Installing Engine

Information 

The tightening specifications for the basic engine are stored centrally.

> 1X00IN TECHNICAL VALUES

/

> 2X00IN TECHNICAL VALUES

or

> 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES AND ASSEMBLY OVERVIEWS .

Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

Information 

• Due to currently correct tightening specifications, the screw specifications can be found in the corresponding repair descriptions for the assemblies chassis, transmission, electrics, etc. 

Information 

The pictures shown in this document may differ from the original.

1. Raise the body to a comfortable working height with the platform lift.
2. Slide the lifting platform -1-  with the engine/transmission assembly to the marked positions -A-  on the workshop floor.

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   Position of lifting platform

3. Raise the engine/transmission unit into the body using the lifting platform > Guiding engine/transmission unit into the body with the lifting platform  . Make sure there is sufficient clearance. The freely-suspended lines (e.g. PDCC) must be routed in such a way that they do not go back into the installation position (the lines must not be trapped). The insertion guides -4-  on the lifting platform must fit into the holes in the body. When doing so, use the markings used for removal as a positioning guide.

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   Lifting platform

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   Guiding engine/transmission unit into the body with the lifting platform

4. Tighten the fastening screws -arrows-  on the front-axle carrier.

   > 4X00IN TIGHTENING TORQUES FOR FRONT AXLE

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   Fastening screws for front-axle carrier and engine carrier

5. Fit fastening screws -A-  for transmission cross member.

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   Fastening screws for transmission cross member

6. Loosen the lateral supports on the wheel hubs. > Wheel hub support 
7. Fit the brake calliper.

   > 473919 Removing and installing front brake calliper - section on "INSTALLING "

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   Wheel hub support

8. Lower the lifting platform slowly and remove it.
9. Plug in electric plug connections -1, 2-  at the bottom of the transfer gear -A, B-  and lock them -a, b- 

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   Plug connections for transfer gear at the bottom

10. Plug in electric plug connections -1, 2-  at the right of the transfer gear -A, B-  and lock them -a, b-  .

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    Plug connections for transfer gear at the right

11. Push new exhaust clamps (clamping sleeves) -3-  onto the exhaust pipes. The threaded joint must be pointing downwards.

    Tighten fastening screws.

    > 260119 Removing and installing exhaust system - section on "INSTALLING "

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    Fitting clamps

12. Fit shift cable -3-  on automatic transmission -4-  .

    > 371519 Removing and installing selector lever cable - section on "INSTALLING "

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    Shift cable on automatic transmission

    1. 12.1 Clip in shift cable -3-  at the ball joint -1-  .
    2. 12.2 Fit the fastening screws -2-  .
13. Fit rear cardan shaft on the transfer gear.

    > 390219 Removing and installing cardan shaft - section on "INSTALLING "

14. Slide hose onto the hydraulic line -2-  in the front left wheel housing and position the clamp -1-  .

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    Front left hydraulic line

15. Fit the coolant line -1-  from the air-conditioning compressor to the condenser -2-  .

    > WM 874319 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR/CONDENSER LINE - section on "Installing"

    Use a new sealing ring. 

    Make sure that the guide pin at the connection point fits into the mounting for the refrigerant line.

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    Line from air-conditioning compressor to condenser

    1. 15.1 Fit the coolant line -1-  on the condenser -2-  and screw in the fastening screw -3-  .
16. Position front part of refrigerant line -2-  from the compressor to the evaporator at the longitudinal member -3-  at the left.

    > WM 874419 REMOVING AND INSTALLING CONDENSER/EVAPORATOR LINE - section on "Installing"

    Use a new sealing ring. 

    Make sure that the guide pin at the connection point fits into the mounting for the refrigerant line.

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    Front left refrigerant line

    Screw in fastening screw -1-  .

17. Attach hoses -2-  to the coolant lines in the engine compartment at the rear left and position the clamps -1-  .

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    Coolant lines in front left wheel housing

18. Fit the steering column -2-  on the steering gear -3-  .

    > 481519 Removing and installing steering column - section on "INSTALLING "

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    Installing steering column

    1. 18.1 Fit the steering column -2-  from above -arrow-  onto the steering gear -3-  (-A-  ).
    2. 18.2 Fit clamping screw.

       > 4X00IN TIGHTENING TORQUES FOR STEERING

       Always use a new clamping screw. 

19. Position the heat shield -2-  on the steering gear and fit the fastening screws -1-  .

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    Heat shield for steering gear

20. Fit ATF lines at the thermostat.

    > 386219 Removing and installing line for ATF cooling - section on "INSTALLING "

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    ATF lines from thermostat to transmission

    1. 20.1 Insert ATF lines -3-  into the thermostat -4-  .
    2. 20.2 Position holder -2-  for ATF lines -3-  to the ATF thermostat -4-  .

       Ensure that the lines are seated correctly.

    3. 20.3 Fit the fastening screw -1-  .
21. Fit the ground point on the right longitudinal member.

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    Ground point on right longitudinal member

22. Fit the wheel bearing housing on the ball joint of the upper trailing arm.

    > 401519 Removing and installing upper trailing arm (steel springs) - section on "INSTALLING "

23. Raise the axle support -1-  as far as required using a suitable jack -4-  until the fastening screw -2-  slides easily through the spring strut -3-  and axle support.

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    Spring strut threaded joint

24. Fit the fastening screw -2-  for the spring strut -3-  and trailing arm -2-  .

    > 4X00IN TIGHTENING TORQUES FOR FRONT AXLE - section on "Installing"

25. Plug in electric plug connection -1-  for the speed sensor on the wheel bearing housing -A-  and lock it -a-  .

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    Electric plug connection for speed sensor (shown as an example)

26. Position and fit the brake calliper on the brake disc at the wheel bearing housing.

    > 473919 Removing and installing front brake calliper - section on "INSTALLING "

27. Fit the holders -1, 2-  for the hydraulic lines on the wheel bearing housing -3-  .

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    Mounting for hydraulic lines

28. Fit the connecting link -2-  on the anti-roll bar -3-  and screw in the fastening screw -1-  .

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    Connecting link for anti-roll bar

29. Lower the vehicle.
30. Attach vacuum line -2-  to the vacuum pump -3-  and lock the connection -1-  .

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    Vacuum pump line

31. Attach coolant hoses -2-  at the top of the engine and fit the clamps -1-  .

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    Coolant hoses at top of engine

32. Fit the intake pipe.

    > WM, 243519 REMOVING AND INSTALLING THE THROTTLE-HOUSING COVER - section on "Installing"

33. Slide the coolant line -4-  at the bottom onto the coolant reservoir -2-  and lock the clamp -3-  .

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    Coolant lines at the reservoir

34. Attach the coolant hose -1-  to the bleeder valve and lock the clamp.
35. Plug in electric plug connections -1-  at the right cross panel -A, B-  and lock them -a, b-  .

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    Plug connections at right cross panel

36. Plug in electric plug connections -1-  at the left cross panel -A, B-  and lock them -a, b-  .

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    Plug connection at left cross panel

37. Route the engine wire harness -1-  in the plenum panel and clip it into the retaining clips -2-  .

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    Engine wire harness in plenum panel

38. Fit B+ transfer point on the left in the engine compartment. > B+ transfer point 

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    B+ transfer point

39. Plug in and lock the three electric plug connections -1-  for the engine wire harness in the relay box.

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    Plug connections in relay box

40. Close the relay box.

    > Refer to the appropriate service information

41. Fit the fuel line -1-  at the plenum panel.

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    Plenum panel lines

42. Attach tank vent lines and lock the clamp -2-  .
43. Attach vacuum hose -3-  to the lower part -4-  of the vacuum line.
44. Fit the ground strap -2-  in the plenum panel at the body and screw on the fastening nut -1-  .

    Secure the ground strap to the engine wire harness with tie-wraps -3-  if necessary.

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    Ground point on body

45. Plug in electric plug connection -1-  on the engine control unit -2-  (-A-  ) and lock it -a-  .

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    Plug connection for engine control unit

46. Fit hydraulic lines -3, 4-  at the hydraulic fluid reservoir -1-  and at the PDCC reservoir -2-  if necessary.

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    Hoses for hydraulic reservoir