Engine, Installation

WARNING: This page is about a different variant/trim than selected.

Tightening Specifications

NOTE:

The tightening specifications apply only 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

Battery Jump Start Terminal -U6- pins

Fig 1: Battery Jump Start Terminal -U6- Pins

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-- Tighten the pins -1- for the Battery Jump Start Terminal -U6- to 15 Nm.

Ground Connection in the Right of the Plenum Chamber

Fig 2: Identifying Engine Control Module (ECM) -J623- -1- And GND Wire Nut -2-

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-- Tighten the nut -2- to 9 Nm.

Fig 3: Identifying Ground (GND) Cable On Longmember

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-- Tighten the nut -1- to 15 Nm.

Engine to Automatic Transmission 09D

Fig 4: Engine To Transmission Bolts And Alignment Sleeves -A-

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Item	Bolt	Nm
1, 2	M10x70	45
3, 4, 5, and 7	M12 x 80	80
6	M12x70	80
8, 9, and 10	M10x70	45
A	Alignment sleeves for centering

Engine and 8-Speed Automatic Transmission 0C8

Fig 5: Engine To Automatic Transmission (0C8) Bolts And Alignment Sleeves -A-

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Item	Bolt	Nm
1	M10x70	65
2	M10x90	65
3, 4, 5, and 7	M12 x 80	80
6	M12x70	80
8, 9, 10	M10x70	45
A	Alignment sleeves for centering

Procedure

Install in reverse order of removal. Note the following:

NOTE:

Replace any bolts that were tightened with an additional turn.

Replace bolts for securing torque converter to drive plate with new original bolts .

Replace self-locking nuts and bolts and seals, gaskets and o-rings.

The hose connections as well as the air guide pipes and hoses must be free of oil and grease before Installation.

Secure all hose connections with hose clamps of the same type as those equipped by the factory.

When Installation, bring all cable ties back to same positions.

-- Install the engine supports and engine mount. Refer to SUBFRAME OVERVIEW .

-- Make sure the rear centering bushing -arrow- is installed into the crankshaft; install a missing centering bushing.

Fig 6: Identifying Torque Converter Centering Bushing

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Vehicles through 05/2010:

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

Fig 7: Engine To Transmission Bolts And Alignment Sleeves -A-

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CAUTION:

Installation the torque converter incorrectly can cause damage to the ATF pump drive plate.

Checking position of torque converter.

When torque converter is installed correctly, distance -a- between the lower contact surface of threaded holes at torque converter and contact surface of bell housing on Automatic Transmission I'D is at least 22 mm.

Fig 8: Measuring Torque Converter Installed Dimension -A-

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NOTE:

If torque converter is not completely inserted, distance is approximately 10 mm.

-- Before guiding engine and transmission together, rotate torque converter and drive plate so that holes or threaded holes are same height as opening for removed starter -arrows-.

Fig 9: Remove/Install Torque Converter Bolts Through Opening For Starter Motor

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Vehicles from 06/2010:

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

Fig 10: Identifying Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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CAUTION:

Installation the torque converter incorrectly can cause damage to the ATF pump drive plate.

Checking position of torque converter.

When torque converter is installed correctly, distance -a- between the lower contact surface of threaded holes at torque converter and contact surface of bell housing on Automatic Transmission 0C8 is at least 23 mm.

Fig 11: Measuring Torque Converter Installed Dimension -A-

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NOTE:

If torque converter is not completely inserted, distance is approximately 11 mm.

-- Before guiding engine and transmission together, rotate torque converter and drive plate so that holes or threaded holes are same height as opening for removed starter -arrows-.

Fig 12: Identifying Cover -2-

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All vehicles:

-- Tighten the transmission to the engine.

CAUTION:

Risk of destroying transmission due to torque converter inserted incorrectly.

Keep checking whether the torque converter behind the drive plate can be turned before and during tightening of the bolts at engine/transmission connection.
If torque converter cannot be rotated, the ATF pump coupling plate and therefore the transmission are destroyed when connections are tightened to final torque.

-- Tighten the torque converter. Refer to OVERVIEW - TORQUE CONVERTER .

The rest of the installation is performed in reverse order of removal, noting the following.

-- Install the power steering hydraulic fluid line. Refer to POWER STEERING PUMP, HYDRAULIC PIPES AND RESERVOIR OVERVIEW .

-- Install the A/C Compressor. Refer to MECHANICALLY DRIVEN A/C COMPRESSOR: .

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

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

-- Install the ATF wires. Refer to ATF COOLER, REMOVING AND INSTALLING .

Vehicles through 05/2010:

-- Tighten the front driveshaft to the transfer case TRANSFER CASE .

Vehicles from 06/2010:

-- Attach the front driveshaft to the transfer case. Refer to TRANSFER CASE .

All Vehicles:

-- Install the left rear coolant pipe to the transmission, refer to COOLANT PIPES OVERVIEW .

-- Install the preliminary catalytic converter and particulate filter, refer to MUFFLER OVERVIEW .

-- Install the turbocharger heat shield. Refer to TURBOCHARGER OVERVIEW .

Vehicles through 05/2010:

Fig 13: Identifying Dimension -a- Between Subframe And Body

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-- Slowly guide the engine/transmission subassembly with subframe into body from below using Scissor Lift Table VAS6131A. Be careful not to damage the boots on the drive axle.

-- Next, raise engine/transmission subassembly high enough using Scissor Lift Table VAS6131A until dimension -a- is reached between subframe and body.

Dimension -a- = 200 mm.

-- Install the selector lever cable and check the adjustment if necessary. Refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING .

All Vehicles:

-- Continue raising the engine/transmission subassembly with the subframe using the Scissor Lift Table VAS6131A.

-- Align subframe, engine carrier and transmission carrier using marks made on longitudinal during removal.

Fig 14: Subframe, Engine Carrier, Crossmember And Bolts

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-- Tighten the bolts for the subframe, engine carrier and transmission carrier only to the specification. Refer to SUBFRAME OVERVIEW and SUBFRAME, STABILIZER BAR AND COUPLING ROD . Do not tighten further. Tighten the bolts only after an axle alignment.

WARNING:

Risk of accident due to loose connections.

Vehicle must not be driven in this condition.

-- Install the universal joint on steering gear. Refer to Steering .

Vehicles from 06/2010:

-- Attach the rear driveshaft to the transfer case. Refer to TRANSFER CASE .

-- Install the selector lever cable and check the adjustment if necessary.

Vehicles through 05/2010:

-- Tighten the front driveshaft to the transfer case. Refer to TRANSFER CASE .

All Vehicles:

-- Install the stabilizer bar. Refer to STABILIZER BAR, REMOVING AND INSTALLING .

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

-- Install the suspension struts and control arms. Refer to COIL SPRING SUSPENSION STRUT, UPPER CONTROL ARM, MOUNTING BRACKET AND LEVEL CONTROL SYSTEM SENSOR .

-- Install the SCR catalytic converter, refer to MUFFLER OVERVIEW .

-- Install the NOX sensor, Heated Oxygen Sensor -G39-, Throttle Valve Control Module -J338-, air filter housing, air filter and engine control module. Refer to Heated Oxygen Sensor -G39- WITH Oxygen Sensor Heater -Z19-, REMOVING AND INSTALLING .

-- Install the air duct hoses and screw-type clamps, refer to Fig 15.

Fig 15: Air Hose Clamp Identification

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-- Install the fuel filter. Refer to FUEL FILTER ASSEMBLY OVERVIEW .

-- Tighten the Fuel Cooler Pump -V166- to the longitudinal member, refer to Fig 16.

Fig 16: Identifying Fuel Cooler Pump Screw -Arrow-

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-- Install the refrigerant lines. Refer to COMPRESSOR REFRIGERANT LINES, DISCONNECTING AND CONNECTING .

-- Electrical Connections and Wiring Routing. Refer to appropriate SYSTEM WIRING DIAGRAM.

-- Install the cover for the plenum chamber E-box. Refer to DRIVER SIDE E-BOX PLENUM CHAMBER, REMOVING AND INSTALLING .

-- Be sure to follow the procedure for connecting the battery and afterwards. Refer to BATTERY, DISCONNECTING AND CONNECTING .

CAUTION:

There is a risk of destroying control modules with excess voltage.

Do not use a charger as a starting aid.

-- Install and adjust the windshield wiper arms. Refer to WINDSHIELD WIPER ARM, REMOVING AND INSTALLING .

-- Fill engine oil and check the oil level. Refer to Maintenance Booklet 406.

-- Before starting engine for the first time, fill the hydraulic oil in the power steering reservoir. Refer to Checking Hydraulic Oil Level, Bleeding Steering System and Checking for Leaks .

NOTE:

The power steering pump must not run dry.

-- Fill the refrigerant circuit. Refer to Refrigerant System - with Refrigerant R134a.

-- Connect the coolant hose to the coupling, refer to Fig 17.

Fig 17: Connecting Coolant Hose Coupling

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

NOTE:

Do not use drained coolant in the following situations:

If the cylinder head or cylinder block was replaced.

If the coolant is contaminated.

-- Align the subframe and engine carrier. Refer to SUBFRAME, SECURING .

-- Align and tighten the transmission carrier. .

-- Install the wheel housing liners. Refer to Wheel Housing Liners .

-- Install the front wheels. Refer to WHEELS AND TIRES, GENERAL INFORMATION

-- Perform axle alignment. .

WARNING:

Risk of accident due to loose connections.

Tighten subframe bolts to final torque after axle alignment.

-- Install the noise insulation and bracket. Refer to NOISE INSULATION, REMOVING AND INSTALLING .

-- Install exhaust system free of stress. Refer to EXHAUST SYSTEM, INSTALLATION WITHOUT TENSION .

-- On a vehicle with air suspension, deactivate vehicle lift mode. Refer to VEHICLE LIFT MODE .