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 torque specifications ±15%.
Tightening specifications. Refer to => [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview, => [ Crankshaft Assembly Overview ] Crankshaft Assembly Overview.
Securing engine to transmission
Procedure
Installation is in reverse order of removal, note the following:
• Replace bolts which have been tightened to torque.
• Replace self-locking nuts and bolts as well as sealing rings, seals and O-rings.
• Replace the torque converter bolts with new original bolts.
• Secure all hose connections with hose clamps appropriate for the model.
• During installation, all cable ties must be re-installed at the same location.
- Check whether alignment sleeves for centering engine and transmission in cylinder block are present, insert missing fitting sleeves.
CAUTION!
Risk of destroying ATF pump coupling plate by inserting torque converter incorrectly.
• Check torque converter installation dimension.
When torque converter is installed correctly, distance - a - between contact surface of threaded holes at torque converter and contact surface of bell housing on Automatic Transmission 09E is at least 19 mm.
- Before guiding engine and transmission together, rotate torque converter and drive plate so that holes and threaded holes are same height as opening on removed starter - arrow -.
CAUTION!
Risk of destroying automatic transmission.
• 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 the torque converter cannot be turned, it must be assumed that it is inserted incorrectly.
• Only secure torque converter to drive plate with new original bolts.
- Install ATF lines.
- Before installing an exchanged engine, check whether O-ring - arrow - is inserted in power steering pump input shaft.
- Install starter.
- Install engine supports. Refer to => [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview.
- Install torque support and torque support bracket. Refer to => [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview.
- Install the exhaust manifolds with catalytic converters. Refer to: Left => [ Left Exhaust Manifold with Catalytic Converter ] Left Exhaust Manifold with Catalytic Converter, right => [ Right Exhaust Manifold with Catalytic Converter ] Right Exhaust Manifold With Catalytic Converter.
- Install right coolant pipe. Refer to => [ Right Coolant Pipe ] Right Coolant Pipe.
- Install left coolant pipe. Refer to => [ Left Coolant Pipe ] Left Coolant Pipe.
- Install left lower coolant pipe. Refer to => [ Lower Left Coolant Pipe ] Lower Left Coolant Pipe.
- Insert oil dipstick guide tube with new O-ring in hole in upper section of oil pan.
- Always clean threaded bores in transmission flanged shaft for driveshaft of locking fluid residue using a tap before installation.
- Turn spindle of left front support element on transmission down.
- Remove left support element base plate from Scissor Lift Table (VAS 6131).
- Turn spindle of right front support element on transmission down.
- Remove right support element base plate from Scissor Lift Table (VAS 6131).
- Place subframe on Scissor Lift Table (VAS 6131).
CAUTION!
Risk of falling due to lack of support.
• After placing subframe, position transmission mounting elements at the front again in the same location.
- Position front transmission mounting elements.
- Turn spindle of left rear support element on engine downward.
- Remove left support element base plate from Scissor Lift Table (VAS 6131).
- Turn spindle of right rear support element on engine downward.
- Remove right support element base plate from Scissor Lift Table (VAS 6131).
• The support points for front of engine and transmission remain unchanged.
- Install engine carrier - arrows -.
- Place subframe on engine carrier and tighten transmission mount at left and right - arrows -.
- Guide engine/transmission unit with subframe and engine carrier into body from below using Scissor Lift Table (VAS 6131).
- Lift engine/transmission subassembly using Scissor Lift Table (VAS 6131) until dimension - a - is reached.
• Dimension - a - = at least 120 mm.
- Install selector lever cable and check adjustment.
- Raise engine/transmission assembly further using Scissor Lift Table (VAS 6131).
- Align the subframe according to the markings on the longitudinal members.
- Tighten subframe bolts only to specified torque, do not tighten further (only tighten bolts after axle alignment).
CAUTION!
Risk of accident due to loose connections.
• If the bolts in the subframe are not tightened to final torque, vehicle must not be driven.
- Tighten engine carrier bolts - 4 -. Refer to => [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview.
- Tighten bolts - arrows - on tunnel cross member.
The rest of installation is in reverse order of removal, note the following:
- Install driveshaft.
- Install front muffler. Refer to => [ Left Front Muffler ] Left Front Muffler, right => [ Right Front Muffler ] Right Front Muffler.
- Align exhaust system free of tension. Refer to => [ Exhaust System, Installing ] Removal and Replacement.
- Install drive axles.
- Install guide control arm, control arm, stabilizer bar, coupling rod and front crossmember.
- Install refrigerant lines.
- Install ATF cooler.
- Install dome brace.
- Install torque support bracket. Refer to => [ Torque Support Bracket ] Torque Support Bracket.
- Electrical connections and routing.
- Observe safety precautions after connecting battery.
- Install wiper arms and adjust.
CAUTION!
Risk of destroying control modules with excess voltage.
• Do not use a battery charger for starting assistance!
- Before starting engine for the first time, fill power steering vacuum reservoir with hydraulic oil.
• Power-steering pump must not run dry.
- Check oil level. Refer to => [ Oil Level, Checking ] Component Tests and General Diagnostics.
- Fill with coolant => [ Filling ] Procedures.
• Only reuse drained coolant if cylinder head or engine block was not replaced.
• Dirty coolant must not be re-used.
- Fill refrigerant circuit.
- Perform axle alignment.
CAUTION!
Risk of accident due to loose connections.
• Tighten subframe bolts to final torque after axle alignment.
- Check ATF level.