Power unit, fitting

/ 9-3 (9440) / 2007 / 2. Engine / V6 petrol / Basic engine / Adjustment/replacement / Power unit, fitting

To remove

Warning A large number of hoses, cables, etc., are secured with cable ties. After tightening, the ties are cut off and leave more or less sharp edges at the fastening point. Watch out for the risk of cuts due to these sharp ends on the cable ties!

1.	Position the trolley lift with power train and adjust its position in relation to the body. Use 82 93 102 Extension, 500 mm, 3/8 square through the holes in the subframe to the attachments in the body. See Centring tool, engine and subframe.

2.	Raise the train until the inner drive shaft universal joints are level with the wheel hubs and insert the hub nuts. Make sure that nothing catches or gets damaged.

3.	Lift a little higher and position the lower swivel joints to the steering swivel members. If necessary, adjust the trolley lift screws to provide even contact with the body. Check that the guide pins are positioned correctly relative the reference holes in the body.

4.	Move the subframe stays back into position. Position and insert the bolts through the subframe to the body.

5.	Raise the engine all the way and tighten the subframe bolts and the rear bolts of the stays. Tightening torque, subframe: 75 Nm + 135° (55 lbf ft +135°) Tightening torque, stay: 90 Nm + 45° (66 lbf ft +45°)

6.	Lower the trolley lift and move it out of the way.

7.	Tighten the bolts on the lower swivel joints. Tightening torque 50 Nm (37 lbf ft). Important Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.

8.	Position the lower anti-roll bar links and tighten them while gripping the flats with a thin spanner. Tightening torque 64 Nm (47 lbf ft)

9.	Position and tighten the outer steering links. Lower the car. Tightening torque 35 Nm (26 lbf ft)

10.	Fit the right and left-hand engine mountings. Tightening torque, right to body: 45 Nm + 90° (33 lbf ft + 90°) Tightening torque, right to engine: 50 Nm + 180° (37 lbf ft + 180°) Tightening torque, left: 80 Nm (59 lbf ft)

11.	Remove the straps and the radiator member.

12.	Aut: Connect the breather hose of the automatic transmission. Remove the cable tie and fit the shifter cable to the gearbox.

13.	Man: Fit the quick coupling on the clutch slave cylinder. Remove the hose pinch-off pliers from the clutch hose. Remove the cable tie and fit the shifter cables on the gearbox.

14.	Connect the quick coupling of the breather line.

15.	Remove the plugs and connect the fuel line to the fuel rail.

16.	Connect the brake servo vacuum pipe.

17.	Fit the coolant hose and position it in the holder on the engine.

18.	Raise the car.

19.	Install the angle sensor cable on the subframe. Plug in the connector.

20.	Remove the centring fixtures from the subframe.

21.	Fit the A/C compressor retaining bolts and A/C compressor connector. Tightening torque 24 Nm (18 lbf ft).

22.	Fit the power steering pipes to the radiator assembly.

23.	Connect the steering shaft to the steering gear. Use locking fluid on the bolts. Tightening torque 30 Nm (22 lbf ft)

24.	Lower the car.

25.	Remove the cable tie and reposition the engine wiring harness.

26.	Plug in the connector on the structural member.

27.	Attach the ground cables and the clamp for the engine harness.

28.	Fit the retaining bolt for the engine harness connector in the main fuse box.

29.	Attach the positive cable to the positive terminal of the battery.

30.	Fit the cover on the electrical centre and undo the two retaining bolts.

31.	Attach the breather hoses to the coolant reservoir.

32.	Attach the charge air pipe between the throttle body and charge air cooler.

33.	Plug in the boost pressure sensor connector (688).

34.	Remove the plugs and install the lower radiator hose. Aut: Connect the oil pipes to the radiator.

35.	Move the radiator assembly forward slightly and install the fan cowling.

36.	Fit the bolts.

37.	Attach the upper radiator hose to the engine.

38.	Fit the upper radiator brackets to the body.

39.	Fit the cover over the radiator core.

40.	Plug in the connector and attach the clips securing the cables on the fan cowling.

41.	Fit the air cleaner casing and connect the intake hose. Fit the air cleaner and the air cleaner casing.

42.	Fit the turbocharger intake pipe.

43.	Attach the secondary air pipe to the turbocharger intake manifold.

44.	Fit the ventilation hose to the turbocharger and attach the dipstick tube breather hose.

45.	Plug in the connector to the mass air flow sensor.

46.	Fit the upper radiator member.

47.	Plug in the horn connector.

48.	Reposition the right-hand headlight.

49.	Fit the bonnet wire quick coupling.

50.	Fit the turbocharger intake manifold to the radiator member.

51.	Plug in the bonnet switch connector, fit the cable clip and install the battery tray.

52.	Fit the cable duct on the battery tray.

53.	Fit the fuse holder on the battery tray.

54.	Fit the filler pipe of the washer fluid reservoir.

55.	Install the main fuse box in front of the battery tray.

56.	Fit the battery.

57.	Raise the car.

58.	Install the rear catalytic converter. Tightening torque, flange: 30 Nm (22 lbf ft) Tightening torque, clip: 40 Nm (30 lbf ft)

59.	Fit the coolant connection.

60.	Fit the dryer filter bolts on the radiator.

61.	Fit the oil cooler's radiator hose to the radiator.

62.	Fit the hose between the charge air cooler and the charge air pipe.

63.	Fit the cover on the right-hand side.

64.	Fit the lower charge air pipe to the fan cowling.

65.	Attach the charge air hose between the charge air pipe and the charge air cooler.

66.	Fit the cover on the left-hand side.

67.	Fit the bumper.

68.	Unload the belt tensioner. Use a ¼ " puller and fit the drive belt. CV: Fit Chassis reinforcement, front subframe, CV, petrol

69.	Install the right wing liner and the front part of the left wing liner.

70.	Plug in the headlight washer hose.

71.	Fit and plug in the connector and fit the lower spoiler shield.

72.	Lower the car slightly and mount the front wheels. See Wheels

73.	Tighten the centre nuts of the drive shafts. Tightening torque 230 Nm (170 lbf ft).

74.	Fit the negative cable and battery cover.

75.	Remove the wing covers.

76.	Check oil level and top up as necessary. Fill with coolant to approx. 20 mm above the mark on the expansion tank. If a new engine is fitted, follow the instructions given in Bleeding the cooling system when working on the oil cooler .

77.	Close the expansion tank cap.

78.	Aut: If the gearbox was drained, check the automatic transmission fluid level as described in Checking oil level .

79.	Remove the wing covers and restore car electrical functions, see After disconnecting the battery .

80.	Fit the upper engine cover.

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