Engine/Transmission, Installing
Engine/transmission, installingSpecial tools: 999 7089 999 7076, 951 2955, 951 2957
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.
Note: For tightening torques, see Specifications.
Note: To ensure that there is no exhaust leakage, see: Flanged joint, assembling.
Installation
Installing the engine and transmission
Raise the vehicle so that the engine / transmission are free beneath the vehicle. Place the engine and transmission on the lifting table. Lower the lifting table to its lowest position.
Lowering the vehicle
Lower the vehicle over the engine / transmission. Align the unit between the frame members and ensure that the air conditioning (A/C) compressor is free. Stop lowering the vehicle just before the engine transmission are in position. Lift up the engine / transmission the last bit until they are in position to install the engine mountings.
Installing the engine pad
Install the engine pad according to the markings.
Installing engine mounting
Install:
- the front engine mounting in the cylinder head.
- the screw for the engine mounting on the transmission.
Installing limiter and engine mounting
Install:
- the limiter
- the screws for the limiter for the right-hand engine mounting.
Removing the lifting table
Disconnect the restraining strap around the engine and remove the lifting table. Raise the vehicle.
Installing the three-way catalytic converter (TWC)
Caution: Ensure that flanges are clean of gasket residue and that they are flat.
Install:
- the catalytic converter. Use new gaskets for both connections
- new nuts at the connections. Tighten
- the front SIPS member. Tighten the screws.
Installing the lower engine stabilizer brace
Install the lower torque rod. Tighten.
Installing the sub-frame
Note: Ensure that the steering gear is not trapped when raising the sub-frame.
Install the adjustment tools. Use: 999 7089. Carefully raise the sub-frame so that the adjustment tools are lined up with the holes in the side members.
Installing sub-frame, continued
Install:
- the screws for the rear sub-frame mounting
- the screws for the front sub-frame mounting
- the support brackets for the rear sub-frame mounting.
Install the three-way catalytic converter (TWC) in the rubber mountings. Connect the connector for the rear heated oxygen sensor (HO2S) and secure the cable harness in the SIPS member. Remove the tool, 999 7089.
Installing the ball joint on the steering knuckle
Pry down the control arm. Use: 999 7076 and install the ball joint. At the same time, guide the drive shaft into the wheel hub. Install the new nuts on both sides. Tighten to specification.
Installing components, front suspension
Note: Counterhold the ball joint so as not to damage the rubber boot.
Install on both sides:
- the anti-roll bar link
- the new nuts. Tighten
- the tie rod for the wheel spindle
- the new nuts. Tighten
- the drive shaft center nut. Counterhold the brake disc. Use a screwdriver. Tighten all the joints.
Installing the air conditioning (A/C) compressor
Caution: Ensure that the belts are correctly positioned in all the grooves.
Install the air conditioning (A/C) compressor. Tighten the screws.
Inner belt
Relieve the load from the tensioner using a Torx wrench. Turn the tensioner counter clockwise as far as it will go. Position the belt and release the tensioner.
Outer belt
Slacken off the tensioner Use: 999 7109 by turning the tensioner clockwise as far as it will go. Position the belt and release the tensioner.
Installing power steering pipe
Install:
- the return line for the servo oil reservoir. Remove the seals
- the pressure line for the power steering pump. Remove the seals. Tighten to specification. Secure the pipes on the engine and in the sub-frame.
Installing components
Install:
- the right-hand fender liner. Tighten the screws
- the right-hand front wheel. Tighten.
- the lower engine splash guard. Lower the vehicle.
Installing the engine coolant hoses
Install the coolant hoses to the radiator. Tighten the hose clamps.
Connect:
- the air bleed hoses at the junction in the middle of the front cover plate. Secure the hoses in clips
- the passenger compartment heater hoses. Lock the connectors by turning the gray catches.
Installing hoses
Caution: Press the connector together until a clicking sound is heard.
Connect:
-the fuel pressure line
- EVAP canister hose.
Installing components on the transmission
Note: Remove the seals.
Install the gear selector cables. Press them into place on the ball joints.
For cars with manual transmission
Press the delivery pipe together with the clutch slave cylinder. Lock with the retaining clip.
Installing the steering shaft
Install:
- the steering shaft on the steering gear
- the screw for the steering shaft. Tighten to specification.
Installing the cable harness
Install:
- the ground lead on the transmission
- the positive cable to the starter motor. Tighten the nut
- the protective cover over the positive terminal on the starter motor
- the clamp for the cable harness for the starter motor
- the ground lead in left-hand and right-hand turrets
- the cable harness for the fuse box. Lock the fuse box with the striker plate
- the clamp for the cable harness that leads to the fuse box
- the fuse box cover
- The dip stick and the oil pipe.
Installing the air cleaner (ACL) module
Install the air cleaner (ACL) module.
Installing the battery box
Install:
- the lower section of the battery box. Tighten the screws
- the battery
- the holder for the battery. Tighten the screws
- the front surround for the battery box
- the battery positive lead
- the battery ground lead
- the battery box cover.
Finishing
Checks
Fill with coolant. Use filling equipment: 951 2957 and cover 951 2955.
Check the oil level in the engine and transmission. Start the engine and run the engine to normal operating temperature. Check the function of the engine. Check for leakage. Fill with fluids if necessary.
For cars with manual transmission
Bleed the clutch and check operation.