Installing engine

Install in the reverse order of removal, observing the following:

Vehicles with manual gearbox

• Check clutch release bearing for wear and renew if necessary.
• Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000 100.

Vehicles with automatic gearbox

• Only use nuts approved in parts programme to secure torque converter to drive plate.

• Check whether dowel sleeves for aligning engine and gearbox are fitted in cylinder block and install if necessary.

• Hook intermediate plate onto sealing flange and slide onto dowel sleeves -arrows-.
• When swinging engine in, ensure that there is clearance between drive shafts.
• Rock engine to align engine mountings stress-free.

• Install drive shafts ⇒ Running gear, axles, steering; Rep. gr. 40; Repairing drive shafts; Removing and installing drive shafts.

Vehicles with air conditioning system

• Install A/C compressor.
• Install poly V-belt ⇒ 1.4 Removing and installing poly-V belt.

• Electrical connections and routing: ⇒ Electrical system; Rep. gr. 97.

Vehicles with manual gearbox

• Install hydraulic clutch slave cylinder ⇒ 5-speed manual gearbox 02T; Rep. gr. 30; Repairing clutch control.
• Install selector mechanism ⇒ 5-speed manual gearbox 02T; Rep. gr. 34; Repairing selector mechanism.
• Install engine splash protection.

Vehicles with automatic gearbox

• Reconnect selector lever cable to gearbox and adjust if necessary: ⇒ Automatic gearbox 001; Rep. gr. 37; Repairing selector mechanism; Dismantling and assembling selector mechanism.

• Add coolant ⇒ 1.6 Draining and adding coolant.
• Install air filter housing ⇒ 1.8 Removing and installing air filter housing.
• Connect Vehicle diagnosis, testing and information system - VAS 5051-.
• Clear learnt values and adapt engine control unit to throttle valve module and exhaust gas recirculation valve - N18- ⇒ Vehicle diagnostic tester “Guided function”.
• Carry out vehicle system test ⇒ Vehicle diagnostic tester “Guided fault finding”.
• Finish the vehicle system test so that any fault entries stored during assembly can be deleted automatically.
• The readiness code must be generated if the fault memory has been erased.

Observe applicable safety precautions during road test.

• Perform road test.

• Read control unit fault memory again.