Engine, Installing
Engine, installing
Note:
^ During assembly, replace self-locking nuts and bolts.
^ Always replace bolts that are tightened to torque as well as sealing rings, gaskets and O-rings.
^ Hose unions and hoses for charge air system must be free of oil and grease before installing.
^ Secure all hose connections using hose clamps appropriate for the model type.
^ During installation, all cable ties must be re-installed at the same location.
Vehicles with manual transmission:
- When installing a new clutch disc in combination with a used SAC clutch pressure plate (self-adjusting pressure plate), the adjustment ring of the pressure plate must be turned back to impact. Otherwise the pressure plate works with decreased contact pressure (clutch slips).
Note:
^ If clutch disc is not being replaced, the adjustment ring must not be turned back.
^ New SAC-pressure plates are already pre-adjusted and must not be reset.
- Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Do not grease guide sleeve.
- If necessary, check centering of clutch drive plate.
- Check clutch release bearing for wear and replace if necessary.
If plastic ring of clutch release bearing is loose:
- Use adhesive AMV 195 KD1 01 to glue plastic ring of clutch release bearing to bearing ring.
^ 3 rectangular tabs - arrows - of the plastic ring reach into cutouts of bearing ring.
^ If grooves with depth of more than 0.5 mm are present, the release bearing must be replaced.
- A pilot needle bearing must be installed in crankshaft in engines for vehicles with manual transmission. Install needle bearing if necessary Needle bearings from crankshaft, pulling out and driving in.
Vehicles with automatic transmission:
- Clean transmission input shaft splines and splines of the damper unit on flywheel, remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Remove all excess grease.
All:
- Make sure centering sleeves for engine to transmission are installed in cylinder block. Install if necessary.
- Make sure that the intermediate plate is hooked in at sealing flange and is pushed onto alignment sleeves - arrows -.
- Install intermediate plate between engine and transmission onto alignment sleeves.
- Adjoin engine to transmission and screw in one bolt hand-tight.
- Lower engine and at the same time guide threaded studs of engine mount into engine mount consoles.
Note:
^ Torque 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 degreased parts.
^ Tolerance for torque specifications ± 15%.
Engine/manual transmission, fastening
Engine/multitronic transmission, fastening
All:
The rest of installation is in reverse order of removal, note the following:
- Install exhaust system and align it free of stress.
- Install A/C compressor.
- Install power steering pump.
- Install ribbed belt.
- Install lock carrier with attachments.
- Place torque support stop onto rubber buffer for torque support under its own weight and tighten the nuts - arrows -.
- Install front bumper cover.
- Fasten ATF lines.
- Electrical connections and routing.
- Observe safety precautions after connecting battery.
CAUTION: Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.
- Check oil level Maintenance.
- Fill with coolant.
Note:
^ Only reuse drained coolant if cylinder head or engine block was not replaced.
^ Dirty coolant must not be re-used.
- Check power steering fluid level.
- Check ATF level.
- Check headlight adjustment.
Torque specifications
Note:
^ Torque 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 degreased parts.
^ Tolerance for torque specifications ± 15%.
