To Fit Power Unit

1. Check that the universal joints are packed with grease.
Fit the drain plugs for the cooling system.





2. Suspend the power unit from the lifting yoke so that the front engine mounting is some-what lower than the rear mountings.
3. Lower the power unit into the engine compartment down to a height at which the oil cooler hoses, the oil pressure sensor and the steering servo pump return hose can be connected.





4. Align the power unit in the following order:
- front engine mounting
- left-hand inner universal joint
- right-hand inner universal joint
Then lower the power unit onto the rear engine mountings and fit the bolts. Don't forget the spacer sleeve for the left-hand mounting.
5. Unhook the lifting yoke hooks and, if applicable, remove the lifting lug from the water pump (car with AC).
6. If the car is equipped with an AC:
Fit the AC compressor.
Fit the drive belt and tension it.





7. Connect the coupling on the delivery side of the steering servo pump.





8. Secure the exhaust pipe loosely to the exhaust manifold.
9. Lift the car to a suitable height and fit the ball joint to the bottom wishbone and antiroll bar.
Refit the wheel.





10. Lift the car and fit the following:
a. The rubber gaiters and clips to the universal joints.





b. The bolts for the exhaust pipe bracket to the gearcase.





The exhaust pipe clamp may have to be slackened slightly to enable the bracket to be bolted to the gearcase.
c. Speedometer cable.





d. Selector rod taper pin.
11. Lower the car to a suitable working height and:
- Connect the earth cable to the timing gear cover.
- On cars with water-cooled turbocharger, connect the coolant pipe to the turbocharger.
- Run the positive cable into place and fit the clips.





12. Remove tool 83 93 209 under the right-hand upper wishbone and tighten the wheel nuts.
Tightening torque for the wheel nuts: 105 - 125Nm (77-92 lb ft)
13. Tighten the exhaust pipe flange bolts.





14. Connect the Lambda sensor connector. Fit the clip to the wheel housing and secure the cable.





15. Connect the radiator hose to the bottom of the radiator and connect the hydraulic line to the clutch slave cylinder.
Bleed the clutch, refer to "Clutch Master Cylinder (or) Clutch Slave Cylinder/Service and Repair/To Bleed the Master and Slave Cylinders. Service and Repair





16. Run the cable harness into place and make the connections to the following terminals in the order listed:
a. full-load enrichment switch

NOTE: Make sure that the cables are connected to the correct terminals on the full-load enrichment switch and to the earthing points on the lifting lug.





b. cold-starting valve





c. temperature switch, Lambda
d. temperature time switch
e. temperature sensor
f. Hall sensor
g. auxiliary air valve
h. temperature switch
i. earthing points on the lifting lug Note the locations of the cables.
j. control pressure regulator
k. knock sensor
l. starter motor:
- At the same time, connect the positive cable.
m. oil pressure sensor
n. alternator





Secure the cable harness with straps to the positive cable and to the mounting points on the flywheel housing.





17. Connect the vacuum hoses for the brake servo to the intake manifold and the vacuum tank system to the throttle housing.





18. Connect the throttle cable and the electric cable.





19. Place the fuel distributor with air cleaner in position and clip them into place.
Make the connections to the fuel distributor in the order listed below:
a. Connect the earth cable to the fuel distributor.





b. Connect the following to the fuel distributor:
- hose from the fuel filter (1)
- hose from the fuel-boosting valve (2)
- fuel return hose (3)
- hose from the control pressure regulator to the fuel-boosting valve (4)





c. Connect the fuel lines to the control pressure regulator.





d. Connect the fuel hose to the cold-starting valve.





e. Connect the fuel lines to all injection valves.





f. Fit the pressure switch and connect the vacuum hose.





g. Fit the air cleaner "snorkel".
20. Fit the pipe for the oil dipstick.





21. Remove the protective cap from the turbocharger inlet pipe and fit the intercooler together with the air pipe.
Fit the cover over the intercooler.
22. Fit the rubber bellows to the fuel distributor.
23. Fit the turbocharger delivery pipe between the intercooler and the throttle housing.
24. Connect the coolant hoses to:





a. heat exchanger valve





b. expansion tank





c. thermostat housing





25. Connect the signal hoses to the solenoid valve.
26. Fit the ignition coil and connect the lead to the distributor cap.
27. Fill the steering servo reservoir with Texaco Power Steering Fluid 4634 or equivalent.
28. Fill the cooling system with coolant and pressure test it.
29. Fit the battery and connect the cables.
30. Fit the bonnet and connect the hose for the windscreen washers.
31. Start the engine, check the various functions and check that none of the hoses are leaking.