Engine, Installing

Engine, installing

Install in reverse order, paying attention to the following:

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 if necessary.

Vehicles with automatic transmission
- On vehicles with automatic transmission, no needle bearing must be installed in crankshaft.
- 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 the torque converter is incorrectly installed, the torque converter drive or the ATF pump will be severely damaged when the transmission is attached to the 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 conditioning compressor.
- Install ribbed belt.

Vehicles with automatic transmission
- Secure ATF lines:
Stress-free alignment of exhaust system.

Vehicles up to 06.03





- Tighten union nut of fuel supply line -1- to 22 Nm.

Vehicles as of 07.03





- Secure fuel hose to connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head -1- and -3- and tighten union nut -2- to 22 Nm.

All
Electrical connections and routing:

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

See Caution for connecting Telematics battery

- After connecting battery, enter radio anti-theft code
-> 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.

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

- Perform adaptation of throttle valve control module:
- Check Diagnostic Trouble Code (DTC) memory:
-> Guided Fault Finding in VAS 5051

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

Vehicles with automatic transmission
- Check ATF level:

All models
- Adjust headlights: