Engine, Installing
Engine, Installing
Tightening Specifications
• 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 degreased parts.
• Tolerance for torque specifications ±15%.
Subframe mount. Refer to => [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview.
Securing Engine to Transmission
Procedure
Installation is in reverse order of removal, note the following:
• Replace bolts which have been tightened to torque.
• Replace self-locking nuts and bolts as well as sealing rings, seals and O-rings.
• The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps appropriate for the model.
• In order to be able to securely mount the air guide hoses on their connectors, spray the screws on the previously used clamps with a rust remover.
• During installation, all cable ties must be re-installed at the same location.
- Install the engine supports with the left and right engine mounts.
- Make sure the alignment sleeves - A - for centering the engine and transmission in the cylinder block are present. Insert the alignment sleeves if they are missing.
- Attach transmission to engine.
- Install the exhaust manifold with catalytic converter. Refer to: Left => [ Left Exhaust Manifold with Catalytic Converter ] Left Exhaust Manifold With Catalytic Converter, right => [ Right Exhaust Manifold with Catalytic Converter ] Right Exhaust Manifold With Catalytic Converter.
- Install starter.
- Electrical connectors and routing on transmission.
- Install the R tronic selector unit heat shield.
- Engage the engine-transmission assembly as show in the illustration.
• To avoid damage, carefully guide engine/transmission assembly into the engine compartment when lowering.
- Lower the engine-transmission assembly with the Shop Crane (VAS 6100) and carefully guide it into the engine compartment.
- Tighten the left and right engine mount bolts.
- Tighten the left and right transmission mount bolts.
- Install the engine control modules.
- Electrical connectors and routing on engine.
- Connect the electrical wiring harness in the interior.
- Install the right side trim, rear shelf, lower right A-pillar trim and right sill trim strip.
- Install secondary air injection (AIR) pump. Refer to => [ Secondary Air Injection Pump ] Service and Repair.
Manual Transmission
- Install the shift cables and adjust.
- Install the clutch slave cylinder hose-line assembly.
All Vehicles
- Install the oil tank. Refer to => [ Oil Tank ] Service and Repair.
- Install the oil lines on the engine, oil cooler and oil tank.
- Install the engine compartment crossmember. Refer to => [ Engine Compartment Crossmember ] Engine Assembly.
- Install the bracket and the power steering hydraulic fluid reservoir.
- Install stabilizer bar.
- Install the fuel supply line.
- Install the transmission fluid lines on the transmission fluid thermostat.
- Install the power steering hydraulic fluid lines.
- Install drive axles.
- Install refrigerant lines.
- Clean locking compound residue from the threaded holes in the drive-through shaft using a thread tap right before installation.
- Install driveshaft.
- Install the rear lid rack.
- Install the tail lamp assemblies.
- Install the rear impact absorber.
- Install the rear wheel housing liners.
- Mount the rear wheels.
- Before starting engine for the first time, fill the hydraulic oil in the power steering reservoir.
• Power-steering pump must not run dry.
- Install air filter housing.
- Fill the engine oil.
- Follow measures after connecting battery.
CAUTION!
Risk of destroying control modules with excess voltage.
• Do not use a battery charger for starting assistance!
- Install the passenger seat.
- Fill with coolant. Refer to => [ Filling ] Procedures.
• Do not use drained coolant in the following situations:
• If the cylinder head or cylinder block was replaced.
• If the coolant is contaminated.
- Empty and fill the refrigerant circuit.
- Install the covers for the side panel and engine compartment trim panels.
- Install the noise insulation.