Installing the engine from the lifting table

• Lift the engine using a workshop crane (1) and the cross-member 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 O-ring (1) with engine oil.

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• Position hydraulic lines (2).
  NOTE: TECHNICAL INFORMATION 
  Collect and dispose of emerging fluids.
  Observe country-specific waste disposal regulations.
• Tighten nuts (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).

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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.

  Parts:  Screws

• First 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).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

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

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• Crankshaft at central bolt may only be turned clockwise. 
• Observe the tightening sequence of the additional five screws (torque converter on flywheel) compulsorily: 

  Tightening sequence: 1 - 4 - 3 - 6 - 5 - 2 

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

  Fig 1: Torque Converter Screws Tightening Sequence

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  TIGHTENING TORQUE SPECIFICATIONS
  
  

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

• Install the cover (1).

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• Position the prop shaft in front (1).
• Replace screws (1).

  Parts:  Screws

• Tighten down screws (1).

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Installing clean air pipe of cylinder bank 1 

• Position the clean air pipe of cylinder bank 1 (2) in direction of arrow and slide it on.

  The retaining clips (1) must engage audibly.

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• Position the tank vent line (2) and push it on.

  The tank ventilation line (2) must be audibly locked to the catch (1).

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• Detach the engine from the engine mounting brackets using a workshop crane and the crossmember 0 490 567 (11 0 020) .

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Installing catalytic converter near the engine above cylinder bank 1 

• Replace the V-ribbon clip (1).

  Parts:  V-band clamp

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• Replace gasket (1).

  Parts:  Seal

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• Position the catalytic converter near engine (1) in the holder (2).

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• Position V-clip (3).
• Tighten down screw (2).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Catalytic converter to exhaust turbocharger
  V-band clamp Replace V-band clamp.	Tightening torque	14 Nm

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• Tighten down screws (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Catalytic converter to cylinder head
  screw	Tightening torque	21.4 Nm

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• Tighten down screws (1).

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Checking the screw connection of the V-ribbon clips 

• Replace the V-ribbon clip (1).

  Parts:  V-band clamp

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Check 

• Check if the screw connection of the V-band clamp is too loose.

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Result 

» The screw connection is too slack. If a gap can be seen between the ends of the V-ribbon clips.

Measure

• Loosen the screw and tighten again.

Check 

• Check if the screw connection of the V-band clamp is too tight.

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Result 

» The screw connection is too tight. The ends of the V-ribbon clip are not positioned parallel.

Measure

• Release the screw and replace the V-ribbon clip.

Parts:  V-band clamp

• Make sure that the ends of the V-band clamp are parallel to each other.

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Installing upper catalytic converter near engine for bank 2 

• Replace the V-ribbon clip (1).

  Parts:  V-band clamp

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• Replace gasket (1).

  Parts:  Seal

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• Position the catalytic converter near engine (1) in the holder (2).

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• Position the catalytic converter (1) near the engine.
• Position V-clip (3).
• Tighten down screw (2).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Catalytic converter to exhaust turbocharger
  V-band clamp Replace V-band clamp.	Tightening torque	14 Nm

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• Tighten down screws (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Catalytic converter to cylinder head
  screw	Tightening torque	21.4 Nm

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• Tighten down screws (1).

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Checking the screw connection of the V-ribbon clips 

• Replace the V-ribbon clip (1).

  Parts:  V-band clamp

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Check 

• Check if the screw connection of the V-band clamp is too loose.

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Result 

» The screw connection is too slack. If a gap can be seen between the ends of the V-ribbon clips.

Measure

• Loosen the screw and tighten again.

Check 

• Check if the screw connection of the V-band clamp is too tight.

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Result 

» The screw connection is too tight. The ends of the V-ribbon clip are not positioned parallel.

Measure

• Release the screw and replace the V-ribbon clip.

  Parts:  V-band clamp

• Make sure that the ends of the V-band clamp are parallel to each other.

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Installing the upper heat shield (engine removed) 

• Snap the upper heat shield (2) into the clamp (1) on the cowl side.

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• Position the top heat shield (2).
• Tighten down screws (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Heat shield, top
  M6x16 screw	Tightening torque	8 Nm

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• Position holder (3).
• Clip the pressure lines into the clamps in the areas (1) and (2).

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• Position the holder for the pressure pipe (2).
• Tighten the screws (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Holders for the pressure pipes on the top heat shield
  M6x16 screw	Tightening torque	8 Nm

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• Position the holder for the expansion tank (1).

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• Snap line (2) into the cable brackets.
• Tighten down screws (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Holder, expansion tank
  M6x16 screw	Tightening torque	8 Nm

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• Engage the hose (1).

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• Secure the wiring harness mounting (1).

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• Position the gasoline particulate sensor holder (2) with the sensor with the centering pin (3).
• Tighten down screw (1).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Holder of gasoline particulate filter to holder for expansion tank
  M6x16	Tightening torque	8 Nm

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• Position the gasoline particulate sensor holder (2) with the sensor with the centering pin (3).
• Tighten down screw (1).

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Installing the Lambda oxygen sensor for the cylinders 5 to 8 

• Position the Lambda oxygen sensor (1).
• Tighten the Lambda oxygen sensor (1) with the special tool 0 491 074 (11 7 020) .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Lambda control sensor
  Front oxygen sensor M18X 1.5	tightening torque	50 Nm

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• Engage cable into the latch mechanisms (2).
• Attach the connector (1) and engage in the holder.

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Installing the Lambda oxygen sensor for the cylinders 1 to 4 

• Position the Lambda oxygen sensor (1).
• Tighten the Lambda oxygen sensor (1) with the special tool 0 491 074 (11 7 020) .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Lambda control sensor
  Front oxygen sensor M18X 1.5	tightening torque	50 Nm

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• Engage cable into the latch mechanisms (2).
• Attach the connector (1) and engage in the holder.

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Installing the catalytic converter near engine, bottom at bank 1 

• Replace gasket (1).

  Parts:  Seal

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• Position the catalytic converter at the bottom of cylinder bank 1 (2).
• Replace nuts (1).

  Parts:  Nuts

• Tighten nuts (1).

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Installing the catalytic converter near engine, bottom at bank 2 

• Replace gasket (1).

  Parts:  Seal

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• Position the catalytic converter at the bottom of cylinder bank 2 (2).
• Replace nuts (1).

  Parts:  Nuts

• Tighten nuts (1).

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• Unlock and disconnect the plug connection (1) from the VTG.
• Release the wiring harness mountings (2).
• Unlock and disconnect the plug connection (3) from the automatic transmission.
• Release the screw in area (4).
• Remove ground cable.

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• Unlock plug connection (1) and disconnect.

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• Lash transmission with commercially available tensioning strap (1).

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• Loosen nut (1).

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• For equipment specification up to 31/07/2018 
• Loosen screw (3).
• Release hydraulic lines (1) and (2) to the transmission oil cooler.

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• For equipment specification up to 31/07/2018 
• Unclip the transmission oil thermostat (1) upward from the decoupling elements (2).
• Remove transmission oil thermostat (1) with the wires.

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• For equipment specification from 01/08/2018 on 
• Loosen screw (1).
• Pull transmission oil lines (2) out of the thermostat (3) and set them aside.
• Catch and dispose of escaping transmission oil.

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• For equipment specification from 01/08/2018 on 
• Loosen screw (1).
• Pull thermostat (2) out of the connections on the transmission and remove.

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• Loosen screws (1).
• Lower and store front prop shaft (1).

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• Remove cover (1).

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• Release converter bolt (1).

  Crankshaft at central bolt may only be turned clockwise. 

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• Prepare special tool 0 494 451 (24 4 160) (1) with the shaped part 0 494 622 (24 4 164) (2) as shown.

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• Insert the special tool 0 494 451 (24 4 160) in the recess of the transmission housing and lightly fix it with the screw (1).
• Screw the bolt (2) in to the stop.
• Tighten screw (1) by hand.

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• Support engine.
• Loosen the screws (arrows) and remove the transmission.

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• Release retaining screws (1) on the lifting table (2) on both sides by a few threads.

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• Secure the engine at the engine mounting brackets using a workshop crane and the cross-member 0 490 567 (11 0 020). 

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• Slide transmission (1) to the rear and disconnect from the engine.

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• Position the equalization tank for the charge air cooler.
• Catch and dispose of escaping coolant.
• Press coolant lines (4) in the lock (3) and lock.
• Position connecting bracket (2) of the coolant line on the charge air cooler.

  The retaining spring (1) must engage audibly.

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• Tighten down screw (2).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Low-temperature coolant circuit expansion tank
  Tightening torque	screw	2.6 Nm

• Top up coolant to maximum mark. 
• Top up coolant.

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• Install sealing cap (1) of the equalization tank for the charge air cooler.
• Connect and lock the coolant ventilation line (2) engine-side.
• Connect and lock the coolant ventilation line (1) radiator-side.
• Tighten down screws (3).
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Coolant reservoir
  M6x20 screw	Tightening torque	11 Nm

• Clip in the fuel lines in area (4).

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