Engine, Installing

Special Tools And Workshop Equipment Required 

• Clutch Module Transportation Lock T40170

Tightening Specifications 

Component			Nm
Bolts and nuts		M6	9
		M7	15
		M8	20
		M10	40
		M12	65

• Subframe mount, refer to OVERVIEW - SUBFRAME MOUNT .
• Engine to transmission, refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

Procedure 

-- Install the engine support and engine mount, refer to OVERVIEW - SUBFRAME MOUNT .

-- The following preparations must be made before connecting the engine and transmission:

-- Turn the torque converter so that hole next to the notch -arrow- is visible in the lower cut-out in the transmission housing as illustrated.

-- Insert the Clutch Module Transportation Lock T40170 in the transmission housing from below and secure it on the flange shaft -1-.

-- When joining the engine and subframe, hold the ATF lines in their installation position.

-- Check if the alignment sleeves -A- for centering the engine/transmission are in the cylinder block and insert them if they are not.

-- Inspect the aluminum bolts used to connect the engine to the transmission to see if they can be used again and mark them, if necessary, refer to THE ALUMINUM BOLTS MAY BE USED TWO TIMES. THEREFORE, THE BOLTS MUST BE MARKED WITH TWO NOTCHES "X" MADE BY A CHISEL AFTER THEY HAVE BE USED THE FIRST TIME .

-- Position the transmission on the engine. Be careful of the starter.

-- Tighten bolts -1 to 14-.

-- Remove the Clutch Module Transportation Lock T40170.

-- Press the torque converter -2- against the drive plate -3- slightly in the direction of the -arrow- using an assembly lever -1-.

-- Install the first bolt -arrow- and tighten by hand (2 Nm).

-- Turn the crankshaft with the Counterhold - Kit - Multiple Use T10172A with the Counterhold - Kit - Multiple Use Adapter 1T10172A/1 in the direction of engine rotation -arrow- 180° further.

-- Tighten the bolts that are accessible in this position to the tightening specification, refer to TORQUE CONVERTER OVERVIEW .

-- Turn the crankshaft 60° farther and tighten the remaining five bolts to the tightening specification, refer to TORQUE CONVERTER OVERVIEW .

-- Install the ribbed belt idler roller, refer to OVERVIEW - RIBBED BELT DRIVE, VEHICLES THROUGH MY 2013 .

-- Tighten the drive axles on the transmission flange shafts, refer to OVERVIEW - DRIVE AXLE .

-- Install the ATF cooler, refer to ATF COOLER, REMOVING AND INSTALLING .

-- Attach the right coolant pipe to the transmission, refer to RIGHT COOLANT PIPE ON TRANSMISSION, REMOVING AND INSTALLING .

-- Install the Secondary Air Injection (AIR) pump, refer to SECONDARY AIR INJECTION PUMP MOTOR -V101- / -V189-, REMOVING AND INSTALLING .

-- Install the ATF lines, refer to ATF PIPES, REMOVING AND INSTALLING .

Vehicles through MY 2013: 

-- Install the power steering hydraulic line, refer to OVERVIEW - HYDRAULIC LINES AND RESERVOIR .

All Vehicles: 

-- Install the exhaust manifold and catalytic converters, refer to EXHAUST MANIFOLD GASKETS, REMOVING AND INSTALLING .

-- Install the transmission mount and the transmission support, refer to TRANSMISSION SUPPORT AND REAR TRANSMISSION MOUNT, REMOVING AND INSTALLING .

-- Next raise engine/transmission subassembly with Scissor Lift Table VAS 6131A only by dimension -a-.

• -a- = minimum 100 mm

-- Install the Air Conditioning (A/C) compressor, refer to AIR CONDITIONING (A/C) COMPRESSOR, REMOVING AND INSTALLING .

-- Lift the engine/transmission assembly further using the Scissor Lift Table VAS 6131 A.

-- Align the subframe and tunnel crossmember using the marks made on the longitudinal members during removal.

-- Tighten the tunnel crossmember bolts, refer to ASSEMBLY MOUNTS OVERVIEW .

-- Tighten the subframe bolts only to the tightening specifications, do not tighten them further (tighten the bolts only after axle alignment), refer to OVERVIEW - SUBFRAME .

Install in reverse order of removal. Note the following:

-- Install the emergency release cable, refer to SELECTOR MECHANISM OVERVIEW .

-- Install the driveshaft, refer to REMOVAL AND INSTALLATION or REMOVAL AND INSTALLATION .

-- Attach the steering intermediate shaft to the steering gear, refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

-- Install the upper control arm and suspension strut, refer to OVERVIEW - SUSPENSION STRUT AND UPPER CONTROL ARM .

-- Install the subframe crossbrace and stabilizer bar, refer to OVERVIEW - SUBFRAME .

-- Install the braces on the transmission mounts, refer to OVERVIEW - SUBFRAME MOUNT .

-- Install the brake caliper, refer to BRAKE CALIPER, REMOVING AND INSTALLING .

Vehicles through MY 2013: 

-- Install the power steering pump, refer to POWER STEERING PUMP, REMOVING AND INSTALLING .

All Vehicles: 

-- Install the ribbed belt, refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Attach the positive cables to the positive terminal, refer to OVERVIEW - BATTERY JUMP START TERMINAL .

-- Install the lower longitudinal member, refer to OVERVIEW - LOCK CARRIER .

-- Install the air guide pipes, refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Install the wires, fuse panel, and engine compartment E-box cover, refer to COMPONENT LOCATION OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES and appropriate SYSTEM WIRING DIAGRAMS information.

-- Install the refrigerant lines, refer to SYSTEM OVERVIEW - REFRIGERANT CIRCUIT .

-- Install the plenum chamber cover, refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Follow all steps after connecting the battery, refer to BATTERY, DISCONNECTING AND CONNECTINGBattery Safety Label .

-- Install the tower brace, refer to OVERVIEW - SUSPENSION STRUT AND UPPER CONTROL ARM .

-- Install the air filter housing, refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Install the upper longitudinal member, refer to OVERVIEW - LOCK CARRIER .

-- Install the engine cover, refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Fill the engine oil and check the oil level, refer to ENGINE OIL LEVEL, FILLING AND CHECKING .

Vehicles through MY 2013: 

-- Before starting engine for the first time, fill the hydraulic oil in the power steering reservoir, refer to POWER STEERING FLUID LEVEL, CHECKING .

All Vehicles: 

-- Connect the coolant hoses with the connector coupling, refer to Fig 8.

-- Fill with coolant, refer to COOLANT, DRAINING AND FILLING .

-- Fill the refrigerant circuit, refer to A/C SYSTEM, STARTING OPERATION AFTER FILLING REFRIGERANT CIRCUIT .

-- Align the subframe, refer to SUBFRAME WITH STEERING GEAR, REMOVING AND INSTALLING .

-- Install the front wheel housing liners, refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

-- Install the lock carrier cover, refer to LOCK CARRIER COVER, REMOVING AND INSTALLING .

-- Perform an axle alignment, refer to AXLE ALIGNMENT PROCEDURE .

-- Fill the ATF, refer to ATF LEVEL, CHECKING .

-- Install the noise insulations, refer to OVERVIEW - NOISE INSULATION .

-- The "combustion misfire adaptation" must be adapted after replacing the engine, select 01 Reset Combustion Misfire Adaptation  in Guided Fault Finding  see Vehicle Diagnostic Tester.