Installation

NOTE:
- Model with a B234 engine, equipped with turbo and Air Conditioning (A/C) shown in the illustrations, other models have positive terminals without removing the cables.

Installation

NOTE: Before starting to install:
- Make sure that the intermediate shaft is in position on the righthand driver and that the aluminium tube has been pressed onto the seal.
- From this point, the car must be down and the engine suspended in a lifting beam.

1. The torque converter must be positioned so that the screw holes for the driver plate align with the holes in the torque converter.
- Attach the torque converter using holder 87 92 293 to a detached transmission.
2. If the engine mounting has been removed from the transmission.
- The engine mounting must be installed so that both arrows are aligned.
3. Insert locating stud tool No. 83 92 128, or equivalent in the front hole in the partition surface in the engine body.
4. Detach the bleeding mechanism.
- Then install lifting sling 87 91 451 to the transmission and install cable 87 92 251.
- Hook the cable into the sling and lift the transmission into installing position.
5. Apply grease to pin.
- Position the transmission on the locating stud in the partition surface and check that the pin on the torque converter is guided into position.
6. Install a screw in the partition surface.
- Check that the aluminium tube is sealing against the transmission.
7. Remove the locating stud and lifting sling.
8. Screw the bleeding mechanism on to the transmission.
9. Attach the two screws in the upper end of the support in the wheel housing.
- Do not tighten.





10. Raise the car.
11. Remove the protective covers and fill the driver with grease.
- Then install the drive shaft.
12. Install the universal joint rubber gaiter with a new clip (if clip cannot be reused).

CAUTION:
- Keep area clean when working with universal joints.
- Sand or dirt, even in small quantities, considerably reduces the service life of universal joints.

13. Suspend the subframe and attach the two joints, each with one screw.
14. Raise the subframe.
- Make sure that the metal clip on the rear of the subframe is correctly positioned.
15. Install the screw in the engine mounting and make sure that the washers are correctly positioned.
- Tighten the nut.
16. Install the two screws to the front corner of the subframe.
17. Install the four screws in the rear corner of the subframe.
18. Then install the two screws securing the rear joint. One screw also holds the steering gear.
19. Install the two screws holding the front joint.
20. Torque tighten all screws in the subframe (12 screws).
- Front attachment, tighten to: 47-63 Nm (32-42 ft. lbs.).
- Rear attachment, tighten to: 47-63 Nm (32-42 ft. lbs.).
21. Install the lower end of the wheel housing support to the subframe
- Tighten to: 43-57 Nm (32-42 ft. lbs.)





22. Install the screws securing the anti-roll bar bearing.
- Tighten to: 25-34 Nm (18-25 ft. lbs.).
23. Install the three screws securing the ball joint to the suspension arm.
- Use new locknuts.
- Tighten to: 26-34 Nm (19-25 ft. lbs.).
24. Install the nut securing the anti-roll bar bracket to the suspension arm.
- Tighten to: 20-27 Nm (15-20 ft. lbs.).
25. Remove holder 87 92 293 securing the torque converter.
26. Install (but do not tighten) the three screws in the torque converter. Then torque tighten the screws. Use Loctite 242 locking compound.
- Tighten to: 49-67 Nm (37-49 ft. lbs.).
27. On models with V6 engine install the plastic plug under the starter.
28. On all models, install the transmission cover plate.
29. Tighten remaining screws in the partition surface which are accessible from underneath.
- Tighten to: 50-90 Nm (35-65 ft. lbs.).





30. Lower the car and remove the lifting beam.
31. Install the nut to the engine mounting screw and tighten.
- Tighten to: 49-91 Nm (34.5-65.5 ft. lbs.).
32. Tighten the two screws for the support at the wheel housing.
- Tighten to: 22-29 Nm (16.5-21.5 ft. lbs.).
Torque tighten remaining screws in partition surface.
- Screws are accessible from above.
- Tighten to: 50-90 Nm (35-65 ft. lbs.).
33. Install the selector lever rubber bushing in the bracket on the gear case, tighten the nut and install the selector arm.
- Tighten to: 15-21 Nm (8-12 ft. lbs.).
34. On models with V6 engine:
- Align intake manifold with the resonating chamber, connect the vacuum hoses and the wiring harness and tighten the hose clips against the intake pipe and the mass air flow sensor.
- Install the accelerator linkage bracket, connect the control rod, connect the throttle cable and the kick down cable.
35. On all models, install the kick-down cable to the throttle body.





36. Adjust the kick-down cable.
37. Plug in the connector on the cable for the vehicle speed sensor.

NOTE: Check that the selector cable, kick-down cable and the cable to the speedometer are correctly located.

38. Install the battery ground lead to the transmission.

CAUTION: It is extremely important not to forget the ground.





39. On models with turbocharger, install the turbo air delivery pipe.
40. Install the hose to the charge air by-pass valve.
41. Install the connector to the intake air temperature sensor on turbo air delivery pipe.
42. Install the hose between the turbocharger air delivery pipe and the transmission
43. On 1995 through 1998 models, install battery tray and components as follows:
a. Hold the battery tray in position and connect the cruise cruise control, then install the battery tray bolts.
b. Install the cable conduit, push the vacuum hose onto the battery tray, then install the positive cable and cable clip.
c. Connect the cruise control cable to the lever.
44. On 1994 models, install the battery tray.
45. Install the connector to the ABS control module and clip on the cable.
46. Install the positive cable to the battery tray using the two clips.
47. Install the positive terminal.
48. On all models, install the front electrical distribution box.
49. Install the battery.
50. On models with V6 engine, install engine covers.
51. On all models, install throttle cable to the throttle body.
52. Connect battery leads.





53. Install the lefthand and center air deflectors.
54. Install the front part of the fender liner.
55. Install the wheel arch trim.
- Check that the fender liner on the righthand side is installed if it has been removed.
56. Install the wheel.
Tighten to: 120 Nm (89 ft. lbs.).
57. Fill with automatic transmission fluid. Then clean the transmission cooling system using flushing equipment 87 91 824.
58. Check and adjust selector lever play.
59. Remove the fender covers.
60. Check fluid level in the transmission and test drive the car.

CAUTION: After carrying out internal repairs on the transmission or after changing to a new transmission, flushing equipment tool No. 87 91 824, or equivalent, should be connected to the transmission cooling system before starting the engine. Otherwise, there is a risk of damage.