Installation

Remounting components on replacement engine





Use:
- new gaskets and seals
- new flywheel bolts
- new flame trap

Inspect and renew as required:
- hoses and clips
- auxiliary drive belts
- clutch components





Install oil trap in cylinder block
Use new 0-rings.





Install intake manifold assembly and wiring harness
Use new gasket at joint with cylinder head.

Tighten bottom bolts a few turns.

Fit intake manifold and lifting lugs. Tighten mounting bolts from center outwards.





Mount oil trap
Position engine wiring harness between oil trap and balance shaft housing.

Insert oil trap and tighten in position.

Install flame trap and hoses, and connect to branch on bottom of intake manifold.





Reconnect connectors under intake manifold
Connect knock sensor and temperature sensors.





Install left-hand engine mounting
Reattach cable clip at upper bolt of engine mounting/intake manifold support.

Install wiring harness bracket and cable clip on trans- mission cover.





Install alternator and auxiliary mounting bracket
Reconnect alternator leads.

Replace protective cap over terminal B+.

On cars equipped with AC: Install compressor mounting bracket.





Reconnect heater hoses
Connect heater hoses to cylinder head and to distribution manifold from water pump.





Install distributor housing
Use new 0-rings in housing and on rotor shaft.

NOTE: Install ignition lead clip beside left-hand mounting bolt.





Install wiring harness bracket under right-hand balance shaft
Connect earth lead to cylinder block and reconnect oil pressure switch.

Install pressure switch cable clip at front of transmission cover.





Install right-hand engine mounting
Reattach upper bracket to cylinder block.





Install exhaust manifold and bottom heat shield
Use new gasket in joint with cylinder head.

Attach lifting lug to center stud.






Turn crankshaft to TDC (ignition) in No.1 cylinder
Align crankshaft pulley (vibration damper) marking with 0 mark on transmission cover.

Check that slot in distributor rotor shaft is at '10 o'clock' or that No.1 cylinder exhaust cams are pointing upwards at approx. 600 to engine center line.





Lift engine from stand
Use attachment 5035 and lifting yoke 2810.

Position engine wiring harness to avoid risk of damage.

CAUTION: Since the following operations are carried out with engine freely suspended, ensure that lifting equipment is securely attached and in perfect condition.





Install flywheel
Use gear sector 5112.

At TDC, mark on flywheel should be positioned between the two lower bolt holes on right-hand side of cylinder block.

CAUTION: If flywheel is not marked, new position is indicated by pins A and B at rear. Pins A and B are located respectively approx. 15° on either side of marking position.

Use new bolts and thread locking compound.

Tighten to 70 Nm (52 ft.lb).





Install clutch plate and pressure plate
Use centering tool 5111 and gear sector 5112. Tighten pressure plate in stages. Work around circumference tightening diagonally-opposite bolts alternately.

Remove centering tool and gear sector.





Install speed pick-up
Use thread locking compound.

Tighten to 5 Nm (3.5 ft.lb).

Check that cylinder block guide pins are in position.





Install gearbox and starter motor
Lubricate input shaft splines with thin coating of grease.

Reconnect starter motor leads.

NOTE: Remember to install exhaust manifold front mounting bracket.





Install reinforcing bracket
Tighten bracket in stages.

Attach bracket first to flywheel housing and then to cylinder block.