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 mount. 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. Attach the heater hoses to the bulkhead.
8. Install the cardan shaft. Tightening torque: 40 Nm
Clean the element of dirt and grease. Use new bolts.
9. Install the coolant expansion tank. Tightening torque: 10 Nm
10. Attach the engine wiring harness. Tightening torque: 10 Nm
11. Connect 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 axle shaft and support bracket. Tightening torque: 25 Nm
16. Establish the left half shaft.
17. Using outside help, install the axle shaft in the hub.
18. Install the axle shafts. Tightening torque: Stage 1: 45 Nm. Stage 2: 80°
19. Connect the A/C compressor refrigerant high pressure line. Tightening torque: 24 Nm
CAUTION: A new O-ring must be installed.
NOTE: Lubricate O-rings with clean compressor oil.
20. Connect the A/C compressor refrigerant low pressure line. Tightening torque: 24 Nm
CAUTION: A new O-ring must be installed.
NOTE: Lubricate 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. Attach the power steering high pressure line. Tightening torque: 10 Nm
24. Install the gear selector cables.
25. Connect a vacuum hose of the vacuum amplifier of brakes.
26. Connect the electrical connectors of the ECM.
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 mounting system, Removal and installation).
30. Install the lower engine stabilizer bar. Refer to Procedure: Engine Lower Mount Insulator (303-01A Engine - 3.2L NA - I6, Removal and installation).
31. Install the catalytic converter. Refer to Procedure: Catalytic Converter - Vehicle Not Included: Diesel Fuel Filter (309-00B Exhaust system - 2.2L Duratorq - Td4, Removal and installation).
32. Fill the cooling system and remove air from it. Refer to Procedure: Drain/Fill Coolant and Bleed Cooling System (303-03B Engine Cooling - 2.2L Duratorq - Td4, General Procedures).
33. Install the air filter assembly. Refer to Procedure: Air Filter (303-12A Intake air distribution and filtration - 3.2L NA - I6, Removal and installation).
34. Install the battery tray. Refer to procedure: Battery installation shelf (414-01 Battery, battery mount and wires, Removal and installation).
35. Install plenum panel. Refer to Procedure: Mixing Chamber (412-01 Climate control, Removal and installation).
36. Replace the engine top cover. Refer to Procedure: Engine Cover - 2.2L Duratorq - Td4 (501-05 Interior trim, Removal and installation).
37. Bleed air from low pressure fuel system. Refer to Procedure: Bleeding the Fuel System - 2.2L Duratorq - Td4 (310-00 Fuel supply system - General information, General procedures).
38. Bleed the clutch system Refer to procedure: Bleeding the clutch system (308-00 Manual Transmission / Transaxle Transmission and Clutch - General Information, General Procedures).
39. Connect the ground wire to the battery and install the cover. Refer to procedure: Specifications (414-00 Charging system - General information, Specifications).
40. Fill the air conditioning system (A/C). Refer to the procedure: Recycling the refrigerant, evacuating and charging the air conditioning system (A/C) (412-00 Climate control system - General information, General procedures).
41. Fill fluid into the power steering system and bleed air from the system. Refer to Procedure: Bleeding Power Steering System (211-00 Steering system - General information, General procedures).
42. Once the vehicle is on its wheels, finally tighten the axle shafts and suspension.
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