Installing Engine

Information 

• The engine/transmission unit is essentially installed in reverse order to removal. 
• First complete the fluid systems opened during removal. 

Information 

• Get a second person to check the engine/transmission clearance when lifting it. 
• Pay particular attention to the clearance between rear-axle cross member and oil tank. 

1. Lift the engine-transmission unit carefully and in steps.
2. Tighten M12 collar nuts on the engine mounting. → Tightening torque: 85 Nm (63 ft. lb.) 
3. Fit M10 collar nuts on transmission support. → Tightening torque: 65 Nm (48 ft. lb.) 
4. Lift the vehicle and move elevating platform out of the work area.
5. Fit crash support. Spray fastening screws with Loctite 574 and tighten them.→ Tightening torque: 23 Nm (17 ft. lb.) 
   Fig 1: Locating Crash Support

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   WARNING: Caustic fluids

   • Danger of chemical burns

   → Avoid contact with caustic fluid.

   → Wear personal protective gear.

   → Ensure that there is good ventilation.

   → If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

   Information 

   • Check O-rings on the plug-in couplings and replace them if necessary. 
   • Clean plug connection and coolant hoses before assembly. 
   • Coat O-rings and coolant hoses with Kluber Plus Gel (Part No. 000.043.205.93). 
   • Remove stoppers before fitting the coolant lines and hoses. 
6. Remove stoppers from the coolant lines before fitting.

   Information 

   • The coolant hoses must lock with an audible click when pushed into the plug-in couplings. 
7. Engage spring clamps -1-  on the coolant pipes and insert large coolant hoses -2-  . Pull to check that the connection is secure.
   Fig 2: Identifying Coolant Hose Henn Coupling

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8. Fit coolant hoses for heating.
   Fig 3: Identifying Coolant Hoses For Heating

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9. Fit coolant hoses on the transmission.
   1. 9.1. On Tiptronic vehicles, fit additional hose on the disc valve.
      Fig 4: Identifying Coolant Hoses (Manual Transmission)

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10. Fit clutch line.

    → WM 303019 REMOVING AND INSTALLING CLUTCH SLAVE CYLINDER .

    → Tightening torque: 30 Nm (22 ft. lb.) 

11. Secure engine ground strap to the body.

    → Tightening torque: 23 Nm (17 ft. lb.) 

    Fig 5: Locating Engine Ground Strap

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12. Fit pressure hose on the turbochargers. Open the screw-type clamp and pull off the hose.
    1. 12.1. Fit hose -2-  and tighten screw-type clamp -1-  .

       → Tightening torque: 3 Nm (2 ft. lb.) 

       Fig 6: Identifying Pressure Hose, Turbocharger And Charge-Air Cooler

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13. Fit electric connections at the starter.

    → 276019 REMOVING AND INSTALLING STARTER .

14. Fit shift and selector cables.

    → 341219 REMOVING AND INSTALLING SHIFT AND SELECTOR CABLES .

15. Fit drive shafts.

    → WM 422119 REMOVING AND INSTALLING REAR DRIVE SHAFT .

    → Tightening torque: 90 Nm (67 ft. lb.) 

    WARNING: Danger of injury and material damage when using Pentosin.

    • Risk of skin irritation and damage to skin.
    • Damage to hoses and wiring.

    → Wear protective gloves and goggles.

    → In the event of contact (eyes or skin), wash immediately with water.

    → Collect emerging Pentosin.

    → Use caps to protect the wiring against soiling and damage.

    → Clean hoses and wiring immediately.

16. Fit power-steering lines.
    1. 16.1. Connect the pressure line -2-  to the supply tank.
       Fig 7: Identifying Power-Steering Line

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    2. 16.2. Fit the return line -1-  and close the spring band clamp -2-  .
       Fig 8: Identifying Power-Steering Connection Position

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    Information 

    Listen for a clearly audible locking sound when fitting all rapid-action coupling connections and cable plugs. Pull to check that connections are secure.

17. Fit rapid-action couplings on fuel lines and make sure they lock with a clearly audible locking sound.
    1. 17.1. Clip fuel lines securely into the holders provided to prevent leaks.
       Fig 9: Identifying Fuel Line Connections

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18. Push on vacuum line for the brake booster and fit plastic snap ring.
19. Fit coolant vent line -4-  on the coolant reservoir and supply line for the coolant pump.
    Fig 10: Identifying Left Engine Compartment Lines

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    Information 

    • Check O-rings on the plug-in couplings and replace them if necessary. 
    • Clean plug connection and coolant hoses before assembly. 
    • Coat O-rings and coolant hoses with Kluber Plus Gel (Part No. 000.043.205.93). 
    • Remove stoppers before fitting the coolant lines and hoses. 
20. Fit large coolant lines in engine compartment.
    1. 20.1. Check O-rings on the Henn couplings and replace them if necessary.
    2. 20.2. First insert the spring clamps, then the couplings. These must lock into place with a clearly audible click.
21. Fit two connectors for the engine wire harness.

    The round connectors are color-coded on the inside.

    • Upper round connector - black
    • Lower round connector - grey
      Fig 11: Identifying Engine Wire Harness Round Connectors

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22. Fit new tie-wrap for securing the engine wire harness on the plastic holder.
    Fig 12: Locating Engine Wire Harness Attachment Point

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23. Lay oxygen sensor cable and exhaust temperature sensor cable carefully and attach connections.
    Fig 13: Identifying Oxygen Sensor And Exhaust Temperature Sensor Connector

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    Information 

    • The steps for removing the air-conditioning compressor are not necessary for vehicles without air conditioning. 
24. Be careful with the spacer sleeve -arrow-  for the air-conditioning compressor.
    Fig 14: Locating Air Conditioning Compressor Threaded Joint

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25. Fit air conditioning compressor.

    → WM 873419 REMOVING AND INSTALLING AIR-CONDITIONING COMPRESSOR .

    Information 

    • Observe sequence for fitting the drive belt. 
26. Fit drive belt.

    → 137819 REMOVING AND INSTALLING DRIVE BELT - GT2 RS .

27. Fit four M10 hexagon nuts and two hexagon-head bolts (M10 x 55) -arrows-  on the transmission bracket and tighten them.

    → Tightening torque: 65 Nm (48 ft. lb.) 

    Fig 15: Locating Transmission Bracket Threaded Joint

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28. Fit rear-axle carrier. Position and tighten four screws and collar nuts.

    → Tightening torque: 110 Nm (81.5 ft. lb.) 

29. Fit transverse struts and diagonal braces.

    → Tightening torque: 65 Nm (48 ft. lb.) 

    → Tightening torque: 65 Nm (48 ft. lb.) 

    → Tightening torque: 110 Nm (81.5 ft. lb.)