Engine, Installing

Procedure 

• Vehicles with dual clutch transmission: always replace the needle bearing in the crankshaft after the engine and transmission have been separated. Refer to CRANKSHAFT NEEDLE BEARING, REPLACING .
• Replace the bolts that were tightened with an additional turn.
• Replace the self-locking nuts and bolts, gaskets, seals and O-rings.
• Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts Information.
• Check the vacuum hoses for damage before the assembly and replace if necessary.
• During installation, all cable ties must be installed at the same location.
• Used coolant cannot be used again.

-- Attach the transmission to the engine. Refer to TRANSMISSION, INSTALLING .

-- Install the starter. Refer to STARTER, REMOVING AND INSTALLING .

-- Guide the engine/transmission assembly into the body.

-- Install the bolts -arrows- for the engine mount by hand all the way.

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-- Install the bolts -arrows- for the transmission mount by hand until it is in position.

Fig 1: Identifying Bolts

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TIP:

Only tighten the bolts to the final specification when adjusting the assembly mounts. Refer to OVERVIEW - ASSEMBLY MOUNTS .

-- Remove the Engine/Gearbox Jack - Engine Support: T10359A  from the engine.

-- Attach the driveshaft to the bevel box. Refer to OVERVIEW - DRIVESHAFT .

-- Install the A/C compressor. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING ON BRACKET .

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

-- Install the drive axles. Refer to OVERVIEW - DRIVE AXLE .

-- Install the drive axle heat shield. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

-- Install the air duct pipes and hoses. Refer to OVERVIEW - CHARGE AIR HOSE CONNECTIONS .

-- Install the fan shroud. Refer to FAN SHROUD, REMOVING AND INSTALLING .

-- Install the gearshift lever cable and adjust. Refer to OVERVIEW - SHIFT MECHANISM .

-- Adjust the assembly mount. Refer to ASSEMBLY MOUNT, ADJUSTING .

-- Connect the fuel line. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Install the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Install the pressure lines and the Exhaust Pressure Sensor 1 -G450-. Refer to OVERVIEW - HEATED OXYGEN SENSOR .

-- Install the battery tray. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

-- Electrical connections and routing. Refer to COMPONENT LOCATION OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES and the appropriate Wiring Diagram.

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

-- Install the subframe. Refer to SUBFRAME WITHOUT STEERING GEAR, REMOVING AND INSTALLING .

-- Install the front wheel housing liner. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

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

-- Add engine oil. Refer to ENGINE OIL, FILLING or check the oil level. Refer to ENGINE OIL LEVEL, CHECKING AND CORRECTING IF NECESSARY .

-- Connect the coolant hoses with the connector coupling. Refer to Fig 2.

Fig 2: Connect the Connector Coupling

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-- Fill the coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Delete the DTC memory entries in the engine control module using the Vehicle Diagnostic Tester.

Additionally after replacing the engine:

• Perform a combustion misfire adaptation.
• Chain length adaptation.

Tightening Specifications 

• The tightening specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
• Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not.
• Do not use any ungreased parts.
• Tightening specification tolerance: ±15%.

• Subframe mount. Refer to OVERVIEW - ASSEMBLY MOUNTS .
• Securing transmission to engine. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .