Engine, Installing

Engine, Installing

Tightening Specifications

• Tightening specifications only apply to lightly greased, oiled, phosphate 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%.

Battery Jump Start Terminal (U6) Pins

- Tighten the bolt - 1 - for the battery jump start terminal 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.

Subframe mount => [ Subframe Overview ] Subframe Overview.

Engine to Automatic Transmission 09D

Engine and 8-Speed Automatic Transmission 0C8

Installing

Install in reverse order of removal. Note the following:

• Replace bolts which have been tightened to an additional torque.

• Replace bolts for securing torque converter to the drive plate with new original bolts, refer to the Parts Catalog.

• Replace self-locking nuts and bolts as well as sealing rings, seals and O-rings.

• The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.

• Secure all hose connections with hose clamps appropriate for the model, refer to the Parts Catalog.

• During installation, all cable ties must be installed at the same location.

- Install the engine supports and engine mount. Refer to => [ Subframe Overview ] Subframe Overview.

- Make sure the rear centering bushing - arrow - is installed into the crankshaft; install a missing centering bushing.

Vehicles Built through 05.10

- 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.

Risk of destroying ATF pump coupling plate by inserting torque converter incorrectly.

• Check torque converter installation dimension.

• When the torque converter is installed correctly, distance - a - between the lower contact surface of threaded holes at torque converter and contact surface of bell housing on the automatic transmission 09D is at least 22 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 the same height as opening for removed starter - arrows -.

Vehicles Built from 06.10

- 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.

• If torque converter is not completely inserted, distance is approximately 11 mm (0.43 in.).

- Before guiding the 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 -.

All Vehicles

- Tighten the transmission to the 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.

- Tighten the torque converter.

The rest of the installation is performed in reverse order of removal, noting the following.

- Install the power steering fluid line.

- Install Air Conditioner (A/C) compressor.

- Install the starter and generator.

- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Install ATF lines.

Vehicles Built through 05.10

- Tighten the front driveshaft to the transfer case.

Vehicles Built from 06.10

- Attach the front driveshaft to the transfer case.

All Vehicles

- Install the left rear coolant pipe to the transmission. Refer to => [ Coolant Pipes Overview ] Coolant Pipes Overview.

- Install the preliminary catalytic converter and particulate filter. Refer to => [ Muffler Overview ] Service and Repair.

- Install the turbocharger heat shield. Refer to => [ Turbocharger Overview ] Turbocharger Overview.

Vehicles Built through 05.10

- Slowly guide the engine/transmission subassembly with subframe into body from below using the (VAS 6131 A). Be careful not to damage the boots on the drive axle.

- Next, raise engine/transmission subassembly high enough using the (VAS 6131 A) until dimension - a - is reached between subframe and body.

• Dimension - a - = 7.87 in.

- Install the selector lever cable and check the adjustment if necessary.

All Vehicles

- Continue raising engine/transmission subassembly with subframe using the (VAS 6131 A).

- Align subframe, engine carrier and transmission carrier using marks made on longitudinal during removal.

- Tighten bolts for subframe, engine carrier and transmission carrier only to specified torque. Refer to => [ Subframe Overview ] Subframe Overview and ; 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.

- Install universal joint on steering gear.

Vehicles Built from 06.10

- Install the selector lever cable and check the adjustment if necessary.

- Attach the rear driveshaft to the transfer case.

Vehicles Built through 05.10

- Tighten the rear driveshaft to the transfer case.

All Vehicles

- Install stabilizer bar.

- Install brake caliper.

- Install the suspension struts and control arms.

- Install the selective catalytic reduction (SCR) catalytic converter. Refer to => [ Muffler Overview ] Service and Repair.

- Install the NOX sensor, heated oxygen sensor (HO2S) (G39) , throttle valve control module (J338) , air filter housing, air filter and engine control module.

- Install the air duct hoses and screw-type clamps. Refer to => [ Install the Air Duct Hoses and Screw-Type Clamps. ] Air Duct Pipes and Air Duct Hoses Overview, Vehicles Built Through 05.10.

- Install the fuel filter.

- Tighten the fuel cooler pump (V166) to the longitudinal member. Refer to => [ Vehicles Built through 05.10 , Tightening Specifications ] Service and Repair.

- Install refrigerant lines.

- Electrical connections and routing.

- Install the cover for the plenum chamber E-box.

- Follow the instructions for connecting the battery.

Risk of destroying control modules with excess voltage.

• Do not use a battery charger for starting assistance!

- Install and adjust the windshield wiper arms.

- Fill engine oil and check oil level.

- Before starting engine for the first time, check the fluid level in power steering reservoir.

• The power steering pump must not run dry.

- Fill the refrigerant circuit.

- Connect the coolant hose to the coupling. Refer to => [ Connect the Coolant Hose to the Coupling ] Radiator Overview.

- Fill with coolant => [ Filling ] Procedures.

• 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 and tighten the transmission carrier.

- Install the wheel housing liners.

- Install the front wheels.

- Perform axle 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.

- Install exhaust system free of stress. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.

- On a vehicle with air suspension, deactivate vehicle lift mode.