Engine, Installing
Engine, Installing
Special tools, testers and auxiliary items required
• Socket (T40058)
• Transportation lock (T40170)
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 parts that have had the lubrication removed.
• Tolerance for tightening specifications ± 15%.
Subframe mount, refer to => [ Subframe Mount Overview ] Subframe Mount Overview.
Engine to Transmission
• The aluminum bolts, - 2 through 6 - and - 8 through 11 - may be used two times. After using the bolts once, mark them with an "X" made by a chisel - arrow -.
• To avoid damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt in a 14 mm socket with a 1/2 inch drive ratchet which is clamped into a vise, as shown in the illustration.
• Do not used bolts marked with an "X" again.
Procedure
• Replace bolts which have been tightened to an additional torque.
• 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 electronic parts catalog ETKA.
• During installation, all cable ties must be installed at the same location.
- Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.
- Before installing a replacement engine, make sure the semi-circular ring - arrow - is inserted in the power steering pump driveshaft.
- Install the engine support and engine mount. Refer to => [ Subframe Mount Overview ] Subframe Mount Overview.
- Install the left coolant pipe in the center. Refer to => [ Left Coolant Pipe In Center ] Left Coolant Pipe In Center.
- Complete the following steps before connecting the engine and transmission:
- Turn the torque converter so that the hole next to the notch - arrow - is visible in the transmission housing in the lower cut-out, as illustrated.
• The notch is only in one location on the circumference, so rotate the torque converter as needed.
- Install the (T40170) into the transmission housing from underneath and secure it to the flange shaft - 1 -.
- When joining the engine and subframe, hold the ATF lines in their installation position.
- 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.
- Determine if the engine/transmission aluminum bolts can be used again and mark them if necessary.
- Position the transmission on the engine. Be careful of the starter.
- Tighten bolts - 1 to 11 -.
- Remove the (T40170).
• The following procedure is necessary to assure that the torque converter contacts the drive plate evenly and does not get bent.
- Press the torque converter - 2 - slightly against the drive plate - 3 - using a pry bar - 1 - in direction of - arrow -.
- Install the first bolt - arrow - by hand (2 Nm).
- Insert the (T40058) guide pins as follows:
• The large diameter - arrow 1 - faces the engine.
• Small diameter - arrow 2 - points to adapter.
- Rotate the crankshaft with the (T40058) 180° in direction of engine rotation - arrow -.
- Tighten the bolts that are accessible in this position to the tightening specifications.
- Turn the crankshaft 60° further and tighten the remaining 5 bolts to the tightening specification.
- Tighten the drive axles on the transmission flange shafts.
- Install the ATF cooler.
- Install right coolant pipe. Refer to => [ Right Coolant Pipe ] Right Coolant Pipe.
- Install the right catalytic converter. Refer to => [ Muffler Overview ] Muffler Overview
- Install ATF lines.
- Install the power steering hydraulic line.
- Install the transmission mount and the transmission support.
- Install the left catalytic converter. Refer to => [ Muffler Overview ] Muffler Overview.
- Raise the engine/transmission assembly using the scissor lift table (VAS 6131 A).
- Align the subframe and tunnel crossmember using the marks made on the longitudinal members during removal.
- Tighten the tunnel crossmember bolts.
- Tighten the subframe bolts only to the tightening specifications, do not tighten them further (tighten the bolts only after axle alignment).
Risk of accident due to loose connections.
• If the bolts in the subframe are not tightened to final torque, vehicle must not be driven.
The rest of the installation is performed in reverse order of removal, noting the following:
- Install he emergency release cable.
- Install the driveshaft.
- Install the front muffler. Refer to => [ Front Muffler ] Front Muffler.
- Install the universal joint on the steering gear.
- Install the subframe crossbrace, upper control arm and stabilizer bar and tighten the suspension strut on the control arm.
- Install the braces on the transmission mounts.
- Install brake caliper.
- Install the auxiliary heater muffler.
- Attach the positive cables to the positive terminal.
- Install the lower longitudinal member and the deflector plate.
- Install the air guide pipes.
- Electrical connections and routing.
- Install the wires, the fuse panel and the engine compartment E-box cover.
- Install refrigerant lines.
- Install front bumper.
- Follow the instructions for connecting the battery.
- Install the tower brace.
- Install the upper longitudinal member.
- Install and adjust the windshield wiper arms.
Risk of destroying control modules with excess voltage.
• Do not use a battery charger for starting assistance!
- Fill engine oil and check oil level. Refer to Maintenance Procedures.
- Before starting engine for the first time, check the fluid level in power steering reservoir.
• The power steering pump must not run dry.
- Connect the coolant hoses with the connector coupling. Refer to => [ Connect the Coolant Hose to the Coupling ] Radiator Assembly Overview.
- Fill the 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.
- Fill the refrigerant circuit.
- Align the subframe.
- Install the wheel housing liners..
- Perform an axle alignment.
Risk of accident due to loose connections.
• Tighten the subframe bolts to the specification after performing axle alignment.
- Fill the ATF.
- Install the noise insulation..