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%.
Subframe mount, refer to => [ Subframe Assembly Overview ] Subframe Assembly Overview.
Battery Jump Start Terminal (U6) Pins
- Tighten the pins - 1 - for the battery jump start terminal (U6) to 15 Nm.
Ground connection in the right of the plenum chamber
- Tighten the nut - 2 - to 9 Nm.
Ground Connection on the Right Longitudinal Member
- Tighten the nut - 1 - to 15 Nm.
Engine/Transmission, Fastening
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.
• Only remove the plugs or caps after installing the lines.
• Secure all hose connections with hose clamps appropriate for the model.
• During installation, all cable ties must be installed at the same location.
- Install left and right engine supports.
- Make sure the alignment sleeves - A - for centering the engine and transmission in the cylinder block are present. Insert the alignment sleeves if they are missing.
- On a vehicle with automatic transmission, check whether bearing bushing - arrow - is inserted at rear of crankshaft. Drive in bushing if necessary.
Risk of destroying ATF pump coupling plate by inserting torque converter incorrectly.
• 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 09D is approximately 22 mm.
If torque converter is not fully engaged, the distance is approximately 10 mm.
- Before installing an exchanged engine, make sure the semi-circular ring - arrow - is inserted in the power steering pump input shaft.
- Before guiding engine and transmission together, rotate torque converter and drive plate so that holes or threaded holes are same height as opening on removed starter - arrows -.
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.
- Bolt transmission to engine.
- Tighten the torque converter.
The rest of the installation is in reverse order of removal, note the following.
- Install power steering pressure line.
- Install starter.
- Install ATF lines.
- Install right rear coolant pipe => [ Rear Right Coolant Pipe ] Rear Right Coolant Pipe.
- Install left rear coolant pipe. Refer to => [ Rear Left Coolant Pipes ] Rear Left Coolant Pipes.
- Install the front driveshaft on the transfer case.
- Install primary catalytic converter. Refer to => [ Left Primary Catalytic Converter ] Left Primary Catalytic Converter, => [ Right Primary Catalytic Converter ] Right Primary Catalytic Converter.
- Using (VAS 6131), slowly guide engine/transmission unit with subframe into body from below.
- Align subframe, engine carrier and transmission carrier according to markings applied on longitudinal members during removal.
- Only tighten the subframe, engine carrier and transmission carrier bolts to the specification and only after the vehicle alignment is complete.
Risk of accident due to loose connections.
• If the bolts in the subframe are not tightened to final torque, vehicle must not be driven.
- Install universal joint on steering gear.
- Install selector lever cable and check adjustment if necessary.
- Align exhaust system free of tension. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.
- Install the rear driveshaft on the transfer case.
- Install stabilizer bar.
- Install brake caliper.
- Install the suspension struts and control arms.
- Install Engine Control Module (ECM).
- Remove the plenum chamber E-box cover.
- Install refrigerant lines.
- Tighten the battery jump start point (U6) pins.
- Tighten the ground connection on the right longitudinal member.
- Electrical connections and routing.
- Observe safety precautions 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 the engine oil and check the oil level.
- Before starting engine for the first time, check the fluid level in power steering reservoir.
• Power-steering pump must not run dry.
- Connect the coolant hoses with the connector coupling. Refer to => [ Connect the Coolant Hose with the Connector
Coupling ] Radiator Assembly Overview.
- 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.
- Fill refrigerant circuit.
- Align subframe and engine carrier.
- Align transmission carrier and tighten it.
- Install the front wheels and perform an alignment.
Risk of accident due to loose connections.
• Tighten subframe bolts to final torque after axle alignment.
- Install the noise insulation bracket and the noise insulation.
- On a vehicle with air suspension, deactivate vehicle lift mode.