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.
Positive Terminal Grip and Ground Pin
- Tighten the nut - 1 - on the positive terminal grip to 20 Nm.
- Tighten the Ground (GND) bolt - 2 - to 9 Nm.
Ground Connection on the Right Longitudinal Member
- Tighten the nut - 1 - to 15 Nm.
Ground Connection on the Left Suspension Strut Tower
- Tighten the nut - arrow - to 9 Nm.
Driveshaft Heat Shield
- Tighten bolts - arrows - to 23 Nm.
Mount, Multitronic Transmission to Engine
Procedure
• Replace bolts which have been tightened to torque.
• Replace self-locking nuts and bolts as well as sealing rings, seals and O-rings.
• Secure all hose connections with hose clamps appropriate for the model.
• During installation, all cable ties must be re-installed at the same location.
- Clean the transmission input shaft splines and damper unit splines on the flywheel, remove corrosion and apply a very thin coating of Clutch Disc Connection Lubricant (G 000 100) on the splines. Remove all excess grease.
- 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.
- Install intermediate plate between engine and transmission onto alignment bushings.
- Install the transmission on the engine using new bolts.
- Secure the ATF pipes.
- Install the front exhaust pipe and catalytic converter: for the left pipe, refer to => [ Left Front Exhaust Pipe with Catalytic Converter ] Left Front Exhaust Pipe with Catalytic Converter, and for the right pipe, refer to => [ Right Exhaust Pipe with Catalytic Converter ] Right Exhaust Pipe with Catalytic Converter.
- Lower the left support element spindles on the engine/transmission subassembly.
- Loosen both right support element base plates on the (VAS 6131 A).
- Lower the right support element spindles on the engine/transmission subassembly.
- Loosen both right support element base plates on the (VAS 6131 A).
• The support points for front of engine and tunnel cross member remain unchanged.
- Set up the (VAS 6131 A) and (VAS 6131/10) as follows:
• A second technician is required to position subframe onto support elements.
- Mount the subframe on both support elements (VAS 6131/10-8).
- Rotate the (VAS 6131/10-8) on both sides up.
- Attach mounting element base plates to (VAS 6131 A) and tighten to 20 Nm.
- Slowly guide the engine/transmission subassembly and the subframe using the (VAS 6131 A) from underneath into the body.
- Align the subframe and engine mount brackets using the marks made on the longitudinal members during removal.
- Tighten the subframe bolts and engine mount brackets only to the tightening specifications, do not tighten them further (tighten the bolts only after axle alignment).
CAUTION!
Risk of accident due to loose connections.
• If the bolts in the subframe are not tightened to final torque, vehicle must not be driven.
- Tighten the tunnel crossmember bolts.
The rest of the installation is performed in reverse order of removal, note the following:
- Install the selector lever cable to the transmission.
- Install the drive axles, guide links, control arms, stabilizer bars, coupling rods, suspension struts and the subframe crossbrace.
- Install the front transverse beam.
- Install exhaust system free of stress. Refer to => [ Exhaust System, Installing ] Service and Repair.
- Install A/C compressor.
- Install the power steering pump hydraulic line.
- Install the fuel supply hose.
- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Install the torque support. Refer to => [ Torque Support ] Torque Support.
- Electrical connections and routing.
- Follow measures after connecting battery.
CAUTION!
Risk of destroying control modules with excess voltage.
• Do not use a battery charger for starting assistance!
- Install wiper arms and adjust.
- Install the tower brace.
- Check oil level.
- Before starting engine for the first time, check the fluid level in power steering reservoir.
• The power steering pump must not run dry.
- Fuel system, bleeding.
- Connect the coolant hoses with the connector coupling. Refer to => [ Connect the Coolant Hose with the Connector
Coupling ] Radiator and Coolant Fan Assembly Overview.
- 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.
- Check ATF level.
- Align the subframe and both engine mount brackets.
- Perform axle alignment.
CAUTION!
Risk of accident due to loose connections.
• Tighten subframe bolts to final torque after axle alignment.
- Install the noise insulation.