Installing engine

Information 

Tightening torques, tightening sequence and assembly overviews for the engine and transmission:

• Group 1:  → 1X00IN TECHNICAL VALUES
• Group 2:  → 2X00IN TECHNICAL VALUES
• Group 3:  → 3X00IN TECHNICAL VALUES

Information 

• Replace O-rings on the cooling system.
• Clean plug connection and coolant hoses before assembly.
• Remove stoppers before fitting the coolant lines and hoses.

Information 

• Replace O-rings.
• Grease O-rings with a light coating of Kluber Syntheso Glep.

1. Align the engine and transmission under the vehicle using the lifting platform and guide it up into the body.
2. Secure locking cable on transmission.
   1. 2.1. Screw on holder for locking cable support on the transmission.
   2. 2.2. Press locking cable onto the ball joint.
3. Guide engine and transmission into installation position in the body and secure them.
   1. 3.1. Secure front-axle carrier to the body. → 400619 REMOVING AND INSTALLING FRONT-AXLE CARRIER Replace screws.
   2. 3.2. Secure transmission support to the body.
4. If the Porsche Doppel Kupplung (PDK) was removed, the following work must be carried out  .
   1. 4.1. Tighten flange screws securing the transmission to the bottom of the engine.

      Always use new aluminum screws.

   2. 4.2. Secure the steering gear to the front-axle carrier. → 489055 REPLACING POWER-STEERING GEAR

      Replace screw.

   3. 4.3. Secure cross-strut to the front-axle carrier. → 400819 REMOVING AND INSTALLING FRONT-AXLE SUPPORT
5. Fit universal joint on the steering gear and secure it.

   Replace screw.

6. Secure upper trailing arm at the wheel carrier.
7. Secure the spring strut to the lower trailing arm.

   Replace screw.

8. Secure brake calliper on the wheel carrier and route electric lines.
9. Secure the ground line on the front side member at the right.
10. Fit pressure pipes and intake pipes on the turbocharger and charge-air cooler.
    1. 10.1. Connect lines for ambient air and tank ventilation.
11. Secure air-conditioning lines.
    1. 11.1. Replace O-ring.
12. Connect coolant lines.
    1. 12.1. Grease O-ring.
13. Connect new fuel lines.
14. Connect ATF lines.
    1. 14.1. Replace O-ring.
15. Connect vacuum line for brake booster to the vacuum pump.
16. Install coolant reservoir. → 194019 REMOVING AND INSTALLING RESERVOIR
17. Install engine control unit and secure engine wire harness in the plenum panel. → 247019 REMOVING AND INSTALLING DME CONTROL UNIT
18. Secure new  throttle-housing cover.
    1. 18.1. Fit and secure vacuum lines.
19. Install torque support. → 103719 REMOVING AND INSTALLING TORQUE SUPPORT