Fitting Powertrain

Fig 1: Illustration For Step 4

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WARNING: A large number of electrical leads, hoses, etc. are secured by means of cable ties. When these ties have been pulled tight, the excess length is cut off and may leave a sharp end at the fixing points. Beware of injuries like cuts and scratches on your hands caused by these sharp ends.

Run the lifting trolley with power train under the raised car.
Lower the car with care and raise the lifting table.
Raise the engine with the lifting trolley, fitting the locating studs in their positions at front left and rear right. Make sure that the steering gear fits in place in the bulkhead.
Fit the drive shafts and screw on the three nuts securing the steering swivel joints.
Tightening torque 60 Nm + 30° (44 lbf ft + 30°)
Fit the subframe retaining bolts and tighten them, using a torque wrench, and remove the lifting table.

Fig 2: Illustration For Steps 5-6
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Tightening torque, Subframe 100 Nm + 45° (74 lbf ft + 45°)

Tightening torque, Support plate 63 Nm (46 lbf ft).

From chassis number W3050999, the inner sleeve in the subframe bushings has been made 38 mm long instead of previously 35 mm. If the bushing is 35 mm, a 3 mm spacer must be fitted between the bushing and washer.

WARNING: The spacer washer must not be fitted together with a bushing with 38 mm inner sleeve.
Fit the exhaust pipe, temperature sensor and air cleaner in the subframe.
Fit the outer track-rod ends and anti-roll bar support in the suspension strut.

Fig 3: Illustration For Steps 7-8
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Tightening torque: 84 Nm (62 lbf ft)

Tightening torque, nut with steel lock: 95 Nm (66 lbf ft)
Fit the hub nuts but do not tighten them.
Fit the A/C-compressor and air filter housing retaining nuts and hose.

Fig 4: Illustration For Step 9
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Lower the car to the floor. Fit the strap and tighten it.

Fig 5: Illustration For Step 10
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Set the steering gear in the straight-ahead position and mount the steering column in the cabin.

Fig 6: Illustration For Step 11
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Tightening torque: 25 Nm (19 lbf ft)
Fit the left-hand engine mounting but without tightening it. Fit the right-hand engine mounting with yoke but do not tighten.

Fig 7: Illustration For Step 12
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Raise the car slightly, remove the wedges and lower the car to the floor.
Tighten the engine mountings, using a torque wrench.
Tightening torque 50 Nm (36 lbf ft)
Fit the selector lever cable. (aut)

Fig 8: Illustration For Step 15
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Lock 4th gear with LOCKING PIN, GEAR POSITION ADJUSTMENT 87 92 335 (ring up) in the gearbox and (ring down) in the gear shift housing. Fit the selector rod. Remove the locking pins and fit a new plastic plug in the gearbox. Try changing gear. (man)

Fig 9: Illustration For Step 16
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Move the bleeder hose up under the main fuse box. (aut)
Connect the hoses to the heat exchanger.

Fig 10: Illustration For Steps 18-19
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Connect the coolant hose to the expansion tank.
Secure the engine wiring harness with bracket to the bulkhead.

Fig 11: Illustration For Steps 20-21
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Fit the engine control module, the cover panel over the wiper mechanism and the wiper arms.
Connect the ground cable to the gearbox.

Fig 12: Illustration For Steps 22-23
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WARNING: The ground cable connection is extremely important. Do not forget it. A fire could start if the ground cable is not connected!
Connect the positive cable to the positive terminal.
(aut.) Plug the connector with electrical leads into the gearbox. Fit the bracket in place.

Fig 13: Illustration For Steps 24 & 26
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(man.) Plug in the reversing lights connector.
Connect the quick-release couplings to the automatic transmission fluid cooler.
Couple together the two fuel connections and the rubber protectors.

Fig 14: Illustration For Steps 27-30
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Connect the vacuum hose from the brake servo to the intake manifold.
Connect the vacuum hose from the EVAP canister purge valve to the intake manifold.
Refit the throttle cable.
Raise the car slightly.
IMPORTANT: To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressures, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean also the connecting pieces. If hose clips are rusty or damaged, they must be replaced with new ones to maintain the correct clamping force.
Fit the hose between the turbocharger and charge air cooler.

Fig 15: Illustration For Steps 33-34
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Mount the engine oil cooler on the other coolers.
Fit the cover under the cooler.
Lower the car to the floor.
Remove the fastening straps supporting the coolers.
Check that the A/C compressor pipe is correctly positioned.
Fit the radiator fans and plug in the electrical connectors.

Fig 16: Illustration For Steps 38 & 40
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Refit the front grille.
Reconnect the upper and lower radiator hoses.
Refit the power steering fluid reservoir.

Fig 17: Illustration For Steps 41-42
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Reconnect the pipes to the power steering pump.
Reconnect the quick-release coupling on the vacuum hose connected to the turbo wastegate.

Fig 18: Illustration For Steps 43-45
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Plug in the A/C compressor's connector.
Refit the mass air flow sensor's rubber gaiter and plug in the connector.
Fit the bypass valve and intake manifold.

Fig 19: Illustration For Steps 46, 47 & 50
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Fit the hose between the pressure pipe and charge air cooler and plug in the connector for the pressure/temperature sensor.
Fit the wheels.
Lower the car to the floor and retighten the hub nuts, using a torque wrench.
Tightening torque: 230 Nm (170 lbf ft)
Fit the battery tray, the battery, the cover over the intake manifold and the battery cover. Remove the wing covers. Fit the vacuum hose to the heat exchanger shutoff valve (cars with AC).
Fill the radiator with coolant and check the system for leaks.
(auto) Add transmission fluid via the transmission dipstick tube.
Top up the engine oil, check other oil and fluid levels and top up as necessary. Make sure that the engine, engine bay and cabin are clean.
Secure all hoses and cables that have been disconnected.
IMPORTANT: It is important to secure all hoses and cables correctly to minimize the risk of rattling noises and chafing.

WARNING: The coolant is very hot and under high pressure. Risk of burn injuries when the pressure cap is opened. Be extremely careful.
Bleed the cooling system as follows: If the car is equipped with A/C or ACC, it must be turned off since these will start the radiator fan. Fill the system to the MAX level, close the pressure cap, start the engine and warm it, preferably at varying engine speeds, until the radiator fan starts. Then fill the system to MAX once more.
Test drive the car and check all functions. Check that the steering wheel stands straight when driving on a straight road. Adjust as necessary. Also check the oil level in the engine and gearbox.
Set the clock to the correct time. Calibrate the ACC.