Engine, Installing
Engine, Installing
• During assembly, replace the self locking nuts and bolts.
• Always replace bolts that have been tightened to specification as well as O-rings and gaskets.
• Secure all hose connections using hose clamps appropriate for the model type.
• During installation, all cable ties must be reinstalled in the same location.
• During installation, reinstall all heat insulation sleeves and heat shields in the same locations.
- Install the torque converter.
- Make sure the alignment pins for the engine to transmission are installed in the cylinder block. Install if necessary.
- No needle bearing is installed in the crankshaft on vehicles with automatic transmission.
- Before connecting the engine and transmission, rotate the torque converter and engine drive plate so that the holes or threaded holes align at the height of the opening for the starter.
- To secure the torque converter to the drive plate, use new original ribbed bolts.
- Install the torque converter to drive plate bolts (Quantity 3).
• To tighten the torque converter bolts, counter hold the main bolt of the crankshaft.
• Tightening specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
• Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not.
• Do not use any de-greased parts.
• Tolerance for tightening specifications ±15%.
- Securing the engine/transmission (flange view of transmission)
Alignment sleeves (- A and B -).
Installation is performed in the reverse order of removal, noting the following:
CAUTION!
To avoid contact corrosion, use only approved bolts, nuts, washers, etc. These fasteners have a special surface coating and can be recognized by their green color.
- Always clean the threaded holes in the transmission flanged shaft of locking fluid residue using a tap before installation.
- Twist the spindles for the attachments from the (VAS 6131/10) and the (VAS 6131/11) downward on the left side of the engine/transmission.
- Twist the spindles for the support elements from the (VAS 6131/10) downward on the right side of the engine/transmission.
- Remove the four base plates for the attachments for the engine carrier and subframe from the (VAS 6131).
• The other attachments remain unchanged.
- Equip the (VAS 6131) with the (VAS 6131/10) and the (VAS 6131/11) as follows:
- Position the engine carrier on both attachments (VAS 6131/10-7).
- Twist the left and right spindles for the support elements (VAS 6131/10-7) upward.
- Tighten the base plates for the attachments to 20 Nm on the (VAS 6131).
• A second technician is required to position the subframe onto the support elements.
- Position the subframe on both attachments (VAS 6131/10-8).
- Twist the left and right spindles for the support elements (VAS 6131/10-8) upward.
- Tighten the base plates for the attachments to 20 Nm on the (VAS 6131).
- Install and tighten the left and right bolts - arrows - for the engine mounts.
- Guide the engine/transmission with subframe and engine carrier into the body from below using the (VAS 6131).
- Install the subframe.
- Tighten the bolts for the subframe only to specifications, do not tighten further (tighten the bolts only after a front alignment).
CAUTION!
Vehicle must not be driven in this condition.
- Install and tighten the engine carrier and bolts - 4 -.
- Install and tighten the tunnel crossmember and bolts - arrows -.
- Install the driveshaft.
- Install the selector lever cable, adjust as necessary.
- Install the exhaust system free of stress. Refer to => [ Exhaust System Installing ] Exhaust System Installing.
- Install the guide link, track control arm and stabilizer bar.
- Install the drive axles.
- Fill the cooling system. Refer to => [ Draining and Filling ] Draining and Filling.
- Install the torque support. Refer to => [ Torque Bracket and Support Valve Assembly Overview ] Torque Bracket and Support Valve Assembly Overview.
- Install the tower brace.
- Install the wiper arms and adjust.
- Before the starting the engine, fill the power steering system with hydraulic fluid; the power steering pump must not run dry.
- Connect the battery.
- Install the lock carrier with attachments.
- Install the front bumper.
- Fill the power steering system and bleed the system.
- Adjust the headlamps.
- Check the engine oil level before starting the engine. Refer to => [ Oil Level, Checking ] Component Tests and General Diagnostics.
- Check the automatic transmission fluid level.
- Perform a front end alignment.
CAUTION!
After the front end alignment, tighten the subframe bolts to final the specification.
- Raise the windows using the electric window regulators up to the stop.
- Activate all power window switches "up" again for at least one second to activate the automatic window raising/lowering.
- Set the clock.
Tightening Specifications
• Tightening specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
• Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not.
• Do not use any de-greased parts.
• Tolerance for tightening specifications ±15%.
