Engine, Installing
Engine, Installing
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 degreased parts.
• Tolerance for tightening specifications ±15%.
Tightening specifications => [ Subframe, Assembly Overview ] Subframe, Assembly Overview.
Additional Tightening Specifications
Transmission to Engine Bolts
Procedure
Installation is in reverse order of removal, note the following:
• Replace bolts which have been tightened to specifications.
• Replace sealing rings, seals and self locking nuts and bolts.
• Replace bolts for securing torque converter to drive plate with new original bolts.
• Secure all hose connections using hose clamps appropriate for the model type.
• When installing, place all cable ties and heat insulating sleeves in same locations.
- Install right engine support.
- If no alignment sleeves for centering engine and transmission are present in cylinder block, insert sleeves.
- Check torque converter installation dimension.
• When 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 25 mm.
• If torque converter is not completely inserted, distance is approximately 10 mm.
- Before guiding engine and transmission together, rotate torque converter and drive plate so that holes or threaded holes are same height as opening for removed starter - arrows -.
- Attach transmission to engine.
Risk of destroying transmission due to torque converter inserted incorrectly.
• Keep checking whether the torque converter behind the drive plate can be turned before and during tightening of the bolts at engine/transmission connection.
• If torque converter cannot be rotated, the ATF pump coupling plate and therefore the transmission are destroyed when connections are tightened to final torque.
- Install ATF lines.
Continuation for All
- Install power steering pressure line.
- Install starter.
With 4 Zone Climate Control
- Install rear coolant pipes => [ Rear Coolant Pipes, with 4 Zone Climate Control ] Rear Coolant Pipes, With 4 Zone Climate Control.
Continuation for All
- Install front driveshaft to transfer case.
- Install primary catalytic converters => [ Primary Catalytic Converters ] Primary Catalytic Converters.
- Install main catalytic converters => [ Main Catalytic Converters ] Main Catalytic Converters.
- Slowly guide engine/transmission assembly with subframe into body from below using scissor lift table (VAS 6131 A), ensuring drive shaft boots are not damaged.
- Align subframe, engine carrier and transmission carrier using marks made on longitudinal members during removal.
- Tighten bolts for subframe, engine carrier and transmission carrier only to specified torque. Do not tighten further (tighten bolts only after axle alignment).
Risk of accident due to loose connections.
• Vehicle must not be driven in this condition.
The rest of installation is in reverse order of removal, note the following:
- Install universal joint on steering gear.
- Install selector lever cable and check adjustment
- Tighten driveshaft to rear of transfer case.
- Install stabilizer bar.
- Install brake caliper.
- Install struts (coil spring).
- Install struts (air suspension).
- Install Engine Control Module (ECM).
- Install refrigerant lines.
- Electrical connections and routing.
- Follow measures after connecting battery.
Risk of destroying control modules with excess voltage.
• Do not use a battery charger for starting assistance!
- Install wiper arms and adjust
- Fill engine oil and check oil level.
- Before starting engine for the first time, check hydraulic oil in power steering reservoir.
• Power steering pump must not run dry.
- Charge A/C system => Refrigerant R134a - Servicing 87.
- Fill with coolant => [ Filling ] Service and Repair.
• Do not use drained coolant in the following situations:
• If the cylinder head or cylinder block was replaced.
• If the coolant is contaminated.
- Align subframe and engine carrier.
- Align transmission carrier and tighten.
- On a vehicle with air suspension, deactivate vehicle lift mode.
- Perform axle alignment.
Risk of accident due to loose connections.
• Tighten subframe bolts to final torque after axle alignment.
- Install exhaust system free of stress => [ Exhaust System, Installing ] Service and Repair.
- Check ATF level.