Installation

NOTE: The method described applies to the car when equipped with AC, automatic transmission, catalytic converter and a hydraulic automatic belt tensioner for the auxiliaries belt.





WARNING: Numerous leads, hoses, etc. are secured by means of plastic ties. After pulling it tight, cut off the end as close as possible to the clip. Help to prevent the risk of chafing damage done by sharp edges.








1. Attach lifting sling 83 92 409 to the eyes on the engine. Before lowering the power train, insert the bolt through the LH engine mounting. Position the power train over the engine bay and lower it slowly and carefully into position. Take great care not to do any damage. Pay particular attention to ensure that the following components do not snag:

In the engine bay:
^ ABS unit
^ Kickdown cable
^ Cooling fan

On the power train:
^ Steering servo pump
^ Alternator pulley





2. Tighten the LH engine mounting.
3. Raise the car and tighten the RH engine mountings.
4. On both sides:





^ Remove the protective caps from the drive-shaft joints and check that there is sufficient grease in the joints.





^ Engage the two halves of the joints and slide the rubber boots into position.





^ Install the top bolts securing the MacPherson struts to the steering-swivel members and tighten the top and bottom securing bolts to 78 - 105 Nm (57.5 - 77.4 ft. lbs.).








^ Install the clips on the rubber boots. If clips of the non-screw type are used, install them as shown. Take care not to damage the boots.





5. Check that the radiator drain plug is screwed in tight.





6. Install the middle infill panel under the spoiler.





7. Remove the plug and connect the steering servo pipe to the pump. Secure the pipe clip to the support bearing bracket. Lower the car.
8. Reconnect the charcoal-canister hose to the inlet manifold.
9. Install the power-steering fluid reservoir.





10. Reconnect the servo pump hose to the reservoir.
11. Install the oil cooler. Clip the top hose to the wheel arch.
12. Plug the connector onto the oil-level sensor.
13. Bolt the exhaust pipe to the exhaust manifold.
14. Reconnect the bottom radiator hose to the water pump.
15. Reconnect the hose to the top of the pump.





16. Install the AC compressor. Tighten mounting bolts to 20 Nm (14.8 ft. lbs.). Plug on the connector and make sure the lead is well clear of the pulley.





17. Ease the belt onto the compressor pulley. Apply a hard upward pull to the belt and remove locking pin 83 94 488. Release the belt and check to see that it is correctly seated in all of the pulleys.





18. Reconnect the radiator hose to the expansion tank and plug on the connector. Put back the tank, secure it and reconnect the expansion hose. Install a plastic tie round the leads and hoses.





19. Reconnect the connectors for the Lambda sensor loom (underneath the inlet manifold).





20. Install the engine torque arm, remembering to secure the radio-suppressor (ground) lead under the fixing bolt.





21. Secure the steering servo hoses, charcoal canister hose and wiring to the torque arm by means of plastic ties.

NOTE: Before reconnecting the gear-selector cable to the transmission, make sure that the kickdown cable is secured in the clip on the steering servo pipe.





22. Reconnect the gear-selector linkage and secure the cable bushing in the bracket.





23. Remove the plugs and reconnect the oil cooler hoses to the transmission. Secure the hoses with ties.
24. Plug the connector onto the brake fluid reservoir.





25. Insert the road-speed sensor lead through the grommet in the bottom of the bulkhead and plug on the connector.

NOTE: On the hose underneath the inlet manifold, position the clip with the screw towards the left and at the top to facilitate installing.





26. Reconnect the hoses from the heater box to the engine.





27. Reconnect the throttle cable.
28. Plug the connector onto the knock detector.





29. Plug in the connector in the engine wiring loom.





30. Reinstall the false bulkhead panel and the rubber moulding.





31. Install the clip securing the engine wiring loom to the false bulkhead panel.





32. Install the cover on top of the false bulkhead panel.
33. Reconnect the washer hose.
34. Reconnect the fuel hose to the fuel-injection rail.





35. Reconnect the fuel return hose to the fuel pressure regulator.








36. Install the air intake complete with silencer, air mass meter and rubber elbow. Plug the connector onto the air mass meter and tie the loom to the heater box hose. Install the steady bar to the air-intake silencer.





37. Reconnect the top radiator hose.











38. Reinstall the battery shelf and terminal block. Clip the battery positive lead to the shelf and reconnect it to the terminal block. Reconnect the battery negative lead to the earthing point on the fender.
39. Plug in the three connectors on the Direct Ignition System (DI) wiring loom and hook them onto the bracket on the battery shelf. Secure the leads in the clips on the bracket.





40. Bolt the bracket for the ABS unit to the battery shelf.
41. Tie the knock-detector lead to the inlet manifold steady bar.





42. Reinstall the washer fluid reservoir. Reconnect the hose and plug on the connectors for the fluid-level sensor and pump (red and black). Tie the hose to the battery positive lead underneath the battery shelf.
43. Install the battery onto the shelf and reconnect the leads.





44. Remove the extension pieces from the hood struts.
45. Raise the car. Install the RH fender liner and the front wheels (remember to torque the bolts to 130 Nm (96 ft. lbs.)).





46. Replenish the coolant and power steering fluid, and top up the washer fluid if necessary. Pressure test the cooling system.
47. Test drive the car. Check that all systems are working properly and listen for rattles and noises indicating loose wiring looms, parts, etc. Inspect all hose connections for leaks.





48. Check the fluid level in the automatic transmission, topping up as necessary.