Engine, Installing
Procedure
- Engine/transmission assembly is secured to Engine Support :T10497A .
If a new engine is installed, pay attention that only the supplied upper toothed belt guard is installed.
The engine data label for the new engine is mounted on this toothed belt guard.
Only this engine date label has the applicable build status data.
Replace the bolts that were tightened with an additional turn.
Replace the self-locking nuts and bolts, gaskets, seals and O-rings.
Secure the hose connections with hose clamps corresponding to the model version. Refer to the Parts Information.
When installing, bring all cable ties back to the same position.
-- Install the intermediate plate. Refer to OVERVIEW - CYLINDER BLOCK, TRANSMISSION SIDE .
-- If the alignment sleeves -A- for centering the engine and transmission are missing inside the cylinder block, then install the alignment sleeves.
After replacing the engine a new engine with alignment sleeves -A- is supplied.
Depending on the transmission version the alignment sleeves have different lengths.
Use the correct alignment sleeves from the Parts Information.
-- Tighten the transmission to the engine at positions -1, 2, 3, 6, 7, 8, 9-.
-- Install the Charge Air Cooling Pump -V188-. Refer to ELECTRIC COOLANT PUMP, REMOVING AND INSTALLING .
-- If removed, install the coolant pump. Refer to COOLANT PUMP, REMOVING AND INSTALLING .
-- Install the transmission support. Refer to OVERVIEW - ASSEMBLY MOUNTS .
-- Lift the engine/transmission assembly using the Engine Support :T10497 .
-- 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 by hand until it is in position.
-- Remove the Engine Support :T10497 from the engine.
-- Install the starter. Refer to OVERVIEW - STARTER .
Vehicles with Manual Transmission
-- Install the clutch slave cylinder. Refer to the appropriate service information .
-- Install the cables with the cable bracket. Refer to the appropriate service information .
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 OVERVIEW - BEVEL BOX .
-- Install the bevel box. Refer to BEVEL BOX, REMOVING .
Continuation for All Vehicles
-- Install the catalytic converter. Refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING .
-- Install the drive axles. Refer to OVERVIEW - DRIVE AXLE .
-- 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 Wiring Diagram.
-- Install the Engine Control Module -J623-. Refer to Engine Control Module -J623-, REMOVING AND INSTALLING .
-- Connect the coolant hoses with the connector coupling. Refer to Fig 2.
-- 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 OVERVIEW - FRONT WHEEL HOUSING LINER .
-- Mount the front wheels. Refer to WHEEL, CHANGING .
-- 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 .
Do not use a charger to jump start.
There is a risk of destroying the control modules due to excessive voltage.
Do not reuse coolant that has been drained.
-- 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 .
- Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .
- Refer to OVERVIEW - STARTER .
- Refer to OVERVIEW - BATTERY .
- Refer to OVERVIEW - A/C COMPRESSOR .