Lift up the engine/transmission unit. Use a lifting table.
Stop the lift approximately 15 cm (5.91 inch) before the sub-frame reaches the frame members.
Note: Make sure that the mating surfaces on the ball joints and control arms are clean. Take great care that no hoses, wiring or anything else catches during lifting.
Install (on both sides)
the drive shaft to the hub.
the ball joint to the control arm. Guide in the lower steering shaft in the boot.
Lift the subframe to the frame members.
Install new screws in the sub-frame. Oil/lubricate screw threads.
Install washers in the front edge and support plates at the rear edge of the sub-frame.
First tighten the screws on the left-hand side of the subframe to 105 Nm (77.4 ft. lbs.) and angle-tighten 1200.
Use bevel protractor 951 2050.
Then tighten screws on right-hand side of sub-frame to the same value.
Tighten the brackets to 50 Nm (36.9 ft. lbs.) .
Remove lifting table.
Connect the pipe to the engine. Use a mobile jack with universal plate 999 5972 as support.
Note: Ensure that the heated oxygen sensor (H02S) wiring is on top of the brake pipe.
Connect to rear exhaust pipe. Install all nuts loosely.
Install screws in front SIPS member.
Remove the mobile jack.
First tighten the exhaust pipe flange to the engine. Then tighten the rear flange. Tighten crosswise to 25 Nm (18.4 ft. lbs.) .
Install rear SIPS member.
Tighten the SIPS member screws to 25 Nm (18.4 ft. lbs.) .
(The illustration is not accurate because the pulsed secondary air injection system (PAIR) pump is discontinued).
Connect heated oxygen sensors (H02S) connectors according to markings made earlier.
Secure heated oxygen sensor (H02S) wiring in sub-frame.
Press the brake pipe into place on the front SIPS member.
Tighten the ball joint/control arm to 80 Nm (59.0 ft. lbs.) .
Counterhold with Torx. 40 so that the ball joint boot does not rotate.
Install
tie rods. Use new locknuts. Tighten to 70 Nm (51.6 ft. lbs.) .
the anti-roll bar links. use new locknuts. Tighten to 50 Nm (36.9 ft. lbs.) .
new center screws for the drive shafts. Tighten to 50 Nm (36.9 ft. lbs.) .
ABS sensors. Tighten to 10 Nm (7.3 8 ft. lbs.) .
Note: Ensure that the ABS sensor seats are absolutely clean.
the ABS sensor cable to the mounting in the spring strut.
the brake pipe racket in the wheel arch.
Install
front splash guard.
the splash guard under the engine.
wheels.
the bearing in the lower steering shaft. Secure it in the rubber boot with a tie strap.
the steering shaft joint in the lower steering shaft. Use a new screw and locknuts. Tighten to 30 Nm (22.1 ft. lbs.) .
Note: Previous measurement for correct steering gear position.
panel under dashboard.
Air conditioning (A/C) compressor Tighten to 25 Nm (18.4 ft. lbs.) .
connector to the dryer bottle.
the magnetic clutch connector with the engine wiring.
auxiliaries belt.
the hose between the charge air cooler (CAC) and turbocharger (TC) pipe. Applies only to B6xx4T.
upper radiator hose.
Connect engine and transmission wiring connectors in control module box base plate.
Press base plate into place in lower section of control module box.
Install intermediate section.
Locate ventilation pipe in rear edge of control module box.
Screw control module box into place on fender liner.
Press control modules down carefully. Lock with mounting bracket 999 5722.
Press the cover into place and the screw ground lead into place.
Install
expansion tank. Connect the hose from the radiator to the expansion tank.
