Engine, Installing

Engine, installing

WARNING:
^ Do not re-use any fasteners that are worn or deformed in normal use.
^ Some fasteners are designed to be used only once, and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.

Engine is installed in reverse order of removal, noting the following:
- Make sure centering sleeves for engine to transmission are correctly installed in cylinder block. Install or replace if necessary.

Vehicles with manual transmission
- Lubricate splines on transmission input shaft lightly using thin coating of G 000 100. Do not lubricate guide sleeve for release bearing.
- Make sure clutch disc is properly centered.
- A pilot needle bearing must be installed in the crankshaft in engines for vehicles with manual transmission. Install if necessary. Refer to Dual-mass flywheel pilot needle bearing, removing and installing.

Vehicles with automatic transmission

CAUTION: DO NOT install a pilot needle bearing; remove if necessary.

- Use original bolts when securing torque converter to clutch disc.
- Before installing torque converter or clutch disc, turn the engine such that a bore or thread is aligned with the starter installation opening.
- Check ATF level.

Installation dimension for torque converter




When torque converter is installed correctly, the distance between contact surfaces at the mounting holes on the torque converter and contact surface of the bellhousing flange (transmission 01V) will be approximately 23 mm (29/32 inch).
If the torque converter is not installed correctly, this distance will be approximately 11 mm (14/16 inch).

CAUTION: If the torque converter is not installed correctly, the torque converter, driveplate or the ATF pump will be seriously damaged when the transmission is attached to the engine.

All models
- Install ribbed belt. Service and Repair
- Fill up cooling system with engine coolant. Service and Repair

CAUTION:
^ Only re-use engine coolant if you use the original cylinder head and cylinder block again.
^ Do not re-use dirty coolant.

Note: All hose connections are secured with clips.

- Install engine mounts without tension or preload. Align engine with rocking motion before tightening engine mounts.
- Install lock carrier with attachments. [1][2]Procedures
- Adjust accelerator pedal cable.
- Align exhaust system free of stress.
- Attach vacuum lines.
- Only remove and install spark plugs using 3122B spark plug removal tool.

For harness connectors and routing:
Refer to Diagrams/Diagnostic Aids.
- After connecting battery, enter anti-theft code for radio.
Refer to Radio Operating.
- Fully close power windows to stop.
- Operate all power window switches again for at least one second in "close" direction to activate "one-touch" opening/closing function.
- Set clock to correct time.
- Check engine oil level before starting engine.