Engine, Installing

Engine, installing
Installation is performed in the reverse order. When installing, note the following:

CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to the confined conditions.
^ Route all the various lines (e.g. for fuel, hydraulic system, EVAP system, coolant, refrigerant, brake liquid, vacuum) and electrical wiring so that the original positions are restored.
^ Ensure that there is sufficient clearance to all moving or hot components.

- Fit new dowel sleeves to centralize transmission on engine block.





- Fit intermediate plate onto sealing flange and slide onto dowel sleeves - arrows -.

Vehicles with a manual transmission
- Check centering of clutch drive plate if necessary.
- Check clutch release bearing for wear, replace if necessary.
- Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000 100.

Vehicles with 5 speed manual transmission 02J
- Install hydraulic clutch slave cylinder.
- Install selector mechanism.
- Adjust selector mechanism if necessary.

Vehicles with 5 & 6 speed manual transmission 02M
- Install hydraulic clutch slave cylinder.
- Install selector mechanism.
- Adjust selector mechanism if necessary.

Vehicles with 4 speed automatic transmission 01M
When securing the torque converter to the drive plate, only use nuts which are authorized for this purpose.
- Connect selector lever cable to transmission.
- Adjust selector mechanism if necessary.

Vehicles with 6 speed automatic transmission 09G
When securing the torque converter to the drive plate, only use nuts which are authorized for this purpose.
- Connect selector lever cable to transmission.
- Adjust selector mechanism if necessary.

Continuation for all models
- Check that clearance exists to axle shafts.

Vehicles with air conditioning
- Install air conditioner compressor.
- Note additional information and removal work on models with air conditioning.

Continuation for all models
- Align engine and transmission assembly mountings.
- Install axle shafts.
- Install protective shield for inner right constant velocity joint.
- Install front exhaust pipe with catalytic converter.
- Connect intake hose (between charge air cooler and throttle valve control module) to throttle valve control module.
- Install power steering pump.
- Check electrical connections and routing.
- Install ribbed belt.
- Install secondary air injection pump motor with bracket.
- Fill cooling system with coolant.
- Remove center, left and right side sound insulation.
- Interrogate Diagnostic Trouble Code (DTC) memories of all control modules, repair faults if necessary and then erase DTC memory.
- Test drive vehicle and interrogate DTC memory of all control modules again.

Note:
^ Observe applicable safety precautions during road test.