Removal and Installation
Special Tools:
- Lifting Yoke tool No. 999 2810, or equivalent
- Lifting Yoke tool No. 999 5428, or equivalent
- Lifting Eyelet tool No. 999 5459, or equivalent
- Extractor Fork tool No. 999 5462, or equivalent
- Lifting Eyelet tool No. 999 5464, or equivalent
- Sealing Plug tool No. 999 5488, or equivalent
- Holder tool No. 999 5533, or equivalent
NOTE:
- For additional information on special tools and equipment used in this procedure, refer to "Tools For Engine Service and Repair". Tools and Equipment
- Lift arm 998 9734, or equivalent is included in the kit for tool no. 999 2810, or equivalent. This arm is necessary when lifting the turbo engine in/out of the car.
- For engine, removal refer to steps 1 through 19
- Engine, installation refer to step 20 through 37
Removal
1. Drain coolant:
- Remove expansion tank cap.
- Raise car.
- Automatics: Remove air baffle under engine.
- Open engine and radiator nipples. Use hoses to collect coolant.
- Disconnect lower charge air pipe from lower charge air cooler (CAC) connecting sleeve.
- Close nipples.
2. Remove:
- left front wheel
- track rod end from left axle shaft
- the three nuts holding ball joint to left control arm
3. Remove:
- ABS-lead and brake pipe hose bracket screw
- left drive shaft, extractor fork tool No. 999 5462, or equivalent must be used to free drive shaft (otherwise the retaining ring may be damaged)
4. Remove:
- track rod end, from right axle shaft
- three nuts holding the ball joint on the right control arm
- right drive shaft and intermediate bearing cap from drive shaft, place carefully on power steering pipes
- two right engine mounting screws (fold right wing liner to one side first)
- torque rod screw in gearbox
NOTE: Install seal plugs tool No. 999 5488, or equivalent, in drive shaft holes.
5. Remove:
- front exhaust pipe lower nut and screw from bracket
- speedometer connector
- front and rear lower engine mounting screws.
Lower car to working height.
6. Remove:
- battery
- battery shelf, if necessary with cruise control slave cylinder (remove from shelf and lay to one side)
- fresh air hose, from air intake to air cleaner (ACL)
- HT lead between distributor and ignition coil
- throttle pulley cover
- throttle cable from throttle pulley
7. Disconnect hoses/connectors:
- disconnect both ends of inlet hose from turbocharger (TC) to ACL
- disconnect PTC valve hose and connector
- disconnect connector from throttle sensor
- disconnect idle speed connector
- disconnect TCV valve connector
8. Remove ACL:
- Disconnect mass air flow (MAF) sensor connector.
- Undo and lift out ACL.
- Undo two TCV bracket screws.
9. Undo:
- torque rod from bracket and firewall
- ground strip, from firewall
- two heating hoses from firewall
- heated oxygen sensor (H02S) connector and clips (North American models are equipped with two H02Ss)
- brake servo hose from engine or disconnect under
10. Remove engine coolant fan:
- Disconnect relays from fan shroud, disconnect relay and engine coolant fan connectors, put wiring to one side.
- Remove control module box cooling air duct.
Disconnect both canister hoses and valve from radiator.
- Undo four fan shroud screws and upper charge air pipe from TC.
Push back fan shroud and remove upper fan shroud.
Remove upper charge air pipe.
- Remove fresh air intake from radiator and disconnect vacuum hoses to TC instruments and EGR regulator.
NOTE: Protect the radiator with a piece of hardboard/plywood etc. Or use shield 999 5474, or equivalent.
11. Remove:
- idle control and lower charge air pipe
- lower radiator hose, from engine
- starter motor cover
- battery negative lead from engine and wheel housing (also from transmission on automatics)
Cars with manual transmission:
- clutch slave cylinder retaining ring (NOTE! Ensure that piston does not slip out)
- slave cylinder from transmission
12. Remove:
- ACL bracket. (Carefully put air filter bracket and clutch slave cylinder to one side so that they are not disconnected.)
Manuals Transmissions:
- Remove: gear selector cables, from transmission mountings (mark up position of cables).
- Remove rubber mounted section of the gear selector cable mounting
Automatics Transmissions:
- Disconnect connector and remove gear selector cable from transmission (mark up position of cables).
- Disconnect two oil cooler hoses from radiator using a victory clip tool.
13. Remove:
- upper radiator hose from thermostat housing
- expansion tank
- auxiliaries belt
- six servo pump screws, (disconnect temperature sensor wiring from bracket on servo pump)
NOTE: Leave servo pump in position until later.
Disconnect two oil cooler hoses from radiator.
14. Remove AC-compressor:
- Remove AC-compressor without removing any hoses and lean against sub-frame. (Remove right screws by folding wing liner to one side.)
15. Remove wiring conduit bracket screws:
- Remove wiring conduit bracket screws.
- Remove starter motor support bracket.
16. Remove:
- fuel distribution manifold cover
- injector connectors
- fuel pipe clips (upper/lower)
- ground strip, from engine
17. Remove fuel distribution manifold
- Install holders tool No. 999 5533, or equivalent (5) on injectors.
- Disconnect fuel pressure regulator vacuum hose.
- Lift up and place fuel distribution manifold and injectors to one side.
NOTE: Ensure that injectors and needles are not damaged.
18. Disconnect engine wiring harness Disconnect all connectors and undo all clips from engine.
NOTE: Note all wiring harness mounting points shown in the illustration above using the Legend below.
1 Thermostat
2 Generator (GEN)
3 A/C (if fitted)
4 Ground point
5 Oil pressures switch
6 Oil level sensor
7 Starter motor (all)
8 Knock sensor (KS)
9 Ground point
10 Ground point
11 Throttle body (TB) switch
12 Idle speed control
13 Flywheel sensor
14 Injectors
15 Camshaft position (CMP) sensor
16 Reversing lights switch
17 Mass air flow (MAF) sensor
18 Vehicle speed sensor (VSS)
19 Heated Oxygen Sensors (automatics use 2) (HO2S)
20 PTC-element
19. Lift out engine with transmission:
- Lift up servo pump and lay to one side.
- Remove front engine mounting when lifting.
- Lift out engine, use lifting yokes tool No. 999 2810 (model with lift arm) and lifting yoke tool No. 999 5428, or equivalent.
- Correct lifting angle throughout entire lift.
- Automatics: Remove TC oil cooler pipes with valve from the right of the oil sump.
NOTE: Carefully ensure that power train is clear of body and any extra equipment.
Installation
20. Lift in engine with transmission:
- Use lifting yokes tool No. 999 2810 (model with lift arm) tool No. 999 5428, or equivalents.
- Adjust lifting yoke to balance engine.
- Correct lifting angle throughout entire lift.
NOTE: Carefully ensure that power train is clear of body and any extra equipment.
- Remove lifting eyelets tool No. 999 5459, tool No. 999 5465, or equivalent).
- Tighten front engine mounting nut.
- Install:
A/C-compressor if fitted
servo pump and collision shield
21. Install engine wiring harness:
- Install wiring conduit bracket.
- Using the illustration above and the legend below, reconnect all connectors.
1 Thermostat
2 Generator (GEN)
3 A/C (if fitted)
4 Ground point
5 Oil pressures switch
6 Oil level sensor
7 Starter motor (all)
8 Knock sensor (KS)
9 Ground point
10 Ground point
11 Throttle body (TB) switch
12 Idle speed control
13 Flywheel sensor
14 Injectors
15 Camshaft position (CMP) sensor
16 Reversing lights switch
17 Mass air flow (MAF) sensor
18 Vehicle speed sensor (VSS)
19 Heated Oxygen Sensors (automatics use 2) (HO2S)
20 PTC-element
22. Install fuel distribution manifold:
- Grease injector O-rings.
- Tighten fuel distribution manifold.
- Remove holder tool No. 999 5533, or equivalent.
23. Install:
- fuel distribution manifold cover
- fuel pipe clips (upper/lower)
- auxiliaries belt
- expansion tank, with radiator hoses
- upper and lower oil cooler hoses
24. Install:
- starter motor bracket and cover
- fresh air hose
- radiator hoses, to firewall
- fresh air hose, to TC
25. Install:
- negative lead to engine, and clamp to frame member
- lower radiator hose
- clutch slave cylinder, to transmission
NOTE: Ensure that piston does not slip out
- slave cylinder retaining ring
- air filter bracket rubber mountings, tighten bracket
- idle speed control, connect connector
26. Install engine coolant fan:
- Remove shield (999 5474, or equivalent) from radiator.
- Lift in engine coolant fan complete with shroud. Connect connector, clamp wiring.
- Install upper charge air pipe between CAC and TO.
- Install fresh air intake.
- Install upper fan shroud. Tighten fan shroud to radiator (ensure that clips are in position).
- Connect pressure hose (for turbo instrumentation).
- USA: Connect vacuum hoses to EGR-regulator.
- Install canister valve on bracket and connect canister vacuum hose.
27. Install:
- control module cooling air duct.
- both relays on upper fan shroud and connect connectors. Clamp wiring
- idle speed control
28. Install:
- PTC-element and oxygen sensor wiring
Cars with manual transmission:
- reversing lights switch wiring (manual)
- rubber mounted gear selector cable mounting.
- gear selector cables to mountings on transmission.
NOTE: Colour markings mounting/cable.
Cars with automatic transmission.
- Connect transmission connector.
- Install gear selector cable (see markings).
- Install two gearbox oil cooler hoses and negative lead to transmission.
29. Install:
- upper torque rod from engine with new screws.
Tighten to: 50 Nm (37 ft lb) and 90°:
- both ground strips
- throttle cable to throttle pulley and cover
- charge air pipe to TC (adjust gap to 15 mm)
30. Install ACL:
- Connect connector and vacuum hoses to idle air control (IAC) valve.
- HT lead between distributor and ignition coil.
NOTE: Yellow marking on first rib on filter cover.
- Install ACL and air hose.
Connect mass air flow (MAF) sensor connector.
- Connect fresh air hose.
- Install TCV valve bracket on ACL.
31. Install:
- battery shelf and battery with leads
NOTE: If the car is fitted with cruise control, vacuum hose and vacuum motor wiring must be connected before battery shelf is screwed on.
32. Install:
- two upper exhaust pipe nuts (do not tighten completely), raise car
- lower exhaust pipe nut (do not tighten completely),
- exhaust pipe bracket screw.
Tighten to: 30 Nm (22 ft lb).
- speedometer connector.
- front and rear engine mounting screws.
Tighten to: 50 Nm (37 ft lb).
- torque rod screws in transmission, use new screws and nuts.
Tighten to 35 Nm (26 ft lb) + 90°.
33. Install:
- two right engine mounting screws (fold right wing liner to one side first)
- right drive shaft and pilot bearing
34. Install:
- left drive shaft, it should be possible to install gently (the retaining ring is easily damaged)
- ABS-lead brake pipe bracket screw
35. Install on both sides:
- control arm to ball joint. Use new nuts.
- wheels
NOTE: Ensure that contact surfaces on ball joint and control arm are clean and free of grease.
- Tighten nuts in order working outwards.
Tighten to: 18 Nm (13 ft lb) + 120°
Use angle gauge tool No. 951 2050, or equivalent.
- Rustproof area between ball joint, control arm and nuts carefully and liberally.
Use rust inhibitor part No. 1 161 432-8, or equivalent.
- (Ball joint new nut torque 70 Nm (52 ft lb).)
36. Lower car:
- Tighten three exhaust pipe nuts and check that surfaces are parallel.
Tighten to 25 Nm (18 ft lb).
- Install heat shield and TC bracket.
37. Fill coolant and engine oil
- Coolant volume about: 7.20 liter (7.6 US qt.).
- Oil capacity including filter: 5.3 liter (5.6 US qt.).
Carry out function test
- Start engine, run until thermostat opens.
- Check for leaks.
- Check and, if necessary, adjust oil and coolant levels.
- Automatics: Check oil level in automatic transmission.