Engine, Installing

Installing

Installation is carried out in the reverse order of removal.

Note:
^ When performing repairs, replace seals, gaskets, self-locking nuts and bolts which have a specified tightening angle.
^ The hose connectors and hoses of charge air system must be free of oil and grease before assembling.

^ Check whether dowel sleeves for centralizing engine/gearbox are in the cylinder block, install if necessary.
^ Install intermediate plate onto dowel sleeves.

Vehicles with manual gearbox
^ Check clutch release bearing for wear, replace if necessary.
^ Lightly grease splines on gearbox input shaft with G 000 100. Do not grease guide sleeve for release bearing.
^ If necessary, check that clutch plate is properly centered.
^ A needle bearing must be installed in crankshaft on vehicles with manual gearbox.
^ Install needle bearing.

Vehicles with automatic gearbox:
^ In vehicles with automatic gearbox, no needle bearing must be fitted in the crankshaft. Remove needle bearing if necessary.
^ To secure torque converter on drive plate, only use correct bolts as specified in parts supplier (same as original equipment).
Refer to, Parts Supplier
^ Tighten bolts of torque converter with attachment SW 15 Matra V/175 or equivalent.

Checking position of torque converter
If the torque converter has been correctly installed, the distance between the bottom contact surfaces at the threaded holes in the torque converter and the joint surface on the torque converter bell housing (with automatic gearbox 01V) is approximately 23 mm.
If the torque converter has not been completely inserted, this distance will be approximately 11 mm.

CAUTION! If the torque converter is not installed correctly, the torque converter drive plate or the ATF pump will be seriously damaged when the gearbox is joined to the engine.

All models:
^ Install engine mounts free of stress. Ensure that engine mounts are free of stress by shaking engine to align it before tightening engine mounts.
^ Install A/C compressor and power steering pump.
^ Install ribbed belt.
^ Install lock carrier.

Vehicles with automatic gearbox:
^ Attach ATF lines.

All models:
^ Align exhaust system free of stress, Refer to Exhaust System, Service and Repair.

For electrical connections and routing:
Refer to, Electrical Wiring Diagrams.

CAUTION! Do not use a battery charger for boost starting! There is a danger of damaging the vehicle control modules.

^ After connecting battery, enter anti-theft code for radio.
Refer to, Radio operating instructions
^ Close windows fully using power window switches.
^ Actuate all power window switches again for at least one second in the "close" direction to activate automatic open/close function.
^ Set clock to correct time.
^ Check oil level before starting engine.
^ Top up coolant.

Note:
^ Drained coolant may only be used again if the original cylinder head and cylinder block are re installed.
^ Coolant must not be used again if it is dirty.

^ Perform throttle valve control module adaption:
^ Check Diagnostic Trouble Code (DTC) memory:
Refer to, On Board Diagnostics.

Note: Codes will have been recorded in the DTC memory because the connectors have been unplugged. Therefore check and erase DTC memory after installing engine.

Vehicles with automatic gearbox:
^ Check ATF level:

All models:
^ Adjust headlights.

Tightening torques

Note:
^ The tightening torques listed apply only to lightly greased, oiled, phosphated, or black finished nuts and bolts.
^ Additional lubricant such as engine or gearbox oil may be used, but do not use graphite lubricant.
^ Do not use degreased parts.
^ Tightening torque tolerance 15%.