Installing Engine

Information 

The tightening specifications for the basic engine are stored centrally (→ 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, 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.
   Fig 1: Position Engine Lifting Platform

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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.
   Fig 2: Lifting Engine Platform

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   Fig 3: Installing Engine/Transmission Unit Into Body

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

   → 4X00IN TIGHTENING TORQUES FOR FRONT AXLE

   Fig 4: Locating Front-Axle Carrier And Engine Carrier Screw

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5. Fit fastening screws -A-  for transmission cross member.
   Fig 5: Identifying Transmission Cross Member Fastening Screws

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6. Loosen the lateral supports on the wheel hubs. → Wheel hub support 
7. Fit the brake calliper. → REMOVING FRONT BRAKE CALLIPER
   Fig 6: Locating Wheel Hub Support

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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- 
   Fig 7: Removing Transfer Gear Plug Connections

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10. Plug in electric plug connections -1, 2-  at the right of the transfer gear -A, B-  and lock them -a, b-  .
    Fig 8: Installing Transfer Gear Plug Connections

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

    Tighten fastening screws. → INSTALLING EXHAUST SYSTEM

    Fig 9: Locating Exhaust Clamps

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

    → INSTALLING SELECTOR LEVER CABLE

    1. 12.1. Clip in shift cable -3-  at the ball joint -1-  .
    2. 12.2. Fit the fastening screws -2-  .
    Fig 10: Identifying Automatic Transmission Shift Cable

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13. Fit rear cardan shaft on the transfer gear. → INSTALLING REAR CARDAN SHAFT
14. Slide hose onto the hydraulic line -2-  in the front left wheel housing and position the clamp -1-  .
    Fig 11: Identifying Front Left Hydraulic Line

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15. Fit the coolant line -1-  from the air-conditioning compressor to the condenser -2-  . → INSTALLING AIR-CONDITIONING COMPRESSOR/CONDENSER LINE

    Use a new sealing ring  .

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

    1. 15.1. Fit the coolant line -1-  on the condenser -2-  and screw in the fastening screw -3-  .
    Fig 12: Identifying Air-Conditioning Compressor To Condenser Line
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16. Position front part of refrigerant line -2-  from the compressor to the evaporator at the longitudinal member -3-  at the left. → INSTALLING CONDENSER/EVAPORATOR LINE AT THE FRONT

    Use a new sealing ring  .

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

    Screw in fastening screw -1-  .

    Fig 13: Identifying Front Left Refrigerant Line

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17. Attach hoses -2-  to the coolant lines in the engine compartment at the rear left and position the clamps -1-  .
    Fig 14: Identifying Front Left Wheel Housing Coolant Lines

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

    → INSTALLING STEERING COLUMN (CENTRE)

    1. 18.1. Fit the steering column -2-  from above -arrow-  onto the steering gear -3-  (-A-  ).
    Fig 15: Installing Steering Column
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    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-  .
    Fig 16: Identifying Steering Gear Heat Shield

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20. Fit ATF lines at the thermostat. → INSTALLING LINES FOR ATF COOLING
    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-  .
    Fig 17: Identifying Thermostat To Transmission ATF Lines

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21. Fit the ground point on the right longitudinal member.
    Fig 18: Locating Right Longitudinal Member Ground Point

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22. Fit the wheel bearing housing on the ball joint of the upper trailing arm. → INSTALLING UPPER TRAILING ARM (STEEL SPRINGS)
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.
    Fig 19: Locating Spring Strut Threaded Joint

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24. Fit the fastening screw -2-  for the spring strut -3-  and trailing arm -2-  . → 4X00IN TIGHTENING TORQUES FOR FRONT AXLE
25. Plug in electric plug connection -1-  for the speed sensor on the wheel bearing housing -A-  and lock it -a-  .
    Fig 20: Locating Speed Sensor Electric Plug Connection

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26. Position and fit the brake calliper on the brake disc at the wheel bearing housing. → INSTALLING FRONT BRAKE CALLIPER
27. Fit the holders -1, 2-  for the hydraulic lines on the wheel bearing housing -3-  .
    Fig 21: Identifying Hydraulic Lines Mounting

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28. Fit the connecting link -2-  on the anti-roll bar -3-  and screw in the fastening screw -1-  .
    Fig 22: Identifying Anti-Roll Bar Connecting Link

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29. Lower the vehicle.
30. Attach vacuum line -2-  to the vacuum pump -3-  and lock the connection -1-  .
    Fig 23: Identifying Vacuum Pump Line

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31. Attach coolant hoses -2-  at the top of the engine and fit the clamps -1-  .
    Fig 24: Identifying Engine Coolant Hoses

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32. Fit the intake pipe. → INSTALLING COWL FOR THROTTLE HOUSING (Y-PIPE)
33. Slide the coolant line -4-  at the bottom onto the coolant reservoir -2-  and lock the clamp -3-  .
34. Attach the coolant hose -1-  to the bleeder valve and lock the clamp.
    Fig 25: Identifying Coolant Reservoir Lines

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35. Plug in electric plug connections -1-  at the right cross panel -A, B  and lock them -a, b-  .
    Fig 26: Attaching Right Cross Panel Plug Connections

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36. Plug in electric plug connections -1-  at the left cross panel -A, B  and lock them -a, b-  .
    Fig 27: Attaching Left Cross Panel Plug Connections

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37. Route the engine wire harness -1-  in the plenum panel and clip it into the retaining clips -2-  .
    Fig 28: Identifying Plenum Panel Engine Wire Harness

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38. Fit B+ transfer point on the left in the engine compartment. → B+ transfer point 
    Fig 29: Attaching B Positive Transfer Point

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39. Plug in and lock the three electric plug connections -1-  for the engine wire harness in the relay box.
    Fig 30: Identifying Relay Box Plug Connections

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40. Close the relay box. → SECURING MAIN WIRE HARNESS IN ENGINE COMPARTMENT AT THE LEFT
41. Fit the fuel line -1-  at the plenum panel.
42. Attach tank vent lines and lock the clamp -2-  .
43. Attach vacuum hose -3-  to the lower part -4-  of the vacuum line.
Fig 31: Identifying Plenum Panel Lines
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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.

    Fig 32: Identifying Body Ground Point

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45. Plug in electric plug connection -1-  on the engine control unit -2-  (-A-  ) and lock it -a-  .
    Fig 33: Locating Engine Control Unit Plug Connection

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46. Fit hydraulic lines -3, 4-  at the hydraulic fluid reservoir -1-  and at the PDCC reservoir -2-  if necessary.
    Fig 34: Identifying Hydraulic Reservoir Hoses

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