Engine, Installing

Special tools and workshop equipment required 

• All special tools listed within Engine, Removing. Refer to ENGINE, REMOVING .

Procedure 

• Replace the bolts that were tightened with an additional turn after removing them.
• Replace the self-locking nuts and bolts, gaskets, seals and O-rings after removing.
• A needle bearing must be installed in the drive plate on vehicles with a manual transmission. Refer to NEEDLE BEARING IN DRIVE PLATE, REPLACING .
• Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts Information.
• During installation, all cable ties must be installed at the same location.
• Used coolant cannot be used again.

-- Install the engine on the transmission but do not tighten the bolts that connect the transmission to the engine yet. Refer to the appropriate Service Information .

TIP:

Fig 1: Identifying Bolt & Spacer Sleeve

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The bolt -2- attaches the starter to the transmission and has an additional spacer sleeve -arrow-.

• The spacer sleeve must be inserted between the starter and the transmission.

-- Install the starter. Refer to STARTER, REMOVING AND INSTALLING .

-- Release the tension on the : 10-222A/11  .

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-- Lower the workshop crane and mount the engine and transmission onto the engine mount.

-- Remove the left and right bolts -2- from the engine mount.

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-- Remove the : VAS6100  and : 2024A  .

-- Tighten the bolts that connect the transmission to the engine. Refer to the appropriate Service Information .

Further installation is performed in reverse order of removal, while noting the following:

-- Connect the fuel hose. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Install the Heated Oxygen Sensor -G39-. Refer to HEATED OXYGEN SENSOR, REMOVING AND INSTALLING .

-- Tighten the drive axle. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Install the drive axle heat shield. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

-- Install the A/C compressor. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING FROM BRACKET .

-- Install the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Install the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- For the electrical connections and routing, refer to the appropriate Wiring Diagram.

-- Install the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Install the exhaust system without tension. Refer to EXHAUST SYSTEM, INSTALLING WITHOUT TENSION .

-- Install the bracket and the heat shield on the cylinder head. Refer to Fig 3Fig 2.

Fig 2: Heat Shield For Vehicles With Particulate Filter

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Fig 3: Bracket For Heat Shield For Vehicles With Particulate Filter

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-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Add engine oil. Refer to ENGINE OIL, FILLING and check the oil level. Refer to ENGINE OIL LEVEL, CHECKING AND CORRECTING IF NECESSARY .

-- Follow all steps after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- If the engine was replaced, perform the adaptations listed in "01 - mechanical engine, functions" using the Vehicle Diagnostic Tester.

TIP:

Risk of component damage: perform the additional adaptation for each component, that was replaced at the same time.

-- Connect the coolant hose to the connector coupling. Refer to Fig 4.

Fig 4: Coolant Hoses Connector Coupling

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-- Fill the coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Install the wheel housing liners and wheel spoilers. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

-- Install the front wheels. Refer to WHEELS AND TIRES .

-- Install the noise insulation. Refer to NOISE INSULATION, REMOVING AND INSTALLING .

Tightening Specifications 

• The 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 ungreased parts.
• Tightening specification tolerance: ±15%.

• Refer to OVERVIEW - SUBFRAME MOUNT 
• Engine to transmission. Refer to the appropriate Service Information .