Engine, Installing

Special tools and workshop equipment required 

• All special tools listed when removing.

Procedure 

• Replace the bolts that were tightened with an additional turn after removing them.
• Replace the self-locking nuts and bolts, gaskets, seals and O-rings after removing.
• Only remove the plugs or caps just before installing the respective lines.
• 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.
• Bonded rubber bushings have a limited range of rotation. Only tighten suspension threaded connections when vehicle is in curb weight position or in the control position.
• A new engine or replacement engine is still filled with a residual amount of test cycle oil from the factory. If a new engine or replacement engine is installed, then the test cycle oil must be bled and new engine oil filled before the first start of the engine.

• Secure the engine with the subframe on the : VAS6131B  .

-- Check the sensor wheel for engine speed sensor. Refer to Crankshaft ; check the sensor wheel.

-- Install the transmission on the engine. Refer to the appropriate service information. .

-- Install the engine supports and engine mount. Refer to OVERVIEW - ASSEMBLY MOUNTS .

-- Install the transmission mount. Refer to TRANSMISSION MOUNT, REMOVING AND INSTALLING .

-- Install the ATF cooler. Refer to the appropriate service information. .

-- Bring the subframe into the installation position.

-- Install bracket to the subframe. Refer to OVERVIEW - SUBFRAME .

-- Carefully guide the engine/transmission assembly into the body using the : VAS6131B  .

-- Tighten the tunnel crossmember bolts. Refer to the appropriate service information. .

-- Remove the subframe. Refer to OVERVIEW - SUBFRAME .

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

-- Install the parking lock emergency release cable. Refer to the appropriate service information. .

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

-- Install the coupling rod. Refer to OVERVIEW - SUBFRAME .

-- Install the lower control arm. Refer to OVERVIEW - LOWER CONTROL ARM AND BALL JOINT .

-- Install the steering gear boot. Refer to BOOT, REMOVING AND INSTALLING .

-- Install the tie rod end. Refer to OVERVIEW - STEERING GEAR .

-- Install the refrigerant line. Refer to REFRIGERANT CIRCUITRefrigerant Circuit .

-- Install the longitudinal member. Refer to OVERVIEW - LOCK CARRIER

-- Install the coolant pipes. Refer to OVERVIEW - COOLANT PIPES .

-- Install the charge air hose connections. Refer to OVERVIEW - CHARGE AIR HOSE CONNECTIONS .

-- Install the catalytic converters. Refer to OVERVIEW - EMISSIONS CONTROL SYSTEM .

-- Install the parking/auxiliary heater. Refer to the appropriate service information. ; Overview - Parking/Auxiliary Heater Components.

-- Connect the fuel hoses. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

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

-- Install the heat shield and engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Install the drive axle heat shield. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

-- Tighten the drive axles. Refer to OVERVIEW - DRIVE AXLE .

-- Install the driveshaft. Refer to the appropriate service information. .

-- Install the exhaust system. Refer to OVERVIEW - MUFFLER .

-- Install the wheel spoiler and wheel housing liner. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

-- Mount the front wheels. Refer to WHEEL, CHANGING or to the appropriate service information. .

-- Install the lock carrier cover. Refer to OVERVIEW - BUMPER COVER .

-- Fill the refrigerant circuit. Refer to REFRIGERANT CIRCUIT or REFRIGERANT CIRCUIT, DISCHARGING .

-- Install the subframe shield. Refer to OVERVIEW - SUBFRAME .

-- Wires and connections. Refer to COMPONENT LOCATION OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES and => Wiring Diagram.

-- If necessary, bleed the test cycle oil. Refer to ENGINE, INSTALLING => .

-- Fill the engine oil:

• RS6. Refer to => 501Maintenance Work; Engine Oil: Fill
• RS7. Refer to => 450Maintenance Work; Engine Oil: Fill

-- Install the plenum chamber bulkhead. Refer to PLENUM CHAMBER BULKHEAD, REMOVING AND INSTALLING .

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

-- Perform adaptations after replacing the engine Vehicle Diagnostic Tester 0001 - Engine Electronics, Functions  .

-- Connect the coolant hoses/coolant ventilation line with the connector coupling. Refer to Fig 1.

• Used coolant cannot be used again.

-- Fill with coolant. Refer to Coolant, Filling .

-- Install the underbody trim panels. Refer to OVERVIEW - UNDERBODY TRIM PANELS .

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

Tightening Specifications 

• The tightening specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
• Additional lubricants, such as engine or transmission oil are permitted, although lubricants containing graphite are not.
• Do not use any ungreased parts.
• Tightening specification tolerance: ±15%.

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