Engine, Installing
Engine, Installing
Special tools, testers and auxiliary items required
• Scissor-Type Assembly Platform (VAS 6131 A)
• Ring Spanner Insert AF 16 (V.A.G 1332/14)
• Assembly Aid (T40169)
• Transportation Lock (T40170)
• Adapter (T40257)
• Wrench (T40263)
Tightening specifications
• The tightening specifications apply only to lightly greased, oiled, phosphated or blackened nuts and bolts.
• Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant.
• Do not use any parts that have had the lubrication removed.
• Tightening specification tolerance ± 15 %.
Subframe mount, refer to => [ Subframe Mount Overview ] Subframe Mount Overview.
Engine to Manual Transmission
• From VIN 8T-9A-008000: the aluminum bolts - 2 through 11 - may be used twice. 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.
• Bolts marked with an "X" may not be used again.
Procedure
• Replace bolts that are tightened to the specification.
• Replace self-locking nuts and bolts and seals, gaskets and O-rings.
• 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 at Drive Plate, Manual Transmission ] Service and Repair.
• Secure all hose connections with hose clamps of the same type as those equipped by the factory. Refer to the Electronic Parts Catalog (ETKA).
• When installing, bring all cable ties back to same positions.
- Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.
- Before installing a replacement engine, make sure the semi-circular ring - arrow - is inserted in the power steering pump driveshaft.
- Install the engine supports and engine mount. Refer to => [ Subframe Mount Overview ] Subframe Mount Overview.
- Installing the lower left coolant pipe. Refer to => [ Lower Left Coolant Pipe ] Lower Left Coolant Pipe.
- 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.
- Insert the (T40170) in the transmission housing from below and secure it on 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.
- Position the transmission on the engine and tighten the bolts - 1 through 11 -.
- Remove the (T40170) and (T40169).
- Tighten the drive axles on the transmission flange shafts.
- Install the wheel housing liners.
- Install the front wheels.
• The following procedure is necessary to assure that the clutch module contacts the drive plate evenly and does not get bent.
- Engage a gear and turn the front wheels in direction of travel until the clutch module is rotated one complete turn (360°).
• The inspection hole - arrow - must be visible through the opening in the transmission housing.
- Secure the clutch module to the drive plate as follows:
• Use the (V.A.G 1332/14) to tighten.
- Install the first bolt - arrow - and tighten by hand (2 Nm).
- Turn the front wheels in direction of travel until the clutch module is rotated one have turn (180°).
- Tighten the bolts that are accessible in this position to the tightening specification.
- Turn the front wheels in direction of travel until the clutch module is rotated 1/6 turn (60°) and tighten the remaining 5 bolts to the tightening specification.
- Install the power steering hydraulic lines.
- Install Secondary Air Injection (AIR) pipe => [ Secondary Air Injection System without Vacuum Control Overview ] Secondary Air Injection System Without Vacuum Control Overview
- Install the catalytic converter. Refer to => [ Muffler Overview ] Muffler Overview.
- Next, raise engine/transmission assembly high enough using (VAS 6131 A) until dimension - a - is reached between tunnel crossmember and body.
• - a - = minimum 100 mm
- Install the shift rod and pivot rod.
- Continue raising the engine/transmission subassembly using the (VAS 6131 A).
- Align the subframe and tunnel crossmember 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:
- Install the clutch slave cylinder.
- 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 ] Service and Repair.
- Install the front crossmember.
- Install the subframe crossbrace, upper control arm and stabilizer bar and tighten the suspension strut on the control arm.
- Install the brake caliper.
- Install the Engine Control Module (ECM).
- Electrical connectors and wiring routing.
- Install the electrical 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 the 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 and adjust the windshield wiper arms.
- Install the air filter housing.
- Install the lock carrier braces.
- Fill with engine oil and check oil level.
- Before starting the engine for the first time, check the fluid level in the power steering reservoir.
• The power steering pump must not run dry.
- Fill the coolant system => [ 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.
- Align the subframe.
- Perform axle alignment.
Risk of accident due to loose connections.
• Tighten the subframe bolts to the specification after performing axle alignment.
- Install the noise insulation.