Installing The 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
- → Secure components to prevent them from falling down.

WARNING: Wheel bearing housing raised incorrectly

Risk of crushing
Risk of damage to components
- → Wear personal protective gear.
- → 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.

Position side brackets -1- and sliding elements -2- .

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Bracket and sliding element
Carefully position engine on > VAS 6832 - Master Gear unit elevating platform under the vehicle.
Install front-axle carrier -1- .

Fig 1: Front-Axle Carrier Assembly Screws Tightening Sequence
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Front-axle carrier assembly
1. 3.1 Move front-axle carrier -1- into installation position and screw in rear screws on front-axle carrier -2- by hand.
2. 3.2 Unscrew > T40327 - locating pin 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. 3.3 Repeat the steps 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. 3.4 Tighten screws on front axle carrier -2- .
  > Initial tightening torque 130 Nm (95.9 ftlb.)
  
  > Final tightening torque + 180°
Tighten -2- screws on transmission support.
> Tightening torque 55 Nm (41 ftlb.)

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Transmission support
Remove > VAS 6832/8 - universal assembly device from > VAS 6832 - Master Gear unit elevating platform and remove > VAS 6832 - Master Gear unit elevating platform from under the vehicle.
Information

The procedure for removing and installing is described for one side as an example. The procedure for the other side is practically identical.
Fit connecting link -3- and secure shock absorber fork.

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Connecting link and shock absorber fork
1. 6.1 Fit connecting link -3- and tighten threaded joint -1 and 2- .
  Variant with PDCC:
  
  -1- : > Initial tightening 60 Nm (44 ftlb.) > Final tightening + 90°
  
  -2- : > Initial tightening 60 Nm (44 ftlb.) > Final tightening + 90°
  
  Variant without PDCC:
  
  -1- > Initial tightening 40 Nm (30 ftlb.) > Final tightening + 90°
  
  -2- > Initial tightening 40 Nm (30 ftlb.) > Final tightening + 90°
2. 6.2 Install shock absorber fork screws -4- .
  > Initial tightening 90 Nm (67 ftlb.)
  
  > Final tightening + 90°
Connect and lock line connection for coolant hose at the radiator -1- .

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Coolant hose on top of radiator
Install coolant hose. -1-

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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- .
Secure electric wire harness for transmission -1- .

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Electric wire harness for automatic transmission
1. 9.1 Connect and lock electric plug connections for automatic transmission -2, 3 and 5- .
2. 9.2 Secure clips -4- on electric wire harness for transmission -1- .
Secure electric wire harness for automatic transmission -3- .

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Electric plug connection for automatic transmission
1. 10.1 Connect and lock electric plug connection for automatic transmission -1- .
2. 10.2 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.
Only if automatic transmission was removed:
Tighten drive plate screws -1- .

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Drive plate screws
1. 11.1 Fit screws -1- by hand.
2. 11.2 Tighten the first screw -1- to 10 Nm (7.5 ftlb.).
3. 11.3 Loosen screw -1- by 90 degrees.
4. 11.4 Tighten screw -1- to 2 Nm (1.5 ftlb.).
5. 11.5 Turn the engine a further 180 degrees.
6. 11.6 Tighten screw -1- .
  > Tightening torque 60 Nm (44 ftlb.)
7. 11.7 Turn the engine a further 60 degrees clockwise and tighten all screws.
  > Tightening torque 60 Nm (44 ftlb.)
8. 11.8 Fit -2- cap.
Fit universal joint for steering -1- .

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Universal joint for steering
1. 12.1 Connect universal joint for steering -1- to the steering gear -2- .
2. 12.2 Replace screw on universal joint for steering -3- .
3. 12.3 Also tighten screw on universal joint for steering -3- .
  > Initial tightening 20 Nm (14.8 ftlb.)
  
  > Final tightening + 90°
Secure ATF cooler -1- .

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ATF cooler
1. 13.1 Connect and lock line connection for coolant hose -2- .
2. 13.2 Only if automatic transmission was removed: Move ATF cooler -1- into installation position.
3. 13.3 Only if automatic transmission was removed: Tighten screws on ATF cooler -3- .
  > Tightening torque 8 Nm (6 ftlb.)
Fit coolant hose -1- .

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Coolant hose (shown on V6 monoturbo)
1. 14.1 Push coolant hose -1- onto coolant line.
2. 14.2 Fit spring band clamp -2- using > VAS 6890 - soring band clamp pliers .
Fit pressure hose -1- on pressure pipes -2- at the left and right.

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Pressure hose on pressure pipe
1. 15.1 Push pressure hose -1- onto pressure pipe -2- .
2. 15.2 Push screw-type clamp -3- onto pressure hose -1- and tighten it.
  > Tightening torque 5.5 Nm (4.1 ftlb.)
Connect coolant hose for radiator -1- .

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Coolant hose on radiator
1. 16.1 Connect and lock coolant hose connection -2- .
2. 16.2 Connect and lock electric plug connection -3- .
Secure side brackets -1- and sliding elements -2- .

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Bracket and sliding element
1. 17.1 Tighten screw on sliding element -3- .
  > Tightening torque 25 Nm (18.4 ftlb.)
2. 17.2 Tighten screws on bracket -4- .
  > Tightening torque 10 Nm (7.4 ftlb.)
Install heat shields on longitudinal member.
> 261420 REMOVING AND INSTALLING HEAT SHIELDS

Information

The procedure for removing and installing is described for one side as an example. The procedure for the other side is practically identical.
Secure front brake calliper -1- .

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Front brake calliper
1. 19.1 Position front brake calliper -1- .
2. 19.2 Tighten brake calliper screws -3- .
  > Initial tightening 30 Nm (22 ftlb.)
  
  > Final tightening + 90°
Information

The procedure for removing and installing is described for one side as an example. The procedure for the other side is practically identical.
Disconnect electric line -1- on the acceleration sensor.

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Wire harness for acceleration sensor
1. 20.1 Release and disconnect electric plug connection -2- .
2. 20.2 Disengage electric line -1- from holder -3- .
Information

The procedure for removing and installing is described for one side as an example. The procedure for the other side is practically identical.
Install bracket for electric lines -3- .

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Electric lines for brake
1. 21.1 Move bracket for electric lines -5- into installation position.
2. 21.2 Tighten screw -5- .
  > Tightening torque 20 Nm (15 ftlb.)
3. 21.3 Connect and lock electric plug connections -2 and 4- .
4. 21.4 Fit retaining clip -6- .
5. 21.5 Engage electric line -1- .
Connect coolant vent line -1- .

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Coolant vent line
1. 22.1 Connect and lock coolant vent line -1- at connection point -3- .
2. 22.2 Fasten clip -2- .
Secure cable duct in engine compartment -1- .

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Ground line and positive cable in engine compartment
1. 23.1 Move cable duct for engine compartment -1- into installation position.
2. 23.2 Tighten screw on cable duct in engine compartment -4- .
  > Tightening torque 4 Nm (3 ftlb.)
3. 23.3 Tighten nut on cable duct in engine compartment -5- .
  > Tightening torque 4 Nm (3 ftlb.)
4. 23.4 Tighten nut on external power connection in engine compartment -2- .
  > Tightening torque 20 Nm (14.8 ftlb.)
5. 23.5 Tighten screw for ground line in engine compartment -3- .
  > Tightening torque 20 Nm (14.8 ftlb.)
Secure electric plug connection -1- .

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Electric plug connection
1. 24.1 Move holder -3- into installation position.
2. 24.2 Tighten screw -2- .
  > Torque 8 Nm (5.9 ftlb.)
3. 24.3 Connect and lock electric plug connection -1- and engage it in holder -3- .
4. 24.4 Position ground lines -5- and tighten nuts
  > Tightening torque 9 Nm (6.5 ftlb.)
Connect coolant hose -1- .

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Coolant hose for auxiliary heating
1. 25.1 Fit coolant hose -1- onto coolant pipe -3- .
2. 25.2 Fasten spring band clamp -2- using > VAS 6890 - spring band clamp pliers .
Connect electric plug connection -2- .

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Electric plug connection on holder in wheel housing
1. 26.1 Connect and lock electric plug connection -2- and attach it to the holder.
2. 26.2 Fit and tighten screw -1- .
  > Torque 8 Nm (5.9 ftlb.)
Secure electric wire harness for anti-roll bar -1- .

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Routing of electric wire harness for anti-roll bar (shown on V6 biturbo)
1. 27.1 Position electric wire harness for anti-roll bar -1- .
2. 27.2 Unclip line clips -2- .
3. 27.3 Clip in clip -3- .
4. 27.4 Connect electric plug connection (signal connector) -4- .
5. 27.5 Connect electric plug connection (engine phase connector) -5- .
6. 27.6 Screw on and tighten nut on ground line -6- .
  > Tightening torque 16 Nm (12 ftlb.)
Secure wire harness for level sensors -1- .

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Wire harness for level sensors
1. 28.1 Connect and lock electric plug connection for level sensors -2- .
2. 28.2 Fasten clips -3- .
Secure electric wire harness for the engine mount to the front-axle carrier.
Connect and lock electric plug connection for engine mount -1- and wire harness for steering gear -2- .

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Electric plug connections for engine mounts and wire harness for steering gear
Connect vacuum line for brake booster -1- .

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Brake booster vacuum line
1. 31.1 Remove stopper.
2. 31.2 Push on brake booster vacuum line connection -2- .
Secure pressure hose -1- .

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Pressure hose
1. 32.1 Slide on pressure hose -1- and tighten screw-type clamps on pressure hose -2- .
  > Tightening torque 5.5 Nm (4.1 ftlb.)
Information

The number of plug connections and clips can vary depending on equipment and engine variant of the vehicle.
Secure electric wire harness for engine -1- .

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Electric wire harness for engine
1. 33.1 Connect and lock all plug connections -2- .
2. 33.2 Fasten clips -3- .
3. 33.3 Secure electric wire harness for engine -1- at the side of the engine control unit holder.
Vehicles with particle filter:
Connect electric plug connection for exhaust temperature sensors -1- , lock it and clip it into the holder -2- .

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Electric plug connection for exhaust temperature sensor
Vehicles with particle filter:
Connect and lock electric plug connection for differential pressure sensors -1- .

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Electric plug connection on differential pressure sensor
Install oil pipe.
1. 36.1 Move oil pipe into installation position and turn it clockwise to lock it.
Loosen and remove tension straps.