Installation

WARNING: A large number of electrical cables, hoses, leads etc. are secured with plastic cable ties. After pulling these cable ties tight, cut the excess length off to leave the ends as short as possible at the attachment points. Bear this in mind and help to reduce the risk of sharp edges scratching bare hands or causing damage by chafing.





1. Install the multi-groove belt, making sure that it runs under the right-hand engine mounting. Carefully lower the power train into the engine compartment and align it with the engine mountings.
2. Install the resonator bracket.
3. Tighten the left-hand engine mounting to 39 Nm (29 ft. lbs.). Unhook the lifting yoke.
4. Tighten the rear and right-hand engine mounting bolts to 39 Nm (29 ft. lbs.). Remove the extenders from the gas springs.





5. Tighten the upper bolts on the A/C compressor (A/C).
6. Connect the grounding lead to the gearbox and the positive lead to the positive terminal block.
7. Connect the brake servo vacuum hose to the intake manifold.
8. Place the servo pump in position and install the hose to the expansion tank.
9. Connect the hoses for the cabin heat exchanger and reconnect the lower radiator hose to the engine.
10. Connect the upper radiator hose to the engine and raise the car.





11. Tighten the lower bolt to the A/C compressor (A/C).
12. Check that the coolant drain plug is tightened and install the center air shield.
13. Lift up the front exhaust pipe and tighten it against the exhaust manifolds. Bolt together the joint under the car.
14. Install the connectors to the bracket and connect the oxygen sensor, the knock sensor and the crankshaft position sensor.
15. Install the clamp on the cylinder block for the cables to the oxygen sensor, the knock sensor and the crankshaft position sensor.
16. Lower the car a little and remove the covers from the universal joints. Align the universal joints and install the boots using new clamps.
17. Tighten the steering swivel member to the MacPherson struts to 92 Nm (68 ft. lbs.).
18. Install the front wheels and lower the car.





19. Connect the fuel hoses and fix them on the timing cover.
20. Place the transmission oil hoses in the correct position and connect them (automatic transmission). Tighten to 25 Nm (18.5 ft. lbs.).
21. Connect the gear selector cable (automatic transmission).
22. Connect the rear oxygen sensor and press the electrical connectors into the bracket.
23. Install the power steering servo pump.
24. Release the tension from the belt tensioner by turning the belt tensioner pulley forward in the car using a 15 mm wrench. Install the belt. Install the servo pipe clamp on the torque arm engine mounting.
26. Install the torque arm and press on the power steering servo oil reservoir holder.
27. Bolt the lead onto the torque arm engine mounting.





28. Position the detachable bulk-head plate. Thread the wiring harness through and connect it.
29. Tighten the detachable bulk-head plate bolts and fix the fuel hose clamps.
30. Connect the washer hoses, refit the cover and press the seal into position.





31. Connect the secondary air injection hoses to the check valves and fix them to the resonator bracket using a cable tie.
32. Align the inlet pipes with the resonator, connect the vacuum hoses and the wiring harness and tighten the hose clamps to the intake manifold and the mass air flow sensor.
33. Tighten the throttle linkage fixing. Connect the control rod and the throttle cable.





34. Turn the control arm to the wide open throttle position and insert adjusting tool 87 92 459, or equivalent into the right-hand hole in the control bracket. Let the control arm rest against the tool. The kick-down wire should be under tension, but not so much that the kick-down function would have been activated if the car had been driven. Pull on the kick-down wire to check that the wire is at, not beyond, the "threshold" of kick-down position.
35. Move the tool to the left-hand hole in the bracket (closed throttle position) and let the control arm rest against the tool.
36. Lift the accelerator cable off the control arm. Adjust the control rod, the rod between the control arm and the butterfly spindle. Adjust the control rod, the rod between the control arm and the butterfly spindle. Adjust the control rod so that the control arm just leaves the tool. Tighten the securing nuts (the securing nut by the throttle body is left-handed).





37. Connect the throttle cable. Adjust the throttle cable so that there is a little slack. Look at the control arm and turn the adjusting device. When the throttle cable is in the rest position, the control arm should also be in its rest position.
38. On the front underside of the control bracket is an adjusting screw which should be adjusted so that when the control arm is in the wide open throttle position, the stops on the throttle body should be no more than 0.3 mm from their end position. Check the clearance using a feeler gauge.
39. Remove the tool. The cruise control cable has no adjusting device.

CAUTION: The engine must not be started with the adjusting tool fitted.





40. Hold the battery shelf in place and connect the cruise control. Tighten the bolts on the battery shelf.
41. Install the cable conduit, clip the vacuum hose onto the battery shelf and refit the positive terminal and the positive lead clamp.
42. Connect the cruise control cable to the lever.
43. Install the front electrical distribution box on the battery shelf.
44. Install the battery and connect the battery leads.
45. Install the covers over the engine, remove the wing covers and check that the engine compartment is clean.
46. Top up with coolant and check the system for leaks.
47. Top up the gearbox oil in the gearbox dip stick pipe (ant.).
48. Top up engine oil, check other oil and fluid levels and top up as necessary. Make sure that engine, engine bay and cabin are clean.

WARNING: Coolant is very hot and under high Pressure Risk of burn injury when the pressure cap is opened. Be extremely careful.

49. Bleed the cooling system as follows:
^ Fill the system up to the MAX level, fit the pressure cap, start the engine and warm it up (preferably at different rpm) until the radiator fan starts.
^ Remove the pressure cap and refill to MAX.
^ Install the pressure cap and run the engine at varying rpm until the radiator fan starts three more times.
^ Switch off the engine and top up to the MAX level, if necessary.
50. Test drive the car and check all functions. Also check oil levels in the engine and gearbox.