Installing motor

Fig 1: Front-Axle Carrier Assembly Screws Tightening Sequence

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Front-axle carrier assembly

1. 2.1 Move front-axle carrier -1-  into installation position and screw in rear screws on front-axle carrier -2-  by hand.
2. 2.2 > T40327 - Locating pin  must be unscrewed at the position of screw -3-  , replace it with screw -3-  and tighten screw -3-  .

   > Initial tightening torque 115 Nm (84.8 ftlb.) 

   > Final tightening torque + 90° 

3. 2.3 Repeat the procedure one after the other in diagonally opposite sequence  for screws -4 to 6-  .

   > Initial tightening torque 115 Nm (84.8 ftlb.) 

   > Final tightening torque + 90° 

4. 2.4 Tighten rear screws on front-axle carrier -2-  .

   > Initial tightening torque 130 Nm (95.9 ftlb.) 

   > Final tightening torque + 180° 

> Tightening torque 55 Nm (41 ftlb.) 

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Transmission support

Information 

The procedure for removing and installing is described for one side as an example. The procedure for the other side is practically identical.

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Threaded joints on chassis

1. 5.1 Position upper trailing arm -2-  , lower trailing arm and tie rod -4-  .
2. 5.2 Replace nut on tie-rod ball -3-  and screw and nut securing spring strut to lower trailing arm -5-  .
   WARNING: Wheel bearing housing raised incorrectly 

   • Risk of crushing 
   • Risk of damage to components 
     1. → Wear personal protective gear.
     2. → Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels).

   Information 

   Threaded joints must only be tightened in zero position to prevent warping in the bearings.

3. 5.3 Before tightening the trailing arm screws: Lift the wheel suspension to zero position using lifting equipment (e.g. > VAS 6931 - engine and gearbox jack  ).

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   Zero position (shown on rear axle as an example)

4. 5.4 Tighten screw on upper trailing arm -1-  and counter at the nut at the same time.

   > Tightening torque 40 Nm (30 ftlb.) 

5. 5.5 Tighten screw securing spring strut to lower trailing arm -5-  and counter at the nut at the same time.

   > Initial tightening 90 Nm (67 ftlb.) 

   > Final tightening + 90° 

6. 5.6 Tighten nut securing tie-rod ball to wheel bearing housing -3-  .

   > Tightening torque 140 Nm (103.3 ftlb.) 

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Connecting link

1. 6.1 Replace screws on connecting link -2-  and nuts on connecting link.
2. 6.2 Tighten screws on connecting link -2-  and counter at the nuts at the same time.

   (Only for vehicles with PDCC) 

   > Initial tightening 60 Nm (44 ftlb.) 

   > Final tightening + 90° 

   (Only for vehicles without PDCC) 

   > Initial tightening 40 Nm (30 ftlb.) 

   > Final tightening + 90° 

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Coolant hose on top of radiator

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Coolant hose

1. 8.1 Move coolant hose -1-  into installation position.
2. 8.2 Fit and lock line connection -2-  .

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High-voltage line guide

1. 9.1 Move high-voltage line guide -1-  into installation position.
2. 9.2 Secure clip -2-  and screw on and tighten nuts -3-  .

   > Tightening torque 9 Nm (6.6 ftlb.) 

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High-voltage line connections

1. 10.1 Connect high-voltage line connections -1-  to the power electronics unit.
2. 10.2 Tighten screws on high-voltage connections -2-  .

   > Tightening torque 7 Nm (5.2 ftlb.) 

3. 10.3 Tighten nuts on line guide -3-  .

   > Torque 5 Nm (3.7 ftlb.) 

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High-voltage line for air-conditioning compressor

1. 12.1 Connect high-voltage plug connection on power electronics unit and air-conditioning compressor until it engages securely and lock the red locking mechanism.

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Cover on high-voltage power electronics

1. 13.1 Move cover for high-voltage power electronics -1-  into installation position.
2. 13.2 Tighten screws -2-  .

   > Tightening torque 25 Nm (19 ftlb.) 

3. 13.3 Tighten nuts -3-  .

   > Tightening torque 25 Nm (19 ftlb.) 

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Electric wire harness for transmission, rear

1. 14.1 Connect and lock electric plug connection -1-  and push sleeve over electric plug connection.
2. 14.2 Fasten clips -2-  .
3. 14.3 Connect and lock electric plug connections -3-  .
4. 14.4 Fasten clips -4 and 5-  .

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Electric wire harness for transmission, front

1. 15.1 Connect and lock electric plug connections -1 to 3-  .
2. 15.2 Fasten clips -4 and 5-  .

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Electric wire harness for transfer gear

1. 16.1 Connect and lock electric plug connection for transfer gear -1-  .
2. 16.2 Fasten clips -2-  .

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Electric plug connection

1. 17.1 Connect and lock electric plug connection -1-  .
2. 17.2 Fasten clips -2-  .

Information 

• Observe mounting specification for torque converter threaded joint! 

Information 

To make it easier to turn the engine, the drive belts can be removed from the generator and air-conditioning compressor.

> Removing and installing drive belt (V8 biturbo) 

Information 

For loosening/tightening the screws on the drive plate, always counter at the central screw on the vibration damper. The help of another person is required.

Fit drive plate screws -1-  .

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Drive plate screws

1. 18.1 Screw in and tighten one drive plate screw -1-  .

   > Tightening torque 60 Nm (44 ftlb.) 

2. 18.2 Turn the engine further and repeat the procedure on all drive plate screws -1-  .
3. 18.3 Fit cap -2-  .

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Universal joint for steering

1. 19.1 Connect universal joint for steering -1-  to the steering gear -2-  .
2. 19.2 Replace screw on universal joint for steering -3-  .
3. 19.3 Tighten universal joint for steering -3-  using > VAS 6928 - socket/bit set, 39-piece  .

   > Initial tightening 20 Nm (14.8 ftlb.) 

   > Final tightening + 90° 

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ATF cooler

1. 20.1 Connect and lock line connection for coolant hose -2-  .
2. 20.2 Only if automatic transmission was removed:  Move ATF cooler -1-  into installation position.
3. 20.3 Only if automatic transmission was removed:  Tighten screws on ATF cooler -3-  .

> Tightening torque 8 Nm (6 ftlb.) 

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Coolant hose

1. 21.1 Push coolant hose -1-  onto coolant line.
2. 21.2 Fit spring band clamp -2-  using > VAS 6890 - spring band clamps pliers  .

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Pressure hose on pressure pipe

1. 22.1 Push pressure hose -1-  onto pressure pipe -2-  .
2. 22.2 Push screw-type clamp -3-  onto pressure hose -1-  and tighten it.

   > Tightening torque 5.5 Nm (4.1 ftlb.) 

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Coolant hose on radiator

1. 23.1 Connect and lock coolant hose connection -2-  .
2. 23.2 Connect and lock electric plug connection -3-  .

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Bracket and sliding element

1. 24.1 Move side brackets -1-  and sliding elements -2-  into installation position.
2. 24.2 Tighten screw on sliding element -3-  .

   > Tightening torque 25 Nm (18.4 ftlb.) 

3. 24.3 Tighten screws on bracket -4-  .

   > Tightening torque 10 Nm (7.4 ftlb.) 

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Heat protection

1. 25.1 Move heat shield -2-  into installation position.
2. 25.2 Tighten screws -2-  .

   Heat protection (one-piece):  on front-axle carrier > Tightening torque 9 Nm (6.6 ftlb.) 

   Heat protection (one-piece):  on longitudinal member > Tightening torque 9 Nm (6.5 ftlb.) (6.6 ftlb.) 

   Heat protection (two-piece):  on front-axle carrier > Tightening torque 9 Nm (6.6 ftlb.) 

   Heat protection (two-piece):  Upper part on longitudinal member > Tightening torque 9 Nm (6.5 ftlb.) (6.6 ftlb.) 

   Heat protection (two-piece):  Upper part on lower part > Tightening torque 9 Nm (6.5 ftlb.) (6.6 ftlb.) 

Information 

The procedure for removing and installing is described for one side as an example. The procedure for the other side is practically identical.

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Electric lines for brake

1. 26.1 Move bracket for electric lines -5-  into installation position.
2. 26.2 Tighten screw -5-  .

   > Tightening torque 20 Nm (15 ftlb.) 

3. 26.3 Connect and lock electric plug connections -2 and 4-  .
4. 26.4 Fit retaining clip -6-  .
5. 26.5 Engage electric line -1-  .

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Coolant vent line

1. 27.1 Connect and lock coolant vent line -1-  at connection point -3-  .
2. 27.2 Fasten clip -2-  .

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Ground line and positive cable in engine compartment

1. 28.1 Move cable duct for engine compartment -1-  into installation position.
2. 28.2 Tighten screw on cable duct in engine compartment -4-  .

   > Tightening torque 4 Nm (3 ftlb.) 

3. 28.3 Tighten nut on cable duct in engine compartment -5-  .

   > Tightening torque 4 Nm (3 ftlb.) 

4. 28.4 Tighten nut on external power connection in engine compartment -2-  .

   > Tightening torque 20 Nm (14.8 ftlb.) 

5. 28.5 Tighten screw for ground line in engine compartment -3-  .

   > Tightening torque 20 Nm (14.8 ftlb.) 

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Electric plug connection

1. 29.1 Move holder -3-  into installation position.
2. 29.2 Tighten screw -2-  .

   > Torque 8 Nm (5.9 ftlb.) 

3. 29.3 Connect and lock electric plug connection -1-  and engage it in holder -3-  .
4. 29.4 Position ground lines -5-  and tighten nuts -4-  .

   > Tightening torque 9 Nm (6.5 ftlb.) 

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Electric plug connections in wheel housing

1. 30.1 Secure retaining clips -3-  .
2. 30.2 Connect and lock electric plug connections -1-  .
3. 30.3 Secure electric wire harness -2-  with new tie-wraps  .

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Wire harness for level sensors

1. 31.1 Connect and lock electric plug connection for level sensors -2-  .
2. 31.2 Fasten clips -3-  .

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Electric plug connections for engine mounts and wire harness for steering gear

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Pressure hose on throttle housing

1. 33.1 Slide on pressure hose -1-  and tighten screw-type clamp on pressure hose -2-  .

   > Tightening torque 5.5 Nm (4.1 ftlb.) 

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Electric wire harness for engine

1. 34.1 Connect and lock plug connections -2-  .
2. 34.2 Fasten clips -3-  .

1. 35.1 Move oil pipe into installation position and lock it by turning it clockwise.