Volvo Truck 2003-05

Engine

Print


NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Removal & Installation



6-Cylinder Engines
  1. Remove the cable from the battery negative terminal.
  2.  
  3. The expansion tank cap.
  4.  
  5. Drain the refrigerant.
  6.  


NOTE
There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.

  1. Remove the 6 bolts.
  2.  
  3. Lift up and slide the plate forward.
  4.  
  5. Remove the protective plate.
  6.  
  7. Remove the splash guard under the engine
  8.  
  9. Disconnect the connectors for the heated oxygen sensors (HO2S). Remove the wiring from the clips and tie straps.
  10.  
  11. Connect a hose to the engine coolant drain cock.
  12.  
  13. Drain the coolant into a clean container.
  14.  
  15. Remove:

    The bolt for the engine stabilizer brace mounting on the engine
     
    The cross stay between the suspension turrets
     
    The plastic charge air pipe over the engine
     
    The charge air pipes which connect to the turbocharger. Seal the openings
     
    The air cleaner.
     

  16.  


NOTE
Note the position of the probes to make it easier to reinstall them. If they are mixed up, diagnostic trouble codes (DTCs) may be stored.

  1. Slide the wiring for the front heated oxygen sensors (HO2S) upwards, Unscrew the heated oxygen sensors (HO2S) from the three-way catalytic converter.

    Remove the heat deflector plates from the turbocharger
     
    Remove the nuts from the flange between the turbocharger and the three-way catalytic converter.
     

  2.  


NOTE
Rustproof the studs.

  1. Separate the connections. Unhook the three-way catalytic converter.
  2.  
  3. Remove the ground strip between the engine and bodywork which is positioned above the turbocharger for cylinders 1, 2 and 3.
  4.  
  5. Remove both the hoses for the heater unit on the firewall.
  6.  
  7. Remove:

    The battery lead from the terminal block at the fusebox
     
    The connector in the fuse box.
     
    The rear radiator hose at the transmission
     
    The gear selector cable from the transmission
     
    The connector for the input speed sensor on the transmission
     
    The connector on the transmission
     
    The vacuum hose on the intake for the power brake booster
     
    The connector on the sensor in the charge air cooler
     
    The ground lead from the engine to the car body (detach in the car body).
     

  8.  
  9. Remove the charge air pipe on the intake between the throttle module and the charge air cooler.
  10.  


NOTE
If necessary use a hot air gun to loosen the pipe.

  1. Detach the upper radiator hoses on the engine.
  2.  
  3. Lift the power steering reservoir. Place it on top of the engine.
  4.  


NOTE
Ensure that no oil leaks out of the reservoir through the ventilation holes in the cover.

  1. Remove the coolant expansion tank. Slacken off the hose clamp on the hose to the engine. Disconnect the connector.
  2.  
  3. Remove the radiator breather tube by the expansion tank. Put the expansion tank to one side.
  4.  
  5. Remove:

    The cover from the distribution box
     
    The control module
     
    The surround from the distribution box.
     

  6.  
  7. Pry out the connector plate from the lower section of the control module box. Pull out the engine and transmission wiring connectors from the plate.
  8.  
  9. Detach the ground lead on the fender liner.
  10.  


NOTE
Seal the openings.

  1. Separate the climate control unit pipe at the frame member inside the central electrical unit.
  2.  
  3. Remove the right-hand headlamp by pulling the 2 lock facings on the lamp straight up. Then carefully pull the headlamp forward. Disconnect the connector and lift out the headlamp.
  4.  
  5. Disconnect the connector from the sensor on the accumulator. Pull the wiring through to the engine compartment.
  6.  
  7. Set the front wheels so that they are straight.
  8.  
  9. Fold back the floor carpet.
  10.  
  11. Bend up the outer section of the steering shaft boot.
  12.  
  13. Remove the retaining clip around the boot.
  14.  
  15. Pull the boot up.
  16.  
  17. Turn the steering wheel to gain the best possible access to the steering shaft nut.
  18.  
  19. Remove the ignition key. Activate the steering wheel lock.
  20.  


WARNING
Do not move the steering wheel. The contact reel in the SRS (supplemental restraint system) could be damaged.

  1. Remove:

    The bolt securing the mounting for the steering shaft in the joint
     
    The joint from the steering shaft by pressing the shaft upwards.
     

  2.  


NOTE
Clean and spray the exposed threads with rust-proofing agent before beginning removal.



The front wheel
 
The tie rod ends from the steering arm.
 
The bolt holding the halfshaft to the hub
 
The nut for the ball joint / link arm
 
The nut for the anti-roll bar.
 


NOTE
Counterhold using Torx 40 so that the ball joint boot does not turn when the nut is removed.


WARNING
The steering shaft must not be turned. The contact reel in the SRS system could be damaged.

  1. On one side, measure the length of the tie rod in relation to the steering gear housing. Note the measurement.
  2.  
  3. Disconnect the brake pipe from the clips on the front SIPS member.
  4.  
  5. Remove the 4 bolts for the front SIPS member.
  6.  
  7. Remove the member.
  8.  
  9. Unhook the three-way catalytic converter (from the rubber mounting.
  10.  
  11. Remove:

    The tie straps from the wiring for the rear probe. Separate the probe wiring
     
    The nut for the flange between the three-way catalytic converter and exhaust system
     
    The propeller shaft.
     

  12.  
  13. Drain the fuel line.
  14.  
  15. Disconnect the fuel line quick-release connector at the engine.
  16.  


NOTE
Seal the openings against dirt.

  1. Place the cable to one side.
  2.  
  3. Separate the EVAP canister cable at the rear right sub-frame mounting.
  4.  
  5. Remove the transmission oil cooling hoses from the transmission. Seal the openings.
  6.  


CAUTION
Ensure that the lifting table is properly centered under the engine.

  1. Position a lifting table under the sub-frame. Secure the table against the sub-frame.
  2.  


CAUTION
Do not damage the brake pipe that runs across the transmission tunnel.

  1. Remove:

    The sub-frame brackets bolts
     
    The bolts for the sub-frame. Lower the engine and transmission approximately 15 cm so that the halfshafts describe a horizontal line between the hub and transmission.
     

  2.  


NOTE
Take great care that no hoses, wiring or anything else catches in the engine/transmission unit when it is lowered.

  1. Unhook the control arms from the ball joint pinion.
  2.  
  3. Remove the halfshafts from the wheel hubs.
  4.  


NOTE
Do not pull the halfshafts. They do not have axial locks.


CAUTION
Do not damage the ABS wiring. Do not damage the brake pipe.

  1. Let the halfshafts rest against the control arms. Lower the three-way catalytic converter.
  2.  
  3. Continue lowering until the hose for the compressor in the climate control unit is accessible. Detach the inner hose for the climate control unit. Seal the openings. Continue lowering the unit.
  4.  

To install:

  1. Lift the engine and transmission unit. Use a lifting table.
  2.  
  3. Stop the lift approximately 15 cm before the sub-frame reaches the frame members.
  4.  
  5. Install (on both sides) the halfshaft on the hub.
  6.  
  7. Lift the three-way catalytic converter up into position. Connect the exhaust system to the rear flange. Use a new gasket. Install new nuts loosely.
  8.  


NOTE
The three-way catalytic converter cannot be raised after the engine has been raised to its correct position.

  1. Continue raising the engine until it is only approximately 50 mmfrom its correct position.
  2.  


NOTE
Guide the lower steering shaft into the hole in the firewall.

  1. Align the ball joint in the control arm.
  2.  
  3. Install the inner pipe on the compressor in the climate control unit. Use a new O-ring.
  4.  
  5. Lift the sub-frame until it is against the frame members.
  6.  
  7. Install new bolts in the sub-frame. Lubricate the bolt threads.
  8.  
  9. Install the washers in the front edge and support plates at the rear edge of the sub-frame.
  10.  
  11. First tighten the bolts on the left side of the sub-frame. Tighten to 47 ft. lbs. (65 Nm) plus 60 degrees.
  12.  
  13. Then tighten the bolts on the right-hand side of the sub-frame to the same values.
  14.  
  15. Tighten the brackets. Tighten to 37 ft. lbs. (50 Nm).
  16.  
  17. Remove the lifting table.
  18.  
  19. Tighten the ball joint and control arm. Tighten to 58 ft. lbs. (80 Nm). Counterhold using Torx 40 so that the ball joint boot does not rotate.
  20.  
  21. Install:

    The anti-roll bar links. Use new locknuts. Tighten to 37 ft. lbs. (50 Nm).
     
    New center bolts for the halfshafts. Tighten to 37 ft. lbs. (50 Nm).
     

  22.  
  23. Install the tie rod using the marking made during removal. Use new locknuts. Tighten to 51 ft. lbs. (70 Nm).
  24.  
  25. Connect the fuel line to the engine.
  26.  
  27. Connect the evaporative emission system (EVAP) line at the right rear sub-frame mounting.
  28.  
  29. Install the oil cooler hoses on the transmission.
  30.  
  31. Install the propeller shaft.
  32.  
  33. Lower the car.
  34.  
  35. Pull up and align the three-way catalytic converter (TWC) against the turbocharger (TC).
  36.  
  37. Lubricate the threads using copper paste 116 1408, or equivalent. Install new nuts loosely.
  38.  
  39. Lower the car.
  40.  
  41. Install the front SIPS member. Press the brake pipe into place in the member.
  42.  
  43. Hook the rubber mounting for the three-way catalytic converter (TWC) in the bracket on the sub-frame.
  44.  
  45. Connect the connector to the rear probe. Secure the wiring as before.
  46.  
  47. Tighten the screwed joint between the three-way catalytic converter (TWC) and the exhaust system. Tighten to 18 ft. lbs. (24 Nm).
  48.  
  49. Install:

    The steering shaft joint on the steering gear and steering shaft
     
    A new bolt. Tighten to 18 ft. lbs. (25 Nm)
     
    The steering shaft boot and snap-ring. Fold back the carpet.
     

  50.  
  51. Connect the engine and transmission wiring connectors to the control module box base plate.
  52.  
  53. Press the base plate into place in the lower section of the control module box.

    The climate control unit pipe at the frame member inside the control unit box. Use a new O-ring
     
    The cable from the engine wiring for the sensor on the receiver to the right of the radiator
     
    The front right headlamp
     

  54.  
  55. Install the intermediate section. Align the ventilation pipe in the rear edge of the control module box.
  56.  
  57. Press the control modules down carefully. Lock into place using mounting bracket 999 5722, or equivalent.
  58.  
  59. Press the cover into place. Screw the ground lead into place on the fender liner.

    The connector for the expansion tank from the engine compartment wiring
     
    The hose from the engine to the expansion tank
     
    The breather tube from the radiator
     
    The expansion tank
     
    The servo reservoir
     
    The upper radiator hose.
     
    The plastic pipe between the charge air cooler and the throttle module.
     

  60.  


NOTE
Use a hot-air gun to facilitate installation of the pipe.



The connector for the sensor on the charge air cooler
 
The ground lead from the engine to the car body
 
The vacuum hose to the intake and power brake booster
 
The connectors for the transmissions
 
The mechanical transmission cable to the transmission
 
The rear radiator hose
 
The connector to the fusebox
 
The battery lead to the terminal block on the fusebox.
 
The radiator hoses on the heater unit. They are coded and will only connect to the correct sleeve connector
 
The ground strip between the engine and the car body
 

  1. Tighten the three-way catalytic converter to the turbocharger. Use new nuts. Tighten to 18 ft. lbs. (24 Nm).
  2.  
  3. Install the upper heated oxygen sensors using the marks made during removal. Lubricate the threads. Use copper paste 116 1408, or equivalent. Tighten to 33 ft. lbs. (45 Nm).
  4.  
  5. Lower the wiring down to the probes. Secure the wiring in the clips and clamps as before. Connect the wiring.
  6.  
  7. Install the heat deflector plates.
  8.  
  9. Install:

    The charge air pipes on the turbocharger
     
    The plastic charge air pipe over the engine
     
    Air cleaner assembly
     
    Mass air flow sensor connector
     
    The turbocharger control valve on the air cleaner
     
    The intake manifold to the air cleaner
     
    The engine stabilizer brace between the suspension turrets.
     

  10.  
  11. Tighten the bolts on the suspension turrets. Tighten to 37 ft. lbs. (50 Nm). Tighten the bolt in the torque bracket. Tighten to 58 ft. lbs. (80 Nm).
  12.  
  13. Install the battery negative lead.
  14.  
  15. Fill with coolant. The coolant volume is approximately 7.2 liters. Top up the engine oil.
  16.  
  17. Start the engine.
  18.  
  19. Warm up the engine until the thermostat opens.
  20.  
  21. Check for leakage.
  22.  
  23. Check the oil and coolant levels. Adjust if necessary.
  24.  
  25. Check the transmission oil level.
  26.  
  27. Install:

    The splash guard under the engine
     
    The front skid plate on the sub-frame
     
    The front wheels
     

  28.  

  1. Remove the cable from the battery negative terminal.
  2.  
  3. The expansion tank cap.
  4.  
  5. Drain the refrigerant.
    NOTE
    There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.

  6.  
  7. Remove the 6 bolts.
  8.  
  9. Lift up and slide the plate forward.
  10.  
  11. Remove the protective plate.
  12.  
  13. Remove the splash guard under the engine
  14.  
  15. Disconnect the connectors for the heated oxygen sensors (HO 2 S). Remove the wiring from the clips and tie straps.
  16.  
  17. Connect a hose to the engine coolant drain cock.
  18.  
  19. Drain the coolant into a clean container.
  20.  
  21. Remove:
    NOTE
    Note the position of the probes to make it easier to reinstall them. If they are mixed up, diagnostic trouble codes (DTCs) may be stored.



    The bolt for the engine stabilizer brace mounting on the engine
     
    The cross stay between the suspension turrets
     
    The plastic charge air pipe over the engine
     
    The charge air pipes which connect to the turbocharger. Seal the openings
     
    The air cleaner.
     

  22.  
  23. Slide the wiring for the front heated oxygen sensors (HO 2 S) upwards, Unscrew the heated oxygen sensors (HO 2 S) from the three-way catalytic converter.
    NOTE
    Rustproof the studs.



    Remove the heat deflector plates from the turbocharger
     
    Remove the nuts from the flange between the turbocharger and the three-way catalytic converter.
     

  24.  
  25. Separate the connections. Unhook the three-way catalytic converter.
  26.  
  27. Remove the ground strip between the engine and bodywork which is positioned above the turbocharger for cylinders 1, 2 and 3.
  28.  
  29. Remove both the hoses for the heater unit on the firewall.
  30.  
  31. Remove:

    The battery lead from the terminal block at the fusebox
     
    The connector in the fuse box.
     
    The rear radiator hose at the transaxle
     
    The gear selector cable from the transaxle
     
    The connector for the input speed sensor on the transaxle
     
    The connector on the transaxle
     
    The vacuum hose on the intake for the power brake booster
     
    The connector on the sensor in the charge air cooler
     
    The ground lead from the engine to the car body (detach in the car body).
     

  32.  
  33. Remove the charge air pipe on the intake between the throttle module and the charge air cooler.
    NOTE
    If necessary use a hot air gun to loosen the pipe.

  34.  
  35. Detach the upper radiator hoses on the engine.
  36.  
  37. Lift the power steering reservoir. Place it on top of the engine.
    NOTE
    Ensure that no oil leaks out of the reservoir through the ventilation holes in the cover.

  38.  
  39. Remove the coolant expansion tank. Slacken off the hose clamp on the hose to the engine. Disconnect the connector.
  40.  
  41. Remove the radiator breather tube by the expansion tank. Put the expansion tank to one side.
  42.  
  43. Remove:

    The cover from the distribution box
     
    The control module
     
    The surround from the distribution box.
     

  44.  
  45. Pry out the connector plate from the lower section of the control module box. Pull out the engine and transaxle wiring connectors from the plate.
  46.  
  47. Detach the ground lead on the fender liner.
    NOTE
    Seal the openings.

  48.  
  49. Separate the climate control unit pipe at the frame member inside the central electrical unit.
  50.  
  51. Remove the right-hand headlamp by pulling the 2 lock facings on the lamp straight up. Then carefully pull the headlamp forward. Disconnect the connector and lift out the headlamp.
  52.  
  53. Disconnect the connector from the sensor on the accumulator. Pull the wiring through to the engine compartment.
  54.  
  55. Set the front wheels so that they are straight.
  56.  
  57. Fold back the floor carpet.
  58.  
  59. Bend up the outer section of the steering shaft boot.
  60.  
  61. Remove the retaining clip around the boot.
  62.  
  63. Pull the boot up.
  64.  
  65. Turn the steering wheel to gain the best possible access to the steering shaft nut.
  66.  
  67. Remove the ignition key. Activate the steering wheel lock.
    WARNING
    Do not move the steering wheel. The contact reel in the SRS (supplemental restraint system) could be damaged.

  68.  
  69. Remove:
    NOTE
    Clean and spray the exposed threads with rust-proofing agent before beginning removal.


    NOTE
    Counterhold using Torx 40 so that the ball joint boot does not turn when the nut is removed.


    WARNING
    The steering shaft must not be turned. The contact reel in the SRS system could be damaged.



    The bolt securing the mounting for the steering shaft in the joint
     
    The joint from the steering shaft by pressing the shaft upwards.
     



    The front wheel
     
    The tie rod ends from the steering arm.
     
    The bolt holding the halfshaft to the hub
     
    The nut for the ball joint / link arm
     
    The nut for the anti-roll bar.
     

  70.  
  71. On one side, measure the length of the tie rod in relation to the steering gear housing. Note the measurement.
  72.  
  73. Disconnect the brake pipe from the clips on the front SIPS member.
  74.  
  75. Remove the 4 bolts for the front SIPS member.
  76.  
  77. Remove the member.
  78.  
  79. Unhook the three-way catalytic converter (from the rubber mounting.
  80.  
  81. Remove:

    The tie straps from the wiring for the rear probe. Separate the probe wiring
     
    The nut for the flange between the three-way catalytic converter and exhaust system
     
    The propeller shaft.
     

  82.  
  83. Drain the fuel line.
  84.  
  85. Disconnect the fuel line quick-release connector at the engine.
    NOTE
    Seal the openings against dirt.

  86.  
  87. Place the cable to one side.
  88.  
  89. Separate the EVAP canister cable at the rear right sub-frame mounting.
  90.  
  91. Remove the transaxle oil cooling hoses from the transaxle. Seal the openings.
    CAUTION
    Ensure that the lifting table is properly centered under the engine.

  92.  
  93. Position a lifting table under the sub-frame. Secure the table against the sub-frame.
    CAUTION
    Do not damage the brake pipe that runs across the transaxle tunnel.

  94.  
  95. Remove:
    NOTE
    Take great care that no hoses, wiring or anything else catches in the engine/transaxle unit when it is lowered.



    The sub-frame brackets bolts
     
    The bolts for the sub-frame. Lower the engine and transaxle approximately 6 inches (15cm) so that the halfshafts describe a horizontal line between the hub and transaxle.
     

  96.  
  97. Unhook the control arms from the ball joint pinion.
  98.  
  99. Remove the halfshafts from the wheel hubs.
    NOTE
    Do not pull the halfshafts. They do not have axial locks.


    CAUTION
    Do not damage the ABS wiring. Do not damage the brake pipe.

  100.  
  101. Let the halfshafts rest against the control arms. Lower the three-way catalytic converter.
  102.  
  103. Continue lowering until the hose for the compressor in the climate control unit is accessible. Detach the inner hose for the climate control unit. Seal the openings. Continue lowering the unit.
  104.  

To install:

  1. Lift the engine and transaxle unit. Use a lifting table.
  2.  
  3. Stop the lift approximately 6 inches (15cm) before the sub-frame reaches the frame members.
  4.  
  5. Install (on both sides) the halfshaft on the hub.
  6.  
  7. Lift the three-way catalytic converter up into position. Connect the exhaust system to the rear flange. Use a new gasket. Install new nuts loosely.
    NOTE
    The three-way catalytic converter cannot be raised after the engine has been raised to its correct position.

  8.  
  9. Continue raising the engine until it is only approximately 2 inches (50mm) from its correct position.
    NOTE
    Guide the lower steering shaft into the hole in the firewall.

  10.  
  11. Align the ball joint in the control arm.
  12.  
  13. Install the inner pipe on the compressor in the climate control unit. Use a new O-ring.
  14.  
  15. Lift the sub-frame until it is against the frame members.
  16.  
  17. Install new bolts in the sub-frame. Lubricate the bolt threads.
  18.  
  19. Install the washers in the front edge and support plates at the rear edge of the sub-frame.
  20.  
  21. First tighten the bolts on the left side of the sub-frame. Tighten to 48 ft. lbs. (65 Nm) plus 60°.
  22.  
  23. Then tighten the bolts on the right-hand side of the sub-frame to the same values.
  24.  
  25. Tighten the brackets. Tighten to 37 ft. lbs. (50 Nm).
  26.  
  27. Remove the lifting table.
  28.  
  29. Tighten the ball joint and control arm. Tighten to 59 ft. lbs. (80 Nm). Counterhold using Torx 40 so that the ball joint boot does not rotate.
  30.  
  31. Install:

    The anti-roll bar links. Use new locknuts. Tighten to 37 ft. lbs. (50 Nm).
     
    New center bolts for the halfshafts. Tighten to 37 ft. lbs. (50 Nm).
     

  32.  
  33. Install the tie rod using the marking made during removal. Use new locknuts. Tighten to 52 ft. lbs. (70 Nm).
  34.  
  35. Connect the fuel line to the engine.
  36.  
  37. Connect the evaporative emission system (EVAP) line at the right rear sub-frame mounting.
  38.  
  39. Install the oil cooler hoses on the transaxle.
  40.  
  41. Install the propeller shaft.
  42.  
  43. Lower the car.
  44.  
  45. Pull up and align the three-way catalytic converter (TWC) against the turbocharger (TC).
  46.  
  47. Lubricate the threads using copper paste 116 1408, or equivalent. Install new nuts loosely.
  48.  
  49. Lower the car.
  50.  
  51. Install the front SIPS member. Press the brake pipe into place in the member.
  52.  
  53. Hook the rubber mounting for the three-way catalytic converter (TWC) in the bracket on the sub-frame.
  54.  
  55. Connect the connector to the rear probe. Secure the wiring as before.
  56.  
  57. Tighten the screwed joint between the three-way catalytic converter (TWC) and the exhaust system. Tighten to 18 ft. lbs. (24 Nm).
  58.  
  59. Install:

    The steering shaft joint on the steering gear and steering shaft
     
    A new bolt. Tighten to 18 ft. lbs. (25 Nm)
     
    The steering shaft boot and snap-ring. Fold back the carpet.
     

  60.  
  61. Connect the engine and transaxle wiring connectors to the control module box base plate.
  62.  
  63. Press the base plate into place in the lower section of the control module box.

    The climate control unit pipe at the frame member inside the control unit box. Use a new O-ring
     
    The cable from the engine wiring for the sensor on the receiver to the right of the radiator
     
    The front right headlamp
     

  64.  
  65. Install the intermediate section. Align the ventilation pipe in the rear edge of the control module box.
  66.  
  67. Press the control modules down carefully. Lock into place using mounting bracket 999 5722, or equivalent.
  68.  
  69. Press the cover into place. Screw the ground lead into place on the fender liner.
    NOTE
    Use a hot-air gun to facilitate installation of the pipe.



    The connector for the expansion tank from the engine compartment wiring
     
    The hose from the engine to the expansion tank
     
    The breather tube from the radiator
     
    The expansion tank
     
    The servo reservoir
     
    The upper radiator hose.
     
    The plastic pipe between the charge air cooler and the throttle module.
     



    The connector for the sensor on the charge air cooler
     
    The ground lead from the engine to the car body
     
    The vacuum hose to the intake and power brake booster
     
    The connectors for the transaxle
     
    The mechanical transaxle cable to the transaxle
     
    The rear radiator hose
     
    The connector to the fuse box
     
    The battery lead to the terminal block on the fuse box.
     
    The radiator hoses on the heater unit. They are coded and will only connect to the correct sleeve connector
     
    The ground strip between the engine and the car body
     

  70.  
  71. Tighten the three-way catalytic converter to the turbocharger. Use new nuts. Tighten to 18 ft. lbs. (24 Nm).
  72.  
  73. Install the upper heated oxygen sensors using the marks made during removal. Lubricate the threads. Use copper paste 116 1408, or equivalent. Tighten to 33 ft. lbs. (45 Nm).
  74.  
  75. Lower the wiring down to the probes. Secure the wiring in the clips and clamps as before. Connect the wiring.
  76.  
  77. Install the heat deflector plates.
  78.  
  79. Install:

    The charge air pipes on the turbocharger
     
    The plastic charge air pipe over the engine
     
    Air cleaner assembly
     
    Mass air flow sensor connector
     
    The turbocharger control valve on the air cleaner
     
    The intake manifold to the air cleaner
     
    The engine stabilizer brace between the suspension turrets.
     

  80.  
  81. Tighten the bolts on the suspension turrets. Tighten to 37 ft. lbs. (50 Nm). Tighten the bolt in the torque bracket. Tighten to 59 ft. lbs. (80 Nm).
  82.  
  83. Install the battery negative lead.
  84.  
  85. Fill with coolant. The coolant volume is approximately 7.6 quarts (7.2 liters).
  86.  
  87. Check the engine oil.
  88.  
  89. Start the engine.
  90.  
  91. Warm up the engine until the thermostat opens.
  92.  
  93. Check for leakage.
  94.  
  95. Check the oil and coolant levels. Adjust if necessary.
  96.  
  97. Check the transaxle oil level.
  98.  
  99. Install:

    The splash guard under the engine
     
    The front skid plate on the sub-frame
     
    The front wheels
     

  100.  

5-Cylinder Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    The battery negative lead
     
    The cross stay between the suspension turrets
     
    The turbocharger control valve from the air cleaner
     
    Mass air flow sensor connector
     
    The brake vacuum hose from the air cleaner
     
    The air cleaner assembly. Seal the openings in the intake pipe for the turbocharger
     
    The plastic charge air pipe above the engine. Seal the opening in the turbocharger
     
    The ground strip at the top/rear of the cylinder head.
     

  6.  
  7. Position a container under the radiator drain cock. Drain the coolant. Close the cock.
  8.  
  9. Drain the fuel line.
  10.  
  11. Remove or disconnect the following:

    The cover over the central electrical unit
     
    The connector for the engine wiring from the central electrical unit
     
    The positive lead for the starter motor from the terminal block
     
    The ground lead at the front frame member
     
    The bolts for the transmission cable bracket at the transmission. Tie up the cable
     
    Separate the transmission wiring
     
    The oil cooler hoses for the transmission. Seal the openings.
     
    The connectors for the temperature and pressure sensors in the charge air cooler
     
    The rubber hose at the intake for the charge air cooler
     
    The brake vacuum hose at the intake manifold
     
    The lower engine coolant hose from the engine
     
    The plastic pipe between the throttle body and the charge air cooler
     
    The dip stick pipe. Separate the wiring from the front heated oxygen sensor (HO2S). Remove the wiring from the clips and clamps.
     
    Connector for the level sensor in the expansion tank
     
    The hoses for the heater unit at the terminal in the firewall
     
    The bleed hose for the radiator at the expansion tank
     
    The ABS line and clips from the power steering hose. Lift up the expansion tank and servo oil reservoir. Place them on top of the engine.
     
    Control module unit cover
     
    The control modules
     
    The surround for the control module box.
     
    The red retaining clip from the connector using a screwdriver
     
    The connector by releasing the catches at the front edge using pliers. Pry out the connector using a screwdriver. Lift up the connector with the protection underneath and put it to one side.
     
    Remove the ground lead from the right fender liner. Pull out the wiring between the front cover plate and the air conditioning pipe.
     
    The right headlamp by pulling up the two lock facings. Disconnect the wiring and put the wiring to one side
     
    The connector on the air conditioning receiver drier
     
    The gray connector on the fan shroud. Remove the wiring from the clips and clamps on the fan shroud.
     
    Remove the upper radiator hose
     
    Unhook the auxiliaries belt
     
    Disconnect the one-pin connector for the compressor magnetic clutch
     
    Remove the four bolts holding the air conditioning compressor to the engine. Tie up the compressor in the front cover plate.
     

  12.  


NOTE
Handle the compressor carefully. Ensure that there are no kinks in the air conditioning pipes.

  1. Set the front wheels so that they are straight
  2.  
  3. Remove the soundproofing panel under the steering wheel. Fold back the floor carpet
  4.  
  5. Bend up the outer section of the steering shaft boot
  6.  
  7. Remove the retaining clip around the boot. Pull the boot up
  8.  
  9. Turn the steering wheel to gain the best possible access to the steering shaft nut
  10.  
  11. Remove the ignition key. Activate the steering wheel lock.
  12.  


WARNING
Do not move the steering wheel. The contact reel in the SRS (supplemental restraint system) could be damaged.

  1. Remove or disconnect the following:

    The bolt securing the mounting for the steering shaft in the joint
     
    The joint from the steering shaft by pressing the shaft upwards
     

  2.  
  3. Raise the car.
  4.  
  5. Remove or disconnect the following:

    The left and right front wheels
     
    The splash guard under the engine.
     
    The 6 bolts. Lift up and slide the plate forward
     
    The protective plate.
     

  6.  


NOTE
There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.

  1. Remove the tie rod from the wheel spindle on the left and right sides.
  2.  
  3. On one side, measure the length of the tie rod in relation to the steering gear housing. Note the measurement.
  4.  
  5. Remove on the left and right sides:

    The link rod from the anti-roll bar
     
    The sound insulation cover for the halfshaft
     
    The nut holding the control arm to the ball joint
     
    The center bolt and the end of the halfshaft.
     

  6.  


NOTE
If an engine block heater is installed, mark the position of the fuel lines.

  1. Separate the quick-release connectors for the fuel pressure line and engine block heater (option).
  2.  
  3. Pull apart the EVAP line at the rubber joint behind the rear right mounting for the sub-frame.
  4.  
  5. Remove the three-way catalytic converter.
  6.  
  7. Remove the propeller shaft.
  8.  
  9. Use a post hoist with a lifting table and stud guides. Position the lifting table against the sub-frame.
  10.  


NOTE
Ensure that the lifting table is centered under the sub-frame for optimal weight distribution. Check that the lifting table is correctly applied against the sub-frame.

  1. Remove or disconnect the following:

    The bumper cover on the left hand side. Use a weatherstrip tool
     
    The M8 nut at the top of the left-hand fender liner for the engine coolant heater
     
    The connector for the engine coolant heater. Press up the engine coolant heater. Lift it out of its upper mounting.
     
    The bolts for the sub-frame brackets
     
    The bolts for the sub-frame. Lower the engine and transmission approximately 15 cm so that the halfshafts describe a horizontal line between the hub and transmission.
     

  2.  


WARNING
Ensure that no hoses, wiring or anything else catch in the engine and transmission unit when it is lowered.



The control arms from the ball joint pinion
 

  1. Hold the constant velocity joint. Pull the halfshaft off the hub
  2.  
  3. Let the halfshafts rest against the control arms
  4.  
  5. Turn the engine block heater out of its position
  6.  
  7. Check that the air conditioning compressor is hanging free. Continue lowering the engine and transmission unit.
  8.  


    Click image to see an enlarged view

    Fig. Sub-frame mounting brackets

    Sub-frame mounting brackets

To install:

  1. Raise the engine and the transmission unit. Use a lifting table with locating pins. Stop when the sub-frame is approximately 15 cm below the frame members.
  2.  
  3. Install, on the left and right sides:

    The halfshaft to the hub. Install the center bolts. Do not tighten yet!
     
    The ball joint to the control arm. Install the nuts. Do not tighten yet!
     

  4.  


NOTE
Ensure that the mating surfaces on the ball joints and control arms are clean. Twist the engine block heater (option) into position. Check that the air conditioning compressor is correctly positioned.

  1. Check that the tie rod is in the correct position. Check that the transmission cable is routed between the steering shaft and the firewall.
  2.  
  3. Align the steering shaft joint with the hole in the firewall.
  4.  
  5. Lift the engine and transmission unit up to the frame members.
  6.  


NOTE
Ensure that no hoses, wiring or anything else catches.

  1. Install or connect the following:

    New bolt in the sub-frame. Lubricate the bolts.
     
    The washers at the front edge and the support plates at the rear edge of the sub-frame
     
    Engine coolant heater left front (option).
     

  2.  
  3. Tighten the bolts for the sub-frame. Tighten to 77 ft. lbs. (105Nm) plus 120 degrees. Start on the left hand side of the sub-frame. Continue with the right hand side.
  4.  
  5. Tighten the bolts for the brackets at the rear of the sub-frame. Tighten to 37 ft. lbs. (50 Nm).
  6.  
  7. Remove the lifting table.
  8.  
  9. Connect the quick-release connectors and fuel line to the engine and engine block heater (option). Press the EVAP line together at the rubber joint.
  10.  
  11. Install and tighten the M8 nut in the upper mounting for the engine coolant heater. Connect the connector. Install the front bumper cover.
  12.  
  13. Install or connect the following:

    The propeller shaft
     
    The three-way catalytic converter (TWC)
     
    The tie rods. Use new nuts. Tighten to 51 ft. lbs. (70 Nm)
     
    The link rod to the anti-roll bar. Use new nuts. Tighten to 37 ft. lbs. (50 Nm). Counterhold using Torx 27
     
    The bracket for the brake pipe to the body
     
    The nut for the ball joint and control arm. Tighten to 58 ft. lbs. (80 Nm). Counterhold using Torx 40.
     
    The center bolt in the halfshaft. Tighten to 37 ft. lbs. (50 Nm).
     
    The front skid plate
     
    The lower engine splash guard
     
    The front wheels
     
    The steering shaft joint on the steering gear and steering shaft. Install a new bolt. Tighten to 18 ft. lbs. (25 Nm).
     
    The steering shaft boot and snapring. Fold back the carpet
     
    Soundproofing panel.
     
    The compressor
     

  14.  


NOTE
Handle the compressor carefully. Ensure that there are no kinks in the air conditioning (A/C) pipes. Connect the one-pin connector to the compressor magnetic clutch.



The connector on the air conditioning receiver/drier
 
The gray connector for the fan shroud
 
The wiring in the clips and clamps on the fan shroud
 
The connectors for the pressure and temperature sensors on the charge air cooler
 
The right-hand headlamp using two lock facings.
 
The engine wiring to the control module box.
 
The ground lead to the ground terminal at the right fender edge in the engine compartment
 
The auxiliary belt
 
The intermediate piece for the control module box
 
The control modules
 
The cover for the control module box
 
Expansion tank. Connect the radiator breather tube to the expansion tank. Tighten the clamp. Connect the connector for the level sensor in the expansion tank
 
Servo oil reservoir. Check that the hoses are correctly positioned.
 

  1. Clamp the ABS cable to the power steering hose.
  2.  
  3. Install or connect the following:

    The transmission cable
     
    The oil cooler hoses
     
    The lower and upper coolant hoses for the engine
     
    The rubber hose on the charge air pipe on the intake for the charge air cooler
     
    The dip stick pipe
     
    The brake vacuum hose to the intake
     
    The plastic charge air pipe between the throttle body and the charge air cooler. Tighten both the clamps.
     

  4.  


NOTE
Use a hot air gun to facilitate installation.



The connector for the engine wiring to the central electrical unit
 
The positive lead for the starter motor to the terminal block
 
The cover over the central electrical unit
 
The ground lead between the engine and body in the front frame member.
 
The ground strip at the top/rear of the cylinder head
 
The plastic charge air pipe over the engine
 
Air cleaner assembly
 
The inlet hose for the turbocharger to the air cleaner
 
Mass air flow sensor connector
 
The turbocharger control valve on the air cleaner
 
The brake vacuum hose in the clamp on the air cleaner housing
 
The intake pipe between the front cover plate and the air cleaner
 
The engine stabilizer brace between the suspension turrets
 
The battery negative lead.
 
Coolant
 
Engine oil
 
Power steering fluid.
 

  1. Start the engine
  2.  
  3. Warm up the engine until the thermostat opens
  4.  
  5. Check for leakage
  6.  
  7. Check the oil and coolant levels. Adjust if necessary
  8.  
  9. Check the transmission oil level.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    The battery negative lead
     
    The cross stay between the suspension turrets
     
    The turbocharger control valve from the air cleaner
     
    Mass air flow sensor connector
     
    The brake vacuum hose from the air cleaner
     
    The air cleaner assembly. Seal the openings in the intake pipe for the turbocharger
     
    The plastic charge air pipe above the engine. Seal the opening in the turbocharger
     
    The ground strip at the top/rear of the cylinder head.
     

  6.  
  7. Position a container under the radiator drain cock. Drain the coolant. Close the cock.
  8.  
  9. Drain the fuel line.
  10.  
  11. Remove or disconnect the following:
    NOTE
    Handle the compressor carefully. Ensure that there are no kinks in the air conditioning pipes.



    The cover over the central electrical unit
     
    The connector for the engine wiring from the central electrical unit
     
    The positive lead for the starter motor from the terminal block
     
    The ground lead at the front frame member
     
    The bolts for the transaxle cable bracket at the transaxle. Tie up the cable
     
    Separate the transaxle wiring
     
    The oil cooler hoses for the transaxle. Seal the openings.
     
    The connectors for the temperature and pressure sensors in the charge air cooler
     
    The rubber hose at the intake for the charge air cooler
     
    The brake vacuum hose at the intake manifold
     
    The lower engine coolant hose from the engine
     
    The plastic pipe between the throttle body and the charge air cooler
     
    The dip stick pipe. Separate the wiring from the front heated oxygen sensor (HO 2 S). Remove the wiring from the clips and clamps.
     
    Connector for the level sensor in the expansion tank
     
    The hoses for the heater unit at the terminal in the firewall
     
    The bleed hose for the radiator at the expansion tank
     
    The ABS line and clips from the power steering hose. Lift up the expansion tank and servo oil reservoir. Place them on top of the engine.
     
    Control module unit cover
     
    The control modules
     
    The surround for the control module box.
     
    The red retaining clip from the connector using a screwdriver
     
    The connector by releasing the catches at the front edge using pliers. Pry out the connector using a screwdriver. Lift up the connector with the protection underneath and put it to one side.
     
    Remove the ground lead from the right fender liner. Pull out the wiring between the front cover plate and the air conditioning pipe.
     
    The right headlamp by pulling up the two lock facings. Disconnect the wiring and put the wiring to one side
     
    The connector on the air conditioning receiver drier
     
    The gray connector on the fan shroud. Remove the wiring from the clips and clamps on the fan shroud.
     
    Remove the upper radiator hose
     
    Unhook the accessory drive belt
     
    Disconnect the one-pin connector for the compressor magnetic clutch
     
    Remove the four bolts holding the air conditioning compressor to the engine. Tie up the compressor in the front cover plate.
     

  12.  
  13. Set the front wheels so that they are straight
  14.  
  15. Remove the soundproofing panel under the steering wheel. Fold back the floor carpet
  16.  
  17. Bend up the outer section of the steering shaft boot
  18.  
  19. Remove the retaining clip around the boot. Pull the boot up
  20.  
  21. Turn the steering wheel to gain the best possible access to the steering shaft nut
  22.  
  23. Remove the ignition key. Activate the steering wheel lock.
    WARNING
    Do not move the steering wheel. The contact reel in the SRS (supplemental restraint system) could be damaged.

  24.  
  25. Remove or disconnect the following:

    The bolt securing the mounting for the steering shaft in the joint
     
    The joint from the steering shaft by pressing the shaft upwards
     

  26.  
  27. Raise the car.
  28.  
  29. Remove or disconnect the following:
    NOTE
    There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.



    The left and right front wheels
     
    The splash guard under the engine.
     
    The 6 bolts. Lift up and slide the plate forward
     
    The protective plate.
     

  30.  
  31. Remove the tie rod from the steering knuckle on the left and right sides.
  32.  
  33. On one side, measure the length of the tie rod in relation to the steering gear housing. Note the measurement.
  34.  
  35. Remove on the left and right sides:
    NOTE
    If an engine block heater is installed, mark the position of the fuel lines.



    The link rod from the anti-roll bar
     
    The sound insulation cover for the halfshaft
     
    The nut holding the control arm to the ball joint
     
    The center bolt and the end of the halfshaft.
     

  36.  
  37. Separate the quick-release connectors for the fuel pressure line and engine block heater (option).
  38.  
  39. Pull apart the EVAP line at the rubber joint behind the rear right mounting for the sub-frame.
  40.  
  41. Remove the three-way catalytic converter.
  42.  
  43. Remove the propeller shaft.
  44.  
  45. Use a post hoist with a lifting table and stud guides. Position the lifting table against the sub-frame.
    NOTE
    Ensure that the lifting table is centered under the sub-frame for optimal weight distribution. Check that the lifting table is correctly applied against the sub-frame.

  46.  
  47. Remove or disconnect the following:
    WARNING
    Ensure that no hoses, wiring or anything else catch in the engine and transaxle unit when it is lowered.



    The bumper cover on the left-hand side. Use a weatherstrip tool
     
    The M8 nut at the top of the left-hand fender liner for the engine coolant heater
     
    The connector for the engine coolant heater. Press up the engine coolant heater. Lift it out of its upper mounting.
     
    The bolts for the sub-frame brackets
     
    The bolts for the sub-frame. Lower the engine and transaxle approximately 6 inches (15cm) so that the halfshafts describe a horizontal line between the hub and transaxle.
     



    The control arms from the ball joint pinion
     

  48.  
  49. Hold the constant velocity joint. Pull the halfshaft off the hub
  50.  
  51. Let the halfshafts rest against the control arms
  52.  
  53. Turn the engine block heater out of its position
  54.  
  55. Check that the air conditioning compressor is hanging free. Continue lowering the engine and transaxle unit.

    Click image to see an enlarged view

    Fig. Sub-frame mounting brackets

    Sub-frame mounting brackets
  56.  

To install:

  1. Raise the engine and the transaxle unit. Use a lifting table with locating pins. Stop when the sub-frame is approximately 6 inches (15cm) below the frame members.
  2.  
  3. Install, on the left and right sides:
    NOTE
    Ensure that the mating surfaces on the ball joints and control arms are clean.



    The halfshaft to the hub. Install the center bolts. Do not tighten yet!
     
    The ball joint to the control arm. Install the nuts. Do not tighten yet!
     

  4.  
  5. Twist the engine block heater (option) into position.
  6.  
  7. Check that the air conditioning compressor is correctly positioned.
  8.  
  9. Check that the tie rod is in the correct position. Check that the transaxle cable is routed between the steering shaft and the firewall.
  10.  
  11. Align the steering shaft joint with the hole in the firewall.
  12.  
  13. Lift the engine and transaxle unit up to the frame members.
    NOTE
    Ensure that no hoses, wiring or anything else catches.

  14.  
  15. Install or connect the following:

    New bolt in the sub-frame. Lubricate the bolts.
     
    The washers at the front edge and the support plates at the rear edge of the sub-frame
     
    Engine coolant heater left front (option).
     

  16.  
  17. Tighten the bolts for the sub-frame. Tighten to 77 ft. lbs. (105 Nm) plus 120°. Start on the left-hand side of the sub-frame. Continue with the right-hand side.
  18.  
  19. Tighten the bolts for the brackets at the rear of the sub-frame. Tighten to 37 ft. lbs. (50 Nm).
  20.  
  21. Remove the lifting table.
  22.  
  23. Connect the quick-release connectors and fuel line to the engine and engine block heater (option). Press the EVAP line together at the rubber joint.
  24.  
  25. Install and tighten the M8 nut in the upper mounting for the engine coolant heater. Connect the connector. Install the front bumper cover.
  26.  
  27. Install or connect the following:
    NOTE
    Handle the compressor carefully. Ensure that there are no kinks in the air conditioning (A/C) pipes. Connect the one-pin connector to the compressor magnetic clutch.



    The propeller shaft
     
    The three-way catalytic converter (TWC)
     
    The tie rods. Use new nuts. Tighten to 52 ft. lbs. (70 Nm)
     
    The link rod to the anti-roll bar. Use new nuts. Tighten to 37 ft. lbs. (50 Nm). Counterhold using Torx 27
     
    The bracket for the brake pipe to the body
     
    The nut for the ball joint and control arm. Tighten to 59 ft. lbs. (80 Nm). Counterhold using Torx 40.
     
    The center bolt in the halfshaft. Tighten to 37 ft. lbs. (50 Nm).
     
    The front skid plate
     
    The lower engine splash guard
     
    The front wheels
     
    The steering shaft joint on the steering gear and steering shaft. Install a new bolt. Tighten to 18 ft. lbs. (25 Nm).
     
    The steering shaft boot and snapring. Fold back the carpet
     
    Soundproofing panel.
     
    The compressor
     



    The connector on the air conditioning receiver/drier
     
    The gray connector for the fan shroud
     
    The wiring in the clips and clamps on the fan shroud
     
    The connectors for the pressure and temperature sensors on the charge air cooler
     
    The right-hand headlamp using two lock facings.
     
    The engine wiring to the control module box.
     
    The ground lead to the ground terminal at the right fender edge in the engine compartment
     
    The auxiliary belt
     
    The intermediate piece for the control module box
     
    The control modules
     
    The cover for the control module box
     
    Expansion tank. Connect the radiator breather tube to the expansion tank. Tighten the clamp. Connect the connector for the level sensor in the expansion tank
     
    Servo oil reservoir. Check that the hoses are correctly positioned.
     

  28.  
  29. Clamp the ABS cable to the power steering hose.
  30.  
  31. Install or connect the following:
    NOTE
    Use a hot air gun to facilitate installation.



    The transaxle cable
     
    The oil cooler hoses
     
    The lower and upper coolant hoses for the engine
     
    The rubber hose on the charge air pipe on the intake for the charge air cooler
     
    The dip stick pipe
     
    The brake vacuum hose to the intake
     
    The plastic charge air pipe between the throttle body and the charge air cooler. Tighten both the clamps.
     



    The connector for the engine wiring to the central electrical unit
     
    The positive lead for the starter motor to the terminal block
     
    The cover over the central electrical unit
     
    The ground lead between the engine and body in the front frame member.
     
    The ground strip at the top/rear of the cylinder head
     
    The plastic charge air pipe over the engine
     
    Air cleaner assembly
     
    The inlet hose for the turbocharger to the air cleaner
     
    Mass air flow sensor connector
     
    The turbocharger control valve on the air cleaner
     
    The brake vacuum hose in the clamp on the air cleaner housing
     
    The intake pipe between the front cover plate and the air cleaner
     
    The engine stabilizer brace between the suspension turrets
     
    The battery negative lead.
     
    Coolant
     
    Engine oil
     
    Power steering fluid.
     

  32.  
  33. Start the engine
  34.  
  35. Warm up the engine until the thermostat opens
  36.  
  37. Check for leakage
  38.  
  39. Check the oil and coolant levels. Adjust if necessary
  40.  
  41. Check the transaxle oil level.
  42.  

8-Cylinder Engine
  1. Remove the battery negative lead.
  2.  
  3. Remove the expansion tank cap.
    NOTE
    There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.

  4.  
  5. Remove the 6 bolts. Lift and slide the protective plate forward. Remove the protective plate.
  6.  
  7. Remove the 6 bolts and the lower engine cover.
  8.  
  9. Drain coolant.
  10.  
  11. Remove the 4 bolts at the suspension turrets, the bolts of the upper engine mount on the engine and the upper cross stay.
  12.  
  13. Remove the air cleaner cover
  14.  
  15. Remove the 2 connectors from the engine control module (ECM); clip the band clamp to the cable harness, remove the connector from the mass air flow sensor.
  16.  
  17. Remove the brake vacuum hose from the vacuum pump.
  18.  
  19. Remove the 2 bolts from the fresh air hose in the front plate.
  20.  
  21. Remove the fresh air hose.
  22.  
  23. Remove the air cleaner by pulling it straight up.
  24.  
  25. Remove the positive lead from the electrical distribution box.
  26.  
  27. Remove the ground cable between the engine and body (loosen in the body).
  28.  
  29. Remove the connector at the electrical distribution box from the brake vacuum valve. Detach the vacuum hose from the valve that leads to the brake vacuum amplifier.
  30.  
  31. Remove the selector lever cable using a break fork to break the cable loose from its ball.
  32.  
  33. Remove the transaxle control module (TCM) connector.
  34.  
  35. Remove the lower line of the transaxle oil cooler.
  36.  
  37. Remove the upper line of the transaxle oil cooler.
    NOTE
    Seal the openings and collect the oil from the oil cooler in a receptacle. Do not reuse the drained oil.

  38.  
  39. Detach the radiator hoses at the quick-release coupling toward the firewall.
  40.  
  41. Remove the upper radiator hose from the distributor housing.
  42.  
  43. Remove the lower radiator hose from the thermostat housing.
  44.  
  45. Remove the upper engine covers.
  46.  
  47. Remove the upper engine covers by pulling them straight up.
  48.  
  49. Remove the 2 bolts on the cover over the servo pump.
  50.  
  51. Remove the cover.
  52.  
  53. Remove the bolt on the washer fluid filler pipe; bend out the pipe.
  54.  
  55. Remove the return line for servo oil from the clips and clamps.
  56.  
  57. Lift up the servo oil reservoir.
  58.  
  59. Remove the 2 coolant hoses from the expansion tank.
  60.  
  61. Remove the 3 ground cables from the body at the expansion tank.
  62.  
  63. Remove the connector from the electric cooling fan.
  64.  
  65. Position the oil reservoir on the engine.
    NOTE
    Make sure no oil runs out. Make sure that the oil return line is on the correct side of the upper coolant hose that runs to the engine.

  66.  
  67. Remove the auxiliary drive belt.
  68.  
  69. Remove the ground cable bolt between the engine and body. It is located beneath the expansion tank.
  70.  
  71. Raise the vehicle.
  72.  
  73. Remove the front wheels.
  74.  
  75. Remove the ball joint from the link arm (on both sides of the vehicle)
    1. Remove the halfshaft bolt. Counterhold with a prybar in the brake disc cooling channels.
    2.  
    3. Remove the rubber sleeve in the wheel hub.
    4.  
    5. Remove the nut between the ball joint and link arm.
    6.  
    7. Remove the nut of the anti-roll bar link in the anti-roll bar.
      NOTE
      Counterhold with a Torx wrench so that the ball joint gaiters do not turn when the nuts are removed.

    8.  

  76.  
  77. Mark the position of the track rod.
  78.  
  79. Remove the track rod end from the guide arm, using a puller.
  80.  
  81. Detach the ball joint pin from the link arm.
  82.  
  83. Fit the cap nut, 7062-1, on the ball joint pin.
  84.  
  85. Tighten the nut toward the link arm. Then turn it back one rotation to create play between the cap nut and the link arm. Position the puller on the link arm and detach the ball joint from the link arm.
  86.  
  87. Remove the nuts at intermediate pipe joints and the intermediate pipes; scrap the gaskets.
    NOTE
    Mark the position of the carrier on the driveshaft.

  88.  
  89. Remove the driveshaft bolts.
    NOTE
    Do not move the steering wheel. The contact reel in the SRS (supplemental restraint system) could be damaged.

  90.  
  91. Set the front wheels in the straight-ahead position.
  92.  
  93. Fold the floor carpet out of the way.
  94.  
  95. Bend up the outer section of the steering shaft boot.
  96.  
  97. Remove the retaining clip around the boot.
  98.  
  99. Pull the boot up.
  100.  
  101. Turn the steering wheel to gain the best possible access to the steering shaft nut.
  102.  
  103. Remove the ignition key and activate the steering wheel lock.
  104.  
  105. Remove the bolt securing the mounting for the steering shaft in the joint
  106.  
  107. Remove the joint from the steering shaft by pressing the shaft upwards.
  108.  
  109. Detach the connector (blue) from the steering gear.
  110.  
  111. Drain the fuel line.
  112.  
  113. Detach the quick-release coupling of the fuel line at the right rear sub-frame mount.
  114.  
  115. Detach the fuel return line.
    NOTE
    Seal the openings against dirt. Detach the connector from the oil level sensor in the oil sump and the oil pressure sensor.

  116.  
  117. Remove the A/C compressor.
  118.  
  119. Pull out the cable harness and bend it aside.
    NOTE
    Ensure that the lifting table is properly centered under the engine.

  120.  
  121. Position a lifting table under the sub-frame. Secure the table against the sub-frame.
  122.  
  123. Remove the connector from the circulation pump.
  124.  
  125. Remove the 4 M10 bolts in the rear edge of the sub-frame brackets.
  126.  
  127. Remove the 4 bolts in the sub-frame. Lower the engine/transaxle unit approx. 6 inches (15cm) so that the halfshafts create a horizontal line between the hub and the transaxle.
    NOTE
    Take great care that no hoses, wiring or anything else catches in the engine/transaxle unit when it is lowered.

  128.  
  129. Tap the link arms off of the ball joint pin. Release the drive shafts from the wheel hubs by pressing the drive shafts into the hub.
  130.  
  131. Remove the 3 A/C compressor bolts.
  132.  
  133. Lift out the A/C compressor and suspend it in a suitable manner.
  134.  
  135. Continue lowering the engine/transaxle unit.
  136.  

To install:


WARNING
Ensure that no hoses, wiring or other components catch or become trapped during lifting.


NOTE
Make sure that the mating surfaces on the ball joints and control arms are clean.

  1. Raise the engine/transaxle unit using a lifting table. Stop approx. 6 inches (15cm) before the sub-frame reaches the frame members.
  2.  
  3. Install the lower radiator hose in the mount on the sub-frame.
  4.  
  5. Install the A/C compressor; tighten 3 bolts
  6.  
  7. Attach the connectors to the A/C compressor, the oil pressure sensor, and the oil level sensor; secure the cable harness in the clips and clamps.
  8.  
  9. Install the drive shaft in the hub on both sides.
  10.  
  11. Continue raising the engine to approximately 2 inches (50mm) before it makes contact.
    NOTE
    Guide the lower steering shaft into the hole in the firewall.

  12.  
  13. Guide the ball joint to the link arm.
  14.  
  15. Raise the sub-frame toward the frame members until it makes contact.
  16.  
  17. Install new bolts on the sub-frame. Oil the bolt threads.
  18.  
  19. Install the washers in the front edge and the support plates in the rear edge of the sub-frame.
  20.  
  21. First tighten the bolts on the left side of the sub-frame. Tighten the M10 bolts to 26 ft. lbs. (35 Nm) plus 60°. Tighten the M8 bolts to 15 ft. lbs. (20 Nm) plus 60°.
  22.  
  23. Then tighten the bolts on the right side of the sub-frame to the same values.
  24.  
  25. Tighten the bolts of the support plates.
  26.  
  27. Remove the lifting table.
  28.  
  29. Tighten the ball joint and link arm to 59 ft. lbs. (80 Nm). Counterhold with Torx 40 so that the ball joint gaiter does not rotate.
  30.  
  31. Install the anti-roll bar links. Use new lock nuts.
  32.  
  33. Install new center bolts and a rubber sleeve on the drive shafts.
  34.  
  35. Install the track rods following the marks made during removal. Use new lock nuts.
    NOTE
    Remove the seals.

  36.  
  37. Connect the fuel lines.
  38.  
  39. Attaching the steering gear connector
  40.  
  41. Attach the connector to the steering gear.
  42.  
  43. Install the anti-roll bar.
  44.  
  45. Install the driveshaft.
  46.  
  47. Install the intermediate pipes using new gaskets.
  48.  
  49. Install the nuts at intermediate pipe joints.
  50.  
  51. Install the gear selector cable in the mount on the transaxle and press the cable into the ball.
  52.  
  53. Install the transaxle control module (TCM) connector.
  54.  
  55. Install the upper radiator hose on the distributor housing; tighten the clamp.
  56.  
  57. Install the lower radiator hose on the thermostat housing; tighten the clamp.
  58.  
  59. Connect the radiator hoses at the firewall.
  60.  
  61. Remove the seals.
  62.  
  63. Install the lower line to the transaxle oil cooler as marked; secure with a quick-acting lock.
  64.  
  65. Install the upper line to the transaxle oil cooler as marked; secure with a quick-acting lock.
  66.  
  67. Install the positive lead in the electrical distribution box.
  68.  
  69. Install the ground cable in the body (between the engine and body)
  70.  
  71. Install the connector at the electrical distribution box.
  72.  
  73. Install the connector to the brake vacuum valve and the vacuum hose on the valve leading to the brake vacuum amplifier.
  74.  
  75. Install the auxiliary belt.
  76.  
  77. Installing the ground cable.
  78.  
  79. Install the servo oil reservoir.
  80.  
  81. Install the cover over the servo pump.
  82.  
  83. Position the upper engine covers and press them into the retainers.
  84.  
  85. Install the upper cross stay.
  86.  
  87. Install the lower engine cover.
  88.  
  89. Install the protective plate.
  90.  
  91. Install the front wheels.
  92.  
  93. Install the battery cable.
    NOTE
    Make sure the outlet hose of filling equipment is not blocked as this could damage the cooling system.

  94.  
  95. Fill with coolant.
  96.  
  97. Check the oil level in the engine and transaxle. Start the engine and allow it to warm to normal operating temperature. Check for leaks and proper function. Fill up fluids as necessary.
  98.  

 
label.common.footer.alt.autozoneLogo