Engine Installation Notes

Engine installation notes

Installation is performed in the reverse sequence, Note the following:

WARNING: When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:
^ Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.

^ Insert new dowel sleeves in cylinder block for centralizing engine and transmission.





^ Fit intermediate plate onto sealing flange and slide onto dowel sleeves (arrows).

Vehicles with manual transmission
^ Lightly grease input shaft splines with G 000 100 grease.
^ Check clutch and clutch operating mechanism, then install.
^ Install gear shift mechanism, adjust gear shift cables if necessary:

Vehicles with automatic transmission
^ Install selector cable on transmission, adjust if necessary:
^ Install selector cable on transmission, adjust if necessary:

Note: Always replace selector cable circlip

Vehicles with air conditioning
^ Install air conditioning compressor:

Continuation for all models
^ When installing engine/transmission assembly, ensure sufficient clearance to engine and transmission mountings and radiator.
^ When doing this guide power steering pressure line past transmission.
^ Align assembly mountings for engine and transmission.

Note: Torque settings; Refer to Engine, Specifications, Mechanical, Torque Settings

^ Install right side axle shaft and attach left side axle shaft to transmission:
^ Install front exhaust pipe.
^ Install power steering pump:
^ Reconnect electrical connections and check routing:
^ Install ribbed belt.
^ Install secondary air injection pump.
^ Install center, left and right insulation trays:
^ Fill system with coolant.

Vehicles without EPC
^ Adjust accelerator cable.

Vehicles with EPC
^ Adapt (match) engine control module to throttle valve control; Refer to Adapt components and functions

Continuation for all models
^ If fault memory has been erased or engine control module was disconnected from permanent positive, respective components must be adapted to engine control module and readiness code generated again.
^ Road test vehicle and interrogate all fault memories:
Refer to Diagnostic tester VAS5051; Guided fault finding; Vehicle system test
Observe the valid safety precautions when performing a road test.
^ Read readiness code.

Vehicles with automatic transmission
^ Adapt transmission control module:
^ Test drive vehicle and interrogate fault memory.