Cylinder Block, Assembly Overview
Cylinder block, assembly overview
Engine bracket and left/right engine mounts, removing and installing
Cylinder block, assembly overview:
1 - 8 Nm
^ Fastened to intake manifold
2 - Guide tube
^ For dipstick
^ Secured by a bolt to intake manifold
3 - Dipstick
^ Oil level must not be above the max. mark!
^ Marks
4 - Oil check valve
^ Note installation position
^ Removing and installing
^ Clean or replace if badly soiled
5 - Knock sensor 1 G61
^ Component location: Between cyl. 1 and cyl. 3
6 - 20 Nm
^ Torque setting influences function of knock sensor
7 - 10 Nm
8 - Oil pump drive cover
9 - O-ring
^ Replace
^ Oil before assembling
10 - Oil pump drive
11 - Cylinder block
12 - Intermediate shaft
13 - Thrust washer
^ Not installed on all engines
14 - 10 Nm
^ Insert using locking fluid D 000 600 A2
15 - Input shaft
^ For oil pump drive
16 - Engine speed (RPM) sensor G28
17 - Oil pump
18 - 23 Nm
19 - 8 Nm
^ Insert using locking fluid D 000 600 A2
20 - Oil drain plug, 30 Nm
^ Replace
21 - Oil pan
22 - Oil Level Thermal Sensor G266
^ Only for vehicles with engine code "AZZ"
23 - Seal
^ Replace
^ Oil before assembling
24 - 20 Nm
25 - Seal
^ Replace
26 - Oil filter housing/left engine bracket
27 - 23 Nm
28 - To thermostat housing
29 - 25 Nm
30 - Fitting bolt, 25 Nm
31 - Compact bracket
^ For generator, air conditioning compressor, and power steering pump
32 - Coolant line
33 - Knock sensor 2 G66
^ Component location: Between cyl. 4 and cyl. 6
34 - Vibration damper
35 - 100 Nm plus an additional 1/2 turn (180°)
^ Replace
^ Use counter-holder tool T10069 for loosening and tightening
^ Tighten using torque wrench VAG 1601
To loosen and tighten securing bolt, lock vibration damper using counter-holder tool T10069
Note:
^ Vibration damper securing bolt must be replaced.
^ Tighten securing bolt using torque wrench V.A.G 1601.
Engine bracket and left/right engine mounts, removing and installing
Special tools, testers and auxiliary items required
^ Engine support bridge 10 - 222 A
^ Shackle 10 - 222 A /12
^ Adapter 10 - 222 A /16
^ Adapter 10 - 222 A /19
Removing
- Completely remove air filter with mass air flow (MAF) sensor.
- Remove nuts - 2 - on right and left engine bracket.
- Position adapter 10 - 222 A /16 on Engine and Transmission Holder 10 - 222 A with high side of threaded spindle guide facing upward as shown in illustration.
- Now place adapter 10 - 222 A /19 on left and right of Engine and Transmission Holder 10 - 222 A. Place Engine and Transmission Holder 10 - 222 A on long members.
- Engage engine with two Shackles 10 - 222 A /12 at Adapter 10 - 222 A /16 and pretension engine slightly.
- Remove bolts - 1 - from left and right engine mount / subframe.
- Be aware of available clearance between cylinder head and bulkhead.
- Now carefully lift engine with adapter 10 - 222 A /16.
- To remove engine mount, engine bracket must also be removed from cylinder block, because engine can not be lifted high enough.
Installing
Installation is in reverse order of removal.
- When installing, make sure alignment pin of engine mount is correctly positioned in engine bracket.
- First install all bolts by hand, and then tighten them all to the specified torque.
Torque specification for bolt - 1 - : 60 Nm.
Torque specification for nut - 2 -: 75 Nm.
Torque specification for oil filter housing/engine bracket bolts to cylinder block at left: 23 Nm.
Torque specification for engine bracket bolts to cylinder block at right: 40 Nm.