Engine, Installing

WARNING: This page is about a different variant/trim than selected.

Tightening Specifications

NOTE:

The tightening specifications apply only 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 ungreased parts.

Tightening specification tolerance: ±15%.

Component		Nm
Bolts and nuts	M6	9
	M7	15
	M8	20
	M10	40
	M12	65

Fig 1: Ground Connection On Right Longitudinal Member

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-- Tighten the nut -2- to 15 Nm.

Engine to Transmission

Fig 2: Identifying Aluminum Bolts - 1 Through 11 -

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Item

Bolt ¹⁾

M10 x 95

15 + 90°

2 to 5

M12x75

30 + 90°

6, 7

M12x140

30 + 90°

8, 9, 10

M10x60

15 + 90°

M10x45

15 + 90°

Alignment sleeves for centering

(1) The aluminum bolts -1 to 11- may be used twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be used the first time -arrow-

⁽¹⁾	To prevent damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt using a 14 mm socket with a 1/2 inch drive, which is inserted in to the vise, as illustrated.

Refer to Fig 3.

The aluminum bolts -1 to 11- may be used twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be used the first time -arrow-.

Fig 3: Identifying Aluminum Bolts Marked With An "X"
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Bolts marked with an "X" may not be used again.

Procedure

NOTE:

Replace any bolts that were tightened with an additional turn.

Replace self-locking nuts and bolts and seals, gaskets and O-rings.

Only remove the plugs or caps after installing the lines.

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 of the same type as those equipped by the factory.

To mount the air guide hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.

When installing, bring all cable ties back to same positions.

-- Install the left and right engine supports. Refer to OVERVIEW - SUBFRAME .

-- Make sure the alignment sleeves -A- for centering the engine and transmission are inside the cylinder block and inside the timing chain guard lower section. Replace them if they are missing.

Fig 4: Identifying Aluminum Bolts - 1 Through 11 -

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CAUTION:

Installing the torque converter incorrectly can cause damage to the ATF pump drive plate.

Checking position of torque converter.

When torque converter is installed correctly, distance -a- between the lower contact surface of threaded holes at torque converter and contact surface of bell housing is at least 23 mm.

Fig 5: Measuring Torque Converter Installed Dimension -A-

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NOTE:

If torque converter is not completely inserted, distance is approximately 11 mm.

-- Before guiding engine and transmission together, rotate torque converter and drive plate so that holes for the bolts are same height as opening for removed starter -1-.

Fig 6: View Of Starter Motor Opening Cover -2-

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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 the generator. Refer to GROUND CABLE WITH Battery Monitoring Control Module -J367- FROM MY 09, REMOVING AND INSTALLING .

-- Tighten the transmission to the engine.

-- Tighten the torque converter. Refer to TORQUE CONVERTER, INSTALLING .

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

-- Install the starter. Refer to STARTER, REMOVING AND INSTALLING .

-- Attach the right coolant pipe to the transmission. Refer to RIGHT COOLANT PIPE ON TRANSMISSION, REMOVING AND INSTALLING .

-- Install the left rear coolant pipes on the transmission. Refer to LEFT REAR COOLANT PIPES ON TRANSMISSION, REMOVING AND INSTALLING .

-- Install the ATF wires. Refer to ATF PIPES, ATF THERMOSTAT AND ATF COOLER, 6-CYLINDER 3.6L FSI, ASSEMBLY OVERVIEW .

-- Attach the front driveshaft to the transfer case. Refer to TRANSFER CASE OVERVIEW .

-- Lift the engine/transmission assembly with the Scissor Lift Table VAS6131A.

-- Install the Air Conditioning (A/C) compressor. Refer to A/C Compressor Regulator Valve -N280-, REMOVING AND INSTALLING .

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

Fig 7: Subframe, Engine Carrier, Crossmember And Bolts

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-- Tighten the bolts for the subframe, engine carrier and transmission carrier only to the specification. Do not tighten further. Tighten bolts only after an axle alignment. Refer to SUBFRAME, SERVICING .

WARNING:

Risk of accident due to loose connections.

If the bolts in the subframe are not tightened to final torque, vehicle must not be driven.

-- Attach the universal joint to the steering gear. Refer to STEERING COLUMN OVERVIEW .

-- Install the selector lever cable and adjust if necessary. Refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING .

-- Install the catalytic converter. Left refer to LEFT CATALYTIC CONVERTER, REMOVING AND INSTALLING , right refer to RIGHT CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Install the exhaust system free of tension. Refer to EXHAUST SYSTEM, INSTALLING WITHOUT TENSION .

-- Attach the rear driveshaft to the transfer case. Refer to REAR DRIVESHAFT .

-- Install the stabilizer bar. Refer to STABILIZER BAR, REMOVING AND INSTALLING .

-- Install the brake caliper. Refer to BRAKE CALIPER, REMOVING AND INSTALLING .

-- Install the suspension struts and control arms. Refer to AIR SUSPENSION STRUT, REMOVING AND INSTALLING .

-- Install the Engine Control Module (ECM). Refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

-- Install the cover for the plenum chamber E-box. Refer to DRIVER SIDE E-BOX PLENUM CHAMBER, REMOVING AND INSTALLING .

-- Attach the electric wire to the Battery Jump Start Terminal -U6-. Refer to Battery Jump Start Terminal -U6-, REMOVING AND INSTALLING .

-- Attach the ground connection to the right longitudinal member. Refer to Fig 1.

-- Electrical connections and wiring routing. Refer to appropriate SYSTEM WIRING DIAGRAM.

-- Be sure to follow the procedure for connecting the battery and afterwards. Refer to BATTERY, DISCONNECTING AND CONNECTING .

CAUTION:

There is a risk of destroying control modules with excess voltage.

Do not use a charger as a starting aid.

-- Install the hydraulic line. Refer to LINES AND HOSES OVERVIEW .

-- Install and adjust the windshield wiper arms.

-- Fill the engine oil and check the oil level. Refer to Standard Maintenance Service .

-- Before starting engine for the first time, fill the hydraulic oil in the power steering reservoir. Refer to Checking Hydraulic Oil Level, Bleeding Steering System and Checking for Leaks .

NOTE:

The power steering pump must not run dry.

-- Connect the coolant hoses with the connector coupling. Refer to Fig 8.

Fig 8: Connecting Coolant Hose Coupling

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-- Fill with coolant. Refer to COOLANT, DRAINING AND FILLING .

NOTE:

Only reuse drained coolant if cylinder head or engine block was not replaced.

Dirty coolant may not be used again.

-- Align the subframe and engine carrier. Refer to SUBFRAME, REMOVING AND INSTALLING .

-- Align and tighten the transmission carrier. Refer to TRANSMISSION, REMOVING AND INSTALLING .

-- Install the front wheel housing liners. Refer to Wheel Housing Liners .

-- Perform axle alignment. Refer to WHEEL ALIGNMENT .

WARNING:

Risk of accident due to loose connections.

Tighten subframe bolts to final torque after axle alignment.

-- Install the noise insulation and bracket. Refer to NOISE INSULATION, REMOVING AND INSTALLING .

-- On vehicles with air suspension, deactivate vehicle lift mode. Refer to VEHICLE LIFT MODE .