Installing

Engine, Installing

Notes: When carrying out repairs, always replace seals and gaskets as well as self-locking nuts and bolts which have a specified tightening angle.

Installation is carried out in the reverse order, when doing this note the following:

- Check whether the dowel sleeves for centering engine/transmission are in the cylinder block, install if necessary.






- Engage intermediate plate on sealing flange, and press onto dowel sleeves (arrows).
- Make sure that clutch plate is properly centered.
- 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.
- Bleed clutch system
- Before securing transmission to engine, insert transmission bracket behind right-hand drive axle flange.





- Slide in small cover plate -2- so that bottom lug on crankcase engages, and secure at the top with bolt -1- (wrench width = 10 mm).






- Align engine mounts so that distance -a-, (measured on right-hand mount) is approx. 13 mm. It should be possible to insert a 12 mm flat iron bar without difficulty (e.g. special tool 2011). To move engine in engine console, bolts -b- on left and right engine supports must be loosened about 2 turns. Refer to adjusting engine mounts Engine Mounts, Adjusting
- Attach selector cables to transmission and adjust.
- Installing power steering vane pump

Vehicles with air conditioner:






- To facilitate installing the air conditioner compressor, knock back threaded bushings -13- for mount bolts -A- slightly in the direction indicated (arrow).

All vehicles:

- Install ribbed belt.
- Install front exhaust pipe.

Note: Avoid excessive bending of the de-coupling element (no more than 10 degrees).

- Stress-free alignment of exhaust system.
- Connect coolant hoses.
- Connect vacuum hoses.
- Fill up with coolant.

Note: Drained-off coolant may only be used again if the original cylinder head and cylinder block are re-installed.
Do not use coolant that is dirty or contaminated.

- Check the oil level before starting engine.
- Electrical connections and routing
- After connecting battery terminals, enter anti-theft code for radio

WARNING! If a battery charger is used to give the engine an assisted start, there is a risk that the control units in the vehicle will be damaged.

- Close electric windows in front doors all the way to their top positions using electric switches.
- Then operate all electric window switches again for at least one second in the "close" direction to activate the automatic one-touch function.
- Set clock to correct time.
- Perform adaption of throttle valve control module

- Interrogate malfunction memory

Note: DTCs will have been stored in the memory because connectors have been disconnected. Therefore interrogate and erase DTC memory after installing engine.

Tightening torques

Note:
The tightening torques apply only to lightly greased, oiled, anodized, or black-finished nuts and bolts.
Additional lubricant such as engine and transmission oil may be used, but do not use molybdenum lubricant.
Do not use degreased parts.
Tolerance for tightening torques is ± 15%.
Tightening torque for screw clamps: 2 Nm






Engine/transmission mounts (manual transmission)

A: centering sleeves