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Assembly mountings > < Securing engine to assembly stand

A2

Installing engine
Installing engine
Installation is carried out in the reverse order; note the following:
  Note
t  Renew self-locking nuts and bolts when performing assembly work.
t  Renew bolts which are tightened to a specified angle as well as oil seals and gaskets.
t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. Do not use lubricant.
t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue.
t  Fit all cable ties in the original positions when installing.
–  Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splines -G 000 100- to the splines. Do not lubricate guide sleeve.
–  Check that the clutch plate is properly centralised (only necessary if you have carried out other work on the clutch).
–  Check clutch release bearing for wear; renew if necessary.
–  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install dowel sleeves if necessary.
   
–  Fit intermediate plate onto dowel sleeves -arrows-.
–  When swivelling engine/gearbox assembly in place, ensure sufficient clearance from gear actuator and starter catalytic converter.
–  Install support arm with engine mounting → Chapter.
–  Install gearbox mounting → Rep. Gr.34.
–  Install motor/pump unit → Rep. Gr.48.
–  Install pendulum support → Chapter.
–  Install starter catalytic converter together with main catalytic converter → Chapter.
–  Install clutch slave cylinder → Rep. Gr.30.
–  Install gear actuator → Rep. Gr.34.
–  Install drive shafts → Rep. Gr.40.
–  Install coupling rod for anti-roll bar → Rep. Gr.40.
–  Install swivel joints → Rep. Gr.40.
–  Fit bumper → Rep. Gr.63.
–  Install wheel housing liners → Rep. Gr.66.
–  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations.
–  Observe notes on procedures required after connecting battery → Rep. Gr.27.
  Caution
Do not use a battery charger to boost starting. There is danger of damaging the vehicle's control units.
–  Install and adjust wiper arms → Rep. Gr.92.
–  Check oil level → Chapter.
–  Fill cooling system → Chapter.
–  Perform basic setting of manual gearbox → Rep. Gr.01.
Tightening torques
  Note
t  Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts.
t  Additional lubricant such as engine oil or gearbox oil may be used, but do not use lubricant containing graphite.
t  Do not use degreased parts.
t  Tolerance for tightening torques ± 15 %.
  A10-0129
Securing engine to gearbox
  N34-1161
ItemBoltNm
1, 2M12x6080
3M12x8080
4M10x5045
5M12x18080
A, BDowel sleeves for centralising

   
ComponentNm
Bolts/nutsM69
 M820
 M1040
 M1265
Except for the following: 
Drive shaft heat shield to gearbox23
Air pipe8

   

Assembly mountings > < Securing engine to assembly stand