Installation

1. Remove all traces of old sealant from the flanges, and clean the surfaces with a suitable solvent.





CAUTION: An anaerobic sealant 45-3028972 must be used on the flanges between the timing cover and block. As before, use Permatex Ultra Blue 45-3020856.for the oil pan flanges. Use the sealant sparingly. Excess sealant can get into the oil-ways and do serious damage to the engine.





2. Apply a bead of anaerobic sealant, about 1.mm wide, as shown. Keep the sealant as near to the middle of the flange as possible.





3. Install the timing cover, taking care not to damage the cylinder head gasket.





4. Reinstall the bolts in the correct positions according to their lengths and tighten to 20 Nm (15 ft. lbs.). Remember the two bolts securing the cover to the cylinder head.





5. Apply an even bead of Permatex Ultra Blue along the oil pan flange.





6. Install the rubber seal for the oil strainer in the groove on the oil pan.








7. Install the oil pan, front edge first and then the back. Install the bolts loosely to start with. Tighten the bolts to 20 Nm (15 ft. lbs.), starting with those in the middle of the oil pan.

NOTE: The longer bolt with washer which goes in the middle on the RH side.

8. Install the two rubber plugs in the back of the transmission case and return the edge of the splash plate to its original position.





9. Install the bolt securing the oil pan to the transmission case at the bottom.





10. Plug the connector onto the oil-level sensor.





11. Install the clip for the coolant pipe from the water pump to the timing cover, leaving it slack. Lower the car.
12. Line up and lower the engine onto its mountings. Remove the lifting beam.
13. Install the bolt in the coolant-pipe clip and secure the crankshaft-sensor lead by means of a tie (underneath the inlet manifold). Raise the car.
14. Install the bolts in the engine mountings.





15. Install the front section of the exhaust pipe. Rotate the Lambda sensor five or six turns counterclockwise and then reinstall it.
16. Tighten the bolt in the coolant-pipe clip on the timing cover.





17. Install the top engine mounting and tighten the two bolts in the bottom.





18. Install the crankshaft sensor and tie the lead to the coolant pipe.





19. Install the bracket for the power-steering pump.





NOTE: Insert the top bolt in the alternator before installation.





20. Install the alternator and tighten the securing bolts.








21. Install the steering servo pump.





22. Install the steady bar between the subframe and wheel arch.





23. Install the crankshaft pulley, tightening the bolt to 190 Nm (140 ft. lbs.).





24. Install the idler-wheel pulley and lower the car.





25. Install the bolts in the top of the top engine mounting.
26. Install the torque arm and secure the hoses and wiring to it by means of ties.
27. Remove the locking segment 83 93 993 from the flywheel.





28. Install the top bracket for the belt tensioner.





29. Inspect the O-rings on the water pump and replace if necessary. Lubricate the rings before installing the pump.





30. Install the water pump, ensuring that the pipes are properly inserted in the pump.
31. Connect the hoses to the pump.





32. Install the bracket for the AC compressor.
33. Install the compressor and remove the protective panel from the oil cooler.
34. Plug the connector onto the compressor. Secure the compressor hoses by means of a tie. Raise the rear.





35. Install the belt tensioner and cock it by means of a ratchet handle. Push in the tensioner slowly.





36. Install the drive belt.
37. Install the wing liner and the wheel, tightening the wheel bolts to 130 Nm (96 ft. lbs.).





38. Check that the oil and coolant drain plugs have been replaced tightly.





39. Reconnect the battery.








40. Fill up the engine oil and coolant.
41. Run the engine up to normal temperature. Top up the coolant as necessary and check that the cooling system is working properly and not leaking anywhere.