Installing

Engine, installing

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

Installation is performed in the reverse order. Note the following:

- Check whether dowel sleeves for centralizing engine/transmission are in 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 engine mounting so that distance -a- (on right side 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 engine within engine console, first loosen bolts -b- on left and right engine supports by about 2 turns each.
- Attach selector cables to transmission and adjust
- Install power steering pump

Installing drive axle

- Insert drive axle.
- Insert outer CV joint as far as possible.
- Lower vehicle making sure wheels do not touch ground.

Note:
Wheel bearings can be damaged.

- Depress brake pedal (second technician needed).
- Tighten 12-point nut.

Note:
Tightening torques for 12-point nuts vary.

Vehicles with air conditioning





- To facilitate installing air conditioning compressor, knock back threaded bushes -13- for mounting bolts -A- slightly in 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 oil level before starting engine.

Electrical connections and routing

- After connecting battery terminals, enter anti-theft code for radio.

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

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

- Check DTC memory.

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