Installing Engine

Installing engine

Note:
^ The engine-transmission unit is installed in the reverse order. The following points must be given special attention!

1. Lift the engine-transmission unit carefully and in steps.

Note:
^ Have a second person observe the engine-transmission clearance during lifting!
^ Pay particular attention to the clearance between rear axle cross member, intake air distributor and oil container!

2. The following assembly work must be carried out before the final installation position is reached:
- Fasten lower coolant hose to expansion tank.





- Position the intake air distributor on the support pins and simultaneously fit the line of the switch-over valves. Fasten the hexagon-head bolt.





3. Fasten vent line on the intake air distributor.





- Fasten fuel filter, fuel supply line (1) and fuel return (2). Tighten the fuel supply line to 30 to 35 Nm (22 to 26 ft. lbs.) and the fuel return line to 25 Nm (19 ft. lbs.).





- After the screw union of the fuel return line has been retightened, there must be a minimum distance of A = 20 mm between the holders of the spring band clamps and the fuel line. If necessary, set this distance with a spacer during the tightening process.





- Push on vacuum line for the brake booster and fit plastic snap ring.
4. Fit engine wiring harness.
The round plugs are color-coded on the inside:
upper round plug - black
lower round plug - grey





- Line up marking of the round connector with marking on the housing.





- Turn round connector clockwise by approximately. 90° (bayonet lock).





5. Insert spacer sleeve.
6. Fit air-conditioning compressor.
7. Fit drive belt.

Note:
^ Observe sequence when fitting the belt!

8. Fit coolant hoses with new O-rings and plenty of water.
9. Attach the safety brackets onto the coolant supports before engaging the coolant hoses.
10. Move coolant hoses into installation position.

Note:
^ The coolant hoses must audibly engage when pushed into the flanges!

11. Fit pressure hoses between the charge air cooler and throttle body with new O-rings and wet with plenty of water.
12. Attach the safety brackets (locking springs) onto the pressure pipe before engaging the pressure hoses.

Note:
^ The pressure hoses must audibly engage!

13. Check correct seating by pulling gently.





14. Fit crash support again. Coat the fastening screws with Loctite 574 and fasten. Tightening torque 23 Nm (17 ft. lbs.).
15. Bleed steering system.
16. Bleed cooling system with the System Tester 2, under menu item "Special functions"

Tightening torques: Removing and installing engine
Location Thread Tightening torque Nm (ft. lbs.)
Engine mount to engine carrier M12 85 (63)
Transmission support to body M10 65 (48)
Drive shaft to transmission M10 81 (60)
Wheel to wheel hub M14 130 (96)
Rear-axle member to carrier side section M12 110 (81)
Cross member at front to carrier side section M10 65 (48)
Diagonal brace to body M10 65 (48)
Diagonal brace to cross member M12 110 (81)
Diagonal brace to carrier side section (collar nut) M10 23 (17)
Stabilizer to carrier side section M8 23 (17)
Stabilizer to stabilizer mount M10 46 (34)
Ground strap to body M8 23 (17)
Fuel return line M14 25 ± 5 (19 ± 3.5)
Fuel supply line M16 30 + 5 (22 + 3.5)
Coolant drain plug M10 10 + 5 (7.5 + 3.5)
Cardan shaft on transmission flange M10 46 (34)
Clutch pressure line 30 (22)