Engine, Installing
Engine, installing
Special tools:
951 2955 Cover 951 2955 Cover
951 2957 Coolant Reservoir 951 2957 Coolant Reservoir
999 7089 Adjustment tool 999 7089 Adjustment Tool
999 7109 Wrench 999 7109 Wrench
Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Note! For tightening torques, see: Tightening torque Tightening Torque.
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Service and Repair.
Preparations
Lifting vehicle
Raise the vehicle so that the engine / transmission unit are free beneath the vehicle. Place the engine and transmission on the lifting table. Lower the lifting table to its lowest position.
Lowering the vehicle
Lower the vehicle over the engine/transmission unit ensuring that the unit is aligned between the frame members and that the compressor is free. Stop lowering the vehicle just before the engine / transmission unit are in position. Raise the engine / transmission unit the last bit until the unit is in position to install the engine mountings.
Installing
Installing engine mount
Install:
- the front engine mounting in the cylinder head. Tighten. See: Tightening torque Tightening Torque
- the screw for the engine mounting on the transmission. Tighten. See: Tightening torque Tightening Torque.
Installing the engine pad
Install the engine pad according to the markings.
Installing limiter and engine mounting
Install:
- the limiter
- the screws for the limiter for the right-hand engine mounting. Tighten. See: Tightening torque Tightening Torque
- ground strip in the right-hand wheel turret.
Removing the lifting table
Slacken off the tension strap from around the engine. Remove the lifting table. Raise the vehicle.
Installing catalytic converter
Caution! Ensure that the flanges are flat and free of gasket residue.
Install:
- the catalytic converter. Use new gaskets for both connections
- new nuts at the connections. Tighten
- the screw for the heat deflector plate in the three-way catalytic converter (TWC)
- the front SIPS member. Tighten.
Installing the propeller shaft
Install the propeller shaft. See: Propeller shaft Propeller Shaft.
Installing lower torque rod
Install the lower torque rod. Tighten.
Installing the sub-frame
Note! Ensure that the steering gear is not trapped when raising the sub-frame.
Install the adjustment tools on the sub-frame. Use: 999 7089 Adjustment tool 999 7089 Adjustment Tool. Carefully raise the sub-frame so that the adjustment tools are lined up with the holes in the side members.
Installing sub-frame, continued
Install:
- the screws for the rear sub-frame mounting
- the screws for the front sub-frame mounting
- the support brackets for the rear sub-frame mountings. Tighten. See: Tightening torque [1][2]Specifications
- the three-way catalytic converter (TWC) in the rubber mountings.
Connect the connector for the rear heated oxygen sensor (HO2S). Secure the cable harness in the SIPS member. Remove the tool 999 7089 Adjustment tool 999 7089 Adjustment Tool.
Installing the ball joint on the steering arm
Pry down the control arm. Use: 999 7076 Lever 999 7076 Lever. Install the ball joint, at the same time align the drive shaft in the wheel hub. Install new nuts on both sides. Tighten. See: Tightening torque [1][2]Specifications.
Installing components, front suspension
Caution! Counterhold so as not to damage the rubber boots on the joints.
Install on both sides:
- the anti-roll bar link
- the new nuts. Tighten
- the tie rod for the wheel spindle
- new nuts. Tighten
- new drive shaft center nut. Counterhold the brake disc. Use a screwdriver. Tighten. See: Tightening torque [1][2]Specifications.
Install the charge air pipe under the engine.
Installing the air conditioning (A/C) compressor
Caution! Ensure that the auxiliaries belts are correctly positioned in all the grooves.
Install the air conditioning (A/C) compressor. Tighten the screws.
Inner belt
Relieve the tension from the belt tensioner. Use a torx socket by turning the tensioner anticlockwise as far as it will go. Position the belt and release the tensioner.
Outer belt
Relieve the tension from the belt tensioner. Use: 999 7109 Wrench 999 7109 Wrench by turning the tensioner clockwise as far as it will go. Position the belt and release the tensioner.
Installing power steering pipe
Install:
- the return line for the servo oil reservoir. Remove the seals
- the pressure line for the power steering pump. Remove the seals. Tighten. See: Tightening torque [1][2]Specifications. Secure the pipes on the engine and in the sub-frame.
Installing parts
Install:
- the right-hand fender liner. Tighten the screws
- the right-hand front wheel. Tighten. See: Wheels Service and Repair
- the lower engine protection plate. Lower the vehicle.
Installing the engine coolant hoses
Install the coolant hoses to the radiator. Tighten the hose clamps.
Connect:
- the air bleed hoses at the junction in the middle of the front cover plate. Secure the hoses in clips.
- the passenger compartment heater hoses. Lock the connectors by turning the gray catches.
Installing hoses
Caution! Press the connector together until a clicking sound is heard.
Connect:
- the fuel pressure line
- EVAP canister hose.
Installing components on the transmission
Note! Ensure that the mechanical cable and sleeve do not crack or break.
Install:
- the oil cooler hoses for the transmission.
- the coolant hoses for the heat exchanger for the oil cooling system
- the gear selector cable for the bracket and lever arm. Adjust the gear selector cable. See: Gear selector cable Service and Repair.
Installing connectors
Connect the connector for the pressure and temperature sensor in the charge air cooler. Install the surround.
Installing the steering shaft
Install:
- the steering shaft on the steering gear
- the screw for the steering shaft. Tighten. See: Tightening torque [1][2]Specifications.
Installing the cable harness
Install/connect:
- the ground lead on the transmission
- the positive cable to the starter motor. Tighten
- the protective cover over the positive terminal on the starter motor
- the clamp for the cable harness for the starter motor
- the ground leads for each wheel turret
- the cable harness for the fuse box. Lock the fuse box with the striker plate
- the clamp for the cable harness to the fuse box
- the fuse box cover
- The dip stick and the oil pipe.
Installing engine compartment components
Install:
- the air cleaner (ACL) module.
- the rubber hose for the throttle housing. Tighten the hose clamp.
Fitting of battery
Install:
- the box for the battery. Connect the connectors for the temperature sensor
- the battery as shown: Battery Removal and Replacement.
Finishing
Checks
Top up with coolant. Use filling equipment: 951 2957 Coolant Reservoir 951 2957 Coolant Reservoir and cover 951 2955 Cover 951 2955 Cover.
Check the oil level in the engine and transmission.
Start the engine. Run the engine to normal operating temperature.
Check its function, and check for any leaks. Top up fluids if needed.