Engine, Installing

Engine, Installing

Installation is performed in the reverse order of removal, noting the following:

CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route lines of all types (e.g. for fuel, hydraulic, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.

• Ensure sufficient clearance to all moving or hot components.

- Insert new centering sleeves for centering engine/transmission in cylinder block.

- Engage intermediate plate at sealing flange and slide onto alignment bushings - arrows -.





With Manual Transmission

- Lightly coat the input shaft splines with grease (G 000 100).

With Automatic Transmission

- Lightly coat the outer splines of the gear shaft with grease (G 000 100).

Continuation for All

- When installing the engine/transmission subassembly, make sure there is sufficient clearance to the other components.

- While doing this, route the power steering pressure line on the transmission.

- Align the powertrain mounts => [ Powertrain Mount, Aligning ] Service and Repair.

- Secure the engine and transmission => [ Powertrain Mount Tightening Specifications ] Powertrain Mount Tightening Specifications.

With Manual Transmission

- Install the hydraulic clutch slave cylinder.

- Install the shift mechanism; if necessary adjust the selector lever cable.

With Automatic Transmission

- Install the selector lever cable.

- Install the subframe.

With Air Conditioning

CAUTION!
The air conditioning refrigerant circuit must not be opened.

• To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.

To facilitate installation of the engine without having to open the refrigerant circuit:

- Remove the A/C compressor from the lock carrier and install the compressor.

- Install the oil dipstick inlet spout.

- Install the generator.

Continuation for All

- Install the right drive axle, and install the left drive axle onto the transmission.

- Install front exhaust pipe => [ Exhaust System Components ] [1][2]Exhaust System Components.

- Install the power steering pump.

- Install ribbed drive belt => [ Ribbed Drive Belt ] Ribbed Drive Belt.

- Fill with coolant => [ Cooling System, Draining and Filling ] Cooling System, Draining and Filling.

- Install the center, left and right noise insulation.

- Install battery.

- Perform vehicle system test using=> Vehicle Diagnosis, Testing and Information System (VAS 5051) "Guided Fault Finding".

- End vehicle system test, this will automatically erase DTC entries which occurred during the assembly.

Observe safety precautions that apply to road tests.

- Perform test drive.

- After that perform vehicle system test anew and repair any occurring malfunctions.