Engine/Transmission, Installing
Engine/transmission, installing
Special tools:
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
999 5972 FIXTURE 999 5972 Fixture
999 5722 Wrench 999 5722 Wrench
Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Note! For tightening torques, see: Tightening torque Tightening Torque.
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Service and Repair.
Installing the engine and transmission unit
Lift the engine and transmission unit. Use a lifting table.
Stop the lift approximately 15 cm before the subframe reaches the frame members.
Note! Make sure that the mating surfaces on the ball joints and control arms are clean. Ensure that no hoses, wiring or anything else catches during lifting.
Install (on both sides)
- the drive shaft on the hub
- the ball joint to the control arm.
Guide in the lower steering shaft in the boot.
Lift the subframe to the frame members.
Install new screws in the subframe. Lubricate the screw threads.
Install the washers in the front edge and support plates at the rear edge of the subframe.
First tighten the screws on the left-hand side of the subframe to 105 Nm. Angle tighten 120°. Use bevel protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.
Then tighten the screws on the right-hand side of the subframe to the same value.
Tighten the brackets. Tighten to 50 Nm.
Remove the lifting table.
Installing the three-way catalytic converter (TWC) and front exhaust pipe
Warning! Avoid skin contact with copper paste.
Install the catalytic converter and the heat deflector plate.
Use a mobile jack with universal plate 999 5972 FIXTURE 999 5972 Fixture as a support.
Use the new nuts and gaskets.
Lubricate the studs on the turbocharger (TC). Use copper paste 116 1408.
Connect to the rear exhaust pipe flange. Install the nuts by hand.
Then connect the exhaust system to the turbocharger (TC). Install the nuts by hand.
Install the brake pipe in the holders on the SIPS member.
Install the screws for the front SIPS member.
Remove the mobile jack.
Tighten the screws for the front SIPS member and the connection to the rear exhaust pipe.
Install the center SIPS member.
Connect the connector for the rear heated oxygen sensors (HO2S) and clamp the wiring.
Install:
- the lower oil cooler hose to the transmission
- the lower radiator hose.
Tighten the ball joint/control arm. See: Counterhold using Torx 40 so that the ball joint boot does not rotate. Tightening Torque
Install
- the tie rods. Use new locknuts. Tighten to 70 Nm.
- the anti-roll bar links. Use new locknuts. Tighten to 50 Nm.
- new center screws for the drive shafts. Tighten to 50 Nm.
- ABS sensors. Tighten to 10 Nm.
Note! Ensure that the ABS sensor seats are absolutely clean.
- the cable for the ABS sensor in the mounting in the spring strut
- the brake pipe bracket in the wheel arch.
Install
- the front splash guard
- the splash guard under the engine
- the wheels. See Installing wheels Service and Repair.
- the bearing in the lower steering shaft. Secure it in the rubber boot using a tie strap
- the steering shaft joint in the lower steering shaft. Use a new screw and locknuts. Tighten to 30 Nm.
Note! Previous measurement for correct steering gear position.
- the panel under the dashboard.
Tighten the three-way catalytic converters (TWC) to the turbocharger (TC). Use new nuts.
Tighten to 24 Nm.
Install:
- the upper heated oxygen sensors (HO2S). Lubricate the threads using copper paste 116 1408. Tighten to 45 Nm.
- the heat deflector plates.
Install:
- the connector for the heated oxygen sensor (HO2S) (turbocharger (TC) 2)
- the intake and charge air pipes
- the plastic charge air pipe
- the plastic intake pipe
- the connector for the heated oxygen sensor (HO2S) (turbocharger (TC) 1). Clamp the wiring for the heated oxygen sensors (HO2S)
- the screw for the mounting for the torque rod on the engine
- the engine stabilizer brace between the suspension turrets.
- the air conditioning (A/C) compressor. Tighten to 25 Nm.
- the connector to the dryer bottle
- the magnetic clutch connector with the engine wiring
- the auxiliaries belt
- the hose between the charge air cooler (CAC) and the turbocharger (TC) pipe. Applies only to B6xx4T.
- the upper radiator hose.
Connect the engine and transmission wiring connectors to the control module box base plate.
Press the base plate into place in the lower section of the control module box.
Install the intermediate section.
Locate the ventilation pipe in the rear edge of the control module box.
Screw the control module box into place in the fender liner.
Press the control modules down carefully. Lock into place using mounting bracket 999 5722 Wrench 999 5722 Wrench.
Press the cover into place. Screw the ground cable into place.
Install
- the expansion tank. Connect the hose from the radiator to the expansion tank
- the servo reservoir.
- the fan shroud on the radiator
- the connectors to the engine cooling fan (FC), evaporative emission system (EVAP) valve and pulsed secondary air injection system (PAIR) pump
- the wiring to the terminal block.
Secure the wiring.
- the charge air pipe to the charge air cooler (CAC). Applies only to B6xx4T.
- the upper oil cooler hose to the transmission
- the transmission cable to the transmission.
- the air intake pipe to the air cleaner (ACL) housing in the fan shroud
- the brake servo hose to the intake manifold
- the air cleaner (ACL) housing with all connections.
- the positive cable to the positive terminal block
- the negative battery cable. First read Battery, disconnecting Battery Disconnecting.
Final check
Top up
- coolant. Coolant volume approximately 7.2 liters.
- engine oil.
Start the engine. Warm up the engine until the thermostat opens.
Check for leakage.
Check the oil and coolant levels. Adjust if necessary.
Applies to cars with automatic transmission:
Check the transmission fluid level.