Engine, Installing

Special tools and workshop equipment required

Torque Wrench 1332 Insert - Ring Wrench - 16mm: VAG1332/14
Clutch Module Transportation Lock: T40170

Tightening Specifications

NOTE:

The tightening specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.

Additional lubricant such as engine oil or transmission fluid may be used, but do not use graphite lubricant.

Do not use any parts that have had the lubrication removed.

Tightening specification tolerance: ±15%.

Component		Nm
Bolts and nuts	M6	9
	M7	15
	M8	20
	M10	40
	M12	65

Refer to OVERVIEW - SUBFRAME MOUNT .
Engine to transmission. Refer to the appropriate Service Information .

Procedure

NOTE:

Replace the bolts that were tightened with an additional turn after removing them.

Replace the self-locking nuts and bolts, gaskets, seals and O-rings after removing.

Only remove the plugs or caps just before installing the respective lines.

The hose connections as well as air duct pipes and hoses must be free of oil and grease before installing.

Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts Information.

To mount the air duct hoses on their connections securely, spray the bolts on the used clamps with rust remover before installing.

During installation, all cable ties must be installed at the same location.

Bonded rubber bushings have a limited range of rotation. Only tighten suspension threaded connections when vehicle is in curb weight position or in the control position.

Secure the engine with the subframe on the : VAS6131B .
Engine secured with the : T10533/1 with : T10533/5 .

-- Install the engine support and engine mount. Refer to OVERVIEW - SUBFRAME MOUNT .

-- Always clean the threaded holes for the engine/transmission threaded connection in the cylinder block using a thread tap before installing the transmission.

-- The following preparations must be made before connecting the engine and transmission:

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-- Clean the contact surface -1- on the lower cover for the timing chain and on the locking piece -2- with Cleaning Solution: D 009 401 04 .

-- Bond the locking piece with the lower cover for the timing chain.

-- Bring the starter into the installation position.

-- Insert the : T40170 in the transmission housing from below and secure it on the flange shaft -1-.

Fig 1: Identifying Transportation Lock T40170

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-- Check if the alignment sleeves -A- for centering the engine and transmission are in the cylinder block and insert them if they are not.

Fig 2: Engine to Transmission Tightening Sequence

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-- Inspect the aluminum bolts used to connect the engine to the transmission to check if they can be used again and mark them if necessary. Refer to the appropriate Service Information .

NOTE:

When guiding together the engine and transmission make sure that the locking piece is seated correctly.

-- Place the transmission on the engine and at the same time turn the bolt -1- for the starter.

-- Install the bolts -2 to 11- all the way by hand.

-- Tighten the bolts -1 to 11-.

-- Remove the : T40170 and : T10533/1 with the : T10533/5 .

NOTE:

The following step is necessary to make sure the torque converter rests on the drive plate evenly and is not tilted.

Fig 3: Pressing Flywheel Slightly Against Drive Plate

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-- Press the torque converter -2- slightly in against the drive plate -3- in direction of -arrow- using an assembly lever -1-.

-- Attach the torque converter to the drive plate as follows:

Fig 4: Locating Hole Next To Notch

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-- Turn the torque converter so that hole next to the notch -arrow- is visible in the lower cut-out in the transmission housing as shown.

NOTE:

There is only one notch on the circumference, so rotate the torque converter as needed.

-- Tighten the bolts -arrow- for the torque converter -1- that are accessible in this position. Refer to the appropriate Service Information .

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NOTE:

Use the : VAG1332/14 to tighten the bolts.

-- Rotate the crankshaft 180° further in direction of engine rotation in direction of -arrow- using the : T40058 and ring wrench.

Fig 5: Counter Hold Crankshaft Using Socket T40058

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-- Turn the crankshaft 60° farther and tighten the remaining five bolts to the tightening specification. Refer to the appropriate Service Information .

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-- Install the parking lock emergency release cable. Refer to the appropriate Service Information .

-- Install the ATF cooler. Refer to the appropriate Service Information .

-- Install the drive axles. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Install the drive axle heat shields. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

-- Install the catalytic converter. Refer to OVERVIEW - MUFFLER .

-- Tighten the tunnel crossmember bolts. Refer to the appropriate Service Information .

-- Remove the subframe locating pin. Refer to SUBFRAME, SECURING .

Installation is performed in reverse order of removal, while noting the following:

-- Install the driveshaft. Refer to the appropriate Service Information .

-- Install the front muffler. Refer to FRONT MUFFLER, REMOVING AND INSTALLING .

-- Attach the steering intermediate shaft to the steering gear. Refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

-- Install the upper control arm and suspension strut. Refer to OVERVIEW - SUSPENSION STRUT AND UPPER CONTROL ARM .

-- Install the subframe crossbrace, shield and stabilizer bar. Refer to OVERVIEW - SUBFRAME .

-- 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 .

-- Install the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Connections and wire routing. Refer to the appropriate Wiring Diagram.

-- Install the cable Terminal 30 Wire Junction 2 -TV22- and the cover for the engine compartment E-box. Refer to OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES .

-- Install the A/C compressor. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING FROM BRACKET .

-- Install the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING, SUB-ASSEMBLY RIBBED BELT .

-- Install the ribbed belt tensioner for the supercharger. Refer to RIBBED BELT TENSIONER, REMOVING AND INSTALLING, SUPERCHARGER RIBBED BELT .

-- Install the front lower longitudinal member. Refer to LOWER LONGITUDINAL MEMBER, REMOVING AND INSTALLING .

-- Follow all steps after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Connect the fuel hose. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

CAUTION:

There is a risk of destroying the control modules due to excess voltage.

Do not use a charger to jump start.

-- Fill with engine oil and check the oil level. Refer to ENGINE OIL, FILLING and ENGINE OIL LEVEL, CHECKING AND CORRECTING IF NECESSARY .

-- Tighten the coolant pipes. Refer to OVERVIEW - COOLANT PIPES .

-- Connect the connection and coolant hoses with the connector coupling. Refer to Fig 6.

Fig 6: Coolant Hoses Connector Coupling

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NOTE:

Used coolant cannot be used again.

-- Fill with coolant. Refer to Filling .

-- Install the wheel housing liners. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Install the front wheels. Refer to WHEEL, CHANGING .

-- Install the underbody trim panels. Refer to UNDERBODY TRIM PANELS, REMOVING AND INSTALLING .

-- Install the noise insulations. Refer to NOISE INSULATION, REMOVING AND INSTALLING .