Engine, Installing: Procedure

WARNING: This page is about a different variant/trim than selected.

Install in reverse order of removal and note the following:

NOTE:

Replace the bolts that were tightened with an additional turn.

Replace the self-locking nuts and bolts, gaskets, seals and O-rings.

Secure hose connections with standard production clamps.

During installation, all cable ties must be installed at the same location.

-- Guide the engine/transmission assembly with a second technician into the body using the :VAS6131B .

-- Install all the engine mount bolts completely by hand.

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-- Tighten the bolts -2 and 3-. The bolt -3- is accessible through the right wheel housing.

-- Install the bolts -3- for the transmission mount by hand all the way.

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-- Align the transmission mount -1- with the transmission bracket -2- so that the distance -a- is the same.

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-- Align the engine mount -1- so that the distance -a- is the same.

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-- Tighten the bolts -4-.

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-- Install the bracket and tighten the bolts -5-.

NOTE:

The bolts are only tightened to the final tightening specification after the subframe mounts have been adjusted. Refer to SUBFRAME MOUNT, ADJUSTING .

-- Remove the T10497 from the engine.

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

-- Install the drive axles. Refer to DRIVE AXLE .

-- Install the selector lever cable. Refer to SELECTOR MECHANISM (02Q, 02QA) , SELECTOR MECHANISM (0CG) and SELECTOR MECHANISM (0AF) .

-- Install the Electrical A/C Compressor -V470-. Refer to A/C COMPRESSOR .

-- Electrical connections and routing. Refer to RELAY CARRIERS, FUSE PANELS AND E-BOXES and the Appropriate Wiring Diagram.

-- Install the Engine Control Module -J623-. Refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

-- Connect the coolant hoses with the connector coupling. Refer to the figure below;

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-- Install subframe with steering gear. Refer to SUBFRAME .

-- Install the pendulum support. Refer to PENDULUM SUPPORT, REMOVING AND INSTALLING .

-- Install the wheel housing liner. Refer to WHEEL HOUSING LINER .

-- Mount the front wheels. Refer to WHEEL, CHANGING or WHEELS AND TIRES .

-- Install the Electric Drive Power and Control Electronics -JX1- bracket. Refer to ELECTRIC DRIVE POWER AND CONTROL ELECTRONICS .

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-- Install the Electric Drive Power and Control Electronics -JX1-. Refer to ELECTRIC DRIVE POWER AND CONTROL ELECTRONICS .

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-- Connect the connector -1- to the contact switch for the connection box -2- for the Electric Drive Motor -V141-.

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-- Install the connection box protective plate for the Electric Drive Motor -V141- -1-.

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-- Install the fan shroud. Refer to FAN SHROUD, REMOVING AND INSTALLING .

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

NOTE:

The drained coolant may be used again only if the cylinder head or the cylinder block were not replaced.

Do not use dirty coolant again.

Vehicles With Secondary Air System

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-- Install the damper -1-.

-- Attach the air line -1 and 2- to the damper -3-.

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Continuation For All Vehicles

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-- Install the damper cover -1-.

-- Connect the 12V battery. Refer to BATTERY .

CAUTION:

Extremely dangerous due to high-voltage.

Severe bodily injury or death by electrocution is possible.

- Have a qualified person put the high-voltage system back into service.

-- Bring the high-voltage system back into operation. Refer to HIGH VOLTAGE SYSTEM, TURNING BACK ON .