Engine, Installing

Engine, Installing

• Engine mounted on engine/trans. support (T10012).

Installation is performed in the reverse of removal, noting the following:

• During installation, all cable ties must be re-installed at the same location.

• Secure all hose connections using hose clamps appropriate for the model type. Refer to the electronic parts catalog ETKA.

• During assembly, replace self-locking nuts and bolts.

• Always replace bolts that are tightened to torque as well as O-rings and gaskets.

• Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of lubricant on splines. Refer to the electronic parts catalog ETKA. Then move the clutch plate back and forth on the input shaft, until the hub can be easily moved on the shaft. Remove all excess grease.

- Make sure alignment sleeves for engine to transmission are installed in cylinder block. Install if necessary.

- Make sure that the intermediate plate is hooked in at the sealing flange and is pushed onto the alignment sleeves - arrows -.






- Check clutch release bearing for wear and replace if necessary.

- Bolt transmission to engine.

• Tightening specifications only apply to lightly greased, oiled, phosphate or blackened nuts and bolts.

• Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not.

• Do not use any degreased parts.

• Tolerance for tightening specifications 15%.

Engine/Transmission, Fastening











A: Alignment bushings for centering

- Push the cover plate - 2 - in so that the lower tab hooks in at the cylinder block, and fasten it at the top with the bolt - 1 -.






• Shown in the illustration with transmission removed.

- Guide the engine/transmission assembly into the body.

- Hand-tighten the bolts - arrows - at engine assembly mounting.






- Hand-tighten the bolts - arrows - at transmission assembly mounting.






• Secure with new bolts.

• The bolts are first tightened to final torque after the engine mounts have been adjusted. Refer to => [ Subframe Overview ] Subframe Overview.

- Remove (T10012) from engine.

- Fasten the pendulum supports to the transmission and subframe - 1 to 3 -.






- Install the drive axles.

- Install exhaust system and align it free of tension. Refer to => [ Exhaust System, Aligning ] Exhaust System, Aligning.

- Install heated oxygen sensor (HO2S) (G39).

- Fill the refrigerant circuit.

- Install the shift mechanism on the transmission and adjust.

- Adjust the engine mounts. Refer to => [ Subframe Mount, Adjusting ] Adjustments.

- Electrical connections and routing.

- Install fuel system.

- Check oil level.

- Connect the battery.

- Fill with coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.

- Air duct pipes with connector, installing. Refer to => [ Hose Connections with Connector Couplings, Assembling ] Hose Connections with Connector Couplings, Assembling.

• Only reuse drained coolant if cylinder head or engine block was not replaced.

• Dirty coolant may not be used again.

Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.

Tightening Specification