Replacing the gearbox: Finishing

Fig 1: Identifying Right Hand Engine Mounting Screws

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Install 

• the right-hand engine mounting. Use new screws  Tighten to 35 Nm  . Angle-tighten 90°  .

Fig 2: Identifying Vibration Damper

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• the vibration damper. Use new screws. Tighten to 35 Nm  . Angle-tighten 90°  . (Applies to cars with 6 cylinder engines.).

Fig 3: Identifying Front Engine Pad Screw

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• the front engine pad. Tighten to 50 Nm  .

Fig 4: Identifying Lower Torque Rod And Nuts

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• lower torque rod. Tighten to 65 Nm  . Angle-tighten 60°  .

  The lower torque rod must be tightened last to avoid tension being introduced.

  Tighten the nuts. Tighten to 80 Nm  .

  NOTE:

  Use new nuts.

Fig 5: Identifying Fender Liner And Nuts

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• the fender liner and the splash guard with both the plastic nuts.

Fig 6: Identifying Nuts And Screw For Steering Gear And Collision Protection

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• the four nuts and screws holding the steering gear. Use new nuts and new screws. Tighten to 50 Nm 

  Clip the cable in position.

  nut (A), holding collision protection lower half. (Applies only to right-hand drive cars). Tighten to 50 Nm  .

Fig 7: Identifying Cable Harness And Connectors At Rear Edge Of Sub-Frame

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• the cable harness at the rear edge of the sub-frame and connect the connectors. (Applies only to cars with 6-cylinder engines)
• the heated oxygen sensor (HO2S) bracket in its mounting.

Fig 8: Identifying Exhaust Pipe Bracket Screws

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• the mounting for the exhaust pipe on the bracket. Tighten to 10 Nm 
• the brake pipe on the exhaust pipe bracket
• the exhaust pipe bracket. Tighten the bracket screws. Tighten to 25 Nm  .

Fig 9: Identifying EVAP Canister Hose

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• EVAP canister hose. Press the joint together. (Does not apply to Diesel).

Fig 10: Identifying Oil Pipes And Steering Gear

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• oil pipes to steering gear
• any fuel line for engine block heater
• any engine block heater.

Fig 11: Identifying Ball Joint Nuts

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• new nuts  on the ball joints. Tighten to 80 Nm  . Counterhold with a Torx wrench so that the ball joint boot is not damaged.

Fig 12: Identifying Anti-Roll Bar Link

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• the anti-roll bar links. Use new  nuts. Tighten to 50 Nm  . Counterhold with a Torx wrench so that the boot is not damaged.

Fig 13: Identifying Screw For Cable Duct

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• the cable duct screw.

Fig 14: Identifying Air Duct Cover And Bolts

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• the air duct cover.

Fig 15: Locating Protective Cover Under Engine

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• the splash guard under the engine. Tighten to 20 Nm  .

• Install the wheels according to Installing wheels .

  Lower the car

• Install the torque rod. See Replacing the torque rod 
• (Diesel models only) Install the engine cover.

Fig 1: Identifying EGR Valve

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Install the EGR valve with a new gasket. Tighten the nuts to 25 Nm  and the Allen screw to 22 Nm  .

Fig 2: Identifying Fuel Filter Nuts And ABS Connector

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Applies only to left-hand drive: 

Install the fuel filter holder. Tighten the nuts to 10 Nm  .

Install the ABS switch.

Fig 3: Identifying Hoses

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Fill the oil return line with engine oil before installing it.

Install 

• the charge air hose.
• the inlet hose.
• the hose on the EGR valve.
• the hose on the boost pressure control valve.
• the pressure oil line between the turbocharger (TC) and the oil cooler.

Replace the gasket between the pressure oil pipe and the oil cooler.

Tighten the cap nut to the turbocharger (TC) to 30 Nm  and both the screws to the oil cooler to 25 Nm  .

Fig 4: Identifying Lower Oil Pipe

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Raise the car.

Install the oil return line from the turbocharger (TC) to the engine. Use a new gasket. Tighten the screws to 30 Nm 

Applies only to right-hand drive cars 

Install the charge air pipe front and rear mountings under the engine. Tighten both to 8 Nm  .

Fig 5: Identifying Collision Protection Over Oil Filter

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Install 

• the oil drain under the oil filter.
• the three-way catalytic converter (TWC) according to Replacing the three-way catalytic converter (TWC) .

Applies only to right-hand drive cars: 

Install the collision protection system over the oil filter. Tighten to 25 Nm  .

Fig 6: Identifying Engine Stabilizer Brace

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Install 

• the torque rod.
• the screws at the suspension turrets. Tighten to 50 Nm  .
• the screw and nut on the torque control arm. Tighten to 80 Nm  .

Check the boost pressure according to Pressure regulator, checking/adjusting .

Check the oil and coolant levels.

Test drive the engine and check for oil and air leakage.

Fig 1: Identifying Cross Member

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Tighten the nuts at the rear edge of the three-way catalytic converter (TWC) to 25 Nm. 

Install 

• The SIPS member.
• the splash guard under the engine. Tighten the screw to 25 Nm. 

Lower the car.

Fig 2: Identifying Exhaust Pipe Connection To Turbocharger

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Tighten the three-way catalytic converter (TWC) to the turbocharger (TC) to 45 Nm. 

Install 

• the engine cover.
• the battery negative lead. Battery, disconnecting .