Engine, Installing

Special tools and workshop equipment required 

• All special tools listed when removing.

Procedure 

• Replace 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 the assembly 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.

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

-- Install the engine support. Refer to OVERVIEW - ASSEMBLY MOUNTS .

• Secure the engine with the subframe on the Scissor Lift Table: VAS6131B  .

-- Install the transmission on the engine. Refer to the appropriate Service Information .

-- Attach the engine mount. Refer to OVERVIEW - ASSEMBLY MOUNTS .

-- Install the right coolant pipe. Refer to RIGHT COOLANT PIPE, REMOVING AND INSTALLING .

-- Install the ATF cooler. Refer to the appropriate Service Information .

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

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

-- Install the ribbed belt tensioner for the A/C compressor. Refer to RIBBED BELT TENSIONER, REMOVING AND INSTALLING .

-- Install the starter generator. Refer to GENERATOR, REMOVING AND INSTALLING .

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

Install in reverse order of removal. Note the following:

-- Tighten the tunnel crossmember bolts. Refer to the appropriate Service Information .

-- Install the parking lock emergency release cable. Refer to the appropriate Service Information .

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

-- Install the coupling rod. Refer to OVERVIEW - SUBFRAME .

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

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

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

-- Install the refrigerant line. Refer to OVERVIEW - REFRIGERANT LINES .

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

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

-- Install the parking/auxiliary heater bracket. Refer to the appropriate Service Information .

-- Wires and connections. Refer to COMPONENT LOCATION 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 DRIVESHAFT, REMOVING AND INSTALLING .

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

-- Install the front muffler. Refer to FRONT MUFFLER, REMOVING AND INSTALLING .

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

-- Install the longitudinal member. Refer to OVERVIEW - LOCK CARRIER .

-- Mount the front wheels. Refer to WHEEL, CHANGING .

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

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

-- 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 .

-- After replacing the engine, perform the adaptations listed in the "0001 - mechanical engine functions" Guided Functions using the Vehicle Diagnostic Tester.

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

Vehicles with 48 Volt Vehicle Electrical System: 

-- Re-energize the 48 Volt system and disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

Vehicles with High-Voltage System 

-- Perform the process of re-energizing the high-voltage system. Refer to HIGH-VOLTAGE SYSTEM, RE-ENERGIZING .

Continuation for All Vehicles 

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%.

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

• Refer to OVERVIEW - ASSEMBLY MOUNTS 
• Engine to transmission. Refer to the appropriate Service Information .