Installing Engine

Removing and installing engine as from MY 02 (Manual transmission)

Caution!
^ Pentosin is hazardous to the health!
^ Wear protective gloves and goggles. If the eyes or skin come into contact with the fluid, wash immediately with water!
^ Collect emerging Pentosin!
^ Protect the leads against soiling and damage with caps!
^ Clean hoses which come into contact with Pentosin thoroughly!
Caution! Coolant is hazardous to the health and irritates the skin!
^ When handling coolant, wear protective gloves and goggles!
^ In case of contact with the skin or eyes, wash immediately with plenty of water!


Installing engine

Note!
^ The engine-transmission unit is installed in the reverse order. The following points must be given special attention.
^ Have a second person observe the engine-transmission clearance when inserting!

1. Lift engine-transmission unit approximately to halfway of the car jack. Also guide the oil filler neck and different hose lines in the left engine compartment when inserting!

Note! The ground cable on the holder of the plug connection of the impulse sender must also be screwed on!





2. Fit plate holder for the plug connection of the pulse sender and the plastic cable retainer. Position 1 M6x12 hexagon-head bolt and tighten with tightening torque. Screw in cable retainer and clip in cable.

Tightening torque: 10 Nm (7.5 ft. lbs.)





3. Connect servo lines. Push plug into the plug-in coupling in a straight line. The plug must audibly engage in the holder.

Note! The plug connection is designed so that there is an axial play of approximately 1 mm in the coupling.





4. Check proper engagement of the plug coupling with special tool Test tool 9623. Insert special tool into the groove (-arrow-) and check that the plug is seated correctly in the coupling by applying slight pressure. The plug must not slide out.

Note!
^ Have a second person observe the engine-transmission clearance when inserting!
^ Also guide the oil filler neck and different hose lines in the left engine compartment when inserting!

5. Move the engine-transmission unit into the installation position and tighten the engine or transmission mount screw connection with tightening torque.

Tightening torque of engine mount to engine carrier: 85 Nm (63 ft. lbs.)
Tightening torque of transmission bracket on body: 65 Nm (48 ft. lbs.)

Note!
^ Allocation of the round connector:
^ Lower plug - gray inner ring
^ Upper plug - black inner ring





6. Fit engine wiring harness. Turn bayonet lock in clockwise direction (approximately 90°) -arrow-, until the marking of the round connector and the housing correspond.





7. Fit air-conditioning compressor: before installing the compressor check whether the aluminum spacer sleeve -arrow- is inserted. Grease and fit sleeve. Also insert ground cable before installation.





8. Place 3 M8 hexagon-head bolts onto the air conditioning compressor (2 short screws at rear -1-, 1 long screw at front -2- ) and tighten to tightening torque.

Tightening torque: 23 Nm (17 ft. lbs.)





9. Fitting drive belt: Observe sequence when fitting -Fig.- the belt and direction of motion if the belt has been used.





10. Insert servo container. Remove plug, insert container into the flange, turn bayonet lock clockwise -arrow- until the markings of the flange and the container are aligned.

11. Top up Pentosin. Check fluid levels. Observe warning notes on use of Pentosin!

12. Top up coolant and bleed cooling system.

13. Fit hall sender on cylinder head bank 4-6. Replace microencapsulated M6 hexagon socket head bolt.

Tightening torque: 10 Nm (7.5 ft. lbs.)







Tightening torques - Removing and installing engine