Engine, Installing

Engine, Installing

WARNING!
- Do not re-use any fasteners that are worn or deformed in normal use.
- Some fasteners are designed to be used only once, and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow the recommendations in this information-replace these fasteners with new parts where indicated and any other time it is deemed necessary by inspection.

Engine is installed in reverse order of removal, noting the following:
- Make sure centering sleeves for engine to transmission are correctly installed in cylinder block. Install or replace if necessary.
- Slide intermediate plate over centering sleeves.

Vehicles with manual transmission
- Check clutch release bearing for wear, and replace if necessary.
- Lubricate splines on transmission input shaft lightly using thin coating of G 000 100. Do not lubricate guide sleeve for release bearing.
- Make sure clutch disc is properly centered.
- A pilot needle bearing must be installed in the crankshaft in engines for vehicles with manual transmission.

Vehicles with automatic transmission

CAUTION! DO NOT install a pilot needle bearing; remove if necessary.

- Use original bolts when securing torque converter to clutch disc, Refer to Parts Supplier.
- Secure torque converter bolts using 15 mm socket Matra V175.




Installation dimension for torque converter, checking
When torque converter is installed correctly, the distance between contact surfaces at the mounting holes on the torque converter and contact surface of the bell housing flange (transmission 01V) will be approximately 23 mm (29/32 inch).
If the torque converter is not installed correctly, this distance will be approximately 11 mm (7/16 inch).

CAUTION! If the torque converter is not installed correctly, the ATF pump will be seriously damaged when the transmission is attached to the engine.

- Check ATF level.

All models
- Install engine mounts without tension or preload. Align engine with rocking motion before tightening engine mounts.
- Install A/C compressor and power steering pump.
- Install ribbed belt. Service and Repair

Note: When installing the ribbed belt, make sure it is seated correctly on the pulleys.

- Install lock carrier.
- Fill up coolant. Service and Repair

Note:
- Only reuse drained coolant if cylinder head or cylinder block was not replaced.
- Dirty coolant cannot be reused.

- Place torque mount on rubber buffer for torque mount and tighten to 25 Nm (18 ft. lbs.).
- Adjust Accelerator Pedal (AP) cable.
- Install exhaust system free of stress.
Harness connectors and routing, Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations.
- Switch ignition off and reconnect battery Ground (GND) strap.
- After connecting battery, enter anti-theft code for radio.
Refer to Radio Operating Manual
- Fully close power windows to stop.
- Operate all power window switches again for at least one second in "close" direction to activate "one-touch" opening/closing function.
- Set clock to correct time.
- Check engine oil level before starting engine.
- Adapt throttle valve control module

Note: Diagnostic Trouble Codes (DTCs) are stored when harness connectors are disconnected. After installation, check DTC memory and erase.

- Adjust headlights.