Engine, Installing

Engine, Installing

Tightening Specifications

• Tightening 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%.

Tightening specifications => [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview.

Additional tightening specifications






Manual transmission to engine fastener










Direct shift automatic transmission to engine mounting










• Ignore - 2 and 4 -.

Procedure

Installation is in reverse order of removal, note the following:

• 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 with hose clamps appropriate for the model.

• During installation, cable ties must be installed at the same location.

- If no alignment sleeves for center engine and transmission are present in cylinder block, insert sleeves.

Manual Transmission

- If a needle bearing is installed in crankshaft, remove needle bearing. Refer to => [ Needle Bearing on Crankshaft ] Needle Bearing on Crankshaft.

- If clutch release bearing is worn, replace it.

- Lightly lubricate transmission input shaft splines with clutch disc connection lubricating grease.

- Check clutch drive plate centering.

Vehicles with DSG transmission:

- If no needle bearing is installed in crankshaft, install needle bearing. Refer to => [ Needle Bearing on Crankshaft ] Needle Bearing on Crankshaft.

All Vehicles

- Attach transmission to engine.

- Secure bevel box bracket - A -.





Vehicles with DSG transmission:

- Install secondary air injection (AIR) pump. Refer to => [ Secondary Air Injection Pump ] Service and Repair.

- Install coolant hose to transmission oil cooler. Refer to => [ Coolant Pipe to Transmission Oil Cooler ] Coolant Pipe to Transmission Oil Cooler.

All Vehicles

- Guide engine/transmission assembly into body.

- Then install engine mounting to engine support bolts - arrows - and tighten by hand.





- Then, install transmission mounting to transmission support bolts - arrows - and tighten by hand.





• Bolts are only tightened to final torque when installing subframe mount. Refer to => [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview.

- Remove (T40074) from engine.

- Tighten pendulum support on transmission. Refer to => [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview.





Vehicles with DSG transmission:

- Install selector lever cable.

All Vehicles

Risk of damaging sealing ring - arrow - in driveshaft flange.

• Press engine/transmission assembly toward bulkhead while carefully guiding bevel box pins into driveshaft flange.







- Tighten pendulum support on subframe. Refer to => [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview.





- Tighten driveshaft with flexible disc on bevel box - arrows -.





The rest of the installation is in reverse order of removal, note the following:

- Install front exhaust pipe. Refer to => [ Front Exhaust Pipe with Catalytic Converters and Front Muffler ] Service and Repair.

- Install exhaust system and align it free of stress. Refer to => [ Exhaust System, Installing ] Removal and Replacement.

- Install drive axles.

- Install driveshaft heat shield.

- Connect electrical connector on starter.

Manual Transmission

- Selector mechanism, installing and adjusting.

Risk of contamination from escaping brake fluid.

• If hose/line assembly is not yet connected to clutch slave cylinder breather, do not press clutch cylinder.

- Connect hose/line assembly to clutch slave cylinder breather and bleed clutch system.

All Vehicles

- Install A/C compressor.

- Install fan shroud. Refer to => [ Fan Shroud ] Service and Repair.

- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.

- Adjust subframe mount. Refer to => [ Subframe Mount, Adjusting ] Adjustments.

- Install wiper arms.

- Electrical connections and routing.

- Follow measures after connecting battery.

- Check oil level. Refer to => [ Oil Level, Checking ] Testing and Inspection

Risk of destroying control modules with excess voltage.

• Do not use a battery charger for starting assistance!

- Fill with coolant. Refer to => [ 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.