Installing engine

⇒ 1.3.1 Notes on installing

⇒ 1.3.2 Additional information and assembly work for vehicles with air conditioner

1.3.1 Notes on installing

Install in reverse order of removal. During this procedure, observe the following:

Repairing the clutch:

• Vehicles with manual gearbox ⇒ Manual gearbox; Rep. gr. 34.

• Check clutch release bearing for wear and renew if necessary.
• Lightly grease clutch release bearing, release bearing guide and splines on input shaft with G 000 100.
• Check whether dowel sleeves for centring engine/gearbox have been fitted in cylinder block, insert if necessary.

• Secure release lever using a suitable bolt -2- -arrow-.
• When swinging engine/gearbox assembly in, ensure that there is clearance between drive shafts.
• Bolt gearbox flange to cylinder block.
• Release again clutch release lever, remove previously fitted bolt.
• Fit genuine bolt again.

Gearbox specified torques: ⇒ Manual gearbox; Rep. gr. 34; Removing and installing gearbox.

Specified torque for starter: ⇒ Electrical system; Rep. gr. 27.

• Rock engine to align engine mountings stress-free.
• When installing »engine«, ensure that there is sufficient clearance to subframe.
• Adjusting assembly mountings ⇒ 2 Assembly mountings.

Vehicles with air conditioning system

• Install air conditioning system compressor ⇒ Heating, air conditioning system; Rep. gr. 87.

Continued for all vehicles

• Electrical connections and routing: ⇒ Electrical system; Rep. gr. 97.
• Install poly V-belt ⇒ 13 – Crankshaft group.
• Add coolant ⇒ 1.3.1 Draining.
• Connect vehicle diagnostic tester.

For example ⇒ Vehicle diagnostic tester

• Erase learnt values and adapt engine control unit - J623- to throttle valve module ⇒ Vehicle diagnostic tester “Guided functions”.

Observe sequence when installing particulate filter.

• Secure particulate filter ⇒ 2.1.2 Assembly overview - particulate filter (RHD).

• Install heat shield for drive shaft (right side) -1-.

  Specified torque ⇒ Manual gearbox; Rep. gr. 34

• Secure refrigerant lines free of stress to air conditioner compressor and to condenser ⇒ Heating, air conditioning; Rep. gr. 87.
• Charge air conditioner ⇒ Heating, air conditioning; Rep. gr. 87.
• Install battery and battery tray ⇒ Electrical system; Rep. gr. 27; Removing and installing battery.
• Observe notes after connecting battery ⇒ Electrical system; Rep. gr. 27; Disconnecting and reconnecting battery.
• Fill fuel system ⇒ 1.3 Filling/bleeding fuel system.
• Carry out a vehicle system test ⇒ Vehicle diagnostic tester “Guided Fault Finding”.
• Finish the vehicle system test so that any event entries stored during assembly can be erased automatically.

Note safety precautions applicable to a road test.

• Carry out road test.
• Then carry out vehicle system test again, rectify any faults which may have occurred.

Specified torques

1) Specified torque for M12 flange bolts: 75 Nm

1.3.2 Additional information and assembly work for vehicles with air conditioner

• Extract refrigerant from air conditioner refrigerant circuit. Open air conditioner refrigerant circuit ⇒ Rep. gr. 87.