Installing Engine

WARNING: This page is about a different variant/trim than selected.

WARNING: Danger of objects or loads falling down

Risk of squashing or crushing
1. → Secure components to prevent them from falling down.

WARNING: Highly inflammable or explosive materials

Danger of fire or explosion
1. → Avoid contact with hot parts or sources of ignition.
2. → Use suction to remove ignitable vapours.
3. → Attach warning sign in a clearly visible position.
4. → Contain leaked media using non-flammable absorbent material and put it in a container designed for this purpose for disposal in accordance with local requirements.
5. → Secure collection containers/vessels to prevent them from tipping over.

NOTIFICATION

Aggressive fluids

Risk of damage to components and surfaces
1. → Do not spill fluids.
2. → In the event of contact, wash the component or surface with water.
3. → Replace components that are already damaged.

Information

O-rings on the cooling system must be replaced.
Plug connections and coolant hoses must be cleaned before fitting.
O-rings and coolant hoses must be coated with Kluber Plus Gel.

Information

O-rings must be replaced.
O-rings must be coated lightly with Kluber Syntheso Glep.

Information

All stoppers must be removed before installing the relevant components.

Check that the intermediate plate on the joint flange is engaged and pushed onto the dowel sleeves -1- Replace any missing dowel sleeves -1- .

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Dowel sleeves

Information

You will need a second mechanic to help you with this step.
Mount engine on transmission.

Fig 1: Engine Flange Screws Tightening Sequence
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Flange screws securing engine to transmission
1. 2.1 Position the starter and fit screw -6- on the starter before fitting the engine.
2. 2.2 Carefully guide the engine into the engine compartment using VAS 6100 - workshop crane and mount it on the transmission, making sure not to damage any add-on parts.
3. 2.3 Fit screws -1 and 2- .
Secure engine to engine mount brackets -1- .

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Engine mount
1. 3.1 Replace screws -2- .
2. 3.2 Relieve tension on 10-222A/10 - spindle of the 10-222A - support bracket .
3. 3.3 Lower the VAS 6100 - workshop crane and set the engine and transmission down on the engine mount brackets -1- .
4. 3.4 Remove VAS 6100 - workshop crane and 10-222A - support bracket .
5. 3.5 Screw in and tighten new screws -2- .
  Initial tightening 90 Nm
Move locking element -1- into installation position -Arrows- .

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Locking element
Loosen and remove tension strap -1- .

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Tension strap on transmission
Place starter in installation position.
Tighten flange screws on engine/transmission.

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Double clutch transmission on R4 engine
1. 7.1 Fit screws and tighten hand-tight.
2. 7.2 Tighten screws -1- .
  Initial tightening 15 Nm (11 ftlb.)
  
  Final tightening + 105°
3. 7.3 Tighten screw -3- .
  Initial tightening 30 Nm (22 ftlb.)
  
  Final tightening + 105°
4. 7.4 Screw Tightening torque 65 Nm (48 ftlb.)
5. 7.5 Tighten screws -5- .
  Initial tightening 30 Nm (22 ftlb.)
  
  Final tightening + 105°
6. 7.6 Tighten screws -6- .
  Initial tightening 30 Nm (22 ftlb.)
  
  Final tightening + 105°
7. 7.7 Tighten screws -7- .
  Initial tightening 30 Nm (22 ftlb.)
  
  Final tightening + 105°
Information

You will need a second mechanic to help you with this step.
Secure flywheel -1- on drive plate.

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Mounting for flywheel on drive plate
1. 8.1 Fit screw -2- hand-tight.
2. 8.2 Turn the crankshaft a further 120° in direction of rotation of the engine.
3. 8.3 Fit the second screw -2- . hand-tight.
4. 8.4 Turn the crankshaft a further 120° in direction of rotation of the engine.
5. 8.5 Fit the third screw -2- .
6. 8.6 Tighten all new screws and get another mechanic to counter the crankshaft pulley at the same time.
  Tightening torque 60 Nm (44.3 ftlb.)
Clip in cover -1- .

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Cover on underside of transmission
Secure transmission support -2- .

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Transmission support
1. 10.1 Position transmission support -2- . as marked before removal.
2. 10.2 Screw in and tighten screws -1 and 3- .
  Tightening torque 20 Nm (15 ftlb.)
  
  Final tightening + 90°
Secure ATF line -1- on transmission.

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ATF lines on transmission
1. 11.1 Move ATF line -1- . into installation position.
2. 11.2 Screw in and tighten screw -2- .
  Tightening torque 20 Nm (15 ftlb.)
Secure ATF lines -1- to the engine.

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ATF lines on engine
1. 12.1 Screw in and tighten screw -2- .
  Tightening torque 8 Nm (6 ftlb.)
Secure electric lines -1 and 3- to the engine mount bracket.

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Lines on engine mount bracket
1. 13.1 Position electric line -2- . and screw on and tighten nut -4- .
  Tightening torque 20 Nm (15 ftlb.)
2. 13.2 Position electric line -1- . and secure with tie-wraps -3- .
Secure electric lines with a tie-wrap -1- .

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Tie-wrap near right wheel housing
Secure ground line -2- . on the bracket in the opposite direction to -direction of arrow- . Make sure that the locking lugs -1- lock correctly.

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Ground line
Secure electric lines on the right longitudinal member.

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Electric lines on right longitudinal member
1. 16.1 Position ground line -3- . and screw on and tighten nut -4- .
  Tightening torque 9 Nm (6.5 ftlb.)
2. 16.2 Position ground lines -1 and 6- and screw on and tighten nut -2- .
  Tightening torque 9 Nm (6.5 ftlb.)
3. 16.3 Connect and lock electric plug connection -5- and secure it to the holder.
4. 16.4 Secure clip -7- on the headlight vent line -8- .
Secure housing cover -2- at the right longitudinal member. Make sure that the locking lug -1- locks correctly.

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Housing cover
Provisionally route engine wire harness -1- .

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Mounting for engine wire harness on body
1. 18.1 Carefully remove all sections of the disconnected engine wire harness -1- including relay carrier from the engine and provisionally route them roughly.
2. 18.2 Position engine wire harness -1- in line bracket -2- position and close it.
3. 18.3 Clip in clips -3- .
Secure electric line for steering -1- .

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Electric line for steering
1. 19.1 Connect and lock electric plug connection -2- .
2. 19.2 Position electric line for steering -1- in line bracket -3- and close it.
Secure electric wire harness for transmission -1- .

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Electric wire harness for transmission
1. 20.1 Connect and lock electric plug connections -2 and 3- .
2. 20.2 Clip in clips -4- .
Secure electric wire harness for engine -1- to the bracket -2- .

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Electric wire harness for engine
1. 21.1 Clip in clips -3-
Secure electric line -1- to coolant reservoir.

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Electric plug connection on coolant reservoir
1. 22.1 Connect and lock electric plug connection -2- .
2. 22.2 Clip in clips -3- .
Secure electric line for right plenum panel -1- .

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Electric line for right plenum panel
1. 23.1 Connect and lock electric plug connection -3- .
2. 23.2 Clip in clips -2- .
Secure electric line for right engine mount -1- .

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Electric plug connection for right engine mount
1. 24.1 Connect and lock electric plug connection -2- .
2. 24.2 Clip in clips -3- .
Secure ground lines -1- next to the fuse box.

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Ground lines next to fuse box
1. 25.1 Clip ground lines -1- into holder -3- as shown.
2. 25.2 Screw on and tighten nut -2- .
  Tightening torque 9 Nm (6.5 ftlb.)
Secure B+ lines -1- next to the fuse box.

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B+ lines next to fuse box
1. 26.1 Position B+ lines -1- on the distributor.
2. 26.2 Fit nuts -2 and 3- .
3. 26.3 Tighten nut -2- .
  Tightening torque 16 Nm (12 ftlb.)
4. 26.4 Tighten nut -3- .
  Tightening torque 7.5 Nm (5.5 ftlb.)
Install B+ cover -1- .

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B+ cover
Secure relay carrier -1- to the fuse box.

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Relay carrier
1. 28.1 Clip relay carrier -1- into the fuse box. Make sure that the locking lugs -4- lock correctly.
2. 28.2 Connect and lock electric plug connections -2- .
3. 28.3 Screw on and tighten nut -3- .
  Tightening torque 9 Nm (6.5 ftlb.)
Install fuse box cover -1- .

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Fuse box cover
1. 29.1 Position fuse box cover -1- and tighten screws -2- .
  Tightening torque 3 Nm (2 ftlb.)
Secure engine wire harness -1- next to the dome.

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Engine wire harness next to left dome
1. 30.1 Clip in clip -2-
Install DME control unit holder -1- .

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DME control unit holder
1. 31.1 Position DME control unit holder -1- .
2. 31.2 Clip in clips -3- .
3. 31.3 Secure electric plug connection -2- to DME control unit holder.
4. 31.4 Screw in and tighten screw -4- .
  Tightening torque 6 Nm (4.5 ftlb.)
5. 31.5 Screw on and tighten nut -5- .
  Tightening torque 6 Nm (4.5 ftlb.)
Secure vacuum line -1- to the engine.

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Vacuum line on engine
1. 32.1 Connect quick connector -3- until it engages securely.
2. 32.2 Clip vacuum line -1- into the holder -2- .
Secure vacuum lines -1- to plastic bracket -2- .

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Vacuum lines on plastic bracket
1. 33.1 Install plastic bracket -2- .
2. 33.2 Clip vacuum lines -1- into plastic bracket -2- .
3. 33.3 Connect quick connectors -4 and 5- until they engage securely.
4. 33.4 Clip in clip -3- .
Secure air-conditioning compressor -1- to the engine.

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Air-conditioning compressor
1. 34.1 Move air-conditioning compressor -1- into installation position.
2. 34.2 Screw in and tighten screws -2- .
  Tightening torque 25 Nm (19 ftlb.)
Secure wiring harness (section: front left of engine compartment) -1- .

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Wiring harness (section: front left of engine compartment)
1. 35.1 Clip in clips -3- .
2. 35.2 Connect and lock electric plug connections -2- .
Position coolant hoses -2 and 3- in clip -1- close it.

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Coolant hoses for radiator
Secure active carbon filter line -1- to the engine.

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Active carbon filter line
1. 37.1 Push on active carbon filter line -1- and secure spring band clamp -2- using VAS 6890 - spring band clamp pliers .
WARNING:
Damaged fuel lines
- Escaping fuel in the engine compartment
- Fire in the engine compartment
  1. → Do not loosen hoses using sharp-edged tools.
  2. → Replace damaged fuel lines.
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Supply line
1. 38.1 Check sealing rings on the plug-in coupling for damage and leaks and replace the supply line if necessary.
2. 38.2 Connect quick connector -3- .
3. 38.3 Clip supply line -1- into bracket -2- .
Secure coolant lines -1 and 2- to the engine.

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Coolant lines on engine
1. 39.1 Push on coolant line -1- and secure with a retaining clip -3- .
2. 39.2 Push on coolant line -2- and secure spring band clamp -4- using VAS 6890 - spring band clamp pliers.
Secure heat shields -1 and 2- to the coolant lines.

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Heat shield on coolant line
1. 40.1 Close heat shield -2- .
2. 40.2 Close heat shield -1- .
Secure coolant line -1- to the bottom of the radiator.

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Coolant line at bottom of radiator
1. 41.1 Push on coolant line -1- at the bottom of the radiator and secure with a retaining clip -4- .
2. 41.2 Clip in clip -2- .
3. 41.3 Connect electric plug connection -3- and lock it.
Secure coolant line -2- to the top of the radiator.

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Coolant line at top of radiator
1. 42.1 Push on coolant line -2- at the top of the radiator and secure with a retaining clip
Secure pressure hose -1- .

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Pressure hose on turbocharger
1. 43.1 Push pressure hose -1- onto the turbocharger.
2. 43.2 Tighten screw-type clamp -2- .
  Tightening torque 5.5 Nm (4 ftlb.)
Install pressure hose -1- .

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Pressure hose on throttle valve
1. 44.1 Move pressure hose -1- into installation position.
2. 44.2 Tighten screw-type clamps -2- .
  Tightening torque 5.5 Nm (4 ftlb.)
3. 44.3 Connect and lock electric plug connection -3- .