Engine, Installing

Engine, installing

Installation is performed in reverse sequence. Note the following:

CAUTION! 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.





- Install 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.
- Install hydraulic clutch slave cylinder.
- 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.

Note: Always replace selector cable circlip.

Vehicles with air conditioning
- Install air conditioner compressor.

Continued for all vehicles
- When installing engine/transmission assembly, ensure sufficient clearance to engine and transmission mountings and radiator.
- Align assembly mountings for engine and transmission.

Note:
Assembly mounting tightening torques.

- Install right axle shaft and attach left axle shaft to transmission.
- Install front exhaust pipe.
- Install power steering pump.
- Route wiring harness and connect all electrical connections to engine.
- Install poly V-belt.
- Install sound insulation at left and right sides.
- Refill with coolant.
- Vehicles with secondary air injection pump, install pump with bracket.
- Adapt (match) engine control module to throttle valve control module.

Vehicles without Electronic Power Control (EPC)
- Adjust throttle cable.

Continued for all vehicles
- Test drive vehicle and check Diagnostic Trouble Code (DTC) memory.
- Generate readiness code again if DTC memory has been erased or engine control module was disconnected from permanent positive.