Engine, Installing
Installing
Installation is reverse of removal, noting the following:
Notes:
^ During installation, all cable ties must be reinstalled at the same locations.
^ Heat boots, which are removed during engine removal must be reinstalled at the same locations when re-installing engine.
^ Secure all hose connections using hose clamps appropriate for the model type:
Refer to Parts Supplier
^ Replace self-locking nuts and bolts during assembly work.
^ Always replace bolts that are secured with tightening torque as well as O-rings and gaskets.
- Make sure centering sleeves for engine to transmission are correctly installed in cylinder block. Install or replace if necessary.
- Slide intermediate plate or intermediate panel onto sleeves.
Vehicles with manual transmission:
- Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Do not grease guide sleeve.
- Check centering of clutch disc.
- Check clutch release bearing for wear and replace if necessary.
- If the plastic ring of the release bearing is loose, adhere it to the bearing ring again using adhesive AMV-195-KD1-01
^ 3 rectangular tabs (arrows) of the plastic ring reach into the cutouts of the bearing ring.
^ If grooves with depth of more than 0.5 mm are present, the release bearing must be replaced.
Vehicles with SAC clutch pressure plate:
When installing a new clutch disc in combination with a used SAC pressure plate (self-adjusting pressure plate), the adjustment ring of the pressure plate must be turned back to impact. Otherwise the pressure plate works with decreased contact pressure (clutch slips).
If the clutch disc is not replaced, the adjustment ring does not have to be turned back.
New SAC pressure plates are already preadjusted and must not be turned back.
Vehicles with automatic transmission 01V:
- Drive plate is bolted to the crankshaft with a centering bushing (arrow).
- Use original bolts when securing torque converter to drive plate:
Refer to Parts Supplier
When torque converter is installed correctly, distance between lower contact surface of threaded holes at torque converter and contact surface of converter housing on Automatic Transmission 01V is approximately 23 mm.
If the torque converter is not inserted completely, this distance will be approximately 11 mm.
WARNING: In case of an incorrectly inserted torque converter, the coupling plate of the torque converter or the ATF-pump will be destroyed, if the transmission is flanged to the engine.
All:
- Carefully guide engine into engine compartment.
^ Set engine onto engine mounts.
WARNING: For vehicles with automatic transmission 01V, keep checking whether the torque converter behind the drive plate can be turned before and during tightening of the bolts at engine/transmission flange. If the torque converter cannot be turned, it must be assumed that it has not been inserted properly and that the coupling plate of the torque converter or the ATF pump will be destroyed during final tightening of the bolts.
- Bolt transmission to engine.
- Tighten T10062 support on the threaded bores for torque support to 20 Nm.
- Lift engine using VAG1383A engine/gearbox jack just far enough so that the connecting bolts at engine/transmission can be installed from below.
Note: When working on a vehicle with all wheel drive, make sure the front constant velocity joint for the drive shaft is not damaged when lifting engine.
- Tighten bottom engine/transmission connecting bolts (arrows).
- Lower engine again.
- Install and align exhaust system tension-free.
- Install starter.
- Install generator.
- Install A/C compressor.
- Install ribbed belt.
- Install lock carrier, Refer to Body and Frame.
Vehicles with automatic transmission
- Secure ATF line:
All:
- For harness connectors and routing:
Refer to, Electrical Wiring Diagrams, Troubleshooting & Component Locations
Notes:
^ Be sure to activate vehicle features (radio/radio-navigation system, clock, electric window regulators) according to owner's manual when the battery is re-connected.
^ Deactivate service mode of telematic control module.
WARNING: Do not use a battery charger for starting assistance! There is risk of damage at the vehicle control modules.
- Check engine oil level before starting engine.
- Top up coolant.
Notes:
^ Only reuse drained coolant if cylinder head or engine block were not replaced.
^ Dirty coolant cannot be reused.
- Fill up power steering fluid and bleed steering system:
Vehicles with automatic transmission
- Check ATF level:
All:
- Adjust headlights:
Tightening torques
Notes:
^ Tightening torques are valid only for nuts and bolts that are lightly greased, oiled, covered with a thin coat of phosphate or blackened.
^ Additional lubricants are permitted, e.g. engine oil or transmission fluid, however no graphite containing lubricants.
^ Do not use any degreased parts.
^ Tightening torque tolerance ± 15%.
Securing engine/transmission for manual transmission
A: Alignment bushing
Securing engine/transmission with automatic transmission 01 J
A: Alignment bushing
Securing engine/transmission with automatic transmission 01 V
A: Alignment bushing
Component Tightening Torques (Part 1 Of 17):
Component Tightening Torques (Part 2 Of 17):
