Engine, Installing, Vehicles With DSG Transmission 0B5: 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 drive plate in the vehicles with the DSG transmission 0B5 must not have any needle bearings. Check if a needle bearing is inserted before installing. Remove the needle bearing in the drive plate, refer to NEEDLE BEARING IN DRIVE PLATE, REPLACING .
Secure all hose connections with hose clamps of the same type as those equipped by the factory .
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.
-- Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.
-- Install the engine supports and engine mount, refer to OVERVIEW - SUBFRAME MOUNT .
-- The following preparations must be made before connecting the engine and transmission:
-- Insert the Clutch Module Assembly Aid T40169 in the transmission housing between the clutch module and the transmission housing as shown in the illustration.
- The assembly aid must engage in the semicircular opening -1- and in the inspection hole -2-.
There is only 1 inspection opening on the circumference; rotate the dual mass flywheel as needed.
-- Install the assembly aid bolt into the hole on the transmission housing.
-- Insert the Clutch Module Transportation Lock T40170in the transmission housing from below and secure it on the flange shaft -1-.
-- 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 ENGINE, INSTALLING, VEHICLES WITH DSG TRANSMISSION 0B5 .
-- Check if the alignment sleeves -A- for centering the engine/transmission are in the cylinder block and insert them if they are not.
-- When jointing the engine and subframe, hold the ATF lines in their installation position.
-- Position the transmission on the engine and tighten the bolts -1 through 10-.
-- Remove the Clutch Module Transportation Lock T40170 and Clutch Module Assembly Aid T40169.
The following procedure is necessary to assure that the clutch module contacts the drive plate evenly and does not get bent.
-- Press the clutch module -2- slightly against the drive plate -3- using a pry bar -1- in -direction of arrow-.
-- Secure the clutch module to the drive plate as follows:
Use the Torque Wrench 1332 Insert - Ring Wrench - 16mm VAG1332/14 to tighten the bolts.
-- Install the first bolt -arrow- and tighten by hand (2 Nm).
-- Insert the Crankshaft Socket T40058 guide pins as follows:
- The large diameter -arrow 1- faces the engine.
- The small diameter -arrow 2- faces the adapter.
-- Continue turning the crankshaft on the vibration damper 180° in the direction of the engine rotation using the Crankshaft Socket T40058 -arrow-.
-- Tighten the bolts that are accessible -arrows- in this crankshaft position to the tightening specification .
-- Turn the crankshaft 60° further and tighten the remaining five bolts to the tightening specification .
-- Install the power steering hydraulic lines, refer to POWER STEERING PUMP, HYDRAULIC LINES AND RESERVOIR .
-- Install the left and right driveshafts on the transmission flange shafts .
-- Install the driveshaft heat shield Figure.
-- Install the catalytic converters: left refer to LEFT CATALYTIC CONVERTER, REMOVING AND INSTALLING, DSG TRANSMISSION 0B5 , right refer to RIGHT CATALYTIC CONVERTER, REMOVING AND INSTALLING, DSG TRANSMISSION 0B5 .
-- Lift the engine/transmission assembly using the Scissor Lift Table VAS6131B.
-- Align the subframe and transmission carrier 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), refer to INSTALLING .
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 -arrows- .
Install in reverse order of removal. Note the following:
-- Install the ATF lines .
-- Attach the universal joint to the steering gear, refer to OVERVIEW - STEERING COLUMN -item 18- .
-- Install the propshaft .
-- Install the selector lever cable .
-- Install the front muffler, refer to FRONT MUFFLER, REMOVING AND INSTALLING .
-- Install the subframe crossbrace, refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .
-- Install the upper control arm, refer to UPPER CONTROL ARM, REMOVING AND INSTALLING .
-- Install the stabilizer bar, refer to STABILIZER BAR, REMOVING AND INSTALLING .
-- Fasten the suspension strut on the control arm, refer to OVERVIEW - SUSPENSION STRUT WITH MOUNTING BRACKET, SHOCK ABSORBER FORK, UPPER CONTROL ARM AND TOWER BRACE .
-- Install the brake caliper, refer to BRAKE CALIPER, REMOVING AND INSTALLING .
-- Install the engine control module, refer to Engine Control Module -J623-, REMOVING AND INSTALLING .
-- Electrical connections and wiring routing, refer to appropriate SYSTEM WIRING DIAGRAM.
-- Install the wires, the Terminal 30 Wire Junction 2 -TV22- and the cover for the engine compartment E-box, refer to Figure, Figure and OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES .
-- Install the tower brace, refer to TOWER BRACE, REMOVING AND INSTALLING .
-- Install the windshield wiper fluid reservoir filler tube, refer to WASHER FLUID RESERVOIR, REMOVING AND INSTALLING .
-- Install the refrigerant lines, refer to REFRIGERANT LINES FOR BATTERY COOLING MODULE IN LUGGAGE COMPARTMENT, REMOVING AND INSTALLING .
-- Follow all steps after connecting the battery, refer to battery - CONNECTING .
There is a risk of destroying control modules with excess voltage.
- Do not use a charger as a starting aid.
-- Install the fuel supply hose (refer to OVERVIEW - HIGH PRESSURE PUMP ) and air filter housing, refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .
-- Install the lock carrier braces, refer to LOCK CARRIER .
-- Fill the engine oil and check the oil level. Refer to ENGINE OIL LEVEL, FILLING AND CHECKING .
-- Before starting engine for the first time, fill the hydraulic oil in the power steering reservoir, refer to POWER STEERING FLUID LEVEL, CHECKING .
Do not run the power steering pump when it is dry.
-- Connect the coolant hose to the coupling Fig 11.
-- Fill the coolant, refer to COOLANT, DRAINING AND FILLING .
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, refer to REFRIGERANT CIRCUIT, CHARGING WITH SERVICE STATION .
-- Install the front wheels, wheel bolt tightening specification: 140 Nm and perform an alignment, refer to OVERVIEW - WHEEL ALIGNMENT PROCEDURE .
Risk of accident due to loose connections.
- Tighten the subframe bolts to the specification after performing axle alignment.
-- Check the ATF level .
-- Install the noise insulations and wheel housing liner, refer to OVERVIEW - NOISE INSULATION and WHEEL HOUSING LINER .