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.
Vehicles with 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 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 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 cutouts of bearing ring.
• If grooves with depth of more than 0.5 mm are present, release bearing must be replaced.
- A pilot needle bearing must be installed in crankshaft in engines for vehicles with manual transmission. Install needle bearing if necessary. Refer to => [ Crankshaft Needle Bearings ] Crankshaft Needle Bearings.
Vehicles with automatic transmission:
- Clean transmission input shaft splines and splines of damper unit on flywheel, remove corrosion and apply only a very thin coating of lubricant (G 000 100) on splines. Remove all excess grease.
All:
- Make sure centering sleeves for engine to transmission are installed in cylinder block. Install if necessary.
- Make sure that the intermediate plate is hooked in at sealing flange and is pushed onto alignment sleeves - arrows -.
- Install intermediate plate between engine and transmission onto alignment sleeves.
- Adjoin engine to transmission and install one bolt hand-tight.
- Lower engine and at the same time guide threaded studs of engine mount into engine mount plates.
• Torque 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%.
Engine/manual transmission, fastening
Engine/multitronic transmission, fastening
All:
The rest of installation is in reverse order of removal, note the following:
- Install exhaust system and align it free of stress. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.
- 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 torque support stop onto rubber buffer for torque support under its own weight and tighten nuts - arrows -.
- Install front bumper cover.
- Fasten ATF lines.
• Automatic transmission 09L. Refer to => Automatic Transmission/Transaxle Automatic Transmission/Transaxle
• Continuously variable transmission 01J. Refer to =>
Automatic Transmission/Transaxle Automatic Transmission/Transaxle
- 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.
- Fill with coolant. Refer to => [ Cooling System, Draining and Filling ] Procedures.
• Only reuse drained coolant if cylinder head or engine block was not replaced.
• Dirty coolant must not be re-used.
- Check power steering fluid level.
- Check ATF level.
• Automatic transmission 09L. Refer to => Automatic Transmission/Transaxle Automatic Transmission/Transaxle
• Continuously variable transmission 01J. Refer to =>
Automatic Transmission/Transaxle Automatic Transmission/Transaxle
- Check headlight adjustment.
Tightening Specifications
• Torque 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%.
