Engine/Transmission, Installing
Engine/transmission, installing
Special tools:
951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor
999 5972 FIXTURE 999 5972 Fixture
Note! As the illustrations in this service information are used for different model years and / or models, some variation may occur. However, the essential information is always correct.
Note! For tightening torques, see Specifications Tightening Torque
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Service and Repair.
Installing the engine and transmission unit
Raise the engine and the transmission unit. Use a lifting table with locating pins.
Stop when the sub-frame is approximately 15 cm below the frame members.
Install (left and right-hand sides)
- the drive shaft to the hub. Install the center screws. Do not tighten yet!
- the ball joint to the control arm. Install the nuts. Do not tighten yet!
Note! Ensure that the mating surfaces on the ball joints and control arms are clean.
Twist the engine block heater (option) into position. Check that the air conditioning (A/C) compressor is correctly positioned.
Check that the tie rod is in the correct position. Check that the transmission cable is routed between the steering shaft and the firewall.
Align the steering shaft joint on the steering gear.
Lift the engine and transmission unit up to the frame members.
Note! Ensure that no hoses, wiring or anything else catches.
Install
- a new screw in the lower steering shaft joint. Tighten to 20 Nm
- new screw in the sub-frame. Lubricate the screws
- the washes at the front edge and the support plates at the rear edge of the sub-frame.
Tighten the screws for the sub-frame. Tighten to 105 Nm. Angle-tighten 120°. Use bevel protractor 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor. Start on the left hand side of the sub-frame. Continue with the right hand side.
Tighten the screws for the brackets at the rear of the sub-frame. Tighten to 50 Nm.
Remove the lifting table.
Installing the propeller shaft (all-wheel drive (AWD) only)
Install the propeller shaft (all-wheel drive (AWD) only). See Pinion seal bevel gear, replacing Pinion Seal Bevel Gear, Replacing.
Installing the three-way catalytic converter (TWC) (all-wheel drive (AWD) only)
Lubricate the studs where the exhaust system separates downstream of the three-way catalytic converter (TWC). Use paste 116 1408.
Warning! Avoid skin contact with the paste.
Lift up the exhaust system and connect it to the rear system. Use a new gasket and new nuts.
Hint: Use a mobile jack with universal plate 999 5972 FIXTURE 999 5972 Fixture as a support.
Note! The routing of the heated oxygen sensor (HO2S) wiring over the brake pipe.
Install the screws holding the SIPS member to the bodywork. Tighten the screws.
Press the brake pipe into place in the holders on the SIPS member.
Installing the front exhaust pipe
Lubricate the studs on the turbocharger (TC). Use paste 116 1408.
Warning! Avoid skin contact with the paste.
Install the front exhaust pipe on the turbocharger (TC). Use new nuts. Tighten to 30 Nm.
Clamp the wiring for the rear heated oxygen sensor (HO2S) into place at
- the bracket at the rear of the sub-frame
- the clips on the power steering pipe at the steering gear
- the clamp at the right-hand side of the steering gear.
Connecting fuel lines
When assembling the fuel lines, see also: Fuel system, quick-release connectors Description and Operation.
Connect the quick-release connector and the fuel line to:
- the motor
- the engine block heater (option).
Press the EVAP line together at the rubber joint.
Assembling the spring strut
Install
- the tie rods. Use new nuts. Tighten to 70 Nm
- the link rod to the anti-roll bar. Use new nuts. Tighten to 50 Nm. Counterhold with Tx27
- the bracket for the brake pipe to the body.
Tighten
- the nut for the ball joint and control arm. Tighten to 80 Nm. Counterhold using Tx40
- the center screw in the drive shaft. Tighten to 50 Nm.
Cars with engine block heaters (option)
Connect the heater connector at the vehicle wiring.
Ensure that the connector and wiring are secured at the body.
Rivet the fender liner to the fender edge.
Check that the quick-release fuel line connector is secure at the engine block heater.
Installing the air conditioning (A/C) compressor
Install the 4 screws whilst the compressor is loose.
Raise the compressor and screw it into place.
Note! Handle the compressor carefully. Ensure that there are no kinks in the air conditioning (A/C) pipes.
Connect the one-pin connector to the compressor magnetic clutch.
Installing components
Connect the engine wiring to the control module box. See Central electrical unit, engine compartment, replacing Central Electrical Unit, Engine Compartment, Replacing.
Install
- the ground lead to the ground terminal at the right fender edge in the engine compartment
- the auxiliaries belt
- the intermediate piece for the control module box
- the control modules. See Engine control module (ECM), replacing Service and Repair
- the cover for the control module box
- expansion tank. Connect the radiator breather tube to the expansion tank. Tighten the clamp. Connect the connector for the level sensor in the expansion tank
- servo oil reservoir. Check that the hoses are correctly positioned.
Clamp the ABS cable to the power steering hose.
Install
- the heat deflector plate above the turbocharger (TC)
- the 2 ground strips on the top of the cylinder head.
Clamp the wiring for the front heated oxygen sensor (HO2S) to
- the coolant pipe
- the heat deflector plate above the manifold
- the turbo control hose at the plastic intake pipe for the turbocharger (TC).
Install
- the positive lead for the starter motor
- the connector for the engine wiring
- the cover over the central electrical unit.
Installing the transmission cable
Automatic transmissions: Install the screws holding the bracket and transmission cable to the transmission.
Manual transmissions: Install the transmission cable. Assemble the clutch cable.
Installing the engine coolant fan (FC)
Install
- the lower engine coolant hose to the radiator. Tighten the clamp
- the lower oil cooler hose for the transmission to the radiator (automatic transmissions only). Use new O-rings
- the plastic charge air pipe between the throttle body (TB) and the charge air cooler (CAC). Only connect the plastic pipe at the throttle body (TB). Do not tighten the clamp.
Remove radiator protection 999 5474
Install
- the engine cooling fan (FC). Tighten the screws securing the fan shroud to the front panel
- the plastic charge air pipe to the connection at the charge air cooler (CAC). Tighten both the clamps. Connect the connectors for the temperature and pressure sensors in the plastic pipe
- the canister purge (CP) valve to the bracket at the fan shroud. Secure the EVAP hose to the clip at the lower section of the fan shroud
- the brake vacuum hoses
- the upper oil cooler hose for the transmission to the radiator (automatic transmissions only). Use new O-rings.
Press down the right side of the cooler unit. Pull the wiring for the pressure switch (Pressostat) into the drier bottle.
Connect the connectors to
- the engine cooling fan (FC) (x2)
- the canister purge (CP) valve.
Secure
- the breather tube for the radiator at the top of the fan shroud
- the wiring at the lower right corner and at the top of the fan shroud.
Install
- the rubber hose to the inlet side of the charge air cooler (CAC)
- the plastic charge air pipe above the engine. Tighten all clamps. Secure the pipe on the engine
- the upper coolant hose. Tighten the clamp
- the ventilation pipe between the control module box and fan shroud
- the air cleaner (ACL) assembly. Connect the plastic hose to the mass air flow (MAF) sensor. Tighten the clamp
- the air cleaner (ACL) intake pipe.
Connect the connector to the mass air flow (MAF) sensor. Secure the wiring at the front of the air cleaner (ACL) housing.
Install the support brace between the suspension turrets. Secure the servo hose to the right mounting on the support brace.
Finishing
Connect the connector to the pressure switch (Pressostat) in the drier bottle. Secure the wiring.
Tighten the lower screw on the cooler unit.
Connect the connectors to both the heated oxygen sensors (HO2S).
Install
- the splash guard under the radiator
- the splash guard under the engine
- the front wheels. See Installing wheels Service and Repair
- the battery negative lead. Also read Battery, disconnecting Battery Disconnecting.
Final check
Top up
- coolant
- engine oil
- power steering fluid.
Start the engine.
Warm up the engine until the thermostat opens.
Check for leakage.
Check the oil and coolant levels. Adjust if necessary.
Check the transmission oil level (automatic transmissions only). Top up if necessary.