Installation Notes

Installation notes
Installation is carried out in the reverse sequence. Also note the following:

CAUTION: When doing any repair work, especially in the engine compartment, due to the cramped conditions, pay attention to the following:
^ Route all sorts of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum lines and hoses, etc.) and electrical wiring so that the original positions are restored.
^ Ensure sufficient clearance to all moving or hot components.

- Check whether dowel sleeves for centering engine/transmission are in cylinder block, install if necessary.





- Install intermediate plate onto sealing flange and slide onto dowel sleeves -arrows-.

Vehicles with manual transmission
- Check centering of clutch drive plate, if necessary.
- 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.

Vehicles with manual transmission 02J
- Install hydraulic clutch slave cylinder:
- Install selector mechanism.
- If necessary, adjust shifter cables:

Vehicles with manual transmission 02M
- Install hydraulic clutch slave cylinder:
- Install selector mechanism.
- If necessary, adjust shifter cables:

Vehicles with automatic transmission
- Only use nuts approved in parts program to secure torque converter to drive plate.
- Install selector cable on transmission, adjust if necessary:
- Adapt control module for automatic transmission:

Continued for all vehicles
- When installing assembly, ensure sufficient clearance to drive shafts.

Vehicles with air conditioner
- Install generator.
- Install compact bracket including tightening element for ribbed V-belt.
- Install A/C compressor.

Continued for all vehicles
- Align engine and transmission mounts.
- Install drive shafts:
- Install right hand inner constant velocity joint protective cover from engine.
- Install front exhaust pipe.
- Install intake hose (between charge air cooler and Throttle Valve Control Module) onto Throttle Valve Control Module -J338- and secure.
- Install power steering pump:
- Check electrical connections and routing:

- Install ribbed belt.





- Install center, left and right insulation trays.
- Install secondary air pump.
- Install connecting hoses between secondary air pump to combination valve and secondary air pump to air cleaner.
- Fill with coolant.
- Perform work sequence "Procedure after correcting voltage supply open circuit".
- Test drive vehicle.

Observe the valid safety precautions when carrying out a road test.
- Check DTC memory and read readiness code:
- Generate readiness code again if DTC memory has been erased or engine control module separated from permanent positive.