Engine, Installing

Special tools and workshop equipment required 

• All special tools listed within Engine, Removing. Refer to ENGINE, REMOVING .

Procedure 

• Replace the bolts that were tightened with an additional turn after removing them.
• Replace the self-locking nuts and bolts, gaskets, seals and O-rings after removing.
• A needle bearing must be installed in the drive plate on vehicles with a manual transmission. Refer to NEEDLE BEARING IN DRIVE PLATE, REPLACING .
• Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts Information.
• During installation, all cable ties must be installed at the same location.
• Used coolant cannot be used again.

-- Install the engine on the transmission but do not tighten the bolts that connect the transmission to the engine yet. Refer to the appropriate Service Information .

TIP:

The bolt -2- attaches the starter to the transmission and has an additional spacer sleeve -arrow-.

• The spacer sleeve must be inserted between the starter and the transmission.

-- Install the starter. Refer to STARTER, REMOVING AND INSTALLING .

-- Release the tension on the : 10-222A/11  .

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-- Lower the workshop crane and mount the engine and transmission onto the engine mount.

-- Remove the left and right bolts -2- from the engine mount.

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-- Remove the : VAS6100  and : 2024A  .

-- Tighten the bolts that connect the transmission to the engine. Refer to the appropriate Service Information .

Further installation is performed in reverse order of removal, while noting the following:

-- Connect the fuel hose. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Install the Heated Oxygen Sensor -G39-. Refer to HEATED OXYGEN SENSOR, REMOVING AND INSTALLING .

-- Tighten the drive axle. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Install the drive axle heat shield. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

-- Install the A/C compressor. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING FROM BRACKET .

-- Install the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Install the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- For the electrical connections and routing, refer to the appropriate Wiring Diagram.

-- Install the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Install the exhaust system without tension. Refer to EXHAUST SYSTEM, INSTALLING WITHOUT TENSION .

-- Install the bracket and the heat shield on the cylinder head. Refer to Fig 3Fig 2.