Engine, Installing

Special tools and workshop equipment required 

• All special tools listed when removing.

Procedure 

• Replace 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.
• Only remove the plugs or caps just before installing the respective lines.
• Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts Information.
• Check the vacuum hoses for damage before the assembly and replace if necessary.
• During installation, all cable ties must be installed at the same location.
• Used coolant cannot be used again.

• Secure the engine on the Scissor Lift Table: VAS6131B  .

-- Insert the alignment sleeves in the cylinder block.

-- Install the intermediate plate. Refer to Fig 1.

-- Install the drive plate. Refer to DRIVE PLATE, REMOVING AND INSTALLING .

-- Install the transmission on the engine. Refer to TRANSMISSION, INSTALLING .

TIP:

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 .

Install in reverse order of removal. Note the following:

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

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

-- Versions with manual transmission: install the push rod, connecting rod and selector lever. Refer to the appropriate Service Information .

-- Versions with Dual clutch transmission: install the emergency release cable for the parking lock. Refer to OVERVIEW - PARKING LOCK EMERGENCY RELEASE .

-- Install the refrigerant lines. Refer to REFRIGERANT LINES, REMOVING AND INSTALLING AT A/C COMPRESSOR .

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

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

-- Install the lock carrier cover. Refer to OVERVIEW - BUMPER COVER .

-- Connections and wire 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 .

-- Check the oil level. Refer to ENGINE OIL .

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

After Replacing the Engine an Adaptation must be Preformed.

-- Perform the adaptations. Refer to PERFORM ADAPTATIONS AFTER COMPONENT REPLACEMENT .

-- Connect the coolant hose to the connector coupling. Refer to Fig 3.

-- Fill the coolant. Refer to COOLANT, FILLING USING Cooling System Charge Kit: VAS6096 [DMSA, DMSB] .

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

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

-- Install the front wheels. Refer to WHEEL BOLTS TIGHTENING SPECIFICATION .

-- Install the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

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%.

Component			Nm
Bolts and nuts		M6	9
		M7	15
		M8	20
		M10	40
		M12	65