Installing Engine

WARNING: This page is about a different variant/trim than selected.

WARNING: Danger of objects or loads falling down

Risk of squashing or crushing
→ Secure components to prevent them from falling down.

Information

When fitting the engine mount screws, make sure that the engine mount bores are aligned with the engine mount bracket to prevent damage to the thread.

Information

If the engine has to be replaced, always read off the IMA values on the new fuel injectors before installing the new engine.

The IMA value can be read off the injector at the positions shown in the illustration -4- .

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Fuel injector with individual parts and marking

1	Teflon ring
2	Lock
3	Position ring
4	Code (IMAvalue for coding in the PIWIS Tester)
5	Part number
6	Fuel injector (piezo injector)
7	Rubber seal
8	O-ring

CAUTION: Risk of damage when inserting the engine/transmission unit into the vehicle

Material damage!
→ Enlist assistance of second and, if necessary, third person

Information

Adjust tilt angle of the lifting platform plate -1- according to the installation position of the engine/transmission unit -Arrow- .

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Tilt angle of lifting platform (view of side tilt angle)

Information

You will need a second mechanic to help you with this step.

Carefully and gradually raise the engine/transmission unit using > VAS 6832 - Master Gear unit elevating platform
Fit transmission support -5- and transmission bracket -3- .

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Transmission support and transmission bracket

Position transmission support -5- and fit nuts -4- .

Fit transmission bracket -3- on transmission mount.

Screw in screws -1- and fit nuts -2 and 4- .

Information

You will need a second mechanic to help you with this step.
CAUTION:
Risk of damage when inserting the engine/transmission unit into the vehicle
- Material damage!
  → Enlist assistance of second and, if necessary, third person
Carefully and gradually raise the engine/transmission unit to installation position using > VAS 6832 - Master Gear unit elevating platform .
For all wheel drive vehicles:
Secure the cardan shaft with new screws on the cardan flange.
Refer to WM, 390219 REMOVING AND INSTALLING CARDAN SHAFT .

Cardan flange on PDK: > Initial tightening 20 (1 5 ftlb.) Nm → > Torque angle 45 Grad

Cardan flange on manual transmission: > Tightening torque 35 (26 ftlb.) Nm
Secure both sides of the engine mount to the engine mount bracket.

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Engine mounts

Replace screws -1- .

Screw in new screws -1- at the grommets on the rear bracket -Arrow- and tighten them.

> Initial tightening 70 (52 ftlb.) Nm

> Final tightening + 45°
Secure transmission support -5- and transmission bracket -2- .

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Transmission support and transmission bracket

Tighten screws -1- .

> Initial tightening 30 Nm (22.1 ftlb.)

> Torque angle 60°

Tighten nuts -2 and 4- .

> Initial tightening 30 Nm (22.1 ftlb.)

> Torque angle 60°
Loosen > 9454 - strapping belts and move > VAS 6832 - Master Gear unit elevating platform out of the work area.
Secure engine ground strap to the body -1- .

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Ground strap from engine to body

Position engine ground strap on the body -1- .

Screw in and tighten screw -2- .

> Tightening torque 23 Nm (17 ftlb.)
Secure B+ line.

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Connection point for B+ line

Fit and tighten nut -2- .

> Tightening torque 23 Nm (17 ftlb.)

Close the cap -1- .
Connect and lock electric plug connections -1- .

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Electric plug connections on double clutch transmission
Install rear axle carrier -1- .

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Rear axle carrier mounting

Position > VAS 6931 - engine and gearbox jack under the rear axle carrier -1- .

Cut tie-wrap.

Raise rear axle carrier -1- to installation position using > VAS 6931 - engine and gearbox jack .

Replace screws -2 and 3- .

Fit and tighten new screws -2 and 3- .

Screws -2- , M12 x 110:

> Initial tightening 70 Nm (51.6 ftlb.)

> Final tightening + 180°

Screws -3- , M12 x 95:

> Initial tightening 70 Nm (51.6 ftlb.)

> Final tightening + 180°
Connect lower trailing arm -1- on both sides.

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Lower trailing arm, left

Replace screw -3- and nut -2- .

Screw in new screw -3- .

Fit new nut -2- but do not tighten yet.
ONLY for vehicles without PDCC:
Connect anti-roll bar with connecting link -1- on both sides.

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Mounting for connecting link (conventional)

Replace nuts -2- .

Fit new nuts -2- but do not tighten yet.

Only carry out steps 15 and 19 to 25 on vehicles with PDCC.
Connect anti-roll bar -1- to connecting link -2- .

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Anti-roll bar - PDCC

Position anti-roll bar -1- on connecting link -2- .

Fit nut -1- , but do not tighten yet. Counter at joint pin on connecting link at the same time.

Information

Threaded joints must only be tightened in zero position to prevent warping in the bearings.
Raise the wheel bearing housing as far as required using a jack (e.g. > VAS 6931 - engine and gearbox jack) until the lower trailing arm is horizontal. > Zero position

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Zero position
Secure lower trailing arm -1- on both sides.

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Lower trailing arm, left

Tighten new nut -2- and counter at screw -3- .

> Initial tightening 70 Nm (51.6 ftlb.)

> Final tightening + 180°
Vehicles without PDCC:
Secure anti-roll bar to connecting link -1- .

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Mounting for connecting link (conventional)

Tighten new nuts -2- .

> Initial tightening 40 Nm (29.5 ftlb.)

> Final tightening + 30°
Secure anti-roll bar -1- to connecting link

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Anti-roll bar - PDCC

Tighten nut Counter at joint pin on connecting link at the same time.

> Initial tightening 50 Nm f36.9 ftlb.)

> Final tightening angle + 50 f37 ftlb.) °
Cut tie-wrap -Arrow- .

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Hydraulic lines
Connect and lock plug-in couplings -1 and 2- .

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Hydraulic lines on valve block
Clip hydraulic lines -1- into holder -2- .

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Holder for hydraulic lines
Connect hydraulic lines -1- to distributor

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Hydraulic lines on distributor

Cut tie-wrap.

Screw in and tighten union nuts -3- .

> Tightening torque 28 Nm (21 ftlb.)
Clip hydraulic lines on the right -1 and 2- into holder -3- .

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Hydraulic lines, right
Secure holder for hydraulic lines -1- on both sides.

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Holder for hydraulic lines

Position holder for hydraulic lines -1- .

Screw in and tighten screws -2- .

> Tightening torque 10 Nm (7.5 ftlb.)
Connect supply connecting lines for engine cooling and heating -2- .

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Coolant hoses on reservoir (shown on Carrera)

Connect supply connecting lines for engine cooling and heating -2- . Make sure that the spring clamps -1- engage securely.
Connect coolant hose -1- at the left-hand side of the engine compartment.

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Left coolant hose

Connect coolant hose -1- Make sure that the spring clamp -2- engages securely.
Connect vent lines -1- to the coolant reservoir.

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Vent lines on coolant reservoir

Attach vent lines -1- and close locks -2- .
Connect and lock plug-in couplings -3- .

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Connection for tank vent line and fuel line in engine compartment
Connect coolant hose -1- at the right-hand side of the engine compartment and vacuum lines.

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Right coolant hose and plug-in couplings for vacuum lines

Connect coolant hose -1- Make sure that the spring clamp -2- engages securely.

Connect and lock plug-in couplings -3- .
Connect electric line -1- on both sides.

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Oxygen sensor upstream of catalytic converter

Connect and lock electric plug connection -2- .

Clip electric line -1- into clips -3- .
Secure intake pipe -1- and lower molded hose -4- .

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Intake pipe and lower molded hose on turbocharger

Position intake pipe -1- with new V-band clamp -2- and tighten V-band clamp

> Tightening torque 5.5 (4 ftlb.) Nm +/- 0.2 (0.1 ftlb.) Nm

Right side only: Connect vent line -3- .

Connect molded hose -4- and tighten screw-type clamp -5- .

> Tightening torque 5.5 (4 ftlb.) Nm +/- 0.2 (0.1 ftlb.) Nm
Connect electric plug connection -1- to electric exhaust flap adjuster -2- and lock it.

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Electric plug connection for electric exhaust flap adjuster
Fit rear wheels (screw in bolts fully, but do not tighten yet).
Information

Make sure that the drive shaft does not hang down as this may damage the joint.
Secure both ends of the drive shaft -1- to transmission flange.

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Drive shaft on transmission flange (shown without wheel)

Replace screws -2- .

Screw in and tighten new bolts -2- and get another person to help by countering and turning each wheel one after the other.

> Initial tightening 40 Nm (29.5 ftlb.)

> Final tightening torque angle + 110°
Secure refrigerant lines -1 and 2- .

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Refrigerant line connections in engine compartment

Position refrigerant lines -1 and 2- with new sealing rings.

Replace screws -3 and 4- .

Screw in and tighten new screws -3 and 4- and counter using > 9822 - assembly tool at the same time.

> Tightening torque 14 Nm (10.3 ftlb.)
Connect and lock electric plug connections for engine wire harness -1- .

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Electric plug connections for engine wire harness

Information

The electric plug connections on the DME control unit are colored differently and the position on the control unit is marked with colored dots accordingly.
Connect the front three electric plug connections -2- on the DME control unit -2- and lock them.

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Electric plug connections on DME control unit
Install cover for DME control unit -2- .

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Cover for DME control unit

Position cover for DME control unit -2- .

Fit and tighten nuts -1- .

> Tightening torque 9 Nm (6.5 ftlb.)
Secure exhaust temperature sensor control unit -1- and electric lines -2- .

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Exhaust temperature sensor control unit

Clip exhaust temperature sensor control unit -1- into holder -4- .

Connect and lock electric plug connection -3- .

Clip electric lines -2- into holders -5 and 6- .
Secure differential pressure sensors -1- .

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Differential pressure sensor

Clip differential pressure sensors -1- into holders -3- .

Connect and lock electric plug connection -2- .
Secure electric line for oxygen sensor downstream of catalytic converter

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Electric plug connection for oxygen sensor downstream of catalytic converter

Connect and lock electric plug connection -2- .

Clip electric plug connection -2- and electric line for oxygen sensor downstream of catalytic converter into holders -3- .