
Note! Ensure that mating faces on ball joint and link are clean and free of grease.
Tighten the nuts in order from inside and outwards.
Tighten to: 18 Nm + 120° Use protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.
Rust protect the area between the ball joint, link and nuts carefully, using plenty of compound. Use rustproofing agent P/N: 1 161 432-8.
(New ball joint nut torque 70 Nm .)
Lower car
Torque the three exhaust pipe nuts and check that the planes are parallel. Torque to 30 Nm .
Install heat deflector plate, with turbocharger (TC) bracket.
Top up coolant and engine oil
Coolant volume approximately: 7.20 liters .
Oil capacity including filter: 5.3 liters.
Test function
Start engine run until thermostat opens.
Check for leaks.
Check and if necessary adjust oil and coolant levels.
Automatic: Check automatic transmission oil level.