Fitting The Powertrain

Fitting the Powertrain

Warning: A large number of hoses, cables, etc., are secured with cable ties. After tightening, the ties are cut off and leave more or less sharp edges at the fastening point. Watch out for the risk of cuts due to these sharp ends on the cable ties!





1. Place the lifting trolley with power train under the raised car. Raise the lifting trolley so that the power train can be positioned. Insert the drive shafts into the hubs and thread on the nuts to the swivel arms and hub.
2. Raise the lifting table a bit further and position the powertrain carefully. Make sure the AC compressor follows above the subframe and fit the lower bolt.
3. Insert all the bolts in the subframe and engine mountings. Make sure the washers for the rear bolts do not fall off. Tighten the engine mountings.
Tightening torque: 50 Nm (37 ft. lbs.)
4. Fit the bolts for the subframe.
Tightening torque front: 115 Nm (85 ft. lbs.)
Tightening torque centre: 190 Nm (141 ft. lbs.)
Tightening torque rear: 110 + 75° Nm (82 ft. lbs. + 75°)





5. Remove the lifting table and tighten the nuts on the suspension arms. Note that new nuts must be used.
Tightening torque: 100 Nm (74 ft. lbs.)
6. Fit the hub nuts but do not tighten them.

Important: Always use new hub centre-nuts with top groove





7. Fit the lower bolts for the AC compressor loosely.
8. Connect the hoses to the oil filter housing. Tighten the nut. Use new O-rings and a new nut.
Tightening torque: 8 Nm (6 ft. lbs.)





9. Clean the joints on the exhaust pipe and fit the holder, nuts and bolts.





10. Connect the coolant hoses to the heater.





11. Connect the ground cable to the gearbox and left-hand wheel housing.
12. Close the coolant drain plug and fit the engine covers.
13. Lower the car to a comfortable working height and fit the brake calipers on both sides.
Tightening torque: 105 Nm (78 ft. lbs.)
14. Fit the wheels. Lower the car. Tighten the hub centre-nuts.
Tightening torque, wheel 110 Nm (81 ft. lbs.).
Tightening torque hub centre-nut with top groove: 170 Nm + 45° (126 ft. lbs. + 45°)
Refit the wheel center emblems





15. Insert the wiring harness through the bulkhead. Check the seal.
16. Connect the engine wiring harness under the dashboard. Fit the air duct.
17. Fit the glove box or, alternatively, the lower dashboard panel and refit the carpet. Make sure the rubber grommet is fitted correctly. Do not forget the connection in the engine bay above the cable lead-through.





18. Man: Fit the connection to the slave cylinder. Bleed the system. See Bleeding the clutch hydraulic system in the car, refer to Transmission and Drivetrain .
19. Fit the reverse gear sensor connection on the gearbox
20. Remove the locking pin from the gear lever and engage 4th gear. Position the pin in the gear shift rod and fit it. Fit the gear lever protection.





21. Aut: Plug in the gearbox electric connections (located on the bracket behind the battery).
- Fit the gear shift cable to the attachment on the gearbox. Fit the locking clamp.
- Fit the gear shift cable to the selector lever.
- Fit the oil cooler pipe to the gearbox. Use new O-rings lubricated with petroleum jelly.





22. Man: Fit the gear shift rod to the gear linkage.
23. Pull up the locking pin and refit the plastic plug.





24. Connect the positive table to the positive terminal block in the maxi fuse board and the ground cable behind the board. Replace the cover.
25. Tighten the top bolt to the A/C compressor and reconnect the electric connection.
26. Tighten the exhaust pipe upper nut.
Tightening torque 25 Nm (18 ft. lbs.)
27. Fit the hose between the radiator and the coolant pump, and the hose between the charge air cooler and the turbocharger.





28. Connect the hose to the expansion tank. Fit the upper hose from the radiator to the cylinder head.





29. Fit the vacuum pipe to the brake servo and the bracket with the bypass valve for the throttle body.





30. Fit the power steering pump, mount the belt and check the position of all the belt pulleys.





31. Relieve the tension on the belt tensioner with a jointed handle and remove the drill.





32. Fit the hose with vacuum hose for the crankcase ventilation. Plug in the connector to the solenoid valve on the bracket.





33. Fit the heat shield over the exhaust manifold and the charge air pipe.
34. Plug in the connectors for the oxygen sensors and secure the cables.
35. Fit the pressure/temperature sensor connector. Fit the charge air pipe and associated components.
Man: Connect the venturi hose to the charge air pipe.
36. Fit the accelerator cable with protective cap. Adjust the accelerator cable as necessary.





37. Fit the fuel hoses.
38. Fit the hose to the crankcase ventilation





39. Fit the air cleaner with hose and connector for the mass air flow sensor.
40. Fit the EVAP canister purge valve with hose and the connector.





41. Fit the wiring harness to the MacPherson strut with cable ties
42. Fit the battery and connect the negative and positive cables and the battery breather. Secure the cables.
43. Raise the car. Tighten the AC compressor lower bolt.
Tightening torque 47 Nm (35 ft. lbs.)
44. Fit the belt circuit cover and the lower engine covers.
45. Top up to the correct level and bleed the cooling system in the following way:

Note: AC/ACC should be OFF.

Fill the cooling system to MAX level. Check system integrity. Close the cap on the expansion tank, start the engine and warm it up without any load at varying engine speed until the radiator fan starts. Carefully open and top up to MAX level.

46. Fit the engine cover, remove the wing protectors and make sure the engine bay is clean.
47. Program SID and the radio. Start the engine and check all functions. Calibrate the ACC. Conduct a road test.