Power Train, to Fit, 4WD
Power train, to fit, 4WDWarning
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!
To fit
1. Position the trolley lift with power train and adjust its position in relation to the body. Use 82 93 102 Extension, 500 mm, 3/8 square through the holes in the subframe to the attachments in the body (A).
2. Raise the train until the inner drive shaft universal joints are level with the wheel hubs and insert the hub nuts. Make sure that nothing catches or gets damaged.
3. Lift a little higher and position the lower swivel joints to the steering swivel members. If necessary, adjust the trolley lift screws to provide even contact with the body. Check that the guide pins are positioned correctly relative the reference holes in the body.
4. Move the subframe stays back into position. Position and insert the bolts through the subframe to the body.
5. Raise the engine all the way and tighten the subframe bolts (B) and the rear bolts of the stays.
Tightening torque, subframe: 75 Nm + 135 degrees (55 lbf ft + 135 degrees)
Tightening torque, stay: 90 Nm + 45 degrees (66 lbf ft + 45 degrees)
6. Lower the trolley lift and move it out of the way.
7. Fit the outer steering links and the nuts (A) of the steering swivel members.
8. Position the lower anti-roll bar links (B) and tighten them while gripping the flats with a thin spanner.
Tightening torque 64 Nm (47 lbf ft)
9. Certain cars: Plug in the connector (C) of the headlamp angle sensor and attach the cable to the subframe.
Important
Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.
10. Tighten the bolts (D) on the lower swivel joints.
Tightening torque 50 Nm (37 lbf ft)
11. Aut: Fit the left engine mounting (A).
Tightening torque: 70 Nm + 45 degrees (52 lbf ft + 45 degrees)
12. Aut: Fit the gear cable (B) to the gearbox. Fit the breather hose (C) of the automatic transmission.
13. Man: Fit the left engine mounting (A).
Tightening torque: 70 Nm + 45 degrees (52 lbf ft + 45 degrees)
14. Man: Attach the gear cables (B) to the gearbox.
15. Man: Remove 30 07 739 Hose pinch-off pliers from the clutch hose and fit the quick coupling (C) to the clutch slave cylinder.
16. Fit the right engine mounting (A).
Tightening torque: 70 Nm + 60 degrees (52 lbf ft + 60 degrees)
17. Fit the quick coupling (D) to the breather line.
18. Remove the Plugs and connect the fuel line (C) to the fuel rail.
19. Connect the brake servo vacuum pipe (A).
20. Raise the car.
21. Fit the A/C compressor retaining bolts (B) and plug in the A/C compressor connector (A).
22. Fit the power steering pipes (A) to the radiator assembly.
23. Fit the steering shaft (A) to the steering gear.
24. Lower the car.
25. Plug in the two connectors (C) on the structural member.
26. Attach the ground cables (B) and the clamp (A) for the engine harness to the body.
27. Tighten the retaining screw on the engine harness connector (C) in the main fuse box.
28. Attach the positive cable (B) to the positive battery terminal.
29. Fit the two retaining bolts (A) and the fuse box cover.
30. Fit the radiator connections (A) to the radiator assembly.
31. Plug in the level sensor connector (A) and the quick coupling of the hose (B). Fit the coolant reservoir (C).
32. Attach the breather hoses (A) to the coolant reservoir.
33. Fit the charge air pipe (B) between the throttle body and charge air cooler.
34. Attach the boost pressure sensor connector (688) (A).
35. Attach the lower radiator hose (A).
Aut: Remove the plugs and attach the oil pipes to the radiator (B).
36. Attach the upper radiator hose (B) to the engine.
37. Fit the cover (A) over the radiator assembly.
38. Fit the air cleaner casing lower section
39. Fit the air filter (A).
40. Fit the cover (B) and attach the pipe to the air cleaner casing cover (A).
41. Fit Fan cowling.
42. Fit the upper engine cover.
43. Fit the propeller shaft
44. Attach the oil cooler's coolant hose (D) to the radiator.
45. Fit the dryer filter bolts (C) on the radiator.
46. Attach the hose (B) to the charge air cooler.
47. Fit the cover (A) on the right-hand side.
48. Fit the lower charge air pipe bracket (C) to the fan cowling and attach the charge air hose (B) between the charge air pipe and charger air cooler.
49. Fit the cover (A) on the left-hand side.
50. Fit Upper radiator member, B284.
51. Unload the belt tensioner. Use a 1/4" puller (B) and fit the drive belt to the AC compressor pulley.
52. Fit the front part of the left wing liner and fit the right wing liner (A).
53. Fit the connector (C) and plug in the connector (B). Fit the spoiler shield bolts (A).
54. Remove the hub caps. Lower the car slightly and fit the front wheels.
55. Lower the car and tighten the hub nuts.
Tightening torque 230 Nm (170 lbf ft).
56. Fit the hub caps.
57. Connect the negative cable and fit the battery cover.
58. Remove the wing covers.
59. Check oil level and top up as necessary. Fill with coolant to approx. 20 mm above the mark on the expansion tank. If a new engine is fitted, follow the instructions given in Bleeding and filling the cooling system.
60. Close the expansion tank cap.
61. Aut: If the gearbox was drained, check the automatic transmission fluid level as described in Checking oil level.
62. Remove the wing covers and restore car electrical functions, see Procedure after reconnecting the battery.
63. Fit the upper engine cover.