Engine, Installing
Engine, Installing
Tightening Specifications
• The tightening specifications apply only 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 ungreased parts.
• Tightening specification tolerance +/- 15%.
Subframe mount, refer to => [ Subframe Overview ] Subframe Overview.
Ground Connection on the Right Longitudinal Member
- Tighten the nut - 2 - to 15 Nm.
Engine to Transmission
• The aluminum bolts - 1 through 11 - may be used two times. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have been used the first time - arrow -.
• To prevent damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt using a 14 mm socket with a 1/2 drive, which is inserted in to the vise, as illustrated.
• Bolts marked with an "X" may not be used again.
Procedure
• Replace bolts that are tightened to the specification.
• Replace self-locking nuts and bolts and seals, gaskets and O-rings.
• Only remove the plugs or caps after installing the lines.
• 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 of the same type as those equipped by the factory. Refer to the Parts Catalog.
• To mount the air guide hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.
• When installing, bring all cable ties back to same positions.
- Install the left and right engine supports. Refer to => [ Subframe Overview ] Subframe Overview.
- Make sure the alignment sleeves - A - for centering the engine and transmission are inside the cylinder block and inside the timing chain guard lower section. Replace them if they are missing.
Installing the torque converter incorrectly can cause damage to the ATF pump drive plate.
• Checking position of torque converter.
• When torque converter is installed correctly, distance - a - between the lower contact surface of threaded holes at torque converter and contact surface of bell housing is at least 23 mm.
• If torque converter is not completely inserted, distance is approximately 11 mm.
- Before guiding engine and transmission together, rotate torque converter and drive plate so that the holes for the bolts are same height as opening for removed starter - 1 -.
Risk of destroying automatic transmission.
• Keep checking whether the torque converter behind the drive plate can be turned before and during tightening of the bolts at engine/transmission connection. If the torque converter cannot be turned, it must be assumed that it is inserted incorrectly.
• Only secure torque converter to drive plate with new original bolts.
- Install the generator.
- Tighten the transmission to the engine.
- Tighten the torque converter.
The rest of the installation is performed in reverse order of removal, noting the following.
- Install the starter.
- Attach the right coolant pipe to the transmission. Refer to => [ Right Coolant Pipe on Transmission ] Right Coolant Pipe on Transmission.
- Install the left rear coolant pipes to the transmission. Refer to => [ Left Rear Coolant Pipes on Transmission ] Left Rear Coolant Pipes on Transmission.
- Install ATF lines.
- Attach the front driveshaft to the transfer case.
- Raise the engine/transmission assembly using the (VAS 6131 A).
- Install Air Conditioning (A/C) compressor.
- Align subframe, engine carrier and transmission carrier using marks made on longitudinal during removal.
- Tighten bolts for the subframe, engine carrier and transmission carrier only to specified torque. Do not tighten further (tighten bolts only after axle alignment).
Risk of accident due to loose connections.
• If the bolts in the subframe are not tightened to final torque, vehicle must not be driven.
- Install the universal joint on the steering gear.
- Install the selector lever cable and adjust if necessary.
- Install the catalytic converter. Refer to => [ Left Catalytic Converter ] Left Catalytic Converter, => [ Right Catalytic Converter ] Right Catalytic Converter.
- Install exhaust system free of stress. Refer to => [ Exhaust System, Installing ] Service and Repair.
- Attach the rear driveshaft to the transfer case.
- Install stabilizer bar.
- Install brake caliper.
- Install the suspension struts and control arms.
- Install the Engine Control Module (ECM).
- Install the cover for the plenum chamber E-box.
- Attach the electric wire to the battery jump start terminal (U6).
- Attach the ground connection to the right longitudinal member.
- Electrical connectors and wiring routing.
- Follow all steps after connecting the battery.
There is a risk of destroying control modules with excess voltage.
• Do not use a charger as a starting aid.
- Install the hydraulic pipe.
- Install and adjust the windshield wiper arms.
- Fill engine oil and 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.
- Connect the coolant hoses with the connector coupling. Refer to => [ Connect the Coolant Hose to the Coupling ] Radiator Overview.
- Fill the coolant system => [ Filling ] Service and Repair.
• Only reuse drained coolant if cylinder head or engine block was not replaced.
• Dirty coolant may not be used again.
- Align subframe and engine carrier.
- Align and tighten the transmission carrier.
- Install the front wheel housing liners.
- Perform axle alignment.
Risk of accident due to loose connections.
• Tighten subframe bolts to final torque after axle alignment.
- Install the noise insulation bracket and the noise insulation.
- On vehicles with air suspension, deactivate vehicle lift mode.