Engine, Installing: Procedure

NOTE:

Replace any bolts that were tightened with an additional turn.

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

When installing, bring all cable ties back to same positions.

-- When removed: install the rear upper and left upper coolant pipe, refer to OVERVIEW - COOLANT PIPES .

-- Install the engine supports and engine mount, refer to OVERVIEW - SUBFRAME MOUNT .

-- Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.

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

Vehicles with DSG Transmission 0B5:

Fig 1: Insert Assembly Aid T40169 Into Transmission Housing

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-- Insert the Clutch Module Assembly Aid T40169 in the transmission housing and the dual mass flywheel from below as shown in the illustration.

The assembly aid must engage in the semicircular opening -1- and in the inspection hole -2-.

NOTE:

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.

Vehicles with an Automatic Transmission 0BK

Fig 2: 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 illustrated.

NOTE:

There is only 1 notch on the circumference; rotate the torque converter as needed.

Continuation for All Vehicles:

Fig 3: Identifying Transportation Lock T40170

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-- Insert the Clutch Module Transportation Lock T40170 in the transmission housing from below and secure it on the flange shaft -1-.

Vehicles with DSG Transmission 0B5:

Fig 4: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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

-- 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 TRANSMISSION TIGHTENING SPECIFICATIONS .

-- Position the transmission on the engine and tighten the bolts -1 through 10-.

Vehicles with an Automatic Transmission 0BK

Fig 5: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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

-- 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 Transmission Tightening Specifications .

-- Position the transmission on the engine and tighten the bolts -1 through 11-.

Continuation for All Vehicles:

-- Remove the Clutch Module Transportation Lock T40170 and Clutch Module Assembly Aid T40169.

NOTE:

The following procedure is necessary to assure that the dual mass flywheel and/or the torque converter contacts the drive plate evenly and does not get bent.

Fig 6: Pressing Torque Converter

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-- Press the dual mass flywheel/torque converter -2- against the drive plate -3- slightly in against the drive plate in direction of -arrow- using an assembly lever -1-.11

-- Attach the dual mass flywheel/torque converter to the drive plate as follows:

NOTE:

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).

Fig 7: Identifying Clutch Module First Bolt Installation Location

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-- Position the Crankshaft Turning Tool T40272 onto the Wrench - 21mm T40263.

Fig 8: Identifying Crankshaft Turning Tool T40272

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-- Attach the adapter to the bolts on the vibration damper.

The semi-round countersink -arrow A- on the Crankshaft Turning Tool T40272 must face the semi-round countersink -arrow B- on the vibration damper.

NOTE:

Ignore the notch on the Crankshaft Turning Tool T40272.

-- Continue to turn the crankshaft 180° in direction of engine rotation in direction of -arrow- using the Wrench - 21mm T40263 and Crankshaft Turning Tool T40272.

-- Tighten the accessible bolts in this crankshaft position to the tightening specification, refer to OVERVIEW - CRANKSHAFT or Transmission Tightening Specifications .

-- Turn the crankshaft 60° farther and tighten the remaining five bolts to the tightening specification, refer to FASTENER TIGHTENING SPECIFICATIONS or Transmission Tightening Specifications .

-- Install the ATF cooler, refer to ATF COOLER, REMOVING AND INSTALLING or ATF Cooler, Removing And Installing .

-- Tighten the drive axles on the transmission flange shafts, Overview - Drive Axle .

-- Install the ATF lines, refer to ATF PIPES, REMOVING AND INSTALLING .

-- Install the catalytic converter, refer to OVERVIEW - MUFFLER .

-- Next, raise engine/transmission subassembly high enough using Scissor Lift Table VAS6131B until dimension -a- is reached between subframe and body.

Fig 9: Lower Transmission To Dimension -a-

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Dimension -a- = minimum 100 mm

-- Install the selector lever cable, and adjust if required, refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING .

-- Lift the engine/transmission assembly further 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 Overview - Subframe .

WARNING:

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 bolts for the tunnel cross member, refer to Subframe Mount .

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

NOTE:

Only remove the plugs or caps after installing the lines.

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

Secure all hose connections with hose clamps of the same type as those equipped by the factory.

When installing, bring all cable ties back to same positions.

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

-- Install the driveshaft, refer to DRIVESHAFT, REMOVING FROM REAR FINAL DRIVE AND INSTALLING .

-- Install the front muffler, refer to OVERVIEW - MUFFLER .

-- Install the upper control arm and suspension strut, refer to Suspension Strut and Upper Control Arm .

-- Install the subframe crossbrace and stabilizer bar, refer to Subframe Crossbrace, Removing And Installing and Stabilizer Bar, Removing And Installing .

-- Install the brake caliper, refer to 47 HYDRAULIC COMPONENTS .

-- Install the engine control module, refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

-- Install the air filter housing and the air duct, refer to OVERVIEW - AIR FILTER HOUSING .

-- Install windshield wiper fluid reservoir filler tube, refer to WASHER FLUID RESERVOIR .

-- Electrical connections and wiring routing, refer to APPROPRIATE SYSTEM WIRING DIAGRAM INFORMATION.

-- Install the cable Terminal 30 Wire Junction 2 -TV22- and the cover for the engine compartment E-box, refer to PLENUM CHAMBER BULKHEAD, REMOVING AND INSTALLING .

-- Install the tower brace, refer to Tower Brace, Removing And Installing .

-- Install the refrigerant lines, refer to Refrigerant Circuit .

-- Follow all steps after connecting the battery, refer to Battery -A-, Disconnecting And Connecting .

CAUTION:

There is a risk of destroying control modules with excess voltage.

Do not use a charger as a starting aid.

-- Install the front bumper cover end plate and the lock carrier cover, refer to FRONT BUMPER COVER END PLATE, REMOVING AND INSTALLING .

-- Install the plenum chamber cover, refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Fill the engine oil and check the oil level, refer to the appropriate FLUID CAPACITY TABLES infromation .

-- Connect the coolant hoses with the connector coupling, refer to Fig 10.

Fig 10: Connecting Coolant Hose Coupling

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NOTE:

Do not reuse used coolant.

-- Fill the coolant, refer to Filling .

-- Fill the refrigerant circuit, refer to Refrigerant System - with Refrigerant R134a.

-- Install the wheel spoiler and wheel housing liners, refer to WHEEL HOUSING LINERS .

-- Perform an axle alignment, refer to VEHICLE ALIGNMENT .

WARNING:

Risk of accident due to loose connections.

Tighten the subframe bolts to the specification after performing axle alignment.

-- Install the noise insulations, refer to OVERVIEW - FRONT AND REAR NOISE INSULATION .

-- Afterwards, perform the basic setting for the assembly mount see Vehicle Diagnostic Tester, BA - assembly mount J931 , Guided Functions , BA - perform basic setting .

-- The "combustion misfire adaptation" must be adapted after replacing the engine, select 01 Reset Combustion Misfire Adaptation in Guided Fault Finding see Vehicle Diagnostic Tester.