Engine, Installing
Engine, Installing
Special tools, testers and auxiliary items required
• Depth gauge for vehicles with automatic transmission 01V
Work procedure
• During assembly, replace self-locking nuts and bolts.
• Always replace bolts that are tightened to torque as well as O-rings and gaskets.
• Secure all hose connections using hose clamps appropriate for the model type.
• During installation, re-install heat insulation sleeves at the same locations.
• During installation, all cable ties must be re-installed at the same location.
- Make sure alignment sleeves for centering engine to transmission are installed in cylinder block. Install if necessary.
- Slide intermediate plate onto alignment sleeves.
Vehicles with manual transmission:
- Clean input shaft splines and (in case of used clutch plates) hub splines, remove corrosion and apply only a very thin coating of clutch disc connection lubricant (G 000 100) on splines. Do not grease the guide sleeve.
- If necessary, check centering of clutch drive plate.
- Check clutch release bearing for wear and check loose plastic ring, replace if necessary.
Vehicles with SAC clutch pressure plate:
- When installing a new clutch disc in combination with a used SAC clutch pressure plate (self-adjusting pressure plate), pressure plate adjustment ring must be turned back to stop. Otherwise the pressure plate works with decreased contact pressure (clutch slips).
• If clutch disc is not being replaced, the adjustment ring must not be turned back.
• New SAC-pressure plates are already pre-adjusted and must not be reset.
Vehicles with 01J automatic transmission:
- Clean transmission input shaft splines and damper unit splines on flywheel, remove corrosion and apply only a very thin coating of clutch disc connection lubricant (G 000 100) on splines. Remove all excess grease.
Vehicles with 01V automatic transmission:
- Install drive plate with centering washer - arrow - on crankshaft.
When torque converter is engaged correctly, distance between lower contact surfaces of threaded holes at torque converter and contact surface of bell housing on Automatic Transmission 01V is approx. 23 mm.
If torque converter is not fully engaged, the distance is approx. 11 mm.
CAUTION!
If torque converter is incorrectly engaged, torque converter coupling and ATF pump could be damaged when transmission and engine are flanged together.
- Before connecting engine and transmission, rotate torque converter and engine drive plate so that one hole or one threaded hole stands at height of opening of the removed starter - arrow -.
- To secure torque converter to drive plate, use new original bolts.
All:
- Carefully guide engine with transmission into body.
- Place engine on engine mounts.
CAUTION!
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 ATF pump and therefore the transmission will be destroyed during final tightening of the bolts.
- Bolt transmission to engine.
- Tighten Support (T10062) at torque support threaded holes to 20 Nm.
- Raise engine using Engine/Transmission Jack ( VAG1383A) enough so that lower engine/transmission connecting screws can be installed.
• On vehicles with All Wheel Drive (AWD), make sure front driveshaft joint is not damaged when raising engine.
- Tighten bottom engine/transmission connecting screws - arrows -.
- Lower engine again.
• Torque specifications only apply 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 degreased parts.
• Tolerance for torque specifications ±15%.
Engine/transmission mounting with manual transmission
Engine/transmission mounting with 01J automatic transmission
Engine/transmission mounting with 01V automatic transmission
The rest of the installation is performed in reverse order of removal, noting the following:
- Align exhaust system free of tension:
• Vehicles with AWD. Refer to => [ Exhaust System, Aligning ] Procedures
• Vehicles with FWD. Refer to => [ Exhaust System, Aligning ] Procedures
- Install starter.
- Install generator.
- Install air conditioning compressor.
- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Install the lock carrier with attachments. Refer to =>
Radiator Support Radiator Support
- Install the front bumper cover.
Vehicles with fuel return line:
- Tighten fuel supply line union nut - 1 - to 22 Nm.
- Secure fuel return line - 2 - using hose clamp appropriate to model type.
Vehicles without fuel return line:
- Secure fuel hose to connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head - 1 - and - 3 - and tighten union nut - 2 - to 22 Nm.
Vehicles with 01J or 01V automatic transmissions
- Fasten the ATF lines:
• 01J transmission. Refer to => Automatic Transmission/Transaxle Automatic Transmission/Transaxle
• 01V transmission. Refer to => Automatic Transmission/Transaxle Automatic Transmission/Transaxle
All:
- Electrical connections and routing.
- Observe safety precautions after connecting battery. Refer to => [ Before beginning repairs on
the electrical system: ] Engine, Removing and.
CAUTION!
Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.
- Install and adjust wiper arms.
- Check oil level. Refer to => [ Oil Level, Checking ] Testing and Inspection.
- Fill with coolant. Refer to => [ Filling ] Procedures.
• Only reuse drained coolant if cylinder head or engine block was not replaced.
• Dirty coolant must not be re-used.
- Fill power-steering system oil and bleed steering system.
Vehicles with 01J or 01V automatic transmissions
- Check ATF level:
• 01J transmission. Refer to => Automatic Transmission/Transaxle Automatic Transmission/Transaxle
• 01V transmission. Refer to => Automatic Transmission/Transaxle Automatic Transmission/Transaxle
Torque specifications
• Torque specifications only apply 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 degreased parts.
• Tolerance for torque specifications ±15 %.
