ENGINE, SECURING ON ASSEMBLY STAND
Special tools and workshop equipment required
- Engine Sling 2024 A
- Shop Crane VAS 6100
- Engine and Transmission Holder VAS 6095
- Engine/Transmission Support T10012
- Transmission separated from engine.
Hook the 2024 A to engine and to the VAS 6100.
Scheme 325
Note. To be aligned to the center of gravity of the engine assembly, the hole rails of the lifting hook must be inserted as shown in the illustration.
| WARNING | Lifting hooks and alignment pins on the engine sling must be secured with securing pins -arrows-. |
Lift the engine off from the T10012 using the VAS 6100.
Secure engine on VAS 6095 when working on engine.
Scheme 326
- Bolt Transmission support to transmission Tightening specification, refer to «SUBFRAME MOUNT ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/manual-trans/#controls-housing-manual-transmission-02q-fwd) Tightening specification, refer to «SUBFRAME MOUNT OVERVIEW»(/audi/a3/8p-2004-2008/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-fwd)
- Bolts Pendulum supports to transmission Tightening specification, refer to «SUBFRAME MOUNT ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/manual-trans/#controls-housing-manual-transmission-02q-fwd) Tightening specification, refer to «SUBFRAME MOUNT OVERVIEW»(/audi/a3/8p-2004-2008/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-fwd)
- Engine Support With support arm
- Bolt 45 Nm Engine support to engine
- Engine Mount
- Bolt Replace 40 Nm plus an additional 90° turn. Engine mount to body
- Bracket
- Bolt Replace 20 Nm plus an additional 90° turn. Bracket to engine mount
- Bolt Replace 20 Nm plus an additional 90° turn. Bracket to body
- Bolt Replace 40 Nm plus an additional 90° turn. Engine mount to body
- Bolts Replace 60 Nm plus an additional 90° turn. Engine mount to engine support
- Pendulum Support
- Bolt Pendulum supports to subframe Tightening specification, refer to «SUBFRAME MOUNT ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/manual-trans/#controls-housing-manual-transmission-02q-fwd) Tightening specification, refer to «SUBFRAME MOUNT OVERVIEW»(/audi/a3/8p-2004-2008/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-fwd)
- Bolt Transmission mount to transmission support Tightening specification, refer to «SUBFRAME MOUNT ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/manual-trans/#controls-housing-manual-transmission-02q-fwd) Tightening specification, refer to «SUBFRAME MOUNT OVERVIEW»(/audi/a3/8p-2004-2008/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-fwd)
- Bolt Transmission mount to body Tightening specification, refer to, «SUBFRAME MOUNT ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/manual-trans/#controls-housing-manual-transmission-02q-fwd) Tightening specification, refer to «SUBFRAME MOUNT OVERVIEW»(/audi/a3/8p-2004-2008/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-fwd)
- Transmission Mount With support arm
- Bolt Transmission support to transmission Tightening specification, refer to «SUBFRAME MOUNT ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/manual-trans/#controls-housing-manual-transmission-02q-fwd) Tightening specification, refer to «SUBFRAME MOUNT OVERVIEW»(/audi/a3/8p-2004-2008/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-fwd)
- Bolt Transmission support to transmission Tightening specification, refer to «SUBFRAME MOUNT ASSEMBLY OVERVIEW»(/audi/a3/8p-2004-2008/remont/manual-trans/#controls-housing-manual-transmission-02q-fwd) Tightening specification, refer to «SUBFRAME MOUNT OVERVIEW»(/audi/a3/8p-2004-2008/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-fwd)
- Transmission Support
SUBFRAME MOUNT, ADJUSTING
Special tools and workshop equipment required
- Engine Support Bridge 10 - 222 A
- Shackles 10 - 222 A /12
- For the correct tightening specifications, refer to «SUBFRAME OVERVIEW»(/audi/a3/8p-2004-2008/remont/mechanical/#20l-engine-assembly-engine-codes-bpy) .
- Remove the engine cover and air filter. Refer to «Removal and Installation»(/audi/a3/8p-2004-2008/remont/fuel-system/#20l-multiport-fuel-injection-engine-codes-bpy) .
Remove the battery. Refer to REMOVAL AND INSTALLATION .
Remove the battery carrier -arrows-.
Scheme 327
Remove EVAP canister with connected lines upward out of bracket -arrow- and lay aside.
Scheme 328
Remove EVAP canister bracket.
Unhook the front of the battery carrier from the air guide.
Install the 10 - 222 A onto the fender bolting edge. The spindles are positioned forward.
Scheme 329
Hook the carabiner hooks of the spindles with the 10 - 222 A /12 into the engine lifting eyes.
Uniformly pre-load engine using both spindles but do not lift it.
Remove the bolts -arrows- from the engine assembly mounts one after the other, replace them (unless already done during engine installation) and screw them in loosely.
Scheme 330
Remove the bolts -arrows- from the transmission assembly mounts one after the other, replace them (unless already done during engine installation) and screw them in loosely.
Scheme 331
Loosen left and right support arm bolts approximately 2 turns.
Slide engine/transmission assembly with a pry bar between engine mount -1- and engine support -4- until the following dimensions are set
Scheme 332
- Both bolts -2- must be parallel to edge of support arm -3-.
- A distance of -x- = 16 mm must be present between engine mount -1- and engine support -4-.
Note. Distance -x- = 16 mm can also be checked with suitable round stock.
Tighten subframe mount to transmission bolts.
The edges on the support arm -1- and transmission mount -2- are parallel on the transmission side.
Scheme 333
- Dimension -x- same size on both sides of bracket.
Tighten subframe mount bolts.
The rest of the installation is performed in reverse order of removal, noting the following
Tighten bolts for front part of longitudinal member.
Install the battery. Refer to REMOVAL AND INSTALLATION .
FASTENER TIGHTENING SPECIFICATIONS
| Component | Bolt Size | Nm |
|---|---|---|
| Bracket to Body 1, 2 | 20 + 90° | |
| Bracket to Engine Mount 1, 2 | 20 + 90° | |
| Bolts and Nuts | ||
| M6 | 10 | |
| M8 | 20 | |
| M10 | 45 | |
| M12 | 65 | |
| Engine Mount to Body 1, 2 | 40 + 90° | |
| Engine Mount to Engine Support 1, 2 | 60 + 90° | |
| Engine Support to Engine | 45 | |
| Exceptions | ||
| Clamp B+ to Starter | 16 | |
| Ground (GND) Cable to Transmission | 23 | |
| Pendulum Supports to Transmission 1, 2 | 40 + 90° | |
| Pendulum Supports to Subframe 1, 2 | 100 + 90° | |
| 1 Replace bolt 2 90° corresponds to a quarter turn. | ||
Engine/Transmission Fastening
Scheme 334
| Item | Bolt | Nm |
|---|---|---|
| 1, 2 | M12 X 65 | 80 |
| 3 1) , 4 1) | M12 X 135 | 80 |
| 5 through 7 | M10 X 60 | 40 |
| 8 | M12 X 90 | 65 |
| 1) Bolt with threaded pin M8 | ||
SUBFRAME MOUNT, CHECKING ADJUSTMENT
Remove the engine cover and air filter. Refer to Removal and Installation .
Pull the EVAP canister with connected lines upward in direction of the -arrow- out of the retainer and lay it aside.
The following dimensions must be attained
Scheme 335
- The clearance between the engine support -2- and the right longitudinal member must be -a- = 16 mm.
- The casting edge of the engine support -2- must be parallel to the support arm -1- (dimension x = dimension x).
Note. The dimension a = 16 mm, can for example also be checked with a suitable cylindrical rod.
If a clearance dimension is too small or too large, proceed as follows
ENGINE, REMOVING
Special tools and workshop equipment required
- Drip Tray VAS 6208
- Engine/Transmission Jack V.A.G 1383 A
- Spring Type Clip Pliers VAS 5024A
- Step Ladder VAS 5085
- Engine/Transmission Support T10012
- Hex Ball Socket 3247
- Engine Bung Set VAS 6122
Note. The engine is removed downward together with the transmission. All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine. Drained coolant must be stored in a clean container for disposal or reuse.
Remove the engine cover and air filter. Refer to Removal and Installation .
Remove electrical connector -arrow- for oxygen sensor before catalytic converter from the bracket, disconnect it and lay it aside.
Scheme 336
| WARNING | Risk of scalding due to hot steam and hot coolant. The coolant system is under pressure when the engine is warm. Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system. |
Open the cap of the coolant expansion tank.
Remove the cover from above battery, by pressing the release button -arrow-.
Scheme 337
| CAUTION | Danger of causing damage to electrical components when disconnecting the battery. Complete the steps for disconnecting the battery. |
With ignition switched off, disconnect battery ground (GND) cable -arrow-.
Scheme 338
Remove the battery. Refer to REMOVAL AND INSTALLATION
Remove the battery carrier -arrows-.
Pry off the caps on the wiper arms with a screwdriver and remove the nuts.
Pull off and remove wiper arms from wiper axles.
Unclip the spray nozzles -arrow-.
Scheme 339
Push the spray nozzles, with lines still attached, back through the opening and into the plenum chamber.
Remove rubber seal -1- for plenum chamber cover.
Scheme 340
Remove the plenum chamber cover -2-.
Free up the rear engine wiring harness at the partition for plenum chamber.
Remove partition for plenum chamber -arrows-.
Scheme 341
Remove engine control module (ECM). Refer to Removal and Installation .
Separate the electrical connector -1- for the engine wiring harness.
Scheme 342
Release pass-through for engine wiring harness -arrow- and pull off upward.
Scheme 343
Open bracket for wiring -arrows-.
Scheme 344
Free up and disconnect the electrical connector -1-.
Scheme 345
Open the underlying wiring guide bracket -2-.
Open the wiring guide bracket -3-.
Remove engine wiring harness to control module from wiring.
Separate the electrical connector -1- for the backup lamp switch.
Scheme 346
Remove the ground (GND) cable -2-.
Push cover -3- toward rear.
Remove the wires -1 and 2- at the starter and free them up.
Scheme 347
Remove the cover from above the battery, by pressing the release buttons -arrows-.
Scheme 348
Remove the electrical harness -arrow- and free up the wiring to the generator.
Scheme 349
Remove both front wheels.
Remove noise insulation. Refer to Removal and Installation .
Remove the left and right noise insulation fasteners -1 to 3-.
Scheme 350
Place the VAS 6208 under engine.
Drain the coolant, by pulling off the lower coolant hose -arrows-.
Scheme 351
Disconnect upper coolant hose from radiator -2-.
Scheme 352
Disconnect coolant hoses to heat exchanger -arrows-.
Scheme 353
Note. The illustration depicts the engine removed from behind.
Remove the accessible nuts -arrows- for the front exhaust pipe/turbocharger from above.
Scheme 354
Disconnect vacuum hose -arrow- from the brake booster.
Scheme 355
Unclip the lock washers -1- and -2- at both cables.
Scheme 356
Pull off the cable retainers from the transmission selector lever and relay lever.
Remove cable mounting bracket from transmission and lay aside -arrows-.
| WARNING | Do not operate the clutch pedal anymore after hose for slave cylinder has been disconnected. |
Pull out clip -2- to the stop in direction of the -arrow- and pull off hose line -1-.
Scheme 357
| WARNING | The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before removing a fuel hose. Then release pressure by carefully pulling hose off connection. |
Mark the fuel line -2- and the EVAP line -1-.
Scheme 358
Disconnect the fuel line -2- and lay it free.
Disconnect the EVAP line -1- and lay it free.
Disconnect the vacuum line -3- to EVAP canister (press release buttons).
Remove EVAP canister upward.
Disconnect coolant hoses -1 and 2-.
Scheme 359
Discharge the air conditioning system. Refer to DESCRIPTION AND OPERATION .
Remove A/C line -arrow- from compressor.
Scheme 360
Unscrew the bolts -arrows- of the engine mountings approximately 2 turns.
Unscrew the bolts -arrows- of the transmission mountings approximately 2 turns.
Disconnect the electrical connector -1-.
Scheme 361
Open the cable retainer -2 and 3- and free up the electrical wiring.
Remove the bolts -1- from above.
Scheme 362
Remove the air duct clamps -1 and 2- for charge air cooler.
Scheme 363
Disconnect the connector -2-.
Remove bolts -3- and remove the fan shroud downward and off.
Disconnect the connector -1- at left longitudinal member and free up the cable.
Scheme 364
Disconnect air guide pipe -arrow- from charge air cooler.
Scheme 365
Remove the A/C pipe from the condenser -arrow-.
Scheme 366
Disconnect the connector from charge air pressure sensor -G31-. Refer to Description and Operation .
Disconnect the electrical connector on the oil level sensor -1-.
Scheme 367
Unclip the retainer -2-.
Disconnect the electrical connector on the after-run coolant pump motor -3- and free up the wires.
Remove heat shield from above the drive axle with the 3247.
Scheme 368
Remove the left and right drive axles. Refer to Removal and Installation .
Remove the right vehicle underbody cover -arrows-.
Scheme 369
Disconnect the oxygen sensor connector -arrow- after the catalytic converter and free up the wire.
Scheme 370
Remove the remaining nuts -arrows- for the front exhaust pipe/turbocharger from below.
Remove the supports for front exhaust pipe with catalytic converter, by removing bolts -1 and 2-.
Note. Flex joints in front exhaust pipe must not be bent more than 10°, otherwise they may be damaged.
Disconnect the exhaust system at the clamping sleeve -arrows-.
Scheme 371
Remove crossmember for vehicle floor -arrows-.
Scheme 372
Remove bracket for exhaust system -arrows-.
Scheme 373
Remove catalytic converter with front exhaust pipe.
Remove the bolts -1 to 3- and the pendulum support.
Scheme 374
Remove auxiliary coolant pump -arrows-.
Scheme 375
Attach the T10012 to the cylinder block using the bolt -1- and nut -2- and tighten to approximately 20 Nm.
Scheme 376
Insert the V.A.G 1383 A into the T10012 and lift slightly.
Note. Use the VAS 5085 to remove bolts for assembly mounting.
Remove bolts -arrows- at engine assembly mounting.
Remove bolts -arrows- at transmission assembly mounting.
Note. Verify that all hose and line connections between engine, transmission and body have been disconnected. While lowering, carefully guide engine/transmission assembly in order to prevent damages.
Pull engine/transmission assembly as far forward as possible and slowly lower it.
ENGINE AND TRANSMISSION, SEPARATING
- Engine/transmission assembly removed and mounted on engine/transmission support T10012.
Remove the bolt -1- from mounted transmission.
Scheme 377
Remove the shield -2- upward and out.
Note. Shown in the illustration with transmission removed.
Remove bolts -1 through 8- at engine/transmission flange.
Remove the starter.
Note. The manual transmission can be pulled off from the engine without the use of the shop crane; the assistance of a second technician is required.
Pull transmission off from engine.
ENGINE, INSTALLING
- Engine mounted on engine/transmission support T10012.
Installation is performed in the reverse of removal, noting the following
Note. During installation, all cable ties must be re-installed at the same location. Secure all hose connections using hose clamps appropriate for the model type. During assembly, replace self-locking nuts and bolts. Always replace bolts that are tightened to torque as well as O-rings and gaskets. Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of lubricant on splines. Then move the clutch plate back and forth on the input shaft, until the hub can be easily moved on the shaft. Remove all excess grease.
Make sure alignment sleeves for engine to transmission are installed in cylinder block. Install if necessary.
Make sure that the intermediate plate is hooked in at the sealing flange and is pushed onto the alignment sleeves -arrows-.
Scheme 378
Check clutch release bearing for wear and replace if necessary.
Bolt transmission to engine.
Note. Tightening specifications only apply to lightly greased, oiled, phosphate or blackened nuts and bolts. Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not. Do not use any degreased parts. Tolerance for tightening specifications 15%.
Securing the engine/transmission
| Item | Bolt | Nm |
|---|---|---|
| 1, 2 | M12 X 65 | 80 |
| 3 1) , 4 1) | M12 X 135 | 80 |
| 5 through 7 | M10 X 60 | 40 |
| 8 | M12 X 90 | 65 |
| 1) Bolt with threaded pin M8 A: Alignment bushings for centering | ||
Push the cover plate -2- in so that the lower tab hooks in at the cylinder block, and fasten it at the top with the bolt -1-.
Note. Shown in the illustration with transmission removed.
Guide the engine/transmission assembly into the body.
Hand-tighten the bolts -arrows- at engine assembly mounting.
Hand-tighten the bolts -arrows- at transmission assembly mounting.
Secure with new bolts.
Note. The bolts are first tightened to final torque after the engine mounts have been adjusted. Refer to SUBFRAME MOUNT, ADJUSTING .
Remove the T10012 from engine.
Fasten the pendulum supports to the transmission and subframe -1 to 3-.
Install the drive axles. Refer to Removal and Installation .
Install exhaust system and align it free of tension. Refer to EXHAUST SYSTEM, ALIGNING .
Fill the refrigerant circuit. Refer to Description and Operation .
Install the shift mechanism on the transmission and adjust. Refer to REMOVAL AND INSTALLATION or REMOVAL AND INSTALLATION .
Install engine control module (ECM). Refer to Removal and Installation .
Adjust the engine mounts. Refer to SUBFRAME MOUNT, ADJUSTING .
Electrical connections and routing. Refer to the appropriate System Wiring Diagram information.
Install air guide pipes and connector. Refer to HOSE CONNECTIONS WITH CONNECTOR COUPLINGS .
Install wiper arm. Refer to REMOVAL AND INSTALLATION .
Install the battery. Refer to REMOVAL AND INSTALLATION .
Install fuel system. Refer to Removal and Installation .
Check oil level.
Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .
Note. Only reuse drained coolant if cylinder head or engine block was not replaced. Dirty coolant may not be used again.
| WARNING | Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged. |
Tightening Specification
| Component | Nm | |
|---|---|---|
| Bolts/nuts | M6 | 10 |
| M8 | 20 | |
| M10 | 45 | |
| M12 | 65 | |
| Exceptions | ||
| Pendulum supports to transmission | 40 + 90° 1)2) | |
| Pendulum supports to subframe | 100 + 90° 1)2) | |
| Clamp B+ to starter | 16 | |
| Ground (GND) cable to transmission | 23 | |
| 1) Replace bolt. 2) 90° corresponds to a quarter turn. | ||
Scheme 379
Special tools and workshop equipment required
- Drip Tray VAS 6208
- Engine/Transmission Jack V.A.G 1383 A
- Spring Type Clip Pliers VAS 5024A
- Step Ladder VAS 5085
- Engine/Transmission Support T10012
- Hex Ball Socket 3247
Scheme 380
Special tools and workshop equipment required
- Engine Sling 2024 A
- Shop Crane VAS 6100
- Engine and Transmission Holder VAS 6095
Special tools and workshop equipment required
Scheme 381
Scheme 382
- Engine Support Bridge 10 - 222 A
- Engine Bung Set VAS 6122
- Not illustrated
- Shackles 10 - 222 A /12
See also:
• SUBFRAME MOUNT ASSEMBLY OVERVIEW
• SUBFRAME MOUNT OVERVIEW
• Removal and Installation
• REMOVAL AND INSTALLATION
• Removal and Installation
• DESCRIPTION AND OPERATION
• Removal and Installation
• EXHAUST SYSTEM, ALIGNING
• Description and Operation
• HOSE CONNECTIONS WITH CONNECTOR COUPLINGS
• REMOVAL AND INSTALLATION
• COOLING SYSTEM, DRAINING AND FILLING
• SUBFRAME OVERVIEW
• SUBFRAME MOUNT, ADJUSTING