Engine, Installing
Engine, Installing
Installation is in reverse order of removal, note the following:
• Always replace self-locking nuts, bolts which have been tightened to tightening specifications as well as gaskets and O-rings.
• Secure all hose connections with hose clamps appropriate for the model.
- Make sure alignment sleeves for engine to transmission are installed in cylinder block. Install if necessary.
- A pilot needle bearing must be installed in the crankshaft in engines for vehicles with DSG transmission. Install needle bearing if necessary. Refer to => [ Needle Bearing in Crankshaft ] Needle Bearing In Crankshaft.
- Bolt transmission to engine.
- Secure with new bolts.
• 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 degreased parts.
• Tolerance for tightening specifications ±15%.
Securing engine/DSG transmission
* Bolt with threaded pin M8.
* Screw only serves to secure starter to transmission.
- Remove bevel box bracket - A - while observing the following installation sequence:
- First tighten bolts - 1 - to 3 Nm.
- Tighten the bolts - 2 - to 35 Nm.
- Finally tighten bolts - 1 - to 45 Nm.
- Guide the engine/transmission assembly into the body.
- Next, hand tighten the engine support bolts to the engine mounts - arrows -.
- Next tighten the transmission mount bolts to the transmission support - arrows -.
- Secure with new bolts.
• The bolts are first tightened to final torque after the engine mounts have been adjusted. Refer to => [ Subframe Mount, Adjusting ] Adjustments.
- Remove engine/transmission support from engine.
- Install drive axles.
• Drive axles must be installed before any further installation.
- Fasten pendulum support to transmission with new bolts items - 2 and 3 -.
- Press engine/transmission assembly toward bulkhead, bevel box pins must be carefully guided into driveshaft flange when doing so.
Seal - arrow - in driveshaft flange must not be damaged when installing engine/transmission assembly. If seal is damaged, driveshaft must be replaced.
- Fasten pendulum support to subframe with new bolt - 1 -.
- Fasten driveshaft with flexible disc to bevel box flange - arrows -.
Further installation is in reverse order of removal, note the following:
- Install exhaust system and align it free of stress. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.
- Install selector lever cable.
- Install bracket for assemblies. Refer to => [ Accessory Assembly Bracket ] Service and Repair.
- To make it easier to install the generator, drive the bushings for the retaining bolts back slightly.
- Install generator.
- Install air conditioning compressor.
- Install fan shroud. Refer to => [ Coolant Fan and Coolant Fan 2 ] Coolant Fan and Coolant Fan 2.
- Install Secondary Air Injection (AIR) pump. Refer to => [ Secondary Air Injection Pump ] Secondary Air Injection Pump.
- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Adjust the engine mounts. Refer to => [ Subframe Mount, Adjusting ] Adjustments.
- Install windshield wiper arms.
- Electrical connections and routing.
- Connect Ground (GND) wire to battery.
- Check oil level. Refer to => [ Oil Level, Checking ] Testing and Inspection.
Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.
- Fill with coolant => [ Filling ] Procedures.
• Only reuse drained coolant if cylinder head or engine block was not replaced.
• Dirty coolant must not be re-used.
Tightening Specifications
* Replace bolts and nuts.
* 90° corresponds to a 1/4 turn