Installing engine

Install in reverse order of removal. The following should be observed:

• Attach engine/gearbox assembly to engine support T10497.

When the gearbox has been separated from the engine:

• Install intermediate plate ⇒ 2.1 Assembly overview - cylinder block, gearbox end.

• If there are no dowel sleeves -A- in the cylinder block for centring the engine and gearbox, insert new dowel sleeves.
• Bolt gearbox to engine at positions -1, 2, 3, 6, 7, 8, 9-.
• Install starter ⇒ Electrical system; Rep. gr. 27; Starter; Removing and installing starter.

Installing engine/gearbox assembly in vehicle:

• Take up engine/gearbox assembly with engine support T10497.
• Guide engine/gearbox assembly into body.
• Install engine mounting ⇒ 2.2 Removing and installing engine mounting.
• Install gearbox mounting ⇒ 2.3 Removing and installing gearbox mounting.
• Detach engine support T10497 from engine.
• Install pendulum support ⇒ 2.4 Removing and installing pendulum support.

Vehicles with manual gearbox

• Install clutch slave cylinder ⇒ Rep. gr. 30; Clutch mechanism; Removing and installing clutch slave cylinder.
• Install cables with cable support bracket ⇒ Rep. gr. 34; Selector mechanism; Assembly overview - selector cables.

Continued for all vehicles

• Install air conditioner compressor ⇒ Heating, air conditioning; Rep. gr. 87; Air conditioner compressor; Removing and installing air conditioner compressor.
• Install poly V-belt ⇒ 1.3 Removing and installing poly-V belt.
• Connect wires to engine control unit - J623- ⇒ 6 Engine control unit.
• Connect wires to alternator ⇒ Electrical system; Rep. gr. 27; Alternator; Assembly overview - alternator.
• Ensure proper electrical connections and routing ⇒ Electrical system; Rep. gr. 97; Relay carriers, fuse carriers, electronics boxes; Overview of fitting locations – relay carriers, fuse carriers, electronics boxes and ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
• Install catalytic converter ⇒ 2.2 Removing and installing catalytic converter.
• Install drive shafts ⇒ Running gear, axles, steering; Rep. gr. 40; Drive shaft; Removing and installing drive shaft.
• Install coolant expansion tank ⇒ 4 Radiator, radiator fan.
• Install radiator cowl ⇒ 4.5 Removing and installing radiator cowl with radiator fan.
• Install air filter housing ⇒ 3.2 Removing and installing air filter housing.
• Install battery and battery tray ⇒ Electrical system; Rep. gr. 27; Battery; Removing and installing battery tray.

• Install wheel housing liners ⇒ General body repairs, exterior; Rep. gr. 66; Wheel housing liner.
• Install noise insulation ⇒ General body repairs, exterior; Rep. gr. 66; Noise insulation.
• Install front wheels ⇒ Running gear, axles, steering; Rep. gr. 44; Wheels, tyres; Specified torque for wheel bolts.
• Add coolant ⇒ 1.3 Draining and adding coolant.

Torque settings