Attaching the engine to the lifting table

Lift the engine using a workshop crane (1) and the special tool 0 490 567 (11 0 020) in the engine mount.

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Tighten down screw (1).

TIGHTENING TORQUE SPECIFICATIONS

Engine mount to engine support bracket
Screw M12x1.5x40	Tightening torque	100 Nm

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Tighten down screw (1).

TIGHTENING TORQUE SPECIFICATIONS

Engine mount to engine support bracket
Screw M12x1.5x40	Tightening torque	100 Nm

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Replace the O-rings (1) on the lines of the engine oil cooler.
Parts: O-rings
Coat the O-rings (1) with engine oil.

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Variant with coolant radiator:
Position the coolant lines (2).

NOTE: TECHNICAL INFORMATION
Collect and dispose of emerging fluids.
Observe country-specific waste disposal regulations.

Tighten nuts (1).

TIGHTENING TORQUE SPECIFICATIONS

Lines to the upstream engine oil cooler
Nut M8	Tightening torque	18 Nm

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Loosen screws (2).
Remove the swivel bearing mount (1) and set it aside.
Hold the swivel bearing with the special tool 2 220 718 .

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Check

Replace the circlip (1).
Parts: Circlip
Coat the contact surface (2) of the output shaft with the recommended front differential oil.
Check the gearing for damage or deformation.

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Result

» The gearing is deformed or damaged.

Measure

Replace the output shaft.
Parts: Output shaft
Clean and degrease front gearing of wheel bearing (1) and output shaft (2).
Install front gearing of wheel bearing (1) and output shaft (2) and establish a positive connection.
Twist both the wheel hub and the output shaft in arrow direction to ensure that the front gearings mesh.

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Replace the screw (1) and the compression spring (2).
Parts: Screw, compression spring
Clean and degrease the screw (1).
Observe the installation position of the compression spring (2)!

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NOTE: TECHNICAL INFORMATION
Radial shaft seal ring are equipped with an installation protection ring. The installation protection ring is used to protect the sealing lip when installing the output shaft.

Open the installation protection ring (1) in the arrow direction before assembly of the output shaft.

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Insert the output shaft (1) in the arrow direction.
Release the installation protection ring (2) and feed it out a little.
Apply force to pull the installation protection ring (2) downward in the arrow direction until the predetermined breaking points (3) on the installation protection ring break.

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Install the stand (2) of the swivel bearing (3).
Hand-tighten the screws (1).

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Tilt the swivel bearing (2) slightly forward in the arrow direction.
Insert the output shaft (3) into the front axle differential up to the stop until you feel the output shaft (3) lock in place.

Tighten screw (1) with the special tool 0 490 504 (00 9 120) .

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TIGHTENING TORQUE SPECIFICATIONS

Output shaft to wheel bearing
M16 Replace collar screw and spring.	Joining torque	210 Nm
	Angle of rotation	90°

Variant with sealing cap:
Attach the sealing cap (1).

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Checking lining sleeves

Check the fitting sleeves (1) for correct seating and damage and replace if necessary.

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Slide transmission (1) to the front and position at the engine.

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Apply retaining screws (1) on the lifting table (2) on both sides hand-tight.

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Flange-mount transmission

Transmission flange-mount.
Rotate torque converter until bore in torque converter is flush with bore in drive plate.

Join and tighten the transmission bolts (arrows).

TIGHTENING TORQUE SPECIFICATIONS

Transmission to engine
M8	tightening torque	19 Nm
M10	tightening torque	38 Nm

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Remove the special tool from the torque converter

Release the screws (1) and (2).
Remove the special tool 0 494 451 (24 4 160) .

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Replace screws (1).
Parts: Screws
Screw the torque converter onto the vertically arranged elongated hole.
It is imperative to first screw the torque converter on the vertically arranged elongated hole.
Turn the torque converter until the elongated hole is visible in the opening.

Tighten down screw (1).

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TIGHTENING TORQUE SPECIFICATIONS

Torque converter to flywheel
M10 Replace screws.	tightening torque	60 Nm

Turn the crankshaft at central bolt only in clockwise direction.

Observe the tightening sequence of the additional five screws (torque converter on flywheel) compulsorily:

Tightening sequence: 4 - 3 - 6 - 5 - 2

The screw connection (1) is the vertically arranged elongated hole in the torque converter.

TIGHTENING TORQUE SPECIFICATIONS

Torque converter to flywheel
M10 Replace screws.	tightening torque	60 Nm

Fig 1: Torque Converter Screws Tightening Sequence

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Install the cover (1).

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Position the front prop shaft (2).
Replace screws (1).
Parts: Screws

Tighten down screws (1).

TIGHTENING TORQUE SPECIFICATIONS

Prop shaft before the front axle differential
Replace screws. Joining torque and angle of rotation must be observed without fail.	Tightening torque	25 Nm
	Angle of rotation	45°

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Detach the engine on the engine mounting bracket with a workshop crane and special tool 0 490 567 (11 0 020) .

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Using suitable screwdrivers (3), unclip the retaining clips (1) upwards from the surrounding guides (2).
Locking of the retaining clips (1) in the unlocking position is not possible due to the design.
Remove clean air pipe of bank 1 (4).

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NOTE: TECHNICAL INFORMATION
Check the plastic components of the locking mechanism or clamp for damage.
Replace the charge air ducts with damaged plastic components on the locking mechanism.

Connect the right charge air line (2) to the exhaust turbocharger.
Lock the lock (1) audibly.

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Replace the sealing ring.
Parts: Sealing ring
Install hydraulic lines (1) on transmission in the arrow direction.

Position and tighten the screw (2).

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TIGHTENING TORQUE SPECIFICATIONS

Transmission oil line to transmission
M6x25 Replace sealing rings.	tightening torque	8 Nm

Tighten nut (1).

TIGHTENING TORQUE SPECIFICATIONS

Transmission oil line to transmission
M6x25 Replace the sealing ring.	tightening torque	8 Nm

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Release the luggage strap (1) from the transmission (2).

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Connect connectors (1) and lock.

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Lock the thermal protection (2) at the push-button (1).

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Connect the connector (1) to the transfer box (TB) and lock it.
Fix wiring harness fasteners (2).
Connect connector (3) on the automatic transmission and lock it.
Remove ground cable.

Tighten down screw (4).

TIGHTENING TORQUE SPECIFICATIONS

Ground connection on transmission
M6x12 screw	Tightening torque	10 Nm

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Feed in and install the catalytic converters (3).

Loosen nuts (1).

TIGHTENING TORQUE SPECIFICATIONS

Catalytic converter to holder
M8 Nut Replace nut.	tightening torque	23 Nm

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Loosen screws (2).

TIGHTENING TORQUE SPECIFICATIONS

Catalytic converter to holder
M8x20 Replace screw.	tightening torque	19 Nm

Replace the circlips (2).
Parts: Clamps

Mount circlips (2) and tighten screws (1).

The clamps (2) must be mounted with the screw connection inwards.

TIGHTENING TORQUE SPECIFICATIONS

Catalytic converter to exhaust turbocharger
cl Replace clamp after disassembly.	Tightening torque	14 Nm

Tighten the screws (3) on the catalytic converters (4).

TIGHTENING TORQUE SPECIFICATIONS

Catalytic converter on cylinder head/cylinder head cover/holder
M8x20	tightening torque	21 Nm

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Feed in the heat shield (3) and (4) at the retaining tabs (2).

Tighten down screws (1).

TIGHTENING TORQUE SPECIFICATIONS

Heat protection plate
M6x16	tightening torque	10 Nm

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Tighten down screws (1).

TIGHTENING TORQUE SPECIFICATIONS

Heat protection plate
M6x16	tightening torque	10 Nm

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Variant with a gasoline particulate filter:

Clip the pressure lines (3) into the retaining clips in areas (1).

Tighten union nuts (2).

TIGHTENING TORQUE SPECIFICATIONS

Pressure line to catalytic converter near engine
Pressure line	Tightening torque	20 Nm

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Position the top heat shield (2).

Tighten down screws (1).

TIGHTENING TORQUE SPECIFICATIONS

Heat protection plate
M6x16	tightening torque	10 Nm

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Position oxygen sensor monitor probe.

Tighten the oxygen sensor monitor with the special tool 0 491 074 (11 7 020) .

TIGHTENING TORQUE SPECIFICATIONS

Front Lambda oxygen sensor/oxygen sensor monitor on catalytic converter
M18x1.5	tightening torque	50 Nm

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Push on the heat protection wire ring (2) until the stop is reached.
Affix the retaining clip (1).
Clip cable of oxygen sensor control probe into holder (1).

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Clip the cable of the oxygen sensor monitor into the clamps (1).

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Connect connectors (1) and lock.

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Clip the cable of the oxygen sensor monitor into the clamp (1).
Slide the plug connector backwards to the stop.

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Install and tighten the oxygen sensor monitor using the special tool 0 491 074 (11 7 020) .

TIGHTENING TORQUE SPECIFICATIONS

Front Lambda oxygen sensor/oxygen sensor monitor on catalytic converter
M18x1.5	tightening torque	50 Nm

Slide the heat protection wire ring (2) over the oxygen sensor monitor.

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Clip in the retaining clip (1).
Clip the cable (1) of the oxygen sensor monitor into the holders (2).

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Clip the cable (1) of the oxygen sensor monitor into the holders (2).

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Clip the cable (1) of the oxygen sensor monitor into the holders (2).

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Pass the connector (2) of the oxygen sensor monitor under the engine ventilation line (1).

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Connect connectors (1) and lock.

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Slide the plug connection of the oxygen sensor monitor (2) downwards in area (1) and secure.

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Attach the holder in the area (1) to the charge air cooler (2).

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Connect the quick-release coupling (1) and lock.

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Clip in the wiring harness mounting (1) at the heat shield.

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Clip in the wiring harness mounting (1) at the heat shield.

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Clip in the connector (2) downwards in the heat shield.
Clip the transmission wiring harness on to the bracket (1).

Tighten the screws (3).

TIGHTENING TORQUE SPECIFICATIONS

Support bridge
M6x16 screw	Tightening torque	10 Nm

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Tighten down screws (1).

TIGHTENING TORQUE SPECIFICATIONS

Support bridge
M6x16 screw	Tightening torque	10 Nm

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Tighten the oxygen sensor monitor at right (1) with the special tool 0 491 074 (11 7 020) .

TIGHTENING TORQUE SPECIFICATIONS

Front Lambda oxygen sensor/oxygen sensor monitor on catalytic converter
M18x1.5	tightening torque	50 Nm

Secure the right Lambda oxygen sensor cable in area (2) in the cable bracket.

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Feed the connector (2) of the Lambda oxygen sensor through.
Connect and lock the engine ventilation line to the retaining clip in the region of (1).

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Connect connectors (1) and lock.

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Clip the cable for the primary oxygen sensor into the holder (1).

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Tighten the oxygen sensor monitor at right (2) with the special tool 0 491 074 (11 7 020) .

TIGHTENING TORQUE SPECIFICATIONS

Front Lambda oxygen sensor/oxygen sensor monitor on catalytic converter
M18x1.5	tightening torque	50 Nm

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Fix the cable of the right Lambda oxygen sensor in the area (1) in the cable bracket.

Guide in the right Lambda oxygen sensor and position.
Connect connectors (1) and lock.

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Connect and lock the engine ventilation line to the retaining clip in the region of (1).

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Clip cable of oxygen sensor control probe into holder (1).

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Clip in the wiring harness from the attachment points (2).
Working downwards, clip in the engine ventilation line (1).