Part 2
Engine, removing and installing (Continued)
Note: Depicted in illustration for a vehicle with manual transmission.
- Disconnect harness connector -1- of electrical wire to A/C compressor clutch.
WARNING! Do not open refrigerant circuit for A/C system.
- Unbolt A/C compressor from bracket (arrows).
- Hang A/C compressor together with condenser with connected lines at right side of vehicle.
- Disconnect electrical lines from generator.
- Unscrew bolts (arrows) and remove generator.
- Remove left and right heat shields for drive axles -1-.
- Remove electrical wires -1- and -2- from starter.
- Disconnect Ground (GND) wire -3-.
- Remove heat shield -1- from solenoid.
- Unscrew bolts -2- and -3- and remove starter.
Vehicles with automatic transmission 01V
- Unscrew 3 Torx bolts (arrow) of torque converter in opening of removed starter (turn crankshaft 1/3 rotation in each case).
Note: To loosen the torque converter bolts counterhold the main harmonic balancer bolt.
- Remove bolts for front vehicle floor crossmember -1- to -4-.
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Note: Flex joint in front exhaust pipe must not be bent more than 10 °, otherwise it may be damaged.
- Disconnect exhaust system at double clamps (arrows).
- Remove nuts -1- and -3- for front exhaust pipe/left exhaust manifold which are accessible from bottom.
Note: Illustration is shown with engine removed.
- Pull front exhaust pipe off of left exhaust manifold.
- Remove nuts -1- and -3- for front exhaust pipe/right exhaust manifold which are accessible from bottom.
Note: Illustration is shown with engine removed.
- Pull front exhaust pipe off of right exhaust manifold.
- Where installed, unbolt heat shield for engine speed (RPM) sensor.
- Remove Engine Speed (RPM) sensor -G28- on left of transmission (arrow) and lay to side.
Vehicles with manual transmission
- Disconnect harness connector for back-up light switch at right of transmission and set aside electrical wire.
Note: Depicted in illustration for a vehicle with manual transmission 01E all wheel drive.
- Disconnect harness connector (arrow) from Speedometer Vehicle Speed Sensor (VSS) -G22- at left of transmission.
Note: Depicted in illustration for a vehicle with manual transmission 01E all wheel drive.
Vehicles with automatic transmission 01J
- Disengage harness connector -A- in direction of arrow and disconnect it from transmission.
- Move wiring harness clear.
Vehicles with automatic transmission 01V
- Swing securing lever and disconnect harness connector for transmission wiring harness -1-.
- Disconnect harness connector -2- on Speedometer Vehicle Speed Sensor (VSS) -G22-.
- Disconnect harness connector -3- from wire for multi-function switch.
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- Mark installation positions for threaded assemblies -1- and positioning sleeves -2-.
Note: Different mounting holes are available depending upon the installed engine.
- Remove lower nuts -1- on left and right engine mounts.
- Slightly loosen upper nuts (arrow) on left and right engine mounts.
- Unbolt torque support (arrows).
- Tighten T10062 support on threaded holes for torque support to 20 Nm.
- Lift engine using VAG1383A engine/transmission jack just far enough so that lower connecting bolts at engine/transmission can be removed.
Note: When working on a vehicle with all wheel drive, make sure the front constant velocity joint of driveshaft is not damaged when lifting engine.
- Remove bottom engine/transmission connecting bolts (arrows).
- Lower engine again.
Vehicles with manual transmission and automatic transmission 01J
- Position 10-222A engine support bridge on bolted flanges of fenders behind gas-filled strut. Spindle is at front.
- Hook 3147 engine support adapter into bolt hole at left of transmission housing.
- Connect 3147 engine support adapter and 10222A engine support bridge with 10222A/2 additional hook.
Note:
- Illustration is shown with engine removed.
- If the engine support adapter 3147 can not be inserted far enough into the hole on transmission bell housing due to a change in wire routing, use a long bolt M10 and additional hook 10-222 A/2 in place of engine support adapter.
Vehicles with automatic transmission 01V
- Position 10-222A engine support bridge on bolted flanges of fenders behind gas-filled strut. Spindle is at front.
- Hook 3147 engine support adapter into middle bolt hole in transmission housing.
- Connect engine support adapter 3147 using engine support bridge 10-222 A.
Note: Illustration is shown with engine removed.
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- Hook in 2024A engine sling at engine and at VAS6100 or 1202A workshop crane as depicted in illustration.
Note: To properly balance assembly, mounting hooks must be inserted in rails as shown in illustration.
WARNING! Take-up hooks and pins at engine sling must be secured using securing pins (arrows) as shown in illustration.
- Remove final mounting bolt.
Note: Verify that all hoses and lines between engine and body have been disconnected.
- Using VAS6100 or VAG1202A workshop crane, lift engine far enough until threaded bolts of engine mount are free.
- Turn 10-222A engine support bridge shaft.
Note: Make sure no lines are damaged at bulkhead.
Vehicles with automatic transmission 01V
- Press transmission off engine, while pressing torque converter off of drive plate.
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- Pull engine off of transmission and lift it out of engine compartment toward front.
Vehicles with automatic transmission 01V
- If necessary, secure torque converter in transmission from falling out using wire.
Installing
Installation is reverse of removal, note the following:
Note:
^ During installation, all cable ties must be re-installed 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.
^ 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 plastic ring of release bearing is loose, adhere it to bearing ring again using adhesive AMV-195-KD1-01.
^ 3 rectangular tabs (arrows) of plastic ring reach into cutouts of bearing ring.
^ If grooves with depth of more than 0.5 mm are present, 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 pre-adjusted and must not be turned back.
Vehicles with automatic transmission 01V
- Drive plate is bolted to crankshaft with a centering bushing (arrow).
- Use original bolts when securing torque converter to drive plate.
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 approx. 23 mm.
If the torque converter is not inserted completely, this distance will be approx. 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.
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- Carefully guide engine with transmission into chassis.
- 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 threaded holes for torque support to 20 Nm.
- Lift engine using VAG1383A engine/transmission jack just far enough so that lower connecting bolts at engine/transmission can be installed.
Note: When working on a vehicle with all wheel drive, make sure the front constant velocity joint of the driveshaft is not damaged when lifting the engine.
- Tighten lower engine/transmission connecting bolts (arrows).
- Lower engine again.
- Install and align exhaust system free of tension.
- Install starter.
- Install generator.
- Install A/C compressor.
- Install ribbed belt.
- Install lock carrier. Lock Carrier, Moving Into Service Position
Vehicles up to 06.03:
- Tighten union nut of fuel supply line -1- to 22 Nm.
- Secure fuel return line -2- with a hose clamp.
Vehicles as of 07.03:
- 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 automatic transmission
- Secure ATF lines.
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- Check harness connectors and routing.
See Caution for connecting Telematics battery.
- Observe safety precautions after connecting battery.
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 off coolant.
Note:
^ 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:
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- Adjust headlights.
Tightening torques
Note:
^ Tightening torques are valid only for nuts and bolts that are lightly greased, oiled, covered with a thin coat of phosphate or blackened.
^ Other lubricants are permitted, e.g. engine oil or transmission fluid, however they may not contain graphite.
^ 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 01J
A: Alignment bushing
Securing engine/transmission with automatic transmission 01V
A: Alignment bushing
