Engine, Installing
Engine, Installing
Tightening Specifications
• Tightening specifications only apply to lightly greased, oiled, phosphate 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.
Engine to Transmission
Procedure
Installation is in reverse order of removal, note the following:
• Replace bolts which have been tightened to an additional 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 installed at the same location.
- Install the engine support 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 and catalytic converter, refer to => [ Left Exhaust Manifold with Catalytic Converter ] Left Exhaust Manifold With Catalytic Converter, or => [ Right Exhaust Manifold with Catalytic Converter ] Right Exhaust Manifold With Catalytic Converter.
- Install the starter.
- Electrical connectors and routing on transmission.
- Install the R-Tronic selector unit heat shield.
- Engage the engine/transmission subassembly as illustrated.
• To avoid damage, carefully guide engine/transmission subassembly into the engine compartment when lowering.
- Lower the engine/transmission subassembly with the shop crane (VAS 6100) and carefully guide it into the engine compartment.
- Tighten the left and right engine mount bolts. Refer to => [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview.
- Tighten the left and right transmission mount bolts.
All Vehicles:
- Install the engine control modules.
- Electrical connectors and routing on engine.
- Connect the wiring harness inside the passenger compartment.
- Install the right rear mid-bass speaker (R160).
- Install the right side trim, rear shelf, lower right A-pillar trim and right sill trim strip.
- Install the secondary air injection pump. Refer to => [ Secondary Air Injection Pump Motor ] Secondary Air Injection Pump Motor.
Vehicles with a 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 ] Oil Tank.
- Install the oil lines on the engine, the engine oil cooler and the oil tank. Refer to => [ Oil Pump and Suction Module Assembly Overview ] Service and Repair, => [ Oil Tank Assembly Overview ] Oil Tank Assembly Overview and => [ Left Engine Oil Cooler Assembly Overview ] Left Engine Oil Cooler Assembly Overview.
- 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 muffler. Refer to => [ Muffler ] Muffler.
- 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 the drive-through shaft and driveshaft.
- Install the rear lid rack.
- Install the tail lamp assembly.
- Install the rear impact absorber.
- Install the rear wheel housing liners.
- Mount the wheels.
- Before starting engine for the first time, fill the hydraulic oil in the power steering reservoir.
• The power steering pump must not run dry.
- Install air filter housing.
- Fill the engine oil and check the level.
- Follow the instructions for connecting the battery.
CAUTION!
Risk of destroying control modules with excess voltage.
• Do not use a battery charger for starting assistance!
- Install the passenger seat.
R8 Spyder:
- Install the connecting brace for the hinge mount.
- Install the mounting plate for the left and right lid hinges.
- Install the service flap.
- Install the power top compartment cover.
- Install the engine compartment side trim panels.
All Vehicles:
- 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.