Engine, Installing: Procedure
Install in the reverse order of removal while noting the following:
- Vehicles with dual clutch transmission: always replace the needle bearing in the crankshaft after the engine and transmission have been separated. Refer to CRANKSHAFT NEEDLE BEARING, REPLACING .
- Replace 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.
- Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Electronic Parts Information (ETKA).
- Check the vacuum hoses for damage before the assembly and replace if necessary.
- During installation, all cable ties must be installed at the same location.
- Used coolant cannot be used again.
-- Attach the transmission to the engine. Refer to TRANSMISSION, INSTALLING .
-- Lift the engine/transmission assembly using the Engine/Gearbox Jack - Engine Support :T10359 .
-- Guide the engine/transmission assembly into the body.
-- Install the bolts -arrows- for the engine mount by hand all the way.
-- Install the bolts -arrows- for the transmission mount -1- by hand all the way.
-- Remove the Engine/Gearbox Jack - Engine Support :T10359A from the engine.
-- Adjust the assembly mount. Refer to ASSEMBLY MOUNT, ADJUSTING .
-- Install the drive axles. Refer to OVERVIEW - DRIVE AXLE .
-- Attach the driveshaft to the bevel box. Refer to the appropriate service information .
-- Install the drive axle heat shield. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .
-- Install the control lines for Particulate Filter Differential Pressure Sensor -G1037-. Refer to OVERVIEW - HEATED OXYGEN SENSOR .
-- Install the A/C compressor. Refer to OVERVIEW - A/C COMPRESSOR .
-- Install the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .
-- Install the front air duct pipe. Refer to FRONT AIR DUCT PIPE, REMOVING AND INSTALLING .
-- Install the fan shroud. Refer to FAN SHROUD, REMOVING AND INSTALLING .
-- Electrical connections and routing. Refer to COMPONENT LOCATION OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES and the appropriate Wiring Diagram.
-- Install the air guide hoses. Refer to OVERVIEW - CHARGE AIR HOSE CONNECTIONS .
-- Install the gearshift lever cable and adjust. Refer to OVERVIEW - SHIFT MECHANISM .
-- Connect the fuel line and the EVAP system hose. Refer to CONNECTOR COUPLINGS, DISCONNECTING .
-- Install the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .
-- Install the connection for the turbocharger. Refer to OVERVIEW - TURBOCHARGER .
-- Install the battery tray. Refer to BATTERY TRAY, REMOVING AND INSTALLING or connect the battery, refer to BATTERY, DISCONNECTING AND CONNECTING .
-- Install the air filter housing bracket. Refer to Figure and Refer to Figure.
-- Install the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .
-- Install the air guide. Refer to OVERVIEW - AIR FILTER HOUSING .
-- Install the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .
-- Install the subframe. Refer to OVERVIEW - SUBFRAME .
-- Install the wheel housing liner. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .
-- Install the underbody trim panel. Refer to OVERVIEW - UNDERBODY TRIM PANELS .
-- Fill engine oil, or check the fluid level. Refer to ENGINE OIL .
-- Follow all steps after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .
There is a risk of destroying the control modules due to excessive voltage.
- Do not use a battery charger to jump start!
-- Connect the coolant hoses with the connector coupling. Refer to Fig 3.
-- Fill the coolant. Refer to COOLANT, FILLING USING Cooling System Charge Kit: VAS 6096 [DNNA, DNNB, DNND, DNVB, DNNE, DYWA] .