Part 4

Tightening Specification for Ground Wires to the Longitudinal Member





- Tighten the nut - arrow - to 9 Nm.

Engine to S-Tronic Transmission 0B5











• The aluminum bolts - 2 through 10 - may be used two times. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be 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.

• Do not used bolts marked with an "X" 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 S-Tronic transmission 0B5, 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 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.

• When installing, bring all cable ties back to same positions.

- Install the engine supports and engine mount. Refer to => [ Subframe Mount Overview ] Subframe Mount Overview.

- When joining the engine and subframe, hold the ATF lines in their installation position.

- 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.

- Install the (T40170) into the transmission housing and the clutch module from underneath and secure it to 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.

- Attach the transmission to the engine and the tighten the bolts - 1 and 6 through 10 -.

- 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.






- Press the clutch module - 2 - slightly against the drive plate - 3 - using a pry bar - 1 - in - arrow -.

- 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).

- Insert the (T40058) guide pins as follows:






• The large diameter - arrow 1 - faces the engine.

• The small diameter - arrow 2 - faces the 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 power steering hydraulic oil lines.

- Install the coolant recirculation pump.

- Install ATF 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 subframe and body.






• - a - = minimum 100 mm

- Install the selector lever cable and adjust if necessary.

- 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:

- 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, the upper control arm and stabilizer bar and tighten the suspension strut on the left and right control arms.

- Install diagonal braces.

- Install brake caliper.

- Install 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 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 with coolant => [ 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.

- Fill with ATF.

- Install the noise insulation.