2. Check the crankshaft radial bearings and clutch release bearing for ease of rotation, and the release lever for ease of shifting, replace if necessary.
3. Check the clutch drive plate for sufficient thickness and condition of the friction linings.
4. Check the front and rear bearings for porosity and damage.
5. If the gearbox has been dismantled, screw it to the engine and insert it together into the engine compartment.
6. Lower the engine very carefully when installing it in the engine compartment so as not to damage the drive shaft, clutch and body.
7. Screw the gearbox to the intermediate flange of the engine (see table Tightening torques). At the same time, the wire "masses" screw on at the bottom left of the gearbox.
8. Insert and hand-tighten the front engine mount bolts.
9. Screw the rear brackets of the engine with fixing bolts with a torque of 40 Nm and a torque of 70 Nm for the fixing nuts.
10. Tighten the bolts of the front engine mounts with a torque of 40 Nm.
11. Insert the propeller shaft into the gearbox.
12. Automatic transmission: put on the plug of the starter lock and reversing light switch and secure with a plastic stopper. Connect the electrical wire to the Kickdown solenoid valve.
13. If the engine was dismantled without a gearbox, install the starter.
14. Screw cable "masses" from gearbox to body.
15. Hang the shift levers on the gearbox and fix with clips. Check adjustment.
16. Install the exhaust system.
17. Air conditioning: screw on the cooling compressor, mount the ribbed V-belt.
18. Install the radiator.
19. Fit all coolant hoses and secure with clamps.
20. Install a hydraulically coupled fan.
21. Establish the bottom covering of a motor compartment.
22. Lower the car to the ground.
23. Screw on the recirculation hose and the high pressure steering servo hose. On vehicles with height adjustment, additionally screw on the high pressure hose and oil line for the dual circuit pump. Bleed the air from the pressure oil pump of the dual circuit pump.
24. Install the throttle cable.
25. Connect the fuel lines.
26. Put on all vacuum hoses that go to the engine.
27. Install the air filter cross tube.
28. Install an air mass meter if it was removed.
29. Check the oil level in the engine and gearbox, top up if necessary.
30. Check the antifreeze content of the coolant and add if required.
31. Clean the air filter insert, replace if necessary and insert into the filter.
32. Connect the positive battery cable first (+), then wire "masses" (–).
33. Fasten the cover on the front wall of the body with a knurled nut and a rivet.
34. Bring the engine up to operating temperature, check the coolant level and the tightness of the hose connections.
35. Close the engine hood. To do this, pull the lock lever in the hood hinge and slowly lower the hood until spring back pressure is felt and the lock lever locks into place.
36. Set the time on the clock.
37. Set the anti-theft code for the radio.
38. Read the engine error memory.
Tightening torques
M 10 x 40 | 55 Nm |
M 10 x 45 | 55 Nm |
M 10 x 90 | 45 Nm |