Fitting The Powertrain, B235R

Fitting The Powertrain, B235R

WARNING:
A large number of hoses, electrical leads, etc., are secured with cable ties of rigid plastic. When these ties have been pulled tight, cut off any excess so that the ends remaining at the fixing points are as short as possible.
Help to prevent cuts and scratches caused by the sharp ends of 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 trolley slightly higher and position the power train exactly. Make sure the A/C compressor is also above the subframe. Thread in the bolts to the subframe and engine mountings. Tighten the engine mounting pads.
Tightening torque: 50 Nm (37 ft. lbs.)
3. Fit the bolts for the subframe.
Tightening torque front: 115 Nm (85 ft. lbs.)
Tightening torque center: 190 Nm (141 ft. lbs.)
Tightening torque rear: 110 + 75° Nm (82 ft. lbs. + 75°)





4. Remove the lifting trolley and tighten the bolts to the swivel arms
Tightening torque: 100 Nm (74 ft. lbs.)
5. Fit the hub center-nuts but do not tighten them.

IMPORTANT: Always use new hub center-nuts.





6. Fit the bottom bolt on the A/C compressor
7. Connect the hoses to the oil filter housing and tighten the nut.
Tightening torque: 8 Nm (6 ft. lbs.)





8. Clean the joint on the exhaust pipe and fit the bolts





9. Connect the ground cable to the gearbox and left-hand wheel housing.
10. Close the coolant drain plug and fit the engine covers.
11. Lower the car to a comfortable working height and fit the brake calipers on both sides.
Tightening torque: 105 Nm (78 ft. lbs.)
12. Fit the wheels. Lower the car. Tighten the hub center-nuts.
Tightening torque, wheel 110 Nm (81 ft. lbs.).
Tightening torque hub center-nut with top groove: 170 Nm + 45° (126 ft. lbs. + 45°)
Tightening torque hub center-nuts: 290 Nm (215 ft. lbs.)
13. Insert the wiring harness through the bulkhead. Check the seal.





14. Connect the engine wiring harness under the dashboard, fit the glove box or, alternatively, the lower section of the dashboard and replace the mat. Make sure the rubber grommet is positioned correctly. Do not forget the connection above the grommet in the engine bay.





15. Fit the connection to the slave cylinder. Bleed the system.
16. Fit the reverse gear sensor connection on the gearbox





17. Remove the locking pin from the gear-lever housing and engage 4th gear. Position the pin in the gear selector rod and insert it.





18. Pull up the locking pin and refit the plastic plug
19. Connect the positive table to the positive terminal block in the maxi fuse board and the ground cable behind the board. Replace the cover.





20. Tighten the top bolt to the A/C compressor and reconnect the electric connection.
21. Fit the hose between the water cooler and the water pump and the hose between the charge air cooler and turbo.





22. Connect the coolant hoses to the heater unit and the hose to the expansion tank. Fit the upper hose from the radiator to the cylinder head.





23. Fit the vacuum pipe to the brake servo and the signal hose to the throttle body.





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





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





26. Fit the turbo inlet pipe, tighten the banjo screw and the screws on the bracket. Connect the signal hoses. Fit the pipe for the crankcase ventilation. Plug in the connector and fit the control valve to the bracket. Connect the vacuum hose to the brake servo.





27. Fit the heat shield over the exhaust manifold and charge air pipe. Plug in the connector on the intake manifold. Connect the hose to the pressure sensor. Connect the hose to the bypass pipe and plug in the temperature sensor. Fit the charge air pipe with accessories.





28. Fit the cable channel. Connect the fuel hoses and the hoses to the crankcase ventilation.
29. Fit the accelerator cable with protective cap. Adjust the accelerator cable as necessary.





30. Fit air cleaner with hose and plug in the mass air flow sensor.
31. Fit the evap canister purge valve with hose and the connector.





32. Fit the wiring harness to the MacPherson strut with cable ties
33. Fit the battery and connect the plus and minus cables and the battery vent.
34. Top up to the correct level and bleed the cooling system in the following way:

NOTE: AC/ACC should be OFF. Fill the system to MAX level. Check for leaks. Close the cap on the expansion tank, start the engine and run it warm at varying speeds until the radiator fan cuts in. Open carefully and top up to MAX level.

35. Start the engine and warm it up until the thermostat opens. Turn oft the engine and check the coolant and oil levels, top-up if necessary.
36. Fit the engine cover, remove the wing protectors and make sure the engine bay is clean.
37. Program SID and the radio. Start the engine and check all functions. Calibrate the ACC. Conduct a road test.