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)
• 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 6| 15%.
Subframe mount, refer to => [ Subframe Mount Overview ] Subframe Mount Overview.
Engine to Automatic Transmission 0B6
• 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 the bolts which are being tightened with an additional turn.
• Replace self-locking nuts and bolts and seals, gaskets and O-rings.
• The hose connections and charge air system hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps of the same type as those equipped by the factory. Refer to the Electronic Parts Catalog (ETKA).
• In order to be able to securely mount the air guide hoses on their connectors, spray the screws on the previously used clamps with a rust remover.
• When installing, bring all cable ties back to same positions.
- Install Secondary Air Injection (AIR) pipe. Refer to => [ Secondary Air Injection System without Vacuum Control Overview ] Secondary Air Injection System Without Vacuum Control Overview.
- 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.
- The following preparations must be made before connecting the engine and transmission:
- Turn the torque converter so that the hole next to the notch - arrow - is visible in the lower cut-out in the transmission housing as illustrated.
• There is only 1 notch on the circumference; rotate the torque converter as needed.
- Insert the (T40170) in the transmission housing from below and secure it on the flange shaft - 1 -.
- When joining the engine and subframe, hold the ATF lines in their installation position.
- Install the engine supports and engine mount. Refer to => [ Subframe Mount Overview ] Subframe Mount Overview.
- 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. Be careful of the starter.
- Tighten bolts - 1 to 11 -.
- Remove the (T40170).
• The following step is necessary to make sure the torque converter rests on the drive plate evenly and is not tilted.
- Press the torque converter - 2 - against the drive plate - 3 - slightly in the direction of the - arrow - using an assembly lever - 1 -.
- Install the first bolt - arrow - and tighten by hand (2 Nm).
- Attach the (T40257) to the (T40263).
- Attach the adapter to the bolts on the vibration damper.
- Turn the crankshaft 180° in the direction of engine rotation - arrow -.
- Tighten the bolts that are accessible in this position to the tightening specifications.
- Turn the crankshaft 60° further and tighten the remaining 5 bolts to the tightening specification.
- Install the power steering hydraulic lines.
- Install the left and right drive axles on the transmission flange shafts.
- Installing the lower left coolant pipe. Refer to => [ Lower Left Coolant Pipe ] Lower Left Coolant Pipe.
- Install selector lever cable.
- Install the ATF lines.
- Install the catalytic converter. Refer to => [ Muffler Overview ] Muffler Overview.
- Raise the engine/transmission assembly using the (VAS 6131 A).
- Align the subframe and the 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:
- 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.
- 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 refrigerant lines.
- Be sure to follow the procedure for connecting the battery 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 engine oil and check oil level.
- Before starting engine for the first time, check the fluid level in 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.
- Install the wheel housing liners.
- Install the front wheels.
- Perform axle alignment.
Risk of accident due to loose connections.
• Tighten the subframe bolts to the specification after performing axle alignment.
- Fill transmission with ATF.
- Install the noise insulation.