Engine, Installing
Engine, Installing
Special tools, testers and auxiliary items required
• Ring Spanner Insert AF 16 (V.A.G 1332/14)
• Assembly Aid (T40169)
• Transportation Lock (T40170)
• Scissor-Type Assembly Platform (VAS 6131 A)
Tightening Specifications
• The tightening specifications apply only 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 parts that have had the lubrication removed.
• Tightening specification tolerance +/- 15%.
Subframe mount, refer to => [ Subframe Mount Overview ] Subframe Mount Overview.
Ground Bolt to Strut Tower - Tightening Specification
- Tighten the ground bolt - 1 - to 9 Nm.
Tightening Specification for Ground Wires to the Longitudinal Member
- Tighten the nut - arrow - to 9 Nm.
Engine to Manual Transmission
• The aluminum bolts - 2 through 11 - may be used two times. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have been used the first time - arrow -.
• To prevent damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt using a 14 mm socket with a 1/2 drive, which is inserted in to the vise, as illustrated.
• Bolts marked with an "X" may not be used again.
Procedure
• Replace the bolts which are being tightened with an additional turn.
• Replace self-locking nuts and bolts and seals, gaskets and O-rings.
• In vehicles with manual transmissions, there is a needle bearing in the drive plate. Check if the needle bearing is inserted before installing. Needle bearing, removing from and installing on drive plate. Refer to => [ Needle Bearing on Drive Plate ] Service and Repair.
• 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 of the same type as those equipped by the factory. Refer to Parts Catalog.
• To mount the air guide hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.
• When installing, bring all cable ties back to the same positions.
- 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.
- The following preparations must be made before connecting the engine and transmission:
- Insert the (T40169) into the transmission housing and clutch module 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 clutch module as needed.
- Install the assembly aid bolt into the hole on the transmission housing.
- Insert the (T40170) in the transmission housing from below and secure it on the flange shaft - 1 -.
- Check if the alignment sleeves - A - for centering the engine/transmission are in the cylinder block and insert them if they are not.
- Inspect the aluminum bolts used to connect the engine to the transmission to see if they can be used again and mark them, if necessary.
- Position the transmission on the engine and tighten the bolts - 1 through 11 -.
- Remove the (T40170) and (T40169).
• The following procedure is necessary to assure that the clutch module contacts the drive plate evenly and does not get bent.
- Insert the (T40058) guide pins as follows:
• The large diameter - arrow 1 - faces the engine.
• The small diameter - arrow 2 - faces the adapter.
- Turn the crankshaft further one complete turn (360°) in direction of engine rotation - arrow - using the (T40058) and ring wrench.
• The inspection hole - arrow - must be visible through the opening in the transmission housing.
- Secure the clutch module to the drive plate as follows:
• Tighten the bolt with the (V.A.G 1332/14).
- Install the first bolt - arrow - and tighten by hand (2 Nm).
- Rotate the crankshaft with the (T40058) 180° in direction of engine rotation.
- Tighten the bolts that are accessible in this position to the tightening specification.
- Turn the crankshaft 60° further and tighten the remaining 5 bolts to the tightening specification.
- Install the power steering hydraulic oil lines.
- Install the left and right drive axles on the transmission flange shafts.
- Install the catalytic converters: for the left one, refer to => [ Left Catalytic Converter ] Left Catalytic Converter and for the right one, refer to => [ Right Catalytic Converter ] Right Catalytic Converter.
- Next, raise engine/transmission subassembly high enough using (VAS 6131 A) until dimension - a - is reached between the subframe and body.
• - a - = minimum 100 mm
- Install the shift rod and pivot rod.
- Continue raising the engine/transmission subassembly using the (VAS 6131 A).
- 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 - arrow -.
Install in reverse order of removal paying attention to the following:
- Install the clutch slave cylinder.
- Attach the steering intermediate shaft to the steering gear.
- Install the driveshaft.
- Install the front muffler. Refer to => [ Front Muffler ] Front Muffler.
- Install exhaust system free of stress. Refer to => [ Exhaust System, Installing ] Removal and Replacement.
- Install the front crossmember.
- Install the subframe cross brace, upper control arm and stabilizer bar and tighten the suspension strut on the control arm.
- Install diagonal braces.
- Install brake caliper.
- Install the Engine Control Module (ECM).
- Electrical connectors and wiring routing.
- Install the wires, terminal 30, wire junction 2 (TV22) and the engine compartment E-box cover.
- Install the tower brace.
- Install the windshield wiper fluid reservoir filler tube.
- Install refrigerant lines.
- Be sure to follow the procedure for connecting the battery and afterwards.
There is a risk of destroying control modules with excess voltage.
• Do not use a charger as a starting aid.
- Install the fuel supply hose and air filter housing.
- Install the lock carrier braces.
- Fill the engine oil and check the level.
- Before starting the engine for the first time, check the fluid level in the power steering reservoir.
• The power steering pump must not run dry.
- Connect the coolant hose to the coupling. Refer to => [ Connect the Coolant Hose to the Coupling ] Radiator and Coolant Fan Overview.
- Fill the coolant. Refer to => [ Filling ] Service and Repair.
• Do not use drained coolant in the following situations:
• If the cylinder head or cylinder block was replaced.
• If the coolant is contaminated.
- 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.