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‒ Insert in the cylinder block new dowel sleeves for centralising engine and gearbox.
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‒ → Fit intermediate plate onto sealing flange and slide onto dowel sleeves -arrows-.
Vehicles with manual gearbox
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‒ Lightly grease input shaft splines with G 000 100.
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‒ Check clutch and clutch operating mechanism, then install:
=> 6-speed manual gearbox 02N; Repair group 30; Servicing clutch control
Continuation for all vehicles
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‒ Screw in all bolts on assembly mountings by hand approx. 5...6 turns.
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‒ Align engine mountings stress-free by rocking.
Note:
Assembly mounting tightening torques
.
Vehicles with manual gearbox
-
‒ Connect pipe/hose on slave cylinder and secure with clip:
=> 6-speed manual gearbox 02N; Repair group 30; Assembly overview - Hydraulics and clutch release mechanism
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‒ Attach operating cable to gearbox, adjust if necessary:
=> 6-speed manual gearbox 02N; Repair group 34; Servicing selector mechanism; Removing and installing operating cables
Vehicles with automatic gearbox
-
‒ Install selector cable on gearbox, adjust if necessary:
=> Automatic gearbox 099; Repair group 37; Servicing selector mechanism
Continuation for all vehicles
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‒ Install front exhaust pipe => Page 26-2, Exhaust manifold, front exhaust pipe and catalyst with attachments.
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‒ Install drive shafts:
=> Running gear, Axles, Steering; Repair group 40; Removing and installing drive shaft
-
‒ Install pendulum support:
=> Running gear, Axles, Steering; Repair group 40; Servicing front wheel suspension; I - Assembly overview, subframe, anti-roll bar, wishbone
-
‒ Installing P.A.S. vane pump:
=> Running gear, Axles, Steering; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes
-
‒ Install ribbed belt => Page 13-11.
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‒ Bolt hydraulic pipe for P.A.S. to right engine bracket
Tightening torque: 20 Nm.
Vehicles with air conditioner
-
‒ Installing air conditioner compressor:
=> Heating, Air conditioning; Repair group 87; removing and installing compressor bracket
Continuation for all vehicles
-
‒ Install battery tray and battery.
-
‒ Install air cleaner with intake hose:
=> Repair group 24; Servicing injection system; Dismantling and assembling air cleaner.
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‒ Electrical connections and routing:
=> Current flow diagrams, Electrical fault finding and Fitting locations
-
‒ Fill with coolant => Page 19-13
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‒ Install noise insulation tray.
-
‒ Carry out a test drive and interrogate fault memory:
=> Repair group 01; Fault memory; Interrogating and erasing fault memory of engine control unit
-
‒ Adapt engine control unit to throttle valve control part and to EGR valve.
=> Repair group 24; Engine control unit; Adapting engine control unit to throttle valve control part and EGR valve
Vehicles with automatic gearbox
-
‒ On vehicles with automatic gearbox the gearbox control unit must be matched additionally:
=> Automatic gearbox 099 self-diagnosis; Repair group 01; Performing self-diagnosis; Initiating basic setting
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