Installation
INSTALLATION PROCEDUREInstall the engine in reverse order of removal and observe the following points:
- Check whether locating sleeves for centering engine/transmission are installed in cylinder block. Install sleeves if necessary.
- Always replace self-locking nuts.
- Always replace seals.
- If necessary, check centering of clutch drive plate.
- Clean splines of transmission input shaft. Thinly coat splines and clutch release bearing with G 000 100. Do not grease guide sleeve for release bearing.
- Make sure that support tab of coolant pipe is not pinched between engine and transmission while pushing these together.
- Install engine mounting torque-free by aligning engine with shaking movements before tightening engine mounting.
- Install coolant pipe, retaining clip for refrigerant pipe and A/C compressor together.
- When tightening exhaust down pipe on turbocharger, ensure freedom of movement between exhaust down pipe and sub-frame.
- Align the exhaust system tension free while system is cold.
- Ensure sufficient clearance between all parts of exhaust system and body.
- When exhaust system is correctly installed, there must be pre-load at rear mounts of rear silencer. Distance between mounts = approximately 10 mm (3/8 in.)
- Secure all cable ties taken out during removal at same location during installation.
- Secure wiring exposed during removal tension-free at same location during installation.
ACCELERATOR CABLE ADJUSTMENT
NOTE:
- The accelerator pedal cable is highly susceptible to kinking and must therefore be carefully handled when installing. A single, slight kink can lead to a break later. Therefore, an accelerator pedal cable that has been kinked may not be installed.
- When installing, ensure that the accelerator pedal cable aligns between the support bracket and the fast idle cam.
1. Connect accelerator pedal cable to accelerator pedal and fast idle cam.
2. Remove securing clip from accelerator pedal cable sleeve.
3. Depress accelerator pedal to Wide Open Throttle (WOT) position.
4. Pull back accelerator pedal cable sleeve until throttle valve lever contacts WOT stop.
5. Insert securing clip behind support bracket at locking segment of accelerator pedal cable sleeve.
FLUID LEVELS
- Fill coolant, do not reuse drained coolant.
- Check oil level before starting engine.
TIGHTENING TORQUES
Exhaust down pipe to turbocharger 30 Nm (22 ft lb)
Exhaust down pipe to corrugated pipe 25 Nm (18 ft lb)
Exhaust down pipe to catalyst 25 Nm (18 ft lb)
Catalyst to transmission support 25 Nm (18 ft lb)
A/C compressor to bracket 25 Nm (18 ft lb)
Torque converter to drive plate 60 Nm (44 ft lb)
OTHER NUTS AND BOLTS:
M6 1O Nm (7 ft lb)
M8 2O Nm (15 ft lb)
M10 45 Nm (33 ft lb)
M12 6O Nm (44 ft lb)
VISCOUS FAN TO CARRIER TORQUE
Without fork wrench 3312 [1] 70 Nm (52 ft lb)
With fork wrench 3312 and torque wrench 1331 37 Nm (27 ft lb)
With fork wrench 3312 and without torque wrench 1331:
220 mm torque wrench [2] 33 Nm (24 ft lb)
280 mm torque wrench [2] 37 Nm (27 ft lb)
300 mm torque wrench [2] 39 Nm (29 ft lb)
440 mm torque wrench [2] 45 Nm (33 ft lb)
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[1] If fork wrench 3312 is not used, torque wrench length does not effect bolt torque.
[2] When using fork wrench 3312, applied torque is affected by torque wrench length. Torque wrench length is measured from center of socket to center of handle.