Engine, Installing, Vehicles With Manual Transmission

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Special tools and workshop equipment required

Torque Wrench 1332 Insert - Ring Wrench - 16mm VAG1332/14
Clutch Module Assembly Aid T40169
Clutch Module Transportation Lock T40170

Tightening Specifications

NOTE:

The tightening specifications apply only 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 parts that have had the lubrication removed.

Tightening specification tolerance: ±15%.

Component		Nm
Bolts and nuts	M6	9
	M7	15
	M8	20
	M10	40
	M12	65

Fig 1: Disengaging Catches -Arrows A- And Remove Upper Part Of Line Pass-Through -2- Upward -Arrow B-

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-- Tighten the GND bolt -1- to 9 Nm.

Fig 2: Disconnecting Ground Wires -Arrow- From Right Longitudinal Member

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-- Tighten the nut -arrow- to 9 Nm.

Engine to Manual Transmission

-- Check if the alignment sleeves -A- for centering the engine/transmission are in the cylinder block and insert them if they are not.

Fig 3: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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Item

Bolt

M10 x 50 ¹⁾

2 to 6

M12 x 100 ²⁾

30 + 90°

M12 x 125 ²⁾

30 + 90°

8, 11

M10 x 60 ²⁾

15 + 90°

9, 10

M10 x 95 ²⁾

15 + 90°

Alignment sleeves for centering

Bolt class 10.9, the steel bolt may be used again unlimited number of times.
The aluminum bolts can be used two times ⁽¹⁾, ⁽²⁾.

⁽¹⁾	The aluminum bolts -2 to 11- may be used twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be used the first time -arrow- (See Fig 4).

⁽²⁾	To prevent damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt using a 14 mm socket with a 1/2 inch drive, which is inserted in to the vise, as illustrated (See Fig 4).

The aluminum bolts -2 to 11- may be used twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be used the first time -arrow-.

Fig 4: Identifying Bolts Marked With An "X"
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Bolts marked with an "X" may not be used again.

Procedure

NOTE:

Replace the bolts which are being tightened with an additional turn.

Replace self-locking nuts and bolts and seals, gaskets and O-rings.

In vehicles with manual transmissions, there is a needle bearing in the drive plate. Check if the needle bearing is inserted before installing. Remove needle bearing from drive plate and install. Refer to NEEDLE BEARING IN DRIVE PLATE, REPLACING .

The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing.

Secure all hose connections with hose clamps of the same type as those equipped by the factory.

To mount the air guide hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.

When installing, bring all cable ties back to same positions.

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

-- Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.

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

Fig 5: Insert Assembly Aid T40169 Into Transmission Housing

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-- Insert the Clutch Module Assembly Aid T40169 in the transmission housing between the clutch module and the transmission housing as shown in the illustration.

The assembly aid must engage in the semicircular opening -1- and in the inspection hole -2-.

NOTE:

The inspection hole is only in one location on the circumference, so rotate the clutch module as needed.

-- Install the assembly aid bolt into the hole on the transmission housing.

-- Insert the Clutch Module Transportation Lock T40170 in the transmission housing from below and secure it on the flange shaft -1-.

Fig 6: Identifying Transportation Lock T40170

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-- Check if the alignment sleeves -A- for centering the engine/transmission are in the cylinder block and insert them if they are not.

Fig 7: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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-- Inspect the aluminum bolts used to connect the engine to the transmission to see if they can be used again and mark them, if necessary. Refer to ENGINE, INSTALLING, VEHICLES WITH MANUAL TRANSMISSION .

-- Position the transmission on the engine and tighten the bolts -1 through 11-.

-- Remove the Clutch Module Transportation Lock T40170 and Clutch Module Assembly Aid T40169.

NOTE:

The following procedure is necessary to assure that the clutch module contacts the drive plate evenly and does not get bent.

Fig 8: Guide Pin And Adapter T40058

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-- Insert the Crankshaft Socket T40058 guide pins as follows:

The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

-- Turn the crankshaft one complete turn (360°) in direction of engine rotation -arrow- using the Crankshaft Socket T40058 and offset open-end wrench.

Fig 9: Counter Hold Crankshaft Using Socket T40058

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The inspection hole -arrow- must be visible through the opening in the transmission housing.

Fig 10: Locating Transmission Housing Check Hole
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-- Secure the clutch module to the drive plate as follows:

Fig 11: Identifying Clutch Module First Bolt Installation Location

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NOTE:

Use the Torque Wrench 1332 Insert - Ring Wrench - 16mm VAG1332/14 to tighten the bolts.

-- Install the first bolt -arrow- and tighten by hand (2 Nm).

-- Continue turning the crankshaft 180° in the direction of the engine rotation using the Crankshaft Socket T40058.

-- Tighten the bolts that are accessible in this position to the tightening specification. Refer to OVERVIEW - CLUTCH .

22 Nm + 90° additional turn
Always replace.
For mounting the pressure plate to the dual mass flywheel
Loosen or tighten according to assembly instructions. Refer to CLUTCH, REMOVING AND INSTALLING, "Single-Disc Clutch - LuK" , or CLUTCH, REMOVING AND INSTALLING, DUAL DISC CLUTCH .

-- Turn the crankshaft 60° farther and tighten the remaining five bolts to the tightening specification. .

-- Install the power steering hydraulic lines. Refer to OVERVIEW - HYDRAULIC PIPES AND RESERVOIR .

-- Tighten the left and right drive axles on the transmission flange shafts. Refer to OVERVIEW - DRIVE AXLE .

-- Install the left and right catalytic converters. Refer to LEFT CATALYTIC CONVERTER, REMOVING AND INSTALLING , and RIGHT CATALYTIC CONVERTER, REMOVING AND INSTALLING .

-- Next, raise engine/transmission subassembly high enough using Scissor Lift Table VAS6131B until dimension -a- is reached between subframe and body.

Fig 12: Lowering/Raising Engine/Transmission Subassembly To Dimension -A-

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Dimension -a- = minimum 100 mm

-- Install the gearshift rod and the push rod. Refer to OVERVIEW - SELECTOR MECHANISM .

-- Lift the engine/transmission assembly further using the Scissor Lift Table VAS6131B.

-- Align the subframe and transmission carrier using the marks made on the longitudinal members during removal.

-- Tighten the subframe bolts only to the tightening specifications. Do not tighten them further (tighten the bolts only after axle alignment). Refer to OVERVIEW - SUBFRAME .

Fig 13: Identifying Subframe Bolts

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WARNING:

Risk of accident due to loose connections.

If the bolts in the subframe are not tightened to final torque, vehicle must not be driven.

-- Tighten the tunnel crossmember bolts -arrows-. Refer to SUBFRAME MOUNT .

Fig 14: Identifying Bolts & Tunnel Crossmember

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Install in reverse order of removal. Note the following:

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

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

-- Install the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING for 0BC, 0BD, 0BE and 0BF, or 39 FINAL DRIVE, DIFFERENTIAL for 0BF and 0BE - with Sport Differential .

-- Install the front muffler. Refer to FRONT MUFFLER, REMOVING AND INSTALLING .

-- Install the exhaust system free of tension. Refer to EXHAUST SYSTEM, INSTALLING WITHOUT TENSION .

-- Install the front crossmember. Refer to OVERVIEW - TUNNEL BRACE .

-- Install the subframe crossbrace and stabilizer bar. Refer to OVERVIEW - SUBFRAME .

-- Install the upper control arm and fasten the suspension strut on the control arm. Refer to OVERVIEW - SUSPENSION STRUT AND UPPER CONTROL ARM .

-- Install the diagonal braces. Refer to OVERVIEW - SUBFRAME .

-- Install the brake caliper. Refer to FRONT BRAKE CALIPER, FN-3 , or BRAKE CALIPER, REMOVING AND INSTALLING .

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

-- Electrical connections and wiring routing. Refer to appropriate SYSTEM WIRING DIAGRAM.

-- Install the wires, the Terminal 30 Wire Junction 2 -TV22- and the cover for the engine compartment E-box. Refer to Fig 1, Fig 2 and OVERVIEW - RELAY CARRIERS, FUSE PANELS AND E-BOXES .

-- Install the tower brace. Refer to TOWER BRACE, REMOVING AND INSTALLING .

-- Install windshield wiper fluid reservoir filler tube. Refer to OVERVIEW - WINDSHIELD WASHER SYSTEM .

-- Install the refrigerant lines. Refer to REFRIGERANT LINES WITH INNER HEAT EXCHANGER, REMOVING AND INSTALLING .

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

CAUTION:

There is a risk of destroying control modules with excess voltage.

Do not use a charger as a starting aid.

-- Install the fuel supply hose and air filter housing. Refer to OVERVIEW - AIR FILTER HOUSING .

-- Install the lock carrier braces. Refer to OVERVIEW - LOCK CARRIER .

-- Fill with engine oil and check the level. Refer to ENGINE OIL, FILLING AND CHECKING LEVEL , also see the appropriate "FLUID CAPACITY TABLES" information.

-- Before starting engine for the first time, fill with hydraulic oil in the power steering reservoir. Refer to POWER STEERING FLUID LEVEL, CHECKING .

NOTE:

The power steering pump must not run dry.

-- Connect the coolant hose to the coupling. Refer to Fig 15.

Fig 15: Connecting Coolant Hose Coupling

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Fig 16: Connecting Coolant Hose Coupling

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

NOTE:

Do not use drained coolant in the following situations:

If the cylinder head or cylinder block was replaced.

If the coolant is contaminated.

-- Fill the refrigerant circuit. Refer to USING SERVICE STATION , and REFRIGERANT CIRCUIT .

-- Install the wheel housing liners. Refer to WHEEL HOUSING LINER .

-- Install the front wheels. Refer to WHEEL BOLT TIGHTENING SPECIFICATIONS .

-- Perform an axle alignment. Refer to VEHICLE ALIGNMENT .

WARNING:

Risk of accident due to loose connections.

Tighten the subframe bolts to the specification after performing axle alignment.

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