Installation

NOTE:
^ Step numbers below refer to numbers used in the illustrations.
^ The method described applies to removal of the power train with A/C and automatic transmission or manual gearbox.

WARNING:
^ A large number of electrical leads, hoses, etc. are secured by plastic cable ties.
^ When these cable ties have been pulled tight the excess length is usually cut off, often leaving a more or less sharp edge on the plastic.
^ Bear this in mind when securing cable ties and avoid leaving sharp edges that could do damage by chafing or scratch bare hands.

1. Install the subframe and tighten the rear engine mounting.
- Insert the rear bolts fitted with washers.
- Run the lifting trolley with power train under the raised car, then tighten the rear engine mounting to: 47 Nm (35 ft. lbs.).
2. Lower the car carefully and raise the lifting table.
- Align the drive shafts and steering swivel joints.
3. Position the A/C compressor and install the retaining bolts loosely. Then tighten the bottom bolt.
4. Raise the engine by means of the lifting trolley and install the front engine mountings, then tighten as follows:
- Front engine mountings: 73 Nm (54 ft. lbs.).
5. Tighten the , then tighten to:
- Front subframe bolts: 115 Nm (85 ft. lbs.).
- Center subframe bolts: 190 Nm (140.6 ft. lbs.).
- Rear subframe bolts: 110 Nm plus an additional 75�° (81.4 ft. lbs. plus an additional 75°).





6. On models with automatic transmission, check that the seals for the automatic transmission oil pipe connections are intact.
- Install the nipples, then tighten to: 25 Nm (18.5 ft. lbs.).
7. On all models, using new gaskets, install the front exhaust pipe.
- Plug in the oxygen sensor connectors.
8 Install the nuts for the steering swivel joints, then tighten to: 75 Nm (55.5 ft. lbs.).
9. Install the spoiler sections and the cover in the right hand wheel housing.
10. Install the brake calipers back in place, then tighten to: 105 Nm (77.7 ft. lbs.).
11. Install the hub centre nuts loosely and install the wheels, then tighten the wheel nuts to: 120 Nm (89 ft. lbs.).
12. Lower the car to the floor and tighten the hub centre nuts to: 290 Nm (214.6 ft. lbs.).

WARNING: Do not forget to tighten the hub centre nuts.





13. Lower the car to the floor and refit the engine wiring harness.
- Insert the wiring through the lead-through in the bulkhead.
- Connect the wiring.
- Install the air ducts and glove box.
- Install the knee shield.
- Check that the seal in the lead-through is correctly fitted.
14. On models with an automatic transmission, install the selector lever cable for the automatic transmission.
- On models with a manual gearbox, lock 4th gear by fitting locking pin tool No. 87 92 335, or equivalent, (with the ring upwards) in the gearbox.
- Engage 4th gear and insert locking pin (with the ring downwards) in the gear lever housing.
- Install the selector rod.
- Extract the locking pins from the gearbox and gear lever housing and install a new plastic plug in the gearbox.
- Try changing gear to check that everything has been correctly fitted.
- Install the clutch cable (which is self-adjusting).
15. On models with an automatic transmission, install the transmission breather hose.
16. On all models, connect the grounding connection to the gearbox.

WARNING: Remembering to ground the gearbox is extremely important. Danger of fire.

17. Connect the positive cable to the positive terminal.
18. On models with an automatic transmission, plug in the two wiring harness connectors for the automatic transmission.
- On models with a manual gearbox, connect the reversing light switch.





19. On all models, install the bottom radiator hose at the engine.
20. Install the radiator hose from the expansion tank at the water connection.
- Install the hoses coming from the heater core at the water connection and coolant bridge.
21. Install the radiator hose connected to the throttle body at the expansion tank.
22. Tighten the two top A/C compressor retaining bolts.
- Plug in the connector.
23. Install the power steering pump and the pump pulley.
- Install the drive belt on the pulley.





24. Check that the coolant drain plug has been properly tightened.
25. Carefully install the fan cowl in place.
- Install the retaining screws and the power steering pipe and plug in the two connectors.
26. Install the top radiator hose.
27. Install the brake servo vacuum hose.
28. Install the tank breather hose.
29. Install the two fuel connections.





30. Install the cruise control unit complete with cable.
- Reconnect the electrical connections and hook the cruise control cable onto the throttle body.
- Hook the throttle cable in place.
31. Install the air cleaner and mass air flow sensor.
- Plug in the two connectors.
32. Install the battery and the engine covers.
- Remove the protective covers from the wings.
33. Top up with coolant and check the system for leaks.
34. Check the other oil and fluid levels and top up as necessary. Make sure that the engine, engine bay and cabin are clean.
35. Bleed the cooling system as follows:
- Fill the system up to the MAX level, install the pressure cap, start the engine and warm it up (preferably at different rpm) until the radiator fan starts.
- Remove the pressure cap and top up to the MAX level again.
- Install the pressure cap and run the engine at varying rpm until the radiator fan starts three more times.
- Switch off the engine and top up to the MAX level, if necessary.
36. Drive the car on the road and check all functions.