Engine, Installing

Engine, installing
Install in reverse order:

Note: When performing repairs, replace seals, gaskets, self-locking nuts and bolts which have a specified tightening angle.

^ Check whether dowel sleeves for centering engine/transmission in cylinder block have been installed and install if necessary.
^ Push intermediate plate onto dowel sleeves.

Vehicles with manual transmission:
^ Check clutch release bearing for wear and replace if necessary.
^ Lightly grease splines on transmission 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 transmission. Install needle bearing.

Vehicles with automatic transmission:
^ On vehicles with automatic transmission, no needle bearing must be installed in crankshaft. Remove needle bearing if necessary.
^ To secure torque converter on drive plate, only use correct bolts:
^ Tighten torque converter bolts with Matra V175 15 mm A/F socket attachment.





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

CAUTION: If torque converter is incorrectly installed, the torque converter drive or the ATF pump will be severely damaged when transmission is attached to engine.

All models:
^ Ensure that engine mounts are installed free of mechanical stress. To do so, shake engine to align it before tightening engine mounts.
^ Install air conditioner compressor.
^ Install ribbed belt.

Vehicles with automatic transmission:
^ Secure ATF lines:
^ Stress-free alignment of exhaust system, Refer to Exhaust System, Adjustments
^ Electrical connections and routing:
^ Electrical Wiring Diagrams, Troubleshooting & Component Locations

CAUTION: Boost-starting using battery charger may damage vehicle control modules.

^ See Caution for connecting Telematics battery.
^ After connecting battery, enter radio anti-theft code
Refer to Radio operating instructions.
^ Use electric window lifters to completely close door windows.
^ Then actuate all window lifter switches again for at least 1 second in "close" position to activate automatic one-touch function.
^ Set clock to correct time.
^ Check oil level before starting engine.
^ Fill cooling system.

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

^ Perform adaption of throttle valve control part:
^ Check Diagnostic Trouble Code (DTC) memory:
^ Guided fault finding in VAS 5051

Note: Diagnostic Trouble Codes (DTCs) will have been recorded in malfunction memory because connectors have been unplugged. Interrogate and if necessary erase malfunction memory after installation.

Vehicles with automatic transmission:
^ Check ATF level:
All models:
^ Adjust headlights: