Engine, Installing

Procedure 

• Engine/transmission assembly is secured to Engine Support: T10497A  .

• 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 .
• The engine/transmission assembly is attached to the Engine Support: T10497A  .
• Replace bolts that were tightened with an additional turn after removing them.
• Replace the self-locking nuts and bolts, gaskets, seals and O-rings.
• Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts Information.
• 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.

-- Install the intermediate plate. Refer to Fig 1.

Vehicles with Manual Transmission: 

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-- Check if on the cylinder block the alignment sleeves -A- for centering the engine and transmission are installed.

-- If a needle bearing is installed in the crankshaft, remove the needle bearing. Refer to CRANKSHAFT NEEDLE BEARING, REPLACING .

-- If the clutch release bearing is worn, replace it. Refer to CLUTCH MECHANISM .

-- Lightly lubricate the transmission input shaft splines with grease for clutch plate shaft splines. Refer to the Parts Information.

-- Check the clutch plate alignment.

Vehicles with Dual-Clutch Transmission: 

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-- Check if on the cylinder block the alignment sleeves -A- for centering the engine and transmission are installed. (Shown for the dual clutch transmission 0CW.)

-- If no needle bearing is installed in the crankshaft, install the needle bearing. Refer to CRANKSHAFT NEEDLE BEARING, REPLACING .

Vehicles with Automatic Transmission 

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-- Check if on the cylinder block the alignment sleeves -arrows- for centering the engine and transmission are installed.

Continuation for All Vehicles: 

-- Install the transmission support. Refer to OVERVIEW - ASSEMBLY MOUNTS (02S) or OVERVIEW - ASSEMBLY MOUNTS (0GC) .

-- Lift the engine/transmission assembly using the Engine Support: T10497A  .

-- Guide the engine/transmission assembly into the body.

-- Install the bolts -arrows- for the engine mount by hand all the way.

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-- Install the bolts -arrows- for the transmission mount by hand until it is in position.

-- Remove the Engine Support: T10497A  from the engine.

-- Install the starter. Refer to STARTER, REMOVING AND INSTALLING .

Vehicles with Manual Transmission 

-- Install the clutch slave cylinder. Refer to CLUTCH SLAVE CYLINDER, REMOVING AND INSTALLING .

-- Install the cables with the cable bracket. Refer to SHIFT MECHANISM .

Vehicles with DSG Transmission 

-- Install the selector lever cable, connect the Mechatronic connector and attach all brackets to the transmission. Refer to [For transmission(s) 0GC] Transmission, Removing and Installing

AWD Vehicles: 

-- Install the driveshaft on the bevel box. Refer to the appropriate Service Information .

-- Install the bevel box bracket. Refer to the appropriate Service Information .

-- Install the bevel box. Refer to the appropriate Service Information .

Continuation for All Vehicles 

-- Install the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Install the drive axles. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

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

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

-- Note the connections and routing. Refer to COMPONENT LOCATION OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES and the appropriate Wiring Diagram.

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

-- Connect the coolant hoses with the connector coupling. Refer to Fig 3.

-- Install the pendulum support. Refer to PENDULUM SUPPORT, REMOVING AND INSTALLING .

-- Install the fan shroud. Refer to FAN SHROUD, REMOVING AND INSTALLING .

-- Install the left and right wheel housing liner. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Mount the front wheels. Refer to WHEEL BOLTS TIGHTENING SPECIFICATION .

-- Adjust the assembly mount. Refer to ASSEMBLY MOUNT, ADJUSTING .

-- Install the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- Install the Secondary Air Injection Pump Motor -V101- with the bracket. Refer to Secondary Air Injection Pump Motor -V101-, REMOVING AND INSTALLING .

-- Install the battery tray. Refer to BATTERY TRAY, REMOVING AND INSTALLING .

-- Install the battery. Refer to BATTERY, REMOVING AND INSTALLING .

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

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

If a New Short Block is Installed:

-- Pay attention to the notes for the vehicle data label. Refer to Vehicle Data Label on the Toothed Belt Guard: .

-- Compare the information on the engine data label with the engine compliments slip. The specified data must match.

-- Perform the 0001 - Adaption after replacing sensor wheel  function using the Vehicle Diagnostic Tester

-- Perform the 0001 - Resetting the fuel injector adaptation values  using the Vehicle Diagnostic Tester

-- Perform the 0001 - Crankshaft position correction value  . Using the Vehicle Diagnostic Tester

-- Perform the 0001 - Camshaft position (intake and exhaust) Correction Value  . Using the Vehicle Diagnostic Tester

-- Perform the 0001 - Charge Air Pressure Actuator -V465 Adapting / Adjusting  . Using the Vehicle Diagnostic Tester

-- Perform the 0001 - Heated oxygen sensor adaptation  . Using the Vehicle Diagnostic Tester

Tightening Specifications 

• Refer to OVERVIEW - ASSEMBLY MOUNTS 
• Refer to OVERVIEW - FAN SHROUD AND RADIATOR FAN
• Refer to OVERVIEW - EMISSIONS CONTROL SYSTEM
• Refer to OVERVIEW - DRIVE AXLE .
• Refer to TRANSMISSION, INSTALLING (0GC) or TRANSMISSION, INSTALLING (02S) .
• Refer to TRANSMISSION TIGHTENING SPECIFICATIONS (0GC) or TRANSMISSION TIGHTENING SPECIFICATIONS (02S) .
• Refer to OVERVIEW - STARTER .
• Refer to OVERVIEW - BATTERY .
• Refer to OVERVIEW - A/C COMPRESSOR .