Engine, Installing
Engine, installing
Note:
^ All cable ties which are opened or cut open on removal must be replaced in same position when installing.
^ Any heat insulation sleeves which are taken off when removing must be re-attached in same position when installing.
^ Secure all hose connections with correct hose clips (same as original equipment) See parts catalog.
^ Remove any traces of oil or grease on hose connections and hoses for charge air system before installing. Do not apply lubricant.
^ When performing repairs, replace seals, gaskets, self-locking nuts and bolts which have a specified tightening angle.
^ Before applying sealant, check updated information: See parts catalog.
- Check whether locating dowel sleeves for engine/transmission are in cylinder block and install if necessary.
- To secure torque converter on drive plate, only use new bolts (same as original equipment). See parts catalog.
- Note differing tightening torques for torque converter bolts.
A - Bolt without ribbing
^ 4 Tightening torque 65 Nm
B - Bolt with ribbing
^ Tightening torque 85 Nm
Checking position of torque converter
If torque converter has been installed correctly, distance -a- between contact surfaces at threaded holes in torque converter and joint surface on torque converter bell housing of automatic transmission 01L is approximately 19 mm.
If torque converter has not been completely inserted, this distance will be approximately 10 mm.
CAUTION: If torque converter is not installed correctly, torque converter drive plate or ATF pump will be seriously damaged when transmission is joined to engine.
- Secure transmission to engine.
CAUTION: Check repeatedly before and while tightening bolts on engine/transmission flange, whether it is possible to rotate torque converter at rear of drive plate. If it is not possible to rotate torque converter, it was not installed correctly; when tightening bolts to torque, ATF pump drive lug and consequently transmission will be damaged.
Note:
^ Tightening torques listed in this manual apply only to lightly greased, oiled, phosphated, or black-finished nuts and bolts.
^ Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant.
^ Do not use degreased parts.
^ Tolerance for tightening torques is ± 15%.
Part 1:
Part 2:
Engine/transmission mountings
A- Locating sleeves
1) Bolt strength rating 10.9
- Install right exhaust manifold.
- Install right turbocharger and align.
- Install right front exhaust pipe.
- Install left exhaust manifold.
- Install left turbocharger and align.
- Install left front exhaust pipe.
- Before installing, use a tap to clean threads in flange shaft for driveshaft on transmission to remove traces of locking compound.
- Attach hook 10-222 A20 to left rear engine lifting eye.
WARNING: Hook 10-222 A20 must be secured with a locating pin (arrow).
- Attach lifting tackle 3033 to shackle 10-222 A12 and hook 10-222 A20, and hook onto workshop crane VAS 6100 as shown in this illustration.
- Lift engine/transmission assembly and bring to front of vehicle using workshop crane.
- Push a floor jack -1- into space between transporting wheels of workshop crane, as shown in this illustration.
- Lower engine/transmission assembly until it is in installation position in engine compartment.
Note: Transmission must not be supported on transmission oil pan.
- Place a wooden block of suitable size on support plate of floor jack and apply floor jack at rear of automatic transmission oil pan at position on transmission housing marked with an (arrow).
- Using floor jack, raise transmission slightly to place engine/transmission assembly into position.
- Place engine mountings onto consoles on carrier.
- Lower VAS 6100 shop crane slightly, insert threaded pins for engine mount into engine support while doing so.
CAUTION! Torque support must be installed before completely lowering the engine.
- Tighten bolts -1- to -3- at torque reaction support by hand.
- Lower VAS 6100 shop crane completely.
- Remove lifting tackle 3033 from engine and move workshop crane and floor jack aside.
Note: Transmission must not be supported on transmission oil pan.
- Place support plate of engine and transmission jack VAG 1383 A behind automatic transmission oil pan at location marked with an (arrow) and raise transmission.
- Install transmission mountings.
- Installing carrier
Refer to Body and Frame
- Lower transmission afterward.
- Secure screwed connections -1- to -6-, placing washers below nuts -3- and -4-.
Remaining installation steps are carried out in reverse sequence - note following points:
- Install driveshaft:
- Install selector lever cable and check selector lever cable setting if necessary:
- Install exhaust system and align free of stress.
- Install drive axles:
- Install guide link and anti-roll bar:
- To help install alternator, knock back bushing on securing bolt slightly.
- Install alternator.
- Install ribbed belt.
- Tighten securing bolts -1- to -3- for torque reaction support to torque.
- Installing lock carrier with attachments:
- Install air filter housing.
- Install front bumper:
CAUTION: Electronic control modules of vehicle can be damaged if a battery charger is used to start engine.
Note:
^ When battery is reconnected, re-activate electrical equipment (radio, combined radio/navigation system, clock, electric windows) as described in Owner's Manual.
^ De-activate service mode in Telematics control module.
^ Further procedures after reconnecting voltage supply.
- Fill with engine oil.
- Fill refrigerant circuit with refrigerant: A/C refrigerant system R134a), evacuating and recharging
- Fill hydraulic fluid into power steering reservoir before starting engine; power steering pump must not run dry.
- Fill up with coolant.
Note:
^ Drained-off coolant may only be used again if original cylinder head and cylinder block are reinstalled.
^ Dirty coolant must not be reused.
- Check oil level.
- Top up PAS fluid and bleed steering system:
- Check ATF level:
- Adjust headlights: