Engine, Installing: Procedure

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

Secure the engine/transmission assembly to the Engine Support :T10497 .

-- Replace the bolts that were tightened with an additional turn.

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

-- Secure all 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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-- Tighten the transmission to the engine at positions -1, 2, 3, 6, 7, 8, 9-.

-- Install the transmission support.

-- Lift the engine/transmission assembly using the :T10497 .

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

-- First install the bolts -1- for the engine mount -2- all the way by hand.

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-- Then install the bolts -2- for the transmission mount all the way by hand.

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NOTE:

The bolts are only tightened to the final tightening specification after the subframe mounts have been adjusted.

-- Remove the :T10497 from the engine.

-- Install the starter. Refer to STARTER .

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

-- Install the air ducts. Refer to the figure below;.

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Vehicles With Manual Transmission

-- Install the clutch slave cylinder. Refer to CLUTCH MECHANISM (0AF) , CLUTCH MECHANISM (oCG) and CLUTCH MECHANISM (02Q, 02QA) .

-- Install the cables with the cable bracket. Refer to SELECTOR MECHANISM (02Q, 02QA) , SELECTOR MECHANISM (0CG) and SELECTOR MECHANISM (0AF) .

Vehicles With Automatic Transmission

-- Install the selector lever cable, connect the Mechatronic connector and attach all brackets to the transmission. Refer to TRANSMISSION, REMOVING AND INSTALLING (02Q, 02QA) , TRANSMISSION, REMOVING AND INSTALLING (0CG) or TRANSMISSION, REMOVING AND INSTALLING (0AF) .

Continuation For All Vehicles

-- Install the catalytic converter.

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

-- Install the transverse link, ball joint and coupling rod. Refer to LOWER CONTROL ARM AND BALL JOINT .

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

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

-- Reconnect the connections and route the wires. Refer to RELAY CARRIERS, FUSE PANELS AND E-BOXES and the Appropriate Wiring Diagram.

-- Install the Engine Control Module -J623-. Refer to ENGINE CONTROL MODULE .

-- Connect the coolant hoses with the connector coupling. Refer to the figure below;

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-- Install the pendulum support. Refer to PENDULUM SUPPORT, REMOVING AND INSTALLING .

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

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

-- Adjust the subframe mount. Refer to SUBFRAME MOUNT, ADJUSTING .

-- Install the battery tray. Refer to BATTERY .

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

NOTE:

Do not use a charger to jump start.

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

The drained coolant may be used again only if the cylinder head or the cylinder block were not replaced.

Do not use dirty coolant again.

The tightening specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.

Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not.

Do not use any ungreased parts.

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

-- Connect the Vehicle Diagnostic Tester.

-- After replacing the engine an adaptation of the combustion misfire must be performed. To do so select the function 01 - Reset Combustion Misfire Adaptation in Guided Functions .