Engine, Installing: Procedure

NOTE:

Replace the bolts that were tightened with an additional turn.

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

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 appropriate for the model. Refer to the Electronic Parts Information (ETKA).

During installation, install all cable ties back at the same position.

-- Check the alignment sleeves for centering the engine/transmission and replace if damaged.

Fig 1: Installing Intermediate Plate

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-- Engage the intermediate plate with the sealing flange and then slide it onto the alignment sleeves -arrows-.

Vehicles with Manual Transmission:

-- If the clutch release mechanism is worn, replace it. Refer to the appropriate service information .

-- Lightly lubricate the transmission input shaft splines. Refer to the Electronic Parts Information (ETKA) for the correct lubricant.

-- Check the clutch plate alignment.

-- Attach the transmission to the engine.

Vehicles with Dual-Clutch Transmission:

-- If the engine and transmission were separated, replace the needle bearing in the crankshaft. Refer to CRANKSHAFT NEEDLE BEARING, REPLACING .

-- Attach the transmission to the engine.

AWD Vehicles:

Fig 2: Bevel Box Bracket (Vehicles with TFSI Engine)

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-- Attach the transmission to the engine.

-- Install the bevel box bracket.

Continuation for All Vehicles:

-- Install the starter. Refer to STARTER, REMOVING AND INSTALLING .

-- Guide the engine/transmission assembly into the body.

-- Install the bolts -arrows- for the engine mount by hand all the way.

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-- Install the bolts -arrows- for the transmission mount by hand until it is in position.

Fig 3: Identifying Bolts

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-- Adjust the subframe mount and tighten the bolts. Refer to ASSEMBLY MOUNT, ADJUSTING .

-- Remove the Engine/Gearbox Jack - Engine Support :T10359A from the engine.

-- Install the drive axles. Refer to OVERVIEW - DRIVE AXLE .

Vehicles with Manual Transmission:

-- Install the clutch slave cylinder. Refer to the appropriate service information .

-- Install the cables with the cable bracket. Refer to the appropriate service information .

Vehicles with Automatic Transmission

-- Install and adjust the selector lever cable. Refer to the appropriate service information .

Continuation for All Vehicles:

-- Install the A/C compressor. Refer to OVERVIEW - A/C COMPRESSOR .

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

-- Install the battery tray. Refer to OVERVIEW - BATTERY .

-- Electrical connections and routing. Refer to COMPONENT LOCATION OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES and the appropriate Wiring Diagram.

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

-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Check the oil level. Refer to ENGINE OIL .

-- Attach the coolant hoses with the connector coupling to the heater core for the heater. Refer to Fig 4.

Fig 4: Connect the Connector Coupling

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-- Install the subframe. Refer to SUBFRAME WITHOUT STEERING GEAR, REMOVING AND INSTALLING .

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

-- Fill the coolant. Refer to COOLANT, FILLING USING Cooling System Charge Kit: VAS 6096 [DRKB, DRKC] .

If only a new base engine or partial engine is installed, additional adaptations must be made in the engine control module. Proceed as follows:

-- Connect the Vehicle diagnostic tester and select the following functions.

0001 - Engine electronics functions
0001 - basic setting
Timing chain length; resetting after changing timing chain

Tightening Specifications

NOTE:

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

Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not.

Do not use any ungreased parts.

Tightening specification tolerance: ± 15 %.

Component		Nm
Bolts and nuts	M6	10
	M7	15
	M8	20
	M10	40
	M12	65

Subframe mount. Refer to OVERVIEW - ASSEMBLY MOUNTS .
Securing the transmission to the engine. Refer to the appropriate service information .