Installation
Special Tools
951 2661
999 2810
999 5186
999 5642
999 5488
Place hood in service position
Install engine complete with transmission in car
Use the lifting beam 999 2810 and the lugs 999 5642 and 999 5186
- Attach the lifting beam so that the engine is balanced
- Always have the tackle hook on hand when lifting
- Install the nut and the bolt in the engine mounting at the distributor side.
Install gear shift mechanism cables
Check the gear shift mechanism cable.
Install:
- The connectors and the bracket
- The ground lead
- The gear shift selector-cable.
Install engine mounting on transmission side
- Mount the bracket on the transmission. Tighten to 45 Nm.
Note! Make sure that the rubber gaiters are in the correct position.
- Install the bolt and the nut on the body bracket
- Remove the lifting system
- Tighten both the left and right engine mounting bolts to 98 Nm.
Place the hood back in the normal position.
Route and attach hoses and wiring
Connect:
- The injectors, tighten the cable
- The wiring ignition coils and the earth lead
- The cable guide to the engine, tighten to 10 Nm
- The PCV valve
- The Throttle Position (TP) and the Idle Air Control (IAC) valves.
Route and fit fuel hose
Fit the fuel hose(s) and pull to check for correct attachment.
Install turbo air outlet hose at top
- Position the air pipe and fit it in the hose at the top
- Position the clamp and fit it to the engine with the spacer. Tighten the hose.
Install AC compressor on engine
Install the AC compressor. Place the bracket at bolt (B), do not tighten the bolt (B). Tighten the other bolts to 25 Nm.
Install connectors
Install the connectors:
- The alternator
- The sensor AC compressor
- The oil pressure.
Install right drive shaft in transmission
Remove the special tool 999 5488 from the transmission.
Place the drive shaft in the transmission and the bearing.
Finger-tighten the bearing cap.
Push the knuckle in the shock absorber. Install the bolts and the nuts.
Tighten the bearing cap bolts to 25 Nm.
Mount rear engine bracket
Install the bracket and tighten the four bolts.
Tighten to 40 Nm.
Mount front engine bracket
Connect the inlet hose of the Charge Air Cooler (CAC) and tighten.
Mount the bracket on the hose and the engine and tighten the three bolts. Tighten to 50 Nm.
Tighten the nut on the clamp.
Tighten to 6 Nm.
Install the AC pipe to the engine bracket.
Install longitudinal beam
Install the heat shield.
Install the longitudinal beam, and push two bolts (B) into the engine rubbers. Tighten the two bolts. Torque setting 69 Nm.
Note! Position the rubbers in the correct position (see illustration). The rear and front of the center member must be in similar positions.
Loosen the front-mounting bolster bolt (A). First tighten the rear-mounting bolster bolt (torque setting 55 Nm), then tighten the front mounting bolt again (torque setting 55 Nm)
Attach exhaust pipe to exhaust manifold
Apply new gasket.
Tighten nuts to 30 Nm.
AT: Install oil pipes
Install the lower pipe. Use a new O-ring.
Install the upper pipe (return pipe) with its mounting in the control system cover. Loosely install the connector.
The pipe cap nut is tightened later.
Install left drive shaft
- Clean the splines and the drive shaft
- Remove the special tool 999 5488 from the transmission
- Remove the bolt from the knuckle/shock absorber
- Push the drive shaft into the transmission until it stops
- Place the hub over the drive shaft splines and fit the nut
- Place the two bolts in the knuckle/shock absorber.
Install cross stay member
- Place the stay and fit the bolts
- Tighten the bolts to 50 Nm.
Install engine splash guards
Install:
- Tighten the two bolts from the knuckle/shock absorber. Tighten to 90 Nm
- The ABS leads into the brackets
- The brake hose in the bracket, fit the clamp.
Fit front wheels
- Install the wheels and tighten the nuts slightly
- Tighten crosswise to 110 Nm
- Re-torque the wheel nuts by hand
- Lower the car.
Note!
^ When tightening with an airgun, only use torque socket 555 2661.
^ Tightening the nuts crosswise and to the correct torque settings is important to avoid causing stresses in the brake disc.
Tighten the central nut (A) to 120 Nm + 60°.
Install wiring
- The ground lead to the transmission
- The brake servo hose to the brake booster
- The starter motor wiring
- The battery positive lead
- Route the cables
- Fit the connectors and tie up.
Attach engine coolant hoses
- Install the clamp and fit the hose expansion tank
- Tighten the cap nut for the oil cooler on the transmission to 30 Nm.
Attach heater hoses
- Install and tighten the two heater hoses to the correct connections
- Install the heat shield on the fire wall.
Install air cleaner (ACL)
See Replacing the Air Cleaner (ACL), refer to Powertrain Management, Fuel Delivery and Air Induction.
Install battery
- Install the battery shelf. Torque setting 16 Nm
- The battery, secure with the locking part.
Note! If the car is equipped with cruise control, the vacuum hose and the leads to the vacuum motor must be installed before the battery shelf is secured.
Attach throttle cable and air inlet hose to Throttle Body (TB)
- Clean the air inlet hose and Throttle Body (TB)
- Install the hose and tighten the clamp
Note! Make sure that the clamp does not touch the throttle cam when the throttle cam is at the idle or Wide Open Throttle (WOT) position.
- Attach the hose to the Idle Air Control (IAC) valve. Use a new clamp.
Install power steering pump
- Position the pump and fit the bolts
- Loosely install the brackets between the alternator and the inlet manifold and lower bracket
- Tighten the bolts. Torque setting 25 Nm
- Fit the cable in the bracket
- Tighten the bracket between the alternator and the inlet manifold to 25 Nm
- Tighten the lower bolt from the bracket to 25 Nm.
Install poly V-belt
- Clean the pulley grooves
- Turn the tensioning device clockwise
- Install the auxiliaries belt as illustrated
- Release the belt tensioner (counterclockwise)
- Tighten the bracket. Torque to 10 Nm.
- Install power steering hose. Torque to 10 Nm.
Fill coolant
See Replacing coolant, refer to Cooling System.
Fit all covers.
Check the Automatic transmission oil level.