Engine, Installing: Procedure

WARNING: This page is about a different variant/trim than selected.

NOTE:

Replace the bolts that were tightened with an additional turn after removing them.

Replace the self-locking nuts and bolts, gaskets, seals and O-rings after removing.

The hose connections as well as air duct pipes and hoses must be free of oil and grease before installing.

Secure all hose connections with standard production hose clamps.

During installation, all cable ties must be installed at the same location.

-- Install the intermediate plate. Refer to the figure below;

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-- If the alignment sleeves -A- for centering the engine and transmission are missing inside the cylinder block, then install the alignment sleeves.

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NOTE:

The illustration shows a vehicle with a manual transmission.

-- If a needle bearing is installed in the crankshaft, remove the needle bearing. Refer to CRANKSHAFT NEEDLE BEARING, REPLACING .

-- If the clutch release mechanism is worn, replace it. Refer to CLUTCH MECHANISM (0AF) , CLUTCH MECHANISM (0CG) and CLUTCH MECHANISM (02Q, 02QA) and CLUTCH (02E) .

-- Lightly lubricate the transmission input shaft splines with grease for clutch plate shaft splines.

-- Check the clutch plate alignment.

-- Tighten the transmission to the engine.

-- Install the transmission support.

-- Lift the engine/transmission assembly using the :T10497A .

-- Guide the engine/transmission assembly into the body.

-- Remove the bolts -arrows- for the engine mount -1- completely.

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Vehicles With Three Transmission Bolted Connections

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-- Completely remove the transmission mount bolts -arrows- completely.

Vehicles With Two Transmission Bolted Connections

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-- Completely remove the transmission mount bolts -arrows- completely.

NOTE:

The bolts are only tightened to the final tightening specification after the subframe mounts have been adjusted. Refer to ASSEMBLY MOUNT, ADJUSTING .

-- Remove the :T10497A from the engine.

-- Install the starter. Refer to STARTER .

-- Install the Charge Air Cooling Pump - V188-. Refer to Charge Air Cooling Pump -V188-, REMOVING AND INSTALLING, VERSION 1 AND 2 .

-- Install the air duct pipe. Refer to OVERVIEW - CHARGE AIR SYSTEM .

-- Install the intake tube. Refer to OVERVIEW - TURBOCHARGER .

-- Install the front exhaust pipe. Refer to FRONT EXHAUST PIPE, REMOVING AND INSTALLING .

-- Install the drive axles. Refer to DRIVE AXLE .

-- Install the A/C compressor. Refer to A/C COMPRESSOR .

-- Install the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Install the engine control module. Refer to ENGINE CONTROL MODULE .

-- Install the right drive axle heat shield. Refer to DRIVE AXLE .

-- Install the subframe. Refer to SUBFRAME .

-- Install the Differential Pressure Sensor - G505-. Refer to Differential Pressure Sensor -G505-, REMOVING AND INSTALLING .

-- Install the selector mechanism on the transmission. Refer to SELECTOR MECHANISM (02E) , SELECTOR MECHANISM (02Q, 02QA) , SELECTOR MECHANISM (0CG) and SELECTOR MECHANISM (0AF) .

-- Connect the clutch slave cylinder. Refer to CLUTCH MECHANISM (0AF) , CLUTCH MECHANISM (0CG) and CLUTCH MECHANISM (02Q, 02QA) and CLUTCH (02E) .

-- Bleed the clutch hydraulic. Refer to CLUTCH MECHANISM (0AF) , CLUTCH MECHANISM (0CG) and CLUTCH MECHANISM (02Q, 02QA) and CLUTCH (02E) .

-- Adjust the assembly mount. Refer to ASSEMBLY MOUNT, ADJUSTING .

-- Install the battery tray. Refer to BATTERY .

-- Wire routing. Refer to RELAY CARRIERS, FUSE PANELS AND E-BOXES . and the Appropriate Wiring Diagram.

-- Connect the vacuum hoses. Refer to CONNECTION DIAGRAM - VACUUM SYSTEM .

-- Install the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Install the fuel filter. Refer to FUEL FILTER .

-- Install the noise insulation. Refer to NOISE INSULATION .

-- Remove the front right and left wheel housing liners. Refer to WHEEL HOUSING LINER .

-- Install the front wheels. Refer to WHEEL, CHANGING or WHEELS AND TIRES .

-- Check the oil level..

CAUTION:

There is a risk of destroying the control modules due to excessive voltage.

Do not use a charger to jump start.

-- Bleed the fuel system. Refer to FUEL SYSTEM, FILLING/BLEEDING .

-- Attach the coolant hoses with the connector coupling to the heater core for the heater. Refer to the figure below;

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-- Fill with coolant. Refer to COOLANT, FILLING .

NOTE:

Used coolant cannot be used again.