Reinstalling the engine and transmission: Finishing

Fig 1: Identifying Control Module Box

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Install the engine and transmission wiring.

Plug in the engine and transmission wiring connectors to the connector plate.

Press the connector plate into place in the lower section of the control module box.

Install the intermediate section. Align the ventilation pipe at the rear edge of the control module box.

Screw the control module box into place in the fender liner.

Press the control modules down carefully.

Lock into place using mounting bracket 9995722 .

Press the cover into place.

Fig 2: Identifying AC Compressor

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Install 

• the AC-compressor

  Tighten with 25 Nm  .

Plug in the connector of the AC compressor's electromagnetic clutch.

• the engine and transmission wiring in the mountings on the subframe.
• power steering pump's 3 screws.

  Tighten with 25 Nm  .

Plug in the connector of the water temperature sensor.

• the expansion tank and coolant hoses
• the upper radiator hose
• the auxiliaries belt

Fig 3: Identifying Gear Selector Cables, Transmission Lever And Connector For Back Up (Reversing) Light Switch

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• the air cleaner housing bracket.

Applies to cars with manual transmissions 

• cable for the reverse light switch.
• the rubber-suspended mounting for the gear selector cables.
• the gear selector cables in the mountings on the transmission.
  NOTE:

  Color marking bracket/wire.

Applies to cars with automatic transmissions 

• Plug in the connector of the transmission.
• Attach the gear selector cable using the previous marking.
• Install the transmission's two oil cooler hoses and the negative cable to the transmission.

Fig 4: Identifying Clutch Cable

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Install: 

• the ground cable on the transmission.
• the wiring to and the cover over the starter motor.
• the lower coolant hose from the radiator.
• the charge air hose to the lower connection of the charge air cooler.

Fig 5: Identifying Engine Cooling Fan (FC)

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Remove: 

• protection 9995474 from the radiator.

Install: 

• the engine cooling fan assembly with shroud.

  Plug in the connector and clamp the wiring.

• upper charge-air pipe between charge-air cooler and turbocharger.

  Remove the seals.

• the fresh air intake.
• upper fan shroud.

  Tighten the fan shroud to the radiator.

  Make sure that the clips are securely in place.

• the canister purge valve in its bracket and connect the EVAP canister vacuum hose.

• the air duct for cooling the control module box.
• both relays on the upper fan shroud and plug in the connectors.

  Clamp the wiring.

• Tighten the clamp by the throttle body (ETM-unit).

Fig 6: Identifying Camshaft Components

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Plug in the heated oxygen sensors' connectors as marked.

• the holder for the heated oxygen sensor wiring on the transmission.
• the brake vacuum hose on the intake manifold.
• the heater hoses on the cowl panel.
• the upper nuts of the front exhaust pipe.

  Do not tighten yet  .

• the ground braid between the engine and the firewall.
• the upper torque rod.

  Tighten on the engine with 35 Nm + 90 °  on engine and with 35 Nm + 60°  at the firewall.

• the air cleaner assembly.
• the solenoid valves at the air cleaner cover.
• the intake hose between the air cleaner housing and the front panel.
• the intake hoses for the turbocharger at the air cleaner cover.

Plug in the connector for the mass air flow sensor (HFM-unit).

• the battery shelf.
• the battery: Battery, disconnecting .

Fig 7: Identifying Lower Torque Rod Screw And Nut

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Lift up the car and plug in the speedometer's connector.

• the front and rear screws for the engine mounts.

  Tighten to 50 Nm  .

• the torque rod's through-bolt in the transmission.

  Use a new  screw and nut.

  Tighten to 35 Nm  and angle tighten 90°  .

• both screws of the right engine mounting.

  First bend the right fender liner slightly so that it is out of the way.

• the right drive shaft and support bearing.

Fig 8: Locating Drive Shaft Circlip & Differential Slot

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• left drive shaft.
  NOTE:

  Press in the drive shaft by hand, since the lock ring is easily damaged.

• the screw of the bracket for the ABS line/brake pipe.

Fig 9: Identifying Link Arm/Ball Joint And Wheel Spindle

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Remove the cover of the ball joint and link arm retainer.

• ball joint/link arm on the wheel spindle.

  Make sure that the ball-joint's groove fits against the screw holes in the wheel spindle.

  Use a new  lock nut.

  Tighten to 50 Nm  .

Fig 10: Identifying Bolt Tightening Sequence

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Install: 

• the front wheels.

Fig 11: Identifying Battery Negative Lead

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Lower the car.

Torque-tighten the exhaust pipe's three nuts and check that the faces are parallel.

Tighten with 25 Nm  .

Install the heat deflector plate with the bracket for the turbocharger.

Connect the battery's minus cable. Battery, disconnecting .

Fig 12: Identifying Coolant & Water

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Top up the coolant.

Coolant volume approx.:7 liters  .

Fill engine oil.

Oil volume, including filter:5.8 liters  .

Fig 13: Identifying VIDA Station

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Check the function 

• Connect a VIDA station.
• Start the engine and run it until the thermostat opens.
• Check with VIDA car communication that no diagnostic trouble codes are stored.
• Check sealing.
• Check and if necessary adjust the oil and coolant levels

Automatic transmissions:  Check the transmission fluid level.

Wipe clean. 

Wipe the engine compartment clean.

Wipe clean steering wheel and gear lever.