Engine, Installing
Engine, Installing
• During assembly, replace self-locking nuts and bolts.
• Always replace bolts that are tightened to torque as well as sealing rings, gaskets and O-rings.
• Hose connections and charge air system hoses must be free of oil and grease before installing.
• Secure all hose connections using hose clamps appropriate for the model type.
• During installation, all cable ties must be re-installed at the same location.
Manual Transmission
- When installing a new clutch disc in combination with a used SAC clutch pressure plate (self-adjusting pressure plate), the adjustment ring of the pressure plate must be turned back to impact. Otherwise the pressure plate works with decreased contact pressure (clutch slips).
• If clutch disc is not being replaced, the adjustment ring must not be turned back.
• New SAC-pressure plates are already pre-adjusted and must not be reset.
- Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of Lubricant (G 000 100) on splines. Do not grease the guide sleeve.
- If necessary, check centering of clutch drive plate.
- Check clutch release bearing for wear and replace if necessary.
If plastic ring of clutch release bearing is loose:
- Use Adhesive (AMV 195 KD1 01) to glue plastic ring of clutch release bearing to bearing ring.
• 3 rectangular tabs - arrows - of the plastic ring reach into the cutouts of the bearing ring.
• If grooves with depth of more than 0.5 mm are present, the release bearing must be replaced.
- In manual transmission vehicles, the needle bearing must be installed inside the crankshaft. Install the needle bearing if necessary. Refer to => [ Needle Bearing in Crankshaft ] Needle Bearing in Crankshaft.
Vehicles with Multitronic:
- Clean the transmission input shaft splines and the splines of the damper unit on the flywheel, remove corrosion and apply only a very thin coating of Lubricant (G 000 100) on splines. Remove all excess grease.
Vehicles with automatic transmission 01V:
- Vehicles with the automatic transmission 01V must not have a needle bearing installed in the crankshaft. Remove the needle bearing if necessary. Refer to => [ Needle Bearing in Crankshaft ] Needle Bearing in Crankshaft.
- To secure torque converter to drive plate, use new bolts.
Installation dimension for torque converter, checking:
When the torque converter is inserted correctly, the distance between the lower contact surfaces of the threaded pins on torque converter and the contact surface of the automatic transmission bell housing is approximately 23 mm.
CAUTION!
If torque converter is incorrectly installed, torque converter coupling and ATF pump could be damaged when transmission and engine are flanged together.
All:
- Make sure alignment sleeves for engine to transmission are installed in cylinder block. Install if necessary.
- Make sure that the intermediate plate is hooked in at the sealing flange and is pushed onto the alignment sleeves - arrows -.
- Install intermediate plate between engine and transmission onto alignment sleeves.
- Connect the engine to the transmission and install one bolt by hand.
- Remove Engine Support Bridge (10-222 A) spindle.
- Lower the engine and at the same time guide the threaded studs of the engine mount into the engine mount brackets.
The rest of the installation is in reverse order of removal, note the following:
- Install the engine mount without tension. Shake the engine to align it before tightening the engine mount.
- Install exhaust system and align it free of stress. Refer to => [ Exhaust System, Aligning ] Procedures.
- Install A/C compressor.
- Install power steering pump.
- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Install lock carrier with attachments. Refer to =>
Radiator Support Radiator Support
- Place the torque support stop on the rubber buffer and tighten the nuts - arrows -.
- Install front bumper cover.
- Fasten ATF lines.
- Electrical connections and routing.
- Observe safety precautions after connecting battery.
CAUTION!
Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.
- Check oil level. Refer to => [ Oil Level, Checking ] Testing and Inspection.
- Fill with coolant => [ Filling ] Procedures.
• Only reuse drained coolant if cylinder head or engine block was not replaced.
• Dirty coolant must not be re-used.
- Check the power steering fluid level. Refer to =>
Suspension, Front and All Wheel Drive 48.
- Check ATF level.
- Check headlamp adjustment.
Tightening Specifications
• Tightening specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
• Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not.
• Do not use any degreased parts.
• Tolerance for torque specifications ±15%.
* Replace bolts on vehicles with Multitronic.
* Use Original bolts.