Engine, Installing
Engine, Installing
Special tools, testers and auxiliary items required
• Counter Hold Tool (T10355) for vehicles with a DSG transmission
• Assembly Aid (T40169)
• Transportation lock (T40170)
Tightening Specifications
• Tightening specifications only apply to lightly greased, oiled, phosphate 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 parts that have had the lubrication removed.
• Tolerance for torque specifications ± 15%.
Subframe mount, refer to => [ Subframe Mount Overview ] Subframe Mount Overview.
• The aluminum bolts may be used two times. After using the bolts once, mark them with an "X" made by a chisel - arrow -.
• To avoid damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt in a 14 mm socket with a 1/2 inch drive ratchet which is clamped into a vise, as shown in the illustration.
• Do not used bolts marked with an "X" again.
Procedure
• Replace bolts which have been tightened to an additional torque.
• Replace self-locking nuts and bolts as well as sealing rings, seals and O-rings.
• The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps appropriate for the model. Refer to the electronic parts catalog ETKA.
• In order to be able to securely mount the air guide hoses on their connectors, spray the bolts on the previously used clamps with a rust remover.
• During installation, all cable ties must be installed at the same location.
- Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.
- Complete the following steps before connecting the engine and transmission:
- Insert the (T40169) into the transmission housing and dual mass flywheel 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 dual mass flywheel as needed.
- Install the assembly aid bolt into the hole on the transmission housing.
- Attach the (T40170) to the transmission housing from underneath and secure it to the flange shaft - 1 -.
• The bolt - 2 - attaches the starter to the transmission and has an additional spacer sleeve - arrow -.
• The spacer sleeve must be inserted between the starter and the transmission.
- Determine if the engine/transmission aluminum bolts can be used again and mark them if necessary.
- Release the tension on the (10 - 222 A /11).
- Lower the shop crane and mount the engine and transmission onto the engine mount.
- Install engine bracket. Refer to => [ Subframe Mount Overview ] Subframe Mount Overview.
- Remove the (VAS 6100) and (2024 A).
- Tighten the remaining engine/transmission bolts.
- Remove the (T40170) and the (T40169).
- Install the catalytic converter. Refer to => [ Catalytic Converter ] Service and Repair.
- Install the front muffler. Refer to => [ Front Muffler ] Front Muffler.
- Install the small coolant pipe. Refer to => [ Small Coolant Pipe ] Small Coolant Pipe.
- Connect the coolant hoses with the connector coupling => [ Connect the Coolant Hose with the Connector
Coupling ] Radiator and Coolant Fan Overview
- Install the power steering pump.
- Install A/C compressor.
- Electrical connections and routing.
- Install Engine Control Module (ECM).
- Install the electric wires, the terminal 30 wire junction 2 (TV22) and the cover for the engine compartment E-box.
- Install the tower brace.
- Install the washer fluid reservoir filler tube
- Follow measures after connecting battery.
Risk of destroying control modules with excess voltage.
• Do not use a battery charger for starting assistance!
- Install air filter housing.
- Check oil level.
- Fill with coolant => [ 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.
- Install the wheel housing liners and noise insulation..
- Mount the front wheels.