Engine, Installing: Notes
Perform the Following Work
Install in reverse order of removal. Pay attention to the following:
For all repair work, especially in the engine compartment due to the tight working conditions, observe the following:
- Route all lines and wires in their original locations.
- Ensure sufficient clearance to all moving or hot components.
During installation, all cable ties must be installed at the same location.
Secure all hose connections with hose clamps.
Use self-locking nuts.
Replace the bolts, which were tighten with an additional turn.
Always replace gaskets and seals.
Vehicles with a Manual Transmission
-- Check clutch release bearing for wear and replace if necessary.
-- Lightly grease the clutch release bearing, guide sleeve for release bearing and drive axle splines with Grease for Clutch Disc Shaft Splines:G 000 100 .
Continuation for All Vehicles
-- Make sure the alignment bushings for centering the engine/transmission are installed inside the cylinder block. Install them if necessary.
-- Engine the intermediate plate with the sealing flange and then slide it onto the alignment sleeves -arrows-.
-- Make sure there is enough clearance for the drive axle when installing the assembly.
-- Adjust the subframe mount. Refer to SUBFRAME MOUNT, ADJUSTING .
-- Install the pendulum support. Refer to OVERVIEW - SUBFRAME MOUNT .
-- Install the right drive axle and attach the left drive axle to the transmission. Refer to DRIVE AXLE .
-- Install the front exhaust pipe. Refer to OVERVIEW - EMISSIONS CONTROL .
-- Install the A/C compressor. Refer to A/C COMPRESSOR .
-- Install the power steering pump. Refer to POWER STEERING HYDRAULICS .
-- Install the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .
Vehicles with a Manual Transmission
-- Install the gearshift mechanism and adjust if necessary. Refer to SELECTOR MECHANISM .
-- Install the hydraulic clutch slave cylinder. Refer to the appropriate information CLUTCH (02E) , CLUTCH MECHANISM (0AF) , CLUTCH (0CG) , and CLUTCH (02Q, 02QA) .
Vehicles with an Automatic Transmission
-- Install and adjust the selector lever cable. Refer to SELECTOR MECHANISM (09G) .
Continuation for All Vehicles
-- Install the battery. Refer to BATTERY .
-- Install the air filter. Refer to OVERVIEW - AIR FILTER HOUSING .
-- Fuel system, bleeding. Refer to FUEL SYSTEM, FILLING/BLEEDING .
-- Fill with coolant. Refer to COOLANT, DRAINING AND FILLING .
-- Erase the adaptation values and adapt the engine control module to the throttle valve control module see Vehicle Diagnostic Tester "Guided Fault Finding " function.
-- Perform a vehicle system test see Vehicle Diagnostic Tester "Guided Fault Finding " function.
-- End the vehicle system test in such a way that possibly existing DTC entries are automatically erased.
-- Perform a road test.
Follow all safety precautions that apply to road tests. Refer to ROAD TEST WITH TESTING EQUIPMENT SAFETY PRECAUTIONS .
-- Perform the vehicle system test once again.
-- Correct any faults.