Engine, Installing
Engine, Installing
Installation is performed in reverse order. When doing this note the following:
CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
• Route lines of all types (for example: fuel, hydraulic, Evaporative Emission (EVAP) , coolant, refrigerant, brake or vacuum) and electrical wires so that the original path is followed.
• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.
• Installing the engine/transmission bolts
• During the installation, all cable ties must be reinstalled in the same location.
• Secure all hose connections with hose clamps.
• During assembly, replace the self locking nuts and bolts.
• Always replace bolts that have been tightened to specification as well as O-rings and seals.
• Electrical connections and routing.
- Insert new alignment pins for centering the engine/transmission.
- Engage the intermediate plate at the sealing flange and slide it onto the alignment pins - arrows -.
With a Manual Transmission
- Check the clutch release bearing for wear and replace, as necessary.
- Grease the splines of the input shaft lightly with grease (G 000 100).
- Check and install the clutch and clutch mechanism. Refer to
Continuation for All Vehicles
- When installing the engine/transmission assembly, ensure there is clearance to the subframe, turbocharger and Air Conditioning (A/C) compressor.
- Align the engine mount free of tension by using a shaking motion, also loosen the engine mount to the longitudinal member if necessary.
• Checking and adjusting the engine and transmission mounts. refer to the following:
• Checking, refer to => [ Engine Mount Adjustment, Checking ] Adjustments.
• Adjusting, refer to => [ Engine and Transmission Mount, Adjusting ] Adjustments.
• Engine and transmission mount tightening specifications. Refer to => [ Fastener Tightening Specifications ] Engine Assembly - Fastener Tightening Specifications.
- Install the pendulum support. Refer to => [ Fastener Tightening Specifications ] Engine Assembly - Fastener Tightening Specifications.
- Install the front exhaust pipe. Refer to => [ Catalytic Converter with Front Exhaust Pipe ] Service and Repair.
- Install the drive axles.
With a Manual Transmission
- Install the shift mechanism and adjust, if necessary.
- Install the hose/pipe assembly to the slave cylinder, see the transmission installing procedure.
With a DSG Transmission
- Install and adjust the selector lever cable.
- Install the A/C compressor to the accessory bracket.
- Install the ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
Continuation for All Vehicles
- Install the plenum chamber bulkhead. Refer to
- Route the engine wiring harness to the control module - 1 - beneath and to the left (in direction of vehicle travel) of the wiring harness - 2 -.
- Install the battery holder and tighten the bolts - arrows -.
- Route the wire - 2 - as shown in the illustration and tighten it to the E-box - 1 -.
- Install the battery and follow the necessary measures after connecting the battery.
- Fill the cooling system. Refer to => [ Draining and Filling ] Draining and Filling.
- Connect the vehicle diagnosis, testing and information system (VAS 5051 B), (VAS 5052) or (VAS 5053).
- Check all Diagnostic Trouble Code (DTC) memories and erase all DTC entries that resulted from removing and installing the engine.
• If the DTC memory was erased, generate a readiness code. Refer to "Guided Function".
- Perform a test drive.
- Then perform the vehicle system test and repair any occurring malfunctions.
Tightening Specifications
