Installation

Power Train, To Fit





1. Run the lifting trolley with power train under the raised car.
2. Lower the car with care and raise the lifting table.





3. Remove the cable tie suspending the A/C compressor. Fit the A/C compressor retaining bolts and tighten them.
4. Fit the drive shafts in the hubs and connect the generator's cooling air duct.





5. Fit the subframe retaining bolts and the triangular stiffeners.
Tightening torque:
Subframe: 115 Nm (84 ft. lbs.)





6. Fit the left-hand engine mount.





7. Lower the car. Fit the multigroove belt. Fit the right-hand engine mount with attachment and bracket.





8. Fit the A/C pipes to the attachment points on the subframe.





9. Remove the cable tie suspending the charge air cooler and condense.
10. Refit the front grille.
11. Fit the hose between the turbo outlet and charge air cooler.





12. Plug in the A/C compressor connector.
13. Fit the radiator.





14. Remove the plugs from the oil cooler connections. Connect the automatic transmission's hydraulic hose
15. Connect the upper and lower radiator hoses as well as the expansion tank and radiator hoses.





16. Connect the hoses for the cabin heat exchanger.





17. Fit the power steering oil reservoir. Secure the hydraulic hoses with a cable tie.
18. Connect the fuel lines.





19. Connect the venting hose to the throttle body.
20. Connect the vacuum hose for the brake servo to the intake manifold connection
21. Connect the vacuum hose to the heater system's shut-off valve.





22. Fit the wiring harness with holder and plug in the connector. Fit the cover over the engine wiring harness connector on the bulkhead.
23. Plug in the engine control module connector and fit the rubber seal.
24. Fit the wiper arms and windscreen cover.





25. Fit the radiator fan and plug in the connectors.
Tightening torque: 8 Nm (6 ft. lbs.)





26. Fit the turbo intake pipe, intake hose and mass air flow sensor. Reconnect the venting hose and plug in the mass air flow sensor's connector.
Tightening torque:
V-clamp 3 Nm (2 ft. lbs.)
U-clamp cylinder head 14 Nm (10 ft. lbs.)
27. Fit the crankcase breather pipe to the turbo intake pipe.
Tightening torque: 24 Nm (18 ft. lbs.)
28. Fit the heat shield to the front exhaust manifold.
Tightening torque: 24 Nm (18 ft. lbs.)





29. Fit the turbo pressure hose together with the charge air bypass pipe, valve and connecting pipe. Connect the vacuum hose the charge air bypass valve.
Tightening torque:
Bypass pipe 8 Nm (6 ft. lbs.)





30. Raise the car and fit the lower steering swivel joint bolts.
Tightening torque: 30 Nm (22 ft. lbs.).
31. Fit the link rods to the anti-roll bar.
32. Fit the outer tie-rod ends to the suspension struts.





33. Fit the front exhaust system.
Tightening torque: 22 Nm (16 ft. lbs.).





34. Fit the air cleaner's rubber mounts to the subframe.
35. Secure the rear heated oxygen sensor's wiring to the floor (certain models).
36. Refit the lower spoiler sections. Connect the turbo pressure hose to the charge air cooler.





37. Plug In the connectors for the turbo pressure sensor, intake air temperature sensor and ground cable for the turbo pressure.
38. Lower the car and fit the turbo pressure hose to the throttle body.





39. Refit the throttle cable.
40. Connect the positive cable to the junction terminal. Secure the cable to the main fuse board.





41. Fit the selector lever cable to the gear actuator.
Tightening torque: 20 Nm (15 ft. lbs.)
42. Connect the ground cable to the gearbox. Fit the gearbox venting hose.
43. Connect the ground cable to the left-hand wheel housing. Fit the front wheel and hub nuts.
Tightening torque:
^ Wheel: 120 Nm (88 ft. lbs.)
^ Hub center-nut 200 Nm + 30° (148 ft. lbs. +30°)
^ Hub center-nut with top groove 170 Nm + 45° (170 ft. lbs. + 45°)





44. Move the battery tray sideways away from the engine as far as possible. Fit the battery tray. Secure the wiring harness to fit battery tray.
45. Fit the battery and connect the battery cables.
46. Fit the battery cover and engine cover.
47. Plug the connectors into the automatic transmission wiring harness. Remove the protective covers from the wings.





48. Bolt the steering column to the steering gear inside the cabin.
Tightening torque: 25 Nm (18.5 Nm)
49. Fill the radiator with coolant and check the system for leaks.
50. Bleed the cooling system as follows:
Fill the system up to the MAX level, close the expansion tank filler cap, start the engine and warm it up (by running it at varying rpm) until the radiator fan starts. Unscrew the expansion tank filler cap and top up again to the MAX level. Close the filler cap and run the engine at varying rpm until the radiator fan starts three more times. Switch off the engine and top up as necessary to the MAX level.

NOTE: The A/C should be OFF.

51. Drive the car on test and check all functions. Also check the engine oil level and gearbox oil level (or transmission fluid level).
52. Reset the clock and the radio, if fitted.