Engine, Installing

Special tools and workshop equipment required 

• All special tools listed when removing.

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.

-- 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 :VAS6131B  .

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

-- Install the coolant pipes. Refer to COOLANT PIPES, REMOVING AND INSTALLING .

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

-- Carefully guide the engine/transmission assembly into the body using the :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 A/C compressor. Refer to OVERVIEW - A/C COMPRESSOR POWER UNIT .

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

Further installation is performed in reverse order of removal, while noting 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 lower control arm. Refer to OVERVIEW - LOWER CONTROL ARM AND BALL JOINT .

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

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

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

-- Install the tunnel brace. Refer to OVERVIEW - UNDERBODY TRIM PANELS .

-- Install the level control system sensor. Refer to OVERVIEW - FRONT LEVEL CONTROL SYSTEM SENSOR .

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

-- Install the Terminal 40 Wire Junction - TV66-. Refer to COMPONENT LOCATION OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES .

-- Tighten the ground wires. Refer to 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 approriate service information .

-- Install the lock carrier cover. Refer to OVERVIEW - BUMPER COVER .

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

-- Mount the front wheels. Refer to WHEELS AND TIRES .

-- Add engine oil. Refer to ENGINE OIL, FILLING And Refer to ENGINE OIL LEVEL, CHECKING AND CORRECTING IF NECESSARY .

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

-- After replacing the engine, perform the "0001 - mechanical engine, functions" listed adaptation using the Vehicle Diagnostic Tester.

-- Connect the coolant hose to the connector coupling. Refer to Fig 1.

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

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

-- Install the underbody trim panels. Refer to OVERVIEW - UNDERBODY TRIM PANELS .

-- 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 service information .