Engine, Installing, Hybrid Vehicles

Special tools and workshop equipment required 

• Counterhold - Vibration Damper T10355
• Clutch Module Transportation Lock T40170

Tightening Specifications

• Refer to OVERVIEW - SUBFRAME MOUNT 
• Engine to transmission, refer to TRANSMISSION TIGHTENING SPECIFICATIONS for 0BW, TRANSMISSION TIGHTENING SPECIFICATIONS for 0BK, or TRANSMISSION TIGHTENING SPECIFICATIONS for 0B6 .

Procedure 

-- 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 Electro-Drive Drive Motor -V141- so that the hold next to the notch -arrow- is visible inside the transmission housing in the lower opening, as illustrated.

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

Fig 2: Identifying Transportation Lock T40170

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NOTE:

The bolt -2- attaches the starter to the transmission and has an additional spacer sleeve -arrow-.

Fig 3: Identifying Bolt & Spacer Sleeve

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The spacer sleeve must be inserted between the starter and the transmission.

-- Bring the starter -2- and the locking piece -1- into the installed position:

Fig 4: Starter, Locking Piece, Wedge And Installed Position

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-- Secure the starter with a plastic wedge -4- on the engine support -3-.

-- Inspect the aluminum bolts used to connect the engine to the transmission to check if they can be used again and mark them, if necessary, refer to Engine to transmission, refer to TRANSMISSION TIGHTENING SPECIFICATIONS for 0BW, TRANSMISSION TIGHTENING SPECIFICATIONS for 0BK, or TRANSMISSION TIGHTENING SPECIFICATIONS for 0B6 .

Fig 5: Engine To Transmission Bolts

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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.

-- Position the transmission on the engine and tighten the bolts -2 through 5-.

-- Release the Engine Support Bridge - Spindle10-222A/11.

Fig 6: Installing T40013 On Transmission

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-- Lower the Shop Crane VAS6100 and mount the engine and transmission onto the engine mount.

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

-- Remove the Shop Crane VAS6100 and Engine Sling 2024A.

-- Tighten the remaining engine/transmission bolts.

-- Remove the Clutch Module Transportation Lock T40170.

• The locking piece -1- must be installed correctly before installing the starter -arrows-.
  Fig 7: Identifying Locking Piece

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-- Install the starter, refer to STARTER, REMOVING AND INSTALLING, VEHICLES WITH 2.0L TFSI ENGINE .

-- Attach the Electro-Drive Drive Motor -V141- to the drive plate as described in the following:

Fig 8: Identifying Clutch Module First Bolt Installation Location

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

-- Continue turning the crankshaft on the vibration damper 240° in direction of engine rotation using the Counterhold - Vibration Damper T10355.

Fig 9: Identifying Vibration Damper "TDC" Position With Special Tool T10355

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-- Tighten the accessible bolts in this crankshaft position to the tightening specification, refer to Engine to transmission, refer to TRANSMISSION TIGHTENING SPECIFICATIONS for 0BW, TRANSMISSION TIGHTENING SPECIFICATIONS for 0BK, or TRANSMISSION TIGHTENING SPECIFICATIONS for 0B6 .

-- Turn the crankshaft 120° farther and tighten the remaining two bolts to the tightening specification.

-- Install the pump unit, refer to OVERVIEW - ELECTRIC COOLANT PUMP, PUMP UNIT, HYBRID VEHICLES .

-- Connect the high voltage cables -arrows- to the Electric Drive Power and Control Electronics -JX1-, refer to OVERVIEW - HIGH VOLTAGE CABLES .

Fig 10: Electric Drive Power And Control Electronics -JX1- High Voltage Cables

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-- Install the catalytic converter, refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING, HYBRID VEHICLES .

-- Install the front muffler, refer to FRONT MUFFLER, REMOVING AND INSTALLING HYBRID VEHICLES .

-- Install front coolant pipe, refer to OVERVIEW - COOLANT PIPES, NON-HYBRID VEHICLES .

-- Connect the coolant hoses with the connector coupling, refer to Figure.

Fig 11: Connecting Coolant Hose Coupling

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-- Install the Electrical A/C Compressor -V470-, refer to A/C COMPRESSOR, REMOVING AND INSTALLING, ELECTRICALLY-DRIVEN A/C COMPRESSOR .

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

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

-- Install the cables Terminal 30 Wire Junction 2 -TV22- and the cover for the engine compartment E-box, refer to OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES and appropriate SYSTEM WIRING DIAGRAM.

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

-- Install the tunnel crossmember, refer to TUNNEL CROSSMEMBER, REMOVING AND INSTALLING for 0BW, TUNNEL CROSSMEMBER, REMOVING AND INSTALLING for 0BK, or TUNNEL CROSSMEMBER, REMOVING AND INSTALLING for 0B6 .

-- Install the subframe, refer to INSTALLING .

-- Install the torque support and crossmember, refer to TORQUE SUPPORT AND CROSSMEMBER, REMOVING AND INSTALLING .

-- Install the air guide pipe, refer to OVERVIEW - CHARGE AIR SYSTEM .

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

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

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

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

-- Install the subframe crossbrace, refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

-- Install the engine cover, refer to ENGINE COVER, REMOVING AND INSTALLING .

Energizing the high voltage system

-- Follow all steps after connecting the battery, refer to Battery -A- AND Auxiliary Battery -A1-, DISCONNECTING AND CONNECTING, VEHICLES WITH HIGH VOLTAGE SYSTEM for engine code CHJA .

-- Check the oil level, refer to => 817.

-- Fill the coolant, refer to COOLANT, DRAINING AND FILLING, HYBRID VEHICLES => Filling .

-- The combustion misfire adaptations must be adjusted after replacing the engine. Select 01 Reset Combustion Misfire Adaptation  in Guided Fault Finding  on the Vehicle Diagnostic Tester.