Engine, installing
Installation is performed in reverse sequence. Note the following:
CAUTION:
When performing repair work, especially due to the confined conditions in the engine compartment, pay attention to the following:
- Route all types of lines (e.g. for fuel, hydraulics, EVAP system, coolant, refrigerant, brake fluid and vacuum) as well as electrical wiring so that the original positions are restored.
- Ensure sufficient clearance to all moving or hot components.
- Insert new dowel sleeves in cylinder block for centralizing engine and transmission.
- Install intermediate plate onto sealing flange and slide onto dowel sleeves (arrows).
Vehicles with manual transmission
- Lightly grease input shaft splines with G 000 100 grease.
- Install hydraulic clutch slave cylinder:
Refer to CLUTCH CONTROL, SERVICING
- Check clutch and clutch operating mechanism, then install.
Refer to CLUTCH CONTROL, SERVICING
- Install gear shift mechanism, adjust gear shift cables if necessary:
Refer to GEAR SELECTOR MECHANISM UP TO 05.99, SERVICING or GEAR SELECTOR MECHANISM FROM 05.99, SERVICING
Vehicles with automatic transmission
- Install selector cable on transmission, adjust if necessary:
NOTE:
Always replace selector cable circlip
Vehicles with air conditioning
- Install air conditioner compressor:
Refer to A/C COMPRESSOR AND BRACKET
- Observe additional information and installation instructions. Refer to Additional information and assembly work on models with an air conditioning system .
Continued for all vehicles
- When installing engine/transmission assembly, ensure sufficient clearance to engine and transmission mountings and radiator.
- Align assembly mountings for engine and transmission. Refer to Engine and transmission mountings, aligning .
NOTE:
Assembly mounting tightening torques. Refer to Assembly mounting
.
- Install right axle shaft and attach left axle shaft to transmission:
Refer to FRONT DRIVE SHAFTS, SERVICING
- Install front exhaust pipe. Refer to Exhaust system components, removing and installing , Exhaust system components, removing and installing.
- Install power steering pump:
Refer to POWER STEERING PUMP WITH HYDRAULIC LINES/HOSES, OVERVIEW
- Route wiring harness and connect all electrical connections to engine
Refer to 97 WIRING
- Install poly V-belt. Refer to Poly V-belt, removing and installing .
- Install sound insulation at left and right sides:
- Refill with coolant. Refer to Cooling system, draining and filling .
- Vehicles with secondary air injection pump, install pump with bracket.
- Adapt (match) engine control module to throttle valve control module. Refer to Adapting components and functions , Adapting components and functions.
Vehicles without Electronic Power Control (EPC)
- Adjust throttle cable. Refer to Accelerator mechanism, servicing .
Continued for all vehicles
- Test drive vehicle and check Diagnostic Trouble Code (DTC) memory.
- Generate readiness code again if DTC memory has been erased or engine control module was disconnected from permanent positive. Refer to Adapting components and functions , Adapting components and functions.