Installation
1. With the help of a second mechanic, carefully install the engine and gearbox. General equipment: Powertrain Jack
2. Right side: Install the engine support. Tightening torque: 80 Nm
3. Install the left engine mount. Tightening torque: 175 Nm
4. Install the bracket. Tightening torque: M12 80 Nm; M8 25 Nm
5. Remove the support from under the engine.
6. Connect the clutch fluid hose.
7. Connect the heater hoses to the bulkhead.
8. Install the propeller shaft. Tightening torque: 40 Nm
Clean the element from dirt and grease. Use new bolts.
9. Install the coolant expansion tank. Tightening torque: 10 Nm
10. Secure the engine wiring harness. Tightening torque: 10 Nm
11. Connect the fuel lines.
12. Connect the upper coolant hose.
13. Connect the lower coolant hose.
14. Connect the cooling fan electrical connector.
15. Install the right half shaft and support bracket. Tightening torque: 25 Nm
16. Install the left axle shaft.
17. Using outside help, install the axle shaft into the hub.
18. Install the axle shafts. Tightening torque: Step 1: 45 Nm. Step 2: 80°
19. Connect the high-pressure refrigerant line of the air conditioning compressor. Tightening torque: 24 Nm
CAUTION: A new O-ring must be installed.
NOTE: Lubricate the O-rings with clean compressor oil.
20. Connect the low pressure refrigerant line of the air conditioning compressor. Tightening torque: 24 Nm
CAUTION: A new O-ring must be installed.
NOTE: Lubricate the O-rings with clean compressor oil.
21. Connect the return line to the power steering pump.
22. Connect the power steering high pressure line to the power steering pump. Tightening torque: 24 Nm
CAUTION: A new O-ring must be installed.
23. Secure the high pressure line of the power steering gear. Tightening torque: 10 Nm
24. Install the gear selector cables.
25. Connect the brake booster vacuum hose.
26. Connect the ECM electrical connectors.
(The original article is located on the website: www.lrman.ru)
27. Install the air intake duct.
28. Install the charge air cooler intake duct. Tightening torque: 10 Nm
29. Install the front subframe. Refer to procedure: Front Subframe (502-00 Uni-Body, Subframe and Fastening System, Removal and Installation).
30. Install the lower engine stabilizer bar. Refer to procedure: Lower Engine Mount Insulator (303-01A Engine - 3.2L NA - I6, Removal and Installation).
31. Install the catalytic converter. Refer to procedure: Catalytic Converter - Vehicles Not Equipped with: Diesel Fuel Filter (309-00B Exhaust System - 2.2L Duratorq - Td4, Removal and Installation).
32. Fill and bleed the cooling system. Refer to procedure: Draining/Filling Coolant and Bleeding the Cooling System (303-03B Engine Cooling - 2.2L Duratorq - Td4, General Procedures).
33. Install the air cleaner assembly. Refer to procedure: Air Cleaner (303-12A Intake Air Distribution and Filtration - 3.2L NA - I6, Removal and Installation).
34. Install the battery tray. Refer to the procedure: Battery Installation Tray (414-01 Battery, Battery Fastener and Cables, Removal and Installation).
35. Install the pressure chamber panel. Refer to procedure: Mixing Chamber (412-01 Climate Control, Removal and Installation).
36. Reinstall the engine top cover. Refer to procedure: Engine Cover - 2.2L Duratorq - Td4 (501-05 Interior Trim, Removal and Installation).
37. Bleed the low pressure fuel system. Refer to procedure: Bleeding the Fuel System - 2.2L Duratorq - Td4 (310-00 Fuel System - General Information, General Procedures).
38. Bleed the Clutch System Refer to procedure: Bleeding the Clutch System (308-00 Manual/Transaxle Transaxle and Clutch - General Information, General Procedures).
39. Connect the ground cable to the battery and install the cover. Refer to Procedure: Specifications (414-00 Charging System - General Information, Specifications).
40. Charge the air conditioning (A/C) system. Refer to the procedure: Refrigerant Recovery, Evacuation, and Charging of the Air Conditioning (A/C) System (412-00 Climate Control System - General Information, General Procedures).
41. Fill the power steering system with fluid and bleed the system. Refer to procedure: Bleeding the Power Steering System (211-00 Steering System - General Information, General Procedures).
42. Once the vehicle is lowered onto its wheels, tighten the axle shafts and suspension completely.
Comments on this article