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 torque.

Installation is carried out in the reverse order.
^ Check whether the dowel sleeves for centralizing engine/gearbox are in the cylinder block and 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.
^ Install slave cylinder for hydraulic clutch release mechanism.





^ Adjust the engine mounting so that distance - a - (on the right-hand mounting) is about 13 mm. It should be possible to insert a 12 mm flat metal bar (e.g. special tool 2011) without any difficulty.
^ To move the engine within the engine console, first loosen bolts - b - on the left and right engine supports by about 2 turns each.
^ Adjusting engine mounting.
^ Attach selector cables to gearbox and adjust.
^ Install power steering pump (vane pump).

Installing drive axle
^ Insert drive axle.
^ Insert outer CV joint as far as possible.
^ Lower vehicle making sure wheels do not touch the ground.
^ Wheel bearings can be damaged.
^ Depress brake pedal (second technician needed).
^ Tighten 12 sided nut to 300 Nm, and loosen by 360° (1 rotation).





^ Tightening torque: 50 Nm + additional 30°

Notes: Special tool 1756 is recommended for tightening 12 sided nut.

^ If special tool 1756 is not available, 30 can be added as follows:





^ Mark 12th side of nut with a line (arrow - A -)
^ Mark second line (arrow - B -) onto edge of wheel hub above next 12th side.
^ The gap between the edges is 30°.
^ Turn 12 sided nut until lines match up.

Vehicles with air conditioner:





^ To facilitate installing the air conditioner compressor, knock back threaded bushes -B - for mounting bolts - A - slightly in the direction indicated (arrow).

All vehicles:
^ Install ribbed belt.
^ Install front exhaust pipe.

Notes: Avoid excessive bending of the de - coupling element (no more than 10°)

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

Notes:
^ 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 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.

^ 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 adaptation of throttle valve control part.
^ Check DTC memory.

Notes: DTCs will be stored in the memory because connectors have been unplugged. Therefore, check and erase DTC memory after installing the engine.

Tightening torques

Notes:
^ The tightening torques listed on this tables apply only to lightly greased, oiled, phosphated, or black - finished nuts and bolts.
^ Additional lubricant such as engine and gearbox oil may be used, but do not use molybdenum lubricant.
^ Do not use degreased parts.
^ Tolerance for tightening torques is ±15%.





Engine/gearbox mountings (manual gearbox)
A: centering sleeves





1) Bolt with M8 stud





1) Stretch bolts - replace
2) 9O° C is a quarter turn