Engine, Installing

Special tools and workshop equipment required 

• Scissor Lift Table :VAS6131B 

Procedure 

• Replace the bolts that were tightened with an additional turn after removing them.
• Replace the self-locking nuts and bolts, gaskets, seals and O-rings after removing.
• Only remove the plugs or caps just before installing the respective lines.
• The hose connections as well as air duct pipes and hoses must be free of oil and grease before installing.
• 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 assembling and replace if necessary.
• During installation, all cable ties must be installed at the same location.
• Bonded rubber bushings have a limited range of rotation. Only tighten suspension threaded connections when vehicle is in curb weight position or in the control position.

-- Bring the starter into the installation position.

-- Install the engine support, engine mount and if necessary the engine support bearing. Refer to OVERVIEW - SUBFRAME MOUNT .

• Secure the engine with the subframe on the :VAS6131B  .

-- Check the sensor wheel for engine speed sensor. Refer to Crankshaft ; check the sensor wheel.

-- Attach the transmission on the engine. Refer to the appropriate service information .

-- Install the plug for "TDC" hole. Refer to OVERVIEW - CRANKSHAFT .

-- Install the coolant pipes. Refer to OVERVIEW - COOLANT PIPES .

-- Install the exhaust system. Refer to OVERVIEW - MUFFLER .

-- Install the ATF cooler. Refer to the appropriate service information .

-- Carefully guide the engine/transmission assembly into the body using the :VAS6131B  .

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

-- Remove the locating pins and install the subframe. Refer to SUBFRAME, SECURING .

-- Tighten the tunnel crossmember bolts. Refer to the appropriate service information .

Further installation is performed in reverse order of removal, while noting the following:

-- Install the parking lock emergency release cable. Refer to the appropriate service information .

-- If removed, install the A/C compressor. Refer to OVERVIEW - A/C COMPRESSOR POWER UNIT .

-- If removed, install the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING and RIBBED BELT, REMOVING AND INSTALLING .

-- If removed, install the refrigerant line on the A/C compressor. Refer to REFRIGERANT LINES, REMOVING AND INSTALLING AT A/C COMPRESSOR .

-- Install the steering intermediate shaft. Refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

-- Install the stabilizer bar and coupling rod. Refer to OVERVIEW - SUBFRAME .

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

-- Install the lower control arm. Refer to OVERVIEW - LOWER CONTROL ARM AND BALL JOINT .

-- Install the subframe shield. Refer to OVERVIEW - SUBFRAME .

-- Install the tie rod end. Refer to OVERVIEW - STEERING GEAR .

-- Install the right tower brace, if removed. Refer to TOWER BRACE, REMOVING AND INSTALLING .

-- Install the differential pressure sensor with the bracket. Refer to Sensors ; Overview - Differential Pressure Sensor.

-- Install the Engine Control Module -J623-. Refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

-- Wires and connections. Refer to OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES and the appropriate Wiring Diagram.

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

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

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

-- Install the driveshaft. Refer to the appropriate service information .

-- Install the bumper cover. Refer to BUMPER COVER, REMOVING AND INSTALLING .

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

-- Mount the front wheels. Refer to Wheels and Tires .

-- Install the lock carrier cover. Refer to Front Bumper .

-- Add engine oil (refer to ENGINE OIL, FILLING ) and check the oil level (refer to ENGINE OIL LEVEL, CHECKING AND CORRECTING IF NECESSARY ).

-- Follow all steps after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- If the engine and transmission were separated or the engine was replaced, then perform the Guided Functions  "0001 - Engine electronics, functions" listed adaptation using the Vehicle Diagnostic Tester.

-- Connect the coolant hoses with the connector coupling. Refer to Fig 1.

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

-- Check the ATF level. Refer to the appropriate service information .

-- Install the noise insulations. Refer to OVERVIEW - NOISE INSULATION .

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 permitted, although lubricants containing graphite are not.
• Do not use any ungreased parts.
• Tightening specification tolerance: ± 15%.

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

• Refer to OVERVIEW - SUBFRAME MOUNT 
• Engine to transmission. Refer to the appropriate service information .