Engine/Transmission, Installing
Engine/transaxle, installing
Special tools:
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
Note! For tightening torques, see Specifications, B6324S Tightening Torque
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Flanged Joint, Assembling
Installing the engine and transmission unit
Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Caution! Ensure that no hoses, wiring or other components catch or become trapped during lifting.
Caution! Do not damage the brake pipe running to the right front wheel.
Note! Make sure that the mating surfaces on the ball joints and control arms are clean.
Lift the engine and transmission unit. Use a lifting table.
Stop the lift approximately 15 cm before the sub-frame reaches the frame members.
- Install (on both sides) the drive shaft to the hub.
- Lift the three-way catalytic converter (TWC) up into position. Connect the exhaust system to the rear flange. Use a new gasket. Install new nuts loosely.
Note! The catalyst cannot be raised after the engine has been raised to its correct position.
Continue raising the engine until it is only approximately 50 mm from its correct position.
Caution! Guide the lower steering shaft into the hole in the firewall.
Align the ball joint in the control arm.
Installing the sub-frame
- Install the inner pipe on the compressor in the climate control unit. Use a new O-ring
- Raise the sub-frame toward the frame members until it makes contact.
- Install new screws in the subframe. Lubricate the screw threads.
- Install the washers in the front edge and support plates at the rear edge of the subframe.
- First tighten the screws on the left side of the sub-frame. Tighten to Tightening torque, B6324S Tightening Torque. Use bevel protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
- Then tighten the screws on the right-hand side of the subframe to the same value.
- Tighten the brackets. Tighten to 50 Nm.
- Remove the lifting table.
Tighten the ball joint and control arm. Tighten to 80 Nm. Counterhold using Torx 40 so that the ball joint boot does not rotate.
Install:
- the anti-roll bar links. Use new locknuts. Tighten to 50 Nm.
- new center screws for the drive shafts. Tighten to 50 Nm.
Installing track rods
Install the tie rod using the marking made during removal. Use new locknuts. Tighten to 70 Nm.
Installing components
- Connect the fuel line to the engine
- Connect the evaporative emission system (EVAP) line at the right rear sub-frame mounting.
- Install the oil cooler hoses on the transmission
- Install the propeller shaft. See and
- Lower the car
- Pull up and align the three-way catalytic converter (TWC) against the turbocharger (TC).
- Lubricate the threads using copper paste 116 1408. Install new nuts loosely.
- Lower the car.
- Install the front SIPS member. Press the brake pipe into place in the member.
- Hook the rubber mounting for the three-way catalytic converter (TWC) in the bracket on the sub-frame
- Connect the connector to the rear probe. Secure the wiring as before.
Tighten the screwed joint between the three-way catalytic converter (TWC) and the exhaust system. Tighten to 24 Nm.
Installing the steering wheel shaft joint
Install:
- the steering shaft joint on the steering gear and steering shaft
- a new screw. Tighten to 25 Nm
- the steering shaft boot and snap ring. Fold back the carpet.
Connect the engine and transmission wiring connectors to the control module box base plate.
Press the base plate into place in the lower section of the control module box.
Install:
- the climate control unit pipe at the frame member inside the control unit box. Use a new O-ring
- the cable from the engine wiring for the sensor on the receiver to the right of the radiator
- the front right headlamp.
Installing the control module
- Install the intermediate section. Align the ventilation pipe in the rear edge of the control module box
- Press the control modules down carefully. Lock into place using mounting bracket 999 5722 Wrench 999 5722 Wrench
- Press the cover into place. Screw the ground lead into place on the fender liner.
Installing components
Install:
- the connector for the expansion tank from the engine compartment wiring
- the hose from the engine to the expansion tank
- the breather tube from the radiator
- the expansion tank
- the servo reservoir
- the upper radiator hose.
Install the plastic pipe between the charge air cooler (CAC) and the throttle module.
Hint: Use a hot-air gun to facilitate installation of the pipe.
Install:
- the connector for the sensor on the charge air cooler (CAC)
- the ground lead from the engine to the car body
- the vacuum hose to the intake and power brake booster
- the connectors for the transaxle
- the transaxle cable to the transaxle
- the rear radiator hose
- the connector to the fusebox
- the battery lead to the terminal block on the fusebox.
Install:
- the radiator hoses on the heater unit. They are coded and will only connect to the correct sleeve connector
- the ground strip between the engine and the car body.
Installing the heated oxygen sensor
Tighten the three-way catalytic converter (TWC) to the turbocharger (TC). Use new nuts. Tighten to 24 Nm.
- Install the upper heated oxygen sensors (HO2S) using the marks made during removal. Lubricate the threads. Use copper paste 116 1408. Tighten to 45 Nm
- Lower the wiring down to the probes. Secure the wiring in the clips and clamps as before. Connect the wiring
- Install the heat deflector plates.
Installing components continued
Install:
- the charge air pipes on the turbocharger (TC)
- the plastic charge air pipe over the engine
- air cleaner (ACL) assembly
- the connector for mass air flow sensor
- the turbocharger control valve on the air cleaner (ACL)
- the intake manifold to the air cleaner (ACL)
- the engine stabilizer brace between the suspension turrets.
Tighten the screws on the suspension turrets. Tighten to 50 Nm.Tighten the screw in the torque bracket. Tighten to 80 Nm.
Installing the battery lead
Install the battery negative lead. First read Battery, disconnecting Battery Disconnecting
Final checks
- Fill with coolant. The coolant volume is approximately 7.2 liters. Top up the engine oil
- Start the engine.
- Warm up the engine until the thermostat opens.
- Check for leakage.
- Check the oil and coolant levels. Adjust if necessary.
- Applies to cars with automatic transaxle: Check the transaxle fluid level.
Finishing
Install:
- the splash guard under the engine
- the front skid plate on the sub-frame
- the front wheels. See Installing wheels Service and Repair