Engine Install PDF
Engine Install PDF
Engine Install PDF
Engine, Installing
Special tools and workshop equipment required
t Counter Hold Tool -T10355- for vehicles with a DSG transmission
t Assembly Aid -T40169-
t Transportation Lock -T40170-
t Engine Support Bridge -10-222 A-
t Drip Tray for VAS 6100 -VAS 6208-
Tightening Specifications
Note
t Tightening specifications only apply to lightly greased, oiled, phosphate or blackened nuts and bolts.
Additional lubricants, such as engine or transmission oil are permissible, although lubricants
t
containing graphite are not.
t Do not use any degreased parts.
t Tolerance for tightening specifications +/- 15%.
For the correct tightening specifications, refer to → Chapter „Subframe Mount Overview“.
Additional Tightening Specifications
Component Nm
Bolts and nuts M6 9
M8 20
M10 40
M12 65
Manual Transmission to Engine Fastener
Item Bolt Nm
1 3) M10 x 50 1) 65
2 3), 7 M12 x 100 2) 30 + 90°
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Engine, Installing Page 2 of 9
Procedure
Note
t Replace bolts which have been tightened to an additional torque.
t Replace self-locking nuts and bolts as well as sealing rings, seals and O-rings.
t The hose connections and charge air system hoses must be free of oil and grease before installing.
t Secure all hose connections with hose clamps appropriate for the model. Refer to the Parts Catalog.
To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust
t
remover before installing.
t During installation, all cable ties must be installed at the same location.
– Check whether alignment sleeves for centering engine and transmission in cylinder block are
present, insert missing alignment sleeves.
– Clean the threaded holes in the cylinder block for connecting the engine and transmission using a
thread tap before installing the transmission.
– Complete the following steps before connecting the engine and transmission:
Make sure the intermediate plate is engaged
–
on the sealing flange and slide onto the
guide sleeves -arrows-.
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Engine, Installing Page 3 of 9
Insert the -T40169- into the transmission
–
housing and clutch module from
underneath as illustrated.
The -T40169- must engage in the semi-
l circular opening -1- and in the inspection
hole -2-.
Note
The inspection hole is only in one location
on the circumference so rotate the clutch
module as needed.
Insert the -T40170- in the transmission
–
housing from below and clamp it onto
the flange shaft -1-.
Note
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Engine, Installing Page 4 of 9
The following step is necessary only if
there is a drive plate with mounting pins -2-
installed.
Align the drive plate to the clutch module
– so the mounting pins -2- (if equipped) on
the drive plate can engage in the large
holes -1- on the clutch module.
Caution
The clutch will not function properly if it
is installed incorrectly.
If the drive plate mounting bolts -2- are
not in the clutch module hole -1-, the
clutch will not function properly.
Note
The bolt -2- attaches the starter to the
t transmission and has an additional spacer
sleeve -arrow-.
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Engine, Installing Page 5 of 9
Pay attention to the spacer sleeve -arrow-
with removing or installing the engine.
t
The spacer sleeve must be inserted
between the starter and the transmission.
Attach the transmission to the engine and
– tighten the bolts -7 through 11-. For the
correct tightening specifications, refer to
→ Anchor.
– Release the tension on the -10-222 A-
spindles.
Lower the -VAS 6100- and mount the
–
engine and transmission onto the engine
mount.
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Engine, Installing Page 6 of 9
– Install the left and right engine mount
bolts -1-.
– Remove the -VAS 6100- and -2024 A-.
– Install and tighten the
engine/transmission bolts -1 through 6-.
Note
Ignore -A-.
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Engine, Installing Page 7 of 9
– Remove the -T40170- and the -T40169-.
Note
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-.
Tightening Sequence - Clutch Module to
the Drive Plate
– Install the first bolt -arrow- hand-tight.
Turn the crankshaft another 120° in the
–
direction of engine rotation and install
the second bolt hand-tight.
– Turn the crankshaft again 120° in the
direction of engine rotation.
Tighten the third bolt to the tightening
–
specification. Refer to → Manual
Transmission; Rep. Gr.30.
– Tighten the remaining bolts to the
tightening specification.
Further installation is performed in reverse
order.
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Engine, Installing Page 8 of 9
– Install the starter. Refer to → Electrical
Equipment; Rep. Gr.27.
– Install the catalytic converter. Refer to
→ Chapter „Catalytic Converter“.
Install the front exhaust pipe/front
–
muffler. Refer to → Chapter „Front
Exhaust Pipe and Front Muffler“.
Install exhaust system free of stress.
–
Refer to → Chapter „Exhaust System,
Aligning“.
Install A/C compressor. Refer to
–
→ Heating, Ventilation and Air
Conditioning; Rep. Gr.87.
– Install the ribbed belt. Refer to
→ Chapter „Ribbed Belt“.
Electrical connections and routing. Refer
–
to → Wiring diagrams, Troubleshooting
& Component locations.
Install Engine Control Module (ECM).
–
Refer to → Fuel Injection and
Ignition; Rep. Gr.24.
Install the electrical wires, terminal 30
– wire junction 2 -TV22- and the engine
compartment E-box cover. Refer to
→ Electrical Equipment; Rep. Gr.97.
Install the tower brace. Refer to
–
→ Suspension, Wheels, Steering; Rep.
Gr.40.
Install the washer fluid reservoir filler
–
tube. Refer to → Electrical
Equipment; Rep. Gr.92.
Follow procedures after connecting the
–
battery. Refer to → Electrical
Equipment; Rep. Gr.27.
Caution
Risk of destroying control modules with
excess voltage.
Do not use a battery charger for starting
assistance!
Install the air filter housing. Refer to
–
→ Fuel Injection and Ignition; Rep.
Gr.24.
– Install the lock carrier in service position.
Refer to → Body Exterior; Rep. Gr.50.
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Engine, Installing Page 9 of 9
Check the oil level. Refer to Maintenance
Procedures Rep. Gr. 03.
– Fill with coolant. Refer to → Anchor.
Note
Do not use drained coolant in the
t
following situations:
If the cylinder head or cylinder block was
t
replaced.
t If the coolant is contaminated.
Install the noise insulation and the wheel
–
housing liners. Refer to → Body
Exterior; Rep. Gr.66.
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