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.
• If a new or replacement engine is installed, then a residual amount of the test cycle oil from the factory is still in the engine. Before starting the engine for the first time, bleed the test cycle oil and fill with engine oil. 

-- Bring the starter into the installation position.

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

-- Install the engine supports and engine mount. 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 Transmission Information .

-- Install the transmission mount. Refer to LEFT TRANSMISSION MOUNT, REMOVING AND INSTALLING .

-- Install the Transmission Coolant Valve -N488-. Refer to OVERVIEW - COOLANT VALVES .

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

-- 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 Transmission Information .

-- Install the parking lock emergency release cable. Refer to the appropriate Transmission 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 lower control arm. Refer to OVERVIEW - LOWER CONTROL ARM AND BALL JOINT .

-- Install the steering gear boot. Refer to BOOT, REMOVING AND INSTALLING .

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

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

-- 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 .

-- 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 charge air hose connections. Refer to OVERVIEW - CHARGE AIR HOSE CONNECTIONS .

-- Install the coolant pipes. Refer to RIGHT COOLANT PIPE ON TRANSMISSION, REMOVING AND INSTALLING .

-- Install the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

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

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

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

-- If necessary, bleed the test cycle oil. Refer to ENGINE, INSTALLING - If a new or replacement engine is installed, then a residual amount of the test cycle oil from the factory is still in the engine. Before starting the engine for the first time, bleed the test cycle oil and fill with engine oil. .

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

-- Check the ground wires are installed correctly.

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

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

-- Install the engine bracket for the driving dynamic support. Refer to DRIVING DYNAMIC SUPPORT ENGINE BRACKET, REMOVING AND INSTALLING .

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

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

-- Install the noise insulation. 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			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 Transmission Information .