Engine, Installing: Procedure

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

-- When jointing the engine and subframe, hold the ATF lines in their installation position.

-- 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 1: 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 as illustrated.

-- Insert the Clutch Module Transportation Lock T40170in the transmission housing from below and secure it on the flange shaft -1-.

Fig 2: Identifying Transportation Lock T40170

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-- Bring the starter and the locking piece -1- into the installed position:

Fig 3: Identifying Locking Piece

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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 4: 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  - "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 Figure).

-- Position the transmission on the engine and tighten the bolts -3 through 11-.

-- Remove the Clutch Module Transportation Lock T40170.

• The locking piece -1- must be installed correctly before installing the starter -arrows-.
  Fig 5: Identifying Locking Piece

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-- Install the starter, refer to STARTER, REMOVING AND INSTALLING, VEHICLES WITH 3.0L TFSI AND 3.2L FSI ENGINE .

NOTE:

The following step is necessary to make sure the torque converter rests on the drive plate evenly and is not tilted.

Fig 6: Pressing Torque Converter

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-- Press the torque converter -2- against the drive plate -3- slightly in against the drive plate in direction of -arrow- using an assembly lever -1-.

-- Attach the torque converter to the drive plate as follows:

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

Fig 7: Identifying Clutch Module First Bolt Installation Location

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

Fig 8: Guide Pin And Adapter T40058

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

-- Rotate the crankshaft 180° further in direction of engine rotation in direction of -arrow- using the Crankshaft Socket T40058 and ring wrench.

Fig 9: Counter Hold Crankshaft Using Socket T40058

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-- Tighten the accessible bolts in this crankshaft position to the tightening specification, refer to TRANSMISSION TIGHTENING SPECIFICATIONS for 0BK .

-- Turn the crankshaft 60° farther and tighten the remaining five bolts to the tightening specification, refer to TRANSMISSION TIGHTENING SPECIFICATIONS for 0BK .

-- Install the Coolant Recirculation Pump -V50-, refer to COMPONENT GROUP "3" .

-- Install the ATF lines, refer to OVERVIEW - ATF CIRCUIT for 0BK, OVERVIEW - ATF CIRCUIT for 0BW, or OVERVIEW - ATF CIRCUIT for 0B6 .

-- Install the left and right drive axles on the transmission flange shafts, refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Install the catalytic converter.

• left, refer to LEFT CATALYTIC CONVERTER, REMOVING AND INSTALLING
• Right, refer to RIGHT CATALYTIC CONVERTER, REMOVING AND INSTALLING

-- Lift the engine/transmission assembly 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, CROSSBRACE, STABILIZER BAR, COUPLING ROD AND SUBFRAME SHIELD .

-- Tighten the tunnel crossmember bolts, refer to OVERVIEW - SUBFRAME MOUNT for 0BK, .

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

-- 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 .

-- 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 - SUBFRAME, CROSSBRACE, STABILIZER BAR, COUPLING ROD AND SUBFRAME SHIELD .

-- Subframe crossbrace, refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING . Upper control arm, refer to UPPER CONTROL ARM, REMOVING AND INSTALLING . Stabilizer installing, refer to STABILIZER BAR, REMOVING AND INSTALLING . Tighten the suspension strut on the left and right control arms, refer to UPPER CONTROL ARM, REMOVING AND INSTALLING .

-- Install the selector lever cable and adjust if necessary, refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING for 0BW, or SELECTOR LEVER CABLE, REMOVING AND INSTALLING for 0BK .

Fig 10: Selector Lever Cable, Ball Socket And Securing Clips

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-- Install the brake caliper, refer to 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 appropriate SYSTEM WIRING DIAGRAM and OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES .

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

-- Install the windshield wiper fluid reservoir filler tube, refer to WASHER FLUID RESERVOIR, REMOVING AND INSTALLING .

-- Install the refrigerant lines, refer to OVERVIEW - REFRIGERANT CIRCUIT .

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

-- Install the fuel supply hose (refer to OVERVIEW - HIGH PRESSURE PUMP ) and air filter housing, refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Install the lock carrier braces, refer to LOCK CARRIER .

-- Fill the engine oil and check the oil level, refer to ENGINE OIL LEVEL, FILLING AND CHECKING .

-- Connect the coolant hose to the coupling, refer to Fig 11.

Fig 11: Connecting Coolant Hose Coupling

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

-- Fill the refrigerant circuit, refer to USING SERVICE STATION .

-- Install the wheel housing liners, refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

-- Install the front wheels, wheel bolt tightening specification: 140 Nm. Refer to WHEEL BOLT TIGHTENING SPECIFICATIONS .

-- Perform an axle alignment, refer to WHEEL ALIGNMENT .

-- Fill the ATF, refer to ATF, DRAINING AND FILLING for 0BK, ATF, DRAINING AND FILLING for 0BW, or ATF, DRAINING AND FILLING for 0B6 .

-- Install the noise insulations, refer to OVERVIEW - NOISE INSULATION .