Installation

WARNING:
^ Numerous electrical leads, hoses, cables, etc. are secured by plastic cable ties.
^ After these ties have been pulled tight, the ends are cut off, often leaving sharp edges.
^ Bear this in mind, during service procedures, to avoid these sharp edges, which could be the cause of cuts and scratches on your hands.





NOTE: Step numbers below refer to numbers used in the illustrations.

1. Install 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.
- Install the drive shafts and end pieces.
3. Hang the AC compressor in position and install the bolts but do not tighten them.
- Then tighten the lower bolt.
4. Lift up the engine and install the front engine mountings, then tighten to : 73 Nm (54 ft. lbs.).
5. Tighten the sub-frame retaining bolts, then tighten as follows:
- Front: 115 Nm (85 ft. lbs.).
- Middle: 190 Nm (140.6 ft. lbs.).
- Rear: 110 Nm + 75° (81.4 ft. lbs. + 75°).





6. Install the oil hoses for the oil cooler, then tighten to: 18 Nm (13.3 ft. lbs.).
7. Install the pipe between the turbocharger and charge air cooler.
8. On models with automatic transmission, reconnect the gearbox oil hoses, then tighten to: 25 Nm (18.5 ft. lbs.).
9. On all models, clean the exhaust pipe joints.
10. Install the bolt securing the catalytic converter to the bracket on the engine but do not tighten it.
- Screw the front exhaust pipe to the turbocharger.
- Before assembly, apply Molykote 1000 to the threaded studs on the turbocharger.
11. Tighten the bolt securing the catalytic converter to the bracket on the engine and screw together the joints under the car.





12. Install the spoiler sections and the covers in the wheel housings.
13. Install the nuts for the end pieces, then tighten to: 75 Nm (55.5 ft. lbs.).
14. Install the brake calipers, then tighten to: 105 Nm (77.7 ft. lbs.).
15. Install the hub nuts loosely and put the wheels back on the car, then tighten the wheel lugs to: 120 Nm (89 ft. lbs.).
16. Lower the car to the floor and tighten the hub nuts to: 290 Nm (214.6 ft. lbs.).

NOTE: 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, install the glove box and fold down the carpet.





19. Hook the clutch cable in place (manual gearbox).
20. Install the selector lever cable (automatic transmission) or assemble the selector rod (manual gearbox), then tighten to 21 +/- 2 Nm (15.5 + 1.5 ft. lbs.).
- Check the gear positions.
21. On models with automatic transmission, reconnect the breather hose to the gearbox.
22. On all models, connect the oxygen (Lambda) sensor lead and (as equipped) 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 AC compressor and plug in the connector.
26. Install the secondary air injection hose (as equipped).
27. Reconnect the coolant hoses.





28. Install the pressure pipe between the charge air cooler and throttle body (turbo).
29. Mount the servo pump, install 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. Install the BPC valve and the vacuum hose for secondary air injection (as equipped).
32. Install the pressure sensor and refit the vacuum hose for the brake servo.
33. Connect the tank breather hose and install the fuel hoses.
34. Install 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. Install the cover or the resonator, take the protective covers off the fenders and make sure that the engine bay presents a neat and clean appearance.
38. Start the engine and check all functions.
- Take the car out on a test drive.