Engine, Installing

Special tools and workshop equipment required 

• All special tools listed when removing.

Procedure

• Replace bolts that were tightened with an additional turn after removing them.
• Replace the self-locking nuts and bolts, gaskets, seals and O-rings after removing.
• Only remove the plugs or caps just before installing the respective lines.
• The hose connections as well as air duct pipes and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts Information.
• Check the vacuum hoses for damage before the assembly and replace if necessary.
• During installation, all cable ties must be installed at the same location.
• Bonded rubber bushings have a limited range of rotation. Only tighten suspension threaded connections when vehicle is in curb weight position or in the control position.

-- Bring the starter into the installation position.

-- Tighten the plug for "TDC" hole. Refer to OVERVIEW - CRANKSHAFT .

-- Install the engine supports and engine mount. Refer to OVERVIEW - ASSEMBLY MOUNTS .

• Secure the engine with the subframe on the Scissor Lift Table:VAS6131B  .

-- Check the sensor wheel for engine speed sensor. Refer to Crankshaft ; check the sensor wheel.

-- Install the transmission on the engine. Refer to TRANSMISSION, INSTALLING .

-- Install the coolant pipes. Refer to COOLANT PIPES, REMOVING AND INSTALLING .

-- Install the exhaust system. Refer to OVERVIEW - MUFFLER .

-- Carefully guide the engine/transmission assembly into the body using the Scissor Lift Table:VAS6131B  .

-- Remove the locating pins and install the subframe. Refer to appropriate Service Information .

-- Install the ribbed belt tensioner for the A/C compressor. Refer to RIBBED BELT TENSIONER, REMOVING AND INSTALLING .

-- Install the A/C compressor. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING .

-- Install the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .

Install in reverse order of removal. Note the following:

-- Tighten the tunnel crossmember bolts. Refer to ASSEMBLY MOUNTS .

-- Install the parking lock emergency release cable. Refer to SHIFT MECHANISM .

-- Install the steering intermediate shaft. Refer to appropriate Service Information .

-- Install the coupling rod. Refer to appropriate Service Information .

-- Tighten the drive axles. Refer to appropriate Service Information .

-- Install the lower control arm. Refer to appropriate Service Information .

-- Install the tie rod end. Refer to appropriate Service Information .

-- Install the steering gear boot. Refer to appropriate Service Information .

-- Install the subframe crossbrace and shield. Refer to appropriate Service Information .

-- Install the tunnel brace. Refer to OVERVIEW - UNDERBODY BRACING .

-- Install the level control system sensor. Refer to appropriate Service Information .

-- Install the Terminal 40 Wire Junction - TV66-. Refer to OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES .

-- Tighten the ground wires. Refer to Wiring Diagram.

-- Connect the fuel hoses. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Install the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Install the heat shield and engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Install the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

-- Install the lock carrier cover. Refer to OVERVIEW - BUMPER COVER .

-- Install the wheel spoiler and wheel housing liner. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

-- Mount the front wheels. Refer to WHEELS AND TIRES .

-- Fill the engine oil:

• A6. Refer to => Maintenance Work; Engine Oil: Fill.
• A7. Refer to => Maintenance Work; Engine Oil: Fill.

-- Check the oil level.

• A6. Refer to => Maintenance Work; Engine Oil; Oil Level, Checking and Correcting if Necessary.
• A7. Refer to => Maintenance Work; Engine Oil; Oil Level, Checking and Correcting if Necessary.

-- Follow all steps after connecting the battery. Refer to BATTERY A, DISCONNECTING AND CONNECTING, VEHICLES WITH HIGH-VOLTAGE SYSTEM, (0K3) .

-- After replacing the engine, perform the adaptations listed in the "0001 - mechanical engine functions" in Guided Functions using the Vehcile Diagnostic Tool.

-- Connect the coolant hose to the connector coupling. Refer to Fig 1.

-- Fill the coolant. Refer to Coolant, Filling .

-- Check the ATF level. Refer to ATF LEVEL, CHECKING .

-- Install the underbody trim panels. Refer to OVERVIEW - UNDERBODY TRIM PANELS .

-- Install the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

Tightening Specifications

• The tightening specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
• Additional lubricants, such as engine or transmission oil are permitted, 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