Engine, Installing
Engine, Installing
Special tools, testers and auxiliary items required
• Ring Spanner Insert AF16 (V.A.G 1332/14)
• Assembly Aid (T40169) for vehicles with a 7-speed transmission 0B5:
• Transportation Lock (T40170)
• Scissor-Type Assembly Platform (VAS 6131 A)
Tightening Specifications
• Tightening specifications only apply to lightly greased, oiled, phosphate 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 parts that have had the lubrication removed.
• Tolerance for tightening specifications ± 15%.
Subframe mount, refer to => [ Subframe Mount Overview ] Subframe Mount Overview.
Engine to S-Tronic Transmission
Engine and Automatic Transmission
• The aluminum bolts may be used two times. After using the bolts once, mark them with an "X" made by a chisel - arrow -.
• To avoid damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt in a 14 mm socket with a 1/2 inch drive ratchet which is clamped into a vise, as shown in the illustration.
• Do not used bolts marked with an "X" again.
Procedure
• Replace bolts which have been tightened to an additional torque.
• Replace self-locking nuts and bolts as well as sealing rings, seals and O-rings.
• The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps appropriate for the model, refer to the Parts Catalog.
• To mount the air guide hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.
• During installation, all cable ties must be installed at the same location.
- Install the engine supports and engine mount. Refer to => [ Subframe Mount Overview ] Subframe Mount Overview.
- Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.
- Determine if the engine/transmission aluminum bolts can be used again and mark them if necessary.
- Complete the following steps before connecting the engine and transmission:
Vehicles with S-Tronic Transmission
- Insert the (T40169) into the transmission housing and dual mass flywheel from underneath as illustrated.
• The assembly aid must engage in the semicircular opening - 1 - and in the inspection hole - 2 -.
• The inspection hole is only in one location on the circumference so rotate the dual mass flywheel as needed.
- Install the assembly aid bolt into the hole on the transmission housing.
- Install the (T40170) into the transmission housing and the dual mass flywheel from underneath and secure it to the flange shaft - 1 -.
- Make sure the alignment sleeves - A - for centering the engine and transmission in the cylinder block are present. Insert the alignment sleeves if they are missing.
- Position the transmission on the engine and tighten the bolts - 1 and 6 through 10 -.
- Remove the (T40170) and the (T40169).
Vehicles with Automatic Transmission
- Turn the torque converter so that the hole next to the notch - arrow - is visible in the transmission housing in the lower cut-out, as illustrated.
• The notch is only in one location on the circumference, so rotate the torque converter as needed.
- Install the (T40170) into the transmission housing from underneath and secure it to the flange shaft - 1 -.
- When joining the engine and subframe, hold the ATF lines in their installation position.
- Make sure the alignment sleeves - A - for centering the engine and transmission in the cylinder block are present. Insert the alignment sleeves if they are missing.
- Position the transmission on the engine. Be careful of the starter.
- Tighten bolts - 1 through 11 -.
- Remove the (T40170).
All Vehicles
• The following procedure is necessary to assure that the dual mass flywheel and/or the torque converter contacts the drive plate evenly and does not get bent.
- Press the dual mass flywheel and / or the torque converter - 2 - in - arrow - slightly against the drive plate - 3 - using a pry bar - 1 -.
- Secure the dual mass flywheel and/or the torque converter to the drive plate as follows:
• Tighten the bolt with the (V.A.G 1332/14).
- Install the first bolt - arrow - by hand (2 Nm).
- Insert the (T40058) guide pins as follows:
• The large diameter - arrow 1 - faces the engine.
• Small diameter - arrow 2 - points to adapter.
- Rotate the crankshaft 180° further in direction of engine rotation - arrow - using the (T40058) and ring wrench.
- Tighten the bolts that are accessible in this position to the tightening specifications.
- Turn the crankshaft 60° further and tighten the remaining 5 bolts to the tightening specification.
- Install the ATF cooler.
- Install the left and right drive axles on the transmission flange shafts.
- Install driveshaft heat shield.
- Install the catalytic converters. Refer to => [ Left Catalytic Converter ] Left Catalytic Converter and for the => [ Right Catalytic Converter ] Right Catalytic Converter.
Vehicles with S-Tronic Transmission
- Next, raise engine/transmission subassembly high enough using the (VAS 6131 A) until dimension - a - is reached between subframe and body.
• Dimension - a - = at least 100 mm.
- Install the selector lever cable and adjust if necessary.
- Continue raising the engine/transmission subassembly using the (VAS 6131 A).
Vehicles with Automatic Transmission
- Raise the engine/transmission assembly using the (VAS 6131 A).
All Vehicles
- Align the subframe and transmission carrier using the marks made on the longitudinal members during removal.
- Tighten the subframe bolts only to the tightening specifications, do not tighten them further (tighten the bolts only after axle alignment).
Risk of accident due to loose connections.
• If the bolts in the subframe are not tightened to final torque, vehicle must not be driven.
- Tighten the tunnel crossmember bolts.
Vehicles with Automatic Transmission
- Install the selector lever cable and adjust if necessary.
All Vehicles
The rest of the installation is performed in reverse order of removal, noting the following:
- Attach the steering intermediate shaft to the steering gear.
- Install the driveshaft.
- Install the front muffler. Refer to => [ Muffler Overview ] Muffler Overview.
- Install exhaust system free of stress. Refer to => [ Exhaust System, Installing ] Service and Repair.
- Install the subframe crossbrace, the upper control arm, the stabilizer bar and the subframe heat shield and then tighten the suspension strut to the control arm.
- Install brake caliper.
- Install Engine Control Module (ECM).
- Install the windshield wiper fluid reservoir filler tube.
- Electrical connections and routing.
- Install the wires, terminal 30 wire junction 2 (TV2) and the plenum chamber E-box cover.
- Install the tower brace.
- Install refrigerant lines.
- Follow the instructions for connecting the battery.
Risk of destroying control modules with excess voltage.
• Do not use a battery charger for starting assistance!
- Install air filter housing.
- Install the lock carrier cover.
- Install the plenum chamber cover and the front lower longitudinal member. - Fill engine oil and check oil level.
- Connect the coolant hose to the coupling. Refer to => [ Connect the Coolant Hose to the Coupling ] Radiator Overview.
- Fill with coolant => [ Filling ] Service and Repair.
• Only reuse drained coolant if cylinder head or engine block was not replaced.
• Dirty coolant may not be used again.
- Fill the refrigerant circuit.
- Install the wheel housing liners.
- Install the front wheels.
- Perform axle alignment.
Risk of accident due to loose connections.
• Tighten the subframe bolts to the specification after performing axle alignment.
- Install the noise insulation.