Engine, Installing
Engine, Installing
• During assembly, replace self-locking nuts and bolts.
• Always replace bolts that are tightened to torque as well as sealing rings, gaskets and O-rings.
• Secure all hose connections using hose clamps appropriate for the model type.
• When installing, bring all cable ties back to the same positions.
Installation dimension for torque converter, checking
When the torque converter is installed correctly, distance between lower contact surfaces of threaded holes at torque converter and contact surface of bell housing on Automatic Transmission is approximately 19 mm.
If the torque converter is incorrectly installed, the torque converter coupling and ATF pump could be damaged when transmission and engine are flanged together.
- Make sure the centering sleeves for the engine to transmission are installed in the cylinder block. Install if necessary.
- Bolt transmission to engine.
Keep checking whether the torque converter behind the drive plate can be turned before and during tightening of the bolts at engine/transmission flange. If the torque converter cannot be turned, it must be assumed that it has not been inserted properly and that the coupling plate of the ATF pump and therefore the transmission will be destroyed during the final tightening of the bolts.
• The tightening specifications apply only 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 ungreased parts.
• Tightening specification tolerance +/- 15%.
Engine/Transmission, Fastening
* Bolt class 10.9.
Further installation is performed in reverse order of removal, noting the following.
- Install front exhaust pipes. Refer to => [ Left Front Exhaust Pipe with Catalytic Converter ] Left Front Exhaust Pipe with Catalytic Converter, => [ Right Exhaust Pipe with Catalytic Converter ] Right Exhaust Pipe with Catalytic Converter.
- Always clean threaded bores in transmission flanged shaft for crankshaft of locking fluid residue using a tap before installation.
- Rotate the spindles of the support elements downward at left of engine/transmission assembly.
- Remove both base plates for left support element on (VAS 6131 A).
- Rotate the spindles of support elements downward at right of engine/transmission assembly.
- Remove both base plates for left support element on (VAS 6131 A).
• Support points for front of engine, rear of the transmission and tunnel cross member remain unchanged.
- Equip (VAS 6131 A) with (VAS 6131/10) as follows:
* Support elements remain unchanged.
* Only install support elements after installing subframe.
• A second technician is required to position subframe onto support elements.
- Position subframe on both attachments (VAS 6131/10-8).
- Twist spindles of support elements upward on both sides.
- Tighten base plates for support elements to 20 Nm on (VAS 6131 A).
- Using (VAS 6131 A) , slowly guide engine/transmission unit with subframe into body from below.
- Align subframe and engine bearing brackets according to the markings applied on the longitudinal members during removal.
- Tighten bolts for subframe and engine mount brackets only to specified torque. Do not tighten further (tighten bolts only after axle alignment).
1. 50 Nm
2. 150 Nm
3. 150 Nm
4. 75 Nm
Vehicle must not be driven in this condition.
- Fasten bolts - arrows - for tunnel cross member.
- Install selector lever cable, adjust if necessary.
- Install driveshaft.
- Fasten the ATF lines.
- Install drive axles.
- Install guide control arm, control arm and stabilizer.
- Install power steering oil lines.
- Install refrigerant lines.
- Install lock carrier with attachments.
- Install front bumper.
- Adjust headlamps.
- Electrical connectors and wiring routing.
Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.
• Be sure to activate vehicle features (radio, radio/navigation system, clock, electric window regulator) according to owner's manual when the battery is re-connected.
• Deactivate service mode of Telematics control module.
• Further measures after reconnecting voltage supply.
- Fill refrigerant circuit.
- Before starting, check engine oil level.
- Before the first engine start, fill hydraulic oil into power steering system refill tank; power steering pump must not run dry.
- Fill the engine with coolant => [ Filling ] Procedures.
• Only reuse drained coolant if cylinder head or engine block was not replaced.
• Dirty coolant may not be used again.
- Fill power-steering system oil and bleed steering system.
- Check ATF level.
Tightening Specifications
• The tightening specifications apply only 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 ungreased parts.
• Tolerance for torque specifications ±15%.
