Engine Installing
Engine installing
Note:
^ Re-attach all cable ties at same location on installation.
^ Re-attach heat insulation sleeves at same location on installation.
^ Secure all hose connections with standard hose clamps; Refer to Parts Supplier.
^ Replace self-locking nuts and bolts when performing assembly work.
^ Replace bolts tightened by turning through a specified angle as well as oil seals and gaskets.
- Check whether dowel sleeves for centering engine/transmission in cylinder block have been fitted and install if necessary.
- Install intermediate plate on dowel sleeves.
Checking torque converter installation dimension
If converter has been correctly installed, the distance between bottom contact surfaces at converter tapped holes and contact surface of torque converter bell housing with automatic transmission 01 V will be approximately 23 mm.
If converter has not been fully inserted, the gap is only approximately 11 mm.
CAUTION: Incorrect insertion of converter will lead to destruction of driver of converter ATF pump when transmission is flanged to engine.
- Screw transmission to engine.
CAUTION: Before tightening bolts at engine/transmission flange and during tightening process, repeatedly check whether torque converter can be turned behind drive plate. If not, it must be assumed that converter has not been correctly inserted and that finish-tightening the bolted joints will destroy driver of ATF pump and thus transmission.
Note:
^ Tightening torques listed in this information apply on/ to lightly greased, oiled, phosphate, or black-finished nuts and bolts.
^ Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant.
^ Do not use degreased parts.
^ Tolerance for tightening torques � 15%
Part 1:
Part 2:
Engine/transmission attachment
A: Dowel sleeves for centering
1) Bolt strength 10.9
- Use new genuine bolts for attaching torque converter to drive plate.;Refer to Parts Supplier.
- Note different tightening torques for torque converter bolts.
A. Non-ribbed bolt
^ Tightening torque 65 Nm
B. Ribbed bolt
^ Tightening torque 85 Nm
Perform further installation in reverse order, note the following:
- Install left and right front exhaust pipe.
- Prior to assembly, always use thread cutter to remove remnants of locking fluid from tapped holes in transmission flange shaft for drive shaft.
- Attach plate 2024 A/2 as shown to left rear engine lifting eye. To do so, screw out bolt at plate and replace with bolt M 10 x 15 mm with packing plate.
Note: To stop tight engine lifting eye and shackle from pressing against fuel rail when lifting engine, a suitable packing must be used (e.g. nuts, washers ...) to fill gap between engine lifting eye and shackle.
- Attach shackle 10-222 A12 to right rear engine lifting eye.
- When doing so, fill gap between shackle 10-222 A12 and engine lifting eye with packing -1- as shown.
- Engage lifting tackle 3033 at shackle 10-222 Al2/plate 2024 A/2 and shop crane VAS 6100 as shown.
- Lift engine/transmission assembly and position it in front of vehicle using shop crane.
- Slide mobile jack -1- into space between runners of shop crane as shown.
Note: For installing engine for Transmission assembly, tie up selector lever cable to stop it from becoming trapped.
- Move engine/transmission assembly into installation position in engine compartment.
Note: Never raise transmission at transmission oil pan.
- Place suitable wooden block on mobile jack and position behind ATF pan at location marked by (arrow) on transmission housing.
- To position engine/transmission assembly, lift transmission slightly using mobile jack.
- Lower shop crane. In doing so, guide threaded pins and locating pins 2- of engine mounts into engine brackets.
- Detach lifting tackle 3033 from engine and move shop crane and mobile jack aside.
- Tighten all nuts -1- for engine mounts.
- Screw on left and right transmission mounts.
- Install selector lever cable, checking adjustment if necessary.
- Install drive shaft.
- Install exhaust system and perform stress-free alignment.
- Attach ATF lines:
- Install drive shafts.
- Fit power steering fluid pipes.
- Install refrigerant lines.
- Install stabilizer bar.
- Install lock carrier with attachments.
- Allow stop for torque reaction support to settle on rubber buffer for torque reaction support and tighten bolts (arrows) to 28 Nm.
- Install front bumper.
- Adjust headlights.
- Electrical connections and routing
Refer to Wiring Diagrams m.y 2003
CAUTION: Never use charger for boost starting, as vehicle control modules could be damaged.
See Caution for connecting Telematics battery
Note:
^ On reconnecting battery, remember to activate vehicle equipment (radio/radio navigation system, clock, electric window filters) in line with owner's manual.
^ Deactivate Telematics control-module service mode.
- Charge refrigerant circuit.
Refer to Air conditioner - with refrigerant R 134a
- Check oil level before starting engine.
- Pour hydraulic fluid into power steering reservoir before starting engine for the first time (power steering pump must not run dry).
- Fill with coolant.
Note:
^ Coolant drained off is only to be re-used if neither cylinder head nor cylinder block has been replaced
^ Never re-use contaminated coolant.
- Fill with power steering fluid and bleed steering system.
- Check ATF level.