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Assembly mountings > < Securing engine to engine and gearbox support

A2

Installing engine
Installing engine
Tightening torques
  Note
t  Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts.
t  Additional lubricants such as engine or gearbox oil may be used, but do not use lubricants containing graphite.
t  Do not use degreased parts.
t  Tolerance for tightening torques: ± 15 %.
Tightening torques → Chapter
Further tightening torques
   
ComponentNm
Bolts/nutsM610
 M715
 M822
 M1040
 M1265

   
Securing gearbox to engine
  A34-0319
ItemBoltNm
1, 3M12x6580
2 1)M12x13580
4M10x5040
5M12x8080
ADowel sleeves for centralising
l  1) Also for starter to gearbox

Procedure
Installation is carried out in the reverse order; note the following:
l  Engine attached to engine support -T40075-
  Note
t  Renew self-locking nuts and bolts.
t  Renew bolts which are tightened to a specified angle as well as oil seals and gaskets.
t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue.
t  Fit cable ties in the original positions when installing.
–  If not already fitted, install dowel sleeves for centring engine and gearbox in cylinder block.
   
–  Ensure that intermediate plate is engaged on sealing flange -arrow A- and pushed onto dowel sleeves -arrows B-.
–  Clean the input shaft splines and the hub splines. Remove corrosion and apply only a very thin coating of grease -G 000 100- to the splines. Remove any excess grease.
–  Check clutch release bearing for wear; renew if necessary → Rep. gr.30.
–  Check oil seal for flange shaft (right-side) for leaks; renew if necessary → Rep. gr.39.
–  Secure gearbox to engine.
–  Install flange shaft (right-side) → Rep. gr.39.
–  Install starter → Rep. gr.27
–  Install bracket for exhaust manifold → Chapter.
–  Make sure there is sufficient clearance for gear selector cables and engine wiring harness when lifting engine/gearbox assembly.
–  Guide engine/gearbox assembly into body.
–  Install gearbox mounting → Rep. gr.34.
–  Install engine mountings → Chapter.
–  Remove engine support -T40075- from engine.
–  Install pressure control valve for crankcase breather system → Fig..
–  Install pendulum support → Chapter.
–  Install drive shafts and swivel joints → Rep. gr.40.
–  Install heat shield for drive shaft → Rep. gr.39.
–  Install air conditioner compressor → Rep. gr.87.
–  Install poly V-belt → Chapter.
–  Install front exhaust pipe with catalytic converter and centre silencer → Chapter.
–  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations.
  Caution
Avoid damage to clutch slave cylinder.
Do not operate clutch pedal with slave cylinder removed.
–  Install clutch slave cylinder → Rep. gr.30.
–  Install and adjust gear selector cable and gate selector cable → Rep. gr.34.
–  Install radiator fan → Chapter.
–  Install connection with guide tube for oil dipstick and oil filler pipe → Fig..
–  Observe notes on procedure for connecting the battery → Rep. gr.27.
–  Check engine oil level → Booklet809.
  Caution
Risk of irreparable damage to control units because of excessive voltage.
Never use battery charging equipment for boost starting.
–  Fill up with coolant → Anchor.
  Note
t  Do not use drained coolant again if:
t  the cylinder head or cylinder block have been renewed.
t  The coolant is contaminated or dirty.
  A13-10521

Assembly mountings > < Securing engine to engine and gearbox support