Installation

Installation





Assembly Note for Removing / Installing Engine:

When removing and installing the engine and transmission assy., it is recommended to allow a constant clearance of 60 cm between drive shaft and shop floor. Have the height of the lifting platform adjusted accordingly by a helper.


NOTE: Observe the following aspects during installation:

1. Replace all fastening nuts.
2. Install engine/transmission unit.





3. Fit toe control arms (2) to cross member.

NOTE:
- Before fitting toe control arms (2) to the cross member, check weight and quality category of the toe eccentrics.
- Required bolt grade is 10.9 (always replace initial version, was grade 8.8 see parts supplier).
- The quality category is indicated on the screw head.
- Replace eccentric, if required (e.g. if thread not o.k. or if quality category 8.8)
- In this case, transfer the position marks to the new eccentrics.

IMPORTANT: To tighten the eccentric (A area), proceed as follows.

4. Tighten the toe eccentric (A area) in zero position.
Tightening torque: 100 Nm (74 ft lb).
Zero position: Toe control arm (2) and rear cross member form a horizontal line.
To obtain this zero position, lift wheel carrier using all-purpose jack.

NOTE: The toe eccentrics can also be tightened after the vehicle has been put on its wheels and has been rocked back and forth approx. 25 mm.

5. Check whether all plugs have been removed completely from the oil hoses and oil pipes and especially from the bends of the hoses and pipes.
6. Tighten the fastening screw of the gearshift rod coupling.
- Tightening torque 23 Nm (17 ft lb).





7. Fit accelerator cable from below.
Make sure the rubber sleeve fits properly.
8. Put the engine compartment rubber seal between body and engine paneling in place correctly before installing the engine/transmission unit in its final position.
9. Make sure the inner rubber seals of the connectors fit correctly.

1 = Lid Left 2 = Lid Right a = 5 mm Dimension - Installation Area:

10. Fit lid of assembly bores of engine suspension:
- Put the metal lid in place from below.
- The holding brackets on the lids must face upwards into the engine compartment.
- As shown in the figure, the holding brackets must be positioned at a right angle to the direction of travel in the "a" area.
- Only in this area is a tight fit ensured.





11. Fit the fuel supply line.
Before final tightening rotate the line until the distance to the edge of the group connector bracket is at least 10 mm without the line touching the pressure hose.
12. Tighten union nut (using torque wrench with open-ended wrench socket, A/F 19); while doing so, lock the fuel collection pipe using an open-ended wrench, A/F 17.
Make sure the line does not get twisted.
Tightening torque 35 Nm (26 ft lb).