Installing Turbocharged Engine With Transmission
Turbocharged engine assembly with the transmission, installing
Special tools:
951 2834 Torque socket 21mm S/V40 951 2834 Torque Socket 21mm
999 2810 LIFTING YOKE 999 2810 Lifting Yoke
999 5186 HOOK 999 5186 Hook
999 5642 Hook 999 5642 Hook
999 5488 PLUGS 999 5488 Plugs
Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Flanged Joint, Assembling.
Place the hood in the service position
Engine assembly with transmission, installing
Install lifting yoke 999 2810 LIFTING YOKE 999 2810 Lifting Yoke and lifting hooks 999 5642 Hook 999 5642 Hook and 999 5186 HOOK 999 5186 Hook.
- Adjust the lifting yoke so that the engine is balanced
- Adjust the lifting hooks continuously throughout the lift
- Install the screw and the nut on the engine mounting on the timing side.
Manual transmissions: Installing the gear selector mechanism cables
Check the gear selector mechanism cables.
Install:
- the mechanical cables using clips on the brackets
- the mechanical cables with washer and clips on the levers. Lubricate using grease 116 1241-3.
Automatic transmission: Installing the gear selector mechanism cables
Check the gear selector mechanism cables.
Install:
- The connectors and the mounting
- Ground lead
- Gear selector cables.
Engine mounting on transmission side, installing
- Install the mounting on the transmission. Tighten to 45 Nm.
Note! Ensure that the rubber protectors are correctly positioned.
- Install the screw and the nut on the engine mounting in the body
- Remove the lifting equipment
- Tighten the screws for the engine mountings on the left and right-hand sides. Tighten to 98 Nm.
Return the hood to the normal position.
Hoses and wiring, routing and connecting
Connect:
- The injectors. Secure the wiring
- The wiring for the ignition coil and the ground lead
- The cable mounting on the engine. Tighten the mounting. Tighten to 10 Nm
- The positive crankcase ventilation (PCV) valve
- The throttle position (TP) sensor and the idle air control (IAC) valve.
Fuel hose, routing and connecting
Connect the fuel hose(s). Pull the hose(s) to check that they are secure.
Charge air hose from the turbocharger (TC), upper hose, installing
- Install the pipe and insert in the upper hose
- Install the clamp. Connect to the engine via the intermediate pipe. Tighten the hose clamps.
Air conditioning (A/C) compressor on engine, installing
Install the air conditioning (A/C) compressor. Install the bracket on screw (B). Do not tighten the screw (B). Tighten the other screws. Tighten to 25 Nm.
Connectors, connecting
Connect the connectors for:
- Generator (GEN)
- The sensor on the A/C compressor
- The oil pressure sensor.
Drive shaft right-hand in transmission, installing
Remove special tool 999 5488 PLUGS 999 5488 Plugs from the transmission.
Install the drive shaft in the transmission and the bearing.
Finger tighten the bearing cap.
Secure the wheel spindle on the spring strut. Install the screws and nuts.
Tighten the bearing cap screws. Tighten to 25 Nm.
Engine mounting rear, installing
Install the mounting. Tighten the 4 screws.
Tighten to 40 Nm.
Engine mounting front, installing
Connect the inlet hose to the charge air cooler (CAC). Tighten the hose.
Secure the hose on the engine mounting. Tighten on the engine with three screws. Tighten to 50 Nm.
Tighten the nut for the clamp.
Tighten to 6 Nm.
Install the air conditioning (A/C) pipe in the engine mounting.
Front-rear member, installing
Install heat shield.
Install the front-rear member. Insert the two screws (B) through the engine pads. Tighten the two screws.
Install the front and rear engine screws (A). Tighten the screws. Tighten to 69 Nm.
Note! Position the rubber elements in the correct positions (see the illustration). The position of the mounting points for the front-rear member must be the same at both the front and the rear.
Slacken off the screw (B) for the front engine pad. First tighten the screw for the rear engine pad. (Tighten to 55 Nm.) Then tighten the screw for the front engine pad. (Tighten to 55 Nm.).
Front exhaust pipe on exhaust manifold, installing
Install a new gasket.
Tighten the nuts. Tighten to 25 Nm.
Automatic transmission: Installing the oil pipes
Install the lower pipe. Use a new O-ring.
Install the upper pipe (the return line) with the mounting in the control system cover. Install the connection loosely.
The pipe cap nut is tightened later.
Drive shaft left-hand side, installing
- Clean the drive shaft and the splines
- Remove special tool 999 5488 PLUGS 999 5488 Plugs from the transmission
- Remove the screw from the wheel spindle / spring strut
- Insert the drive shaft into the transmission. Press the drive shaft in as far as it will go
- Position the hub over the drive shaft splines. Install the nut
- Install the two screws on the wheel spindle / spring strut.
Lateral strut, installing
- Install the lateral strut. Use screws
- Tighten the screws. Tighten to 50 Nm.
Engine splash guards, installing
Install:
- Tighten the two screws on the wheel spindle / spring strut. Tighten to 90 Nm
- Secure the ABS lines in their mountings
- Install the brake hose in the mounting. Secure using a clamp.
Front wheel, installing
- Install the wheels. Tighten the nuts slightly
- Then tighten crosswise. Tighten to 110 Nm
- Torque tighten the wheel nuts one more time
- Lower the car.
Note! When tightening using a pneumatic impact wrench, only use torque socket 951 2834 Torque socket 21mm S/V40 951 2834 Torque Socket 21mm.
Note! Tightening crosswise to the correct torque is important to prevent stresses in the brake disc.
Tighten the center nut (A). Tighten to 120 Nm +60°.
Wiring, installing
- The ground lead to the transmission
- The brake servo hose to the power brake booster
- The wiring for the starter motor
- The battery positive terminal
- Route the wiring
- Connect the connectors. Clamp the wiring into place.
Coolant hoses, installing
- Install the expansion tank. Tighten the clamp
- Tighten the cap nut on the oil cooler pipe connector on the transmission. Tighten to 30 Nm.
Heater hoses, installing
- Install and tighten the two heater hoses. Check that the hoses are correctly connected
- Install the heat shield on the firewall.
Air cleaner (ACL), installing
See Replacing the air cleaner (ACL) Removal and Replacement.
Battery, installing
- Install the battery shelf. Tighten to 16 Nm
- Install and secure the battery with the clamp.
Note! Cars with cruise control: The vacuum hose and vacuum motor wiring must be connected before the battery shelf is screwed into place.
Throttle cable and the air intake hose on the throttle body (TB), securing
- Clean the air intake hose and the throttle body (TB)
- Install the hose. Tighten the clamp
Note! Ensure that the clamp never comes into contact with the throttle pulley in the idling or wide open throttle (WOT) positions.
- Connect the idle hose to the idle air control (IAC) valve. Use a new hose clamp.
Power steering pump, installing
- Install the power steering pump and the screws
- Loosely install the support bracket between the generator (GEN) and the intake manifold. Install the lower bracket
- Tighten the screws. Tighten to 25 Nm
- Secure the cable in the bracket
- Tighten the support bracket between the generator (GEN) and the intake manifold. Tighten to 25 Nm
- Tighten the lower screw on the support bracket. Tighten to 25 Nm.
Poly V-belts, installing
- Clean the belt pulley track
- Turn the belt tensioner unit clockwise
- Install the auxiliaries belt as illustrated
- Release the belt tensioner equipment (counter-clockwise)
- Tighten the bracket. Tighten to 10 Nm
- Install the power steering hose. Tighten to 10 Nm.
Coolant, filling
See Replacing coolant Removal and Replacement
Install all covers.
Check the oil level in the automatic transmission.