Engine, Installing

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Special tools and workshop equipment required

Clutch Module Transportation Lock:T40170
Torque Wrench 1332 Insert - Ring Wrench - 16mm:VAG1332/14
Scissor Lift Table:VAS6131B
Chain Tensioner Lever
Cleaning Solution:D 009 401 04

Procedure

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.
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.
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.

-- Bring the starter into the installation position.

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

Secure the engine with the subframe on the :VAS6131B .

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

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

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-- Bond the sealing piece with the lower timing chain cover.

-- 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 in the cylinder block are installed.

Fig 2: Engine to Transmission Bolts And Alignment Sleeves -A-

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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 appropriate service information. .

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-. Refer to appropriate service information. .

-- Remove the :T40170 .

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.

TIP:

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 appropriate service information. .

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TIP:

Use the :VAG1332/14 to tighten the bolts.

CAUTION:

Components could be destroyed by the camshaft timing chain skipping.

Turn the crankshaft only in direction of engine rotation -arrow-.

-- Then turn the crankshaft 60° farther -arrow- and tighten the remaining five bolts to the tightening specification. Refer to appropriate service information. .

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-- Install the plug for "TDC" hole. Refer to OVERVIEW - CRANKSHAFT .

-- Install the coolant pipes. Refer to COOLANT PIPES, REMOVING AND INSTALLING .

-- Install the exhaust system. Refer to OVERVIEW - MUFFLER .

-- Install the ATF cooler. Refer to appropriate service information. .

-- Carefully guide the engine/transmission assembly into the body using the Scissor Lift Table:VAS 6131 B .

-- Remove the locating pins and install the subframe. Refer to SUBFRAME, SECURING .

-- Tighten the tunnel crossmember bolts. Refer to appropriate service information. .

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

-- Install the parking lock emergency release cable. Refer to appropriate service information. .

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

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

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

-- Install the stabilizer bar and coupling rod. Refer to OVERVIEW - SUBFRAME .

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

-- Install the lower control arm. Refer to OVERVIEW - LOWER CONTROL ARM AND BALL JOINT .

-- Install the tie rod end. Refer to TIE ROD END, REMOVING AND INSTALLING .

-- Install the steering gear boot. Refer to BOOT, REMOVING AND INSTALLING .

-- Install the Engine Control Module -J623-. Refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

-- Wires and connections. Refer to OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES

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

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

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

-- Install the driveshaft. Refer to appropriate service information. .

-- Install the wheel spoiler and wheel housing liner. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

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

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

-- Install the lock carrier cover. Refer to LOCK CARRIER COVER, REMOVING AND INSTALLING .

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

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

CAUTION:

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

Do not use a charger to jump start.

-- If the engine is replaced, perform the "01 - mechanical engine, functions" listed adaptation using the Vehicle Diagnostic Tester.

CAUTION:

Risk of component damage.

Perform the additional adaptation for each component, that was replaced at the same time.

-- Connect the coolant hoses with the connector coupling. Refer to Fig 5.

Fig 5: Connect the Connector Coupling

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-- Fill with coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Check the ATF level. Refer to appropriate service information. .

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

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

Tightening Specifications

The tightening specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
Additional lubricants, such as engine or transmission oil are permitted, although lubricants containing graphite are not.
Do not use any ungreased parts.
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 appropriate service information. .