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2.0l - Engine Assembly - Engine Code(s): Ceta & Ccta (coupe) Audi TT RS 8J

Mechanical 82 illustrations ~3375 words

Scheme 263

Scheme 263: SUBFRAME ASSEMBLY OVERVIEW
  1. Bolt Bracket to transmission Tightening specification, refer to «Specifications»(/audi/tt-rs/8j-2009-2014/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-coupe)
  2. Bolts Pendulum supports to transmission Different lengths Tightening specification, refer to «Specifications»(/audi/tt-rs/8j-2009-2014/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-coupe)
  3. Engine Support With support arm Illustration does not correspond to version in vehicle
  4. Bolt 40 Nm plus an additional 180° turn Replace Engine support to engine Different lengths
  5. Engine Mount With support arm
  6. Bolt 40 Nm plus an additional 90° turn Replace Engine mount to body
  7. Bracket
  8. Bolt 20 Nm plus an additional 90° turn Replace Bracket to engine mount
  9. Bolt 20 Nm plus an additional 90° turn Replace Bracket to body
  10. Bolt Engine mount to body Replace 40 Nm plus an additional 90° turn
  11. Bolts Engine mount to engine support Replace 60 Nm plus an additional 90° turn
  12. Pendulum Support
  13. Bolt Pendulum supports to subframe Tightening specification, refer to «Specifications»(/audi/tt-rs/8j-2009-2014/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-coupe)
  14. Bolt Transmission mount to transmission bracket Tightening specification, refer to «Specifications»(/audi/tt-rs/8j-2009-2014/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-coupe)
  15. Bolt Transmission mount to body Tightening specification, refer to «Specifications»(/audi/tt-rs/8j-2009-2014/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-coupe)
  16. Transmission Mount With support arm S-Tronic transmission 02E is illustrated
  17. Bolt Bracket to transmission Tightening specification, refer to «Specifications»(/audi/tt-rs/8j-2009-2014/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-coupe)
  18. Bolt Transmission console to transmission Tightening specification, refer to «Specifications»(/audi/tt-rs/8j-2009-2014/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-coupe)
  19. Transmission Bracket

SUBFRAME MOUNT, ADJUSTING

Special tools and workshop equipment required

  1. Engine support bridge 10 - 222 A
  2. Special Hook 10 - 222 A /20
  3. Engine Sling 2024 A
  4. Adapter T40093/6 qty. 2

Adjusting

Scheme 264

Scheme 264
  1. For the correct tightening specifications, refer to «SUBFRAME ASSEMBLY OVERVIEW»(/audi/tt-rs/8j-2009-2014/remont/mechanical/#20l-engine-assembly-engine-codes-ceta-ccta-coupe) .

Remove the engine cover -arrows-.

Remove the air filter housing and the air filter housing bracket. Refer to Removal and Installation .

Scheme 265

Scheme 265

Place 10 - 222 A on upper edge of the web plates with the following tool parts

Scheme 266

Scheme 266
  1. Engine brackets 10 - 222 A /1, quantity: 2
  2. Spindle 10 - 222 A /11; quantity: 2
  3. Adapter 10 - 222 A /20
  4. Mounting hooks from 2024 A
  5. Adapter T40093/6

Engage the spindle 10 - 222 A /11 with the 10 - 222 A /20 and mounting hooks from the 2024 A on the transmission lifting eye.

WARNINGRisk of accident due to loose engine support bridge spindles. Secure the mounting hooks and pins on the engine support bridge using securing pins -arrows-.

Engage the spindle 10 - 222 A /11 at the lifting eye 2024 A /2 on the engine lifting eye.

Note. The S-Tronic transmission 02E is shown in the illustration.

Tension engine/transmission subframe by evenly tightening the 2 spindles.

Remove subframe mount bolts on the engine -arrows-.

Scheme 267

Scheme 267

Remove subframe mount bolts on transmission -arrows-.

Scheme 268

Scheme 268

Replace all four or five bolts in succession (if not already done when installing the engine) and tighten them by hand.

Loosen left and right support arm bolts approximately 2 turns.

Slide the engine/transmission assembly between the engine mount -1- and support arm -3- using a pry bar until the following dimensions are established

Scheme 269

Scheme 269
  1. Both bolt heads -2- must be parallel to the edge of the engine mount support arm -3-.
  2. 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 corresponding 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 270

Scheme 270
  1. Dimension -x- same size on both sides of bracket.

Tighten subframe mount bolts.

Installation is carried out in the reverse order while noting the following

Install the battery. Refer to [For transmission(s) 02E] Removal and Installation .

Install the air filter housing. Refer to Removal and Installation .

FASTENER TIGHTENING SPECIFICATIONS

ComponentBolt SizeNm
Bracket to Engine Mount 120 + 90°
Bracket to Body 120 + 90°
Engine Mount with Support Arm 1, 2
40 + 90°
60 + 90°
Engine Support With Support Arm 140 + 180°
Bolts/Nuts
M610
M715
M822
M1040
M1265
1 Always replace 2 For bolt tightening clarification, refer to SUBFRAME ASSEMBLY OVERVIEW and see items -6, 10 and 11

Attaching the S-Tronic Transmission 02E to the engine

Scheme 271

Scheme 271
ItemBoltNm
1, 3, 10M12x5580
5, 9M12x7080
6, 7, 8M10x5040
AAlignment sleeves for centering
Bolts -2 and 4- : Attaching starter to transmission, refer to [For transmission(s) 02E] Removal and Installation .

SUBFRAME MOUNT, CHECKING ADJUSTMENT

Procedure

Scheme 272

Scheme 272: SUBFRAME MOUNT, CHECKING ADJUSTMENT

Release the EVAP canister -B arrow-, remove it upward -A arrow- and lay it aside.

Note. Ignore items -1 and 2-.

Check dimensions on the right mount for engine and transmission

  1. Both bolt heads -2- must be parallel to the edge of the engine mount support arm -3-.
  2. 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 corresponding round stock.

Adjust the subframe if the distance measured is too small or too large. Refer to SUBFRAME MOUNT, ADJUSTING .

ENGINE, REMOVING

Special tools and workshop equipment required

  1. Pry Lever - Rmv Outside Mirror 80 - 200
  2. Engine Support T10359
  3. Engine/Transmission Jack V.A.G 1383 A
  4. Hose Clip Pliers V.A.G 1921
  5. Step Ladder VAS 5085
  6. Drip Tray for VAS 6100 VAS 6208
  7. Ring Spanner 7-Piece Set 3337
  8. Locking Pin T10060A
  9. Puller T10369
  10. Engine Bung Set VAS 6122

Procedure

Note. Assemble engine with transmission downward. During installation, cable ties must be installed at the same location. Collect escaping coolant in a clean container for disposal or reuse. Always seal off any open channels in the intake and exhaust tract with plugs. For example, use the plugs from the VAS 6122.

WARNINGThere is a risk of injury because the fuel is under very high pressure. When removing the engine, the high pressure area of the fuel injection system is not opened. If the engine is removed and the high pressure area is opened for the following steps, the fuel pressure in the injection system must be reduced to a residual pressure before opening the high pressure area.

Reduce fuel pressure in high pressure area. Refer to General Information .

CAUTIONRisk of destroying electronic components when disconnecting the battery. Observe measures for disconnecting battery.

Remove luggage compartment floor covering.

Remove the rear lid trim panel if the cover for the battery negative pole it located underneath it. Refer to Removal and Installation .

Release retaining clips -arrows- and remove the negative post cover.

Scheme 273

Scheme 273

Loosen the nut a few turns and remove battery terminal -arrow- on Ground (GND) cable from the battery post.

Scheme 274

Scheme 274
WARNINGRisk 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 coolant reservoir cap.

Remove the bolts -arrows- and air guide.

Scheme 275

Scheme 275

Note. Shown on the 2.0L engine.

Disconnect the connector -1- from the Mass Airflow (MAF) sensor -G70-.

Scheme 276

Scheme 276

Remove the air guide hose -2-.

Remove the bolt -4- and the air filter housing.

Note. Ignore -3-.

Remove the bolts -arrows- and the air filter housing bracket.

Note. Shown on the 2.0L engine.

Remove both front wheels. Refer to Removal and Installation .

Remove the noise insulation. Refer to Removal and Installation .

Remove the left and right noise insulation -arrows-.

Scheme 277

Scheme 277

Remove the frame for the noise insulation. Refer to Removal and Installation .

Remove the air guide pipe -1 and 2-.

Scheme 278

Scheme 278

Disconnect the connector -2-.

Scheme 279

Scheme 279

Remove the bolts -3-.

Disconnect the connector -2- from the Engine Coolant Temperature (ECT) sensor on radiator -G83-.

Scheme 280

Scheme 280

Note. Collect escaping coolant in a clean container for disposal or reuse.

Place VAS 6208 under the engine.

Remove the coolant hose -1- by pulling the retaining clip out and letting the coolant drain.

Remove the coolant hose from the after-run coolant pump -V51- -arrow- and drain the remaining coolant.

Scheme 281

Scheme 281

Remove the bolt -1-.

Scheme 282

Scheme 282

Note. Ignore items -2, 3 and 4 and the arrow-.

Remove the bolts -1- and remove the fan shroud upward.

Note. Ignore -2 and 3-.

Loosen the hose clamp -2-.

Disconnect the electrical connectors -arrow- and free up the electrical wire.

Remove the bolt -4- and the air guide pipe.

Note. Ignore -1 and 3-.

Remove the upper coolant hose from the radiator -arrow-.

Scheme 283

Scheme 283

Remove the bolts -arrows- on the rear side of the radiator.

Scheme 284

Scheme 284

Remove the radiator downward.

CAUTIONRisk of destroying due to reversed running direction on a used ribbed belt. Before removing ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later.

To release ribbed belt tension, rotate tensioner in direction of -arrow-.

Scheme 285

Scheme 285

Remove ribbed belt and release tensioning device.

Note. Ignore the T10060 A.

WARNINGRisk of injury from fuel. To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.
CAUTIONFollow the guidelines for cleanliness when working on the fuel supply system. Refer to CLEAN WORKING CONDITIONS .

Remove the fuel hose -1- and free it up.

Scheme 286

Scheme 286

Remove the hose -1-.

Release the Evaporative Emission (EVAP) canister -B arrow-, remove it upward -A arrow- and lay it aside.

Disconnect the coolant hoses -arrows- and move them to the side.

Scheme 287

Scheme 287

Note. The installation location is shown with the engine removed.

Remove the air guide pipe bolt -arrow-.

Remove the air guide pipe; to do this, loosen the hose clamp -1-.

Press the release buttons and remove the air guide hose -2-.

Remove the coolant hose -1-.

Scheme 288

Scheme 288

Remove the bolt -2-.

Remove the coolant hoses -1 and 2-.

Scheme 289

Scheme 289

Remove the bolt -3-.

Note. Be careful of the GND wire -arrow- when installing.

Remove the heat shield -arrows-.

Scheme 290

Scheme 290

Remove the coolant hoses from the heater heat exchanger -arrows-.

Scheme 291

Scheme 291

From above, remove the nuts -arrows- on the front exhaust pipe connection to the turbocharger.

Scheme 292

Scheme 292

Remove the vacuum hose from the brake booster -arrow-.

Scheme 293

Scheme 293

Pry cover caps off windshield wiper arms with screwdriver.

Scheme 294

Scheme 294

Loosen nuts -arrows- a few turns.

Position the T10369/1 on the windshield wiper arm -1- as illustrated.

Scheme 295

Scheme 295

Mount the pressure piece -2- on the wiper axle.

Turn the screw -3- clockwise until the wiper arm is pulled off the wiper axle.

Remove nuts completely and remove wiper arms.

Remove gasket -1-.

Scheme 296

Scheme 296
CAUTIONThe plenum chamber cover could be damaged. Coat the transition area between the windshield and plenum chamber cover -2- with soapy water and carefully pull the cover vertically up out of the retainers on the windshield, beginning at the edge of the window.

Remove plenum chamber cover -2- by carefully pulling cover out of retainer on windshield.

Free up engine wiring harness on the back of the plenum chamber bulkhead.

Remove Engine Control Module (ECM). Refer to Removal and Installation .

Scheme 297

Scheme 297

Disconnect the engine wiring harness electrical connector -1- -arrow-.

Release engine wiring harness feed through -1- and remove upward -arrow-.

Scheme 298

Scheme 298

Remove E-box cover by sliding both latches in direction of -arrow-.

Scheme 299

Scheme 299

Open wiring router bracket -arrows-.

Scheme 300

Scheme 300

Unclip electrical connector -1- from bracket and disconnect.

Scheme 301

Scheme 301

Open wiring router bracket below.

Unclip engine wiring harness to engine control module from wiring router.

Place engine wiring harness with the ECM on the engine.

Secure the ECM against falling down.

Unclip electrical connector -2- from bracket and disconnect.

Remove the terminal 30 wire -arrow- at the engine compartment E-box and free it up.

Scheme 302

Scheme 302

Note. To unclip spiral clip, use 80 - 200.

Metal Selector Relay Lever -B

Scheme 303

Scheme 303

Remove the lock washer -arrow 1- from the transmission shift lever -A- and remove the shift cable.

Remove the lock washer -arrow 2- from the selector relay lever -B- and then remove the selector cable.

Plastic Selector Relay Lever

Scheme 304

Scheme 304

Remove the lock washer -arrow 1- and the shift cable.

Press the retainer -arrow 2- down as far as the stop and remove the selector relay lever and cable retainer. Move it in the direction of operation.

Tie cables with cable bracket off to the side.

Remove the transmission support -A arrows-.

Scheme 305

Scheme 305

Remove the clutch slave cylinder -B arrows-, move it to the side and secure it with wire. Do not open the line system.

CAUTIONDo not press the clutch pedal when the clutch slave cylinder is removed.

Cut off cable ties -arrow- for protective boot -3-.

Scheme 306

Scheme 306

Disconnect the connector -2-.

Fold back protective boot and remove the battery positive wire from the starter solenoid.

Remove the GND wire nut -1-.

Remove upper starter bolt.

Vehicles with FWD

Scheme 307

Scheme 307

Remove the right drive axle heat shield -arrows-.

Remove the left and right drive axles from the transmission flange shafts.

Remove GND wire -3-.

Scheme 308

Scheme 308

Cut through the cable tie -arrow- for the protective boot.

Disconnect the connector -2-.

Fold back the protective boot -1- and remove the battery positive wire from the starter solenoid.

CAUTIONRisk of destroying control module (Mechatronic) with static discharge. Do not touch contacts in transmission connector with hands.

To discharge static electricity, touch vehicle ground with hand (without gloves).

Disconnect electrical connector -4- by turning twist lock counterclockwise.

Free up the wiring harnesses -arrows- and disengage the electrical connector -1- at the bracket.

Scheme 309

Scheme 309

AWD Vehicles

Scheme 310

Scheme 310

Remove the right drive axle heat shield from bevel box -arrows-.

Remove the left drive axle from the transmission flange.

Remove the right drive axle from the bevel box flange.

Raise the drive axles and secure them with a cable tie.

Note. Make sure the drive axle surface protection is not damaged.

Remove the left nut -1- if applicable.

Scheme 311

Scheme 311

Remove the left nuts -arrows- for the control arm. Refer to Removal and Installation .

Scheme 312

Scheme 312

Disengage the control arm from the transverse link.

Tilt the left suspension strut outward and support it with the extension 2024 A /1 as shown in the illustration.

Scheme 313

Scheme 313
WARNINGLoose support components could cause an accident. Secure the securing pin and transverse link with the securing pin -arrow- and nut -1-.

Vehicles with S-Tronic Transmission 02E

Scheme 314

Scheme 314

Remove the bolts -1- from the cable bracket -2-.

Remove locking washer -3- -arrow- and remove selector lever cable from transmission.

AWD Vehicles

Scheme 315

Scheme 315

Mark position of flexible disc to bevel box flange for reinstallation.

Remove the driveshaft flexible disc bolts -arrows- from the bevel box while counter holding at the triangular flange with a lever.

Scheme 316

Scheme 316
CAUTIONThe shaft seal -arrow- in the driveshaft flange could be damaged. Press driveshaft horizontally as far back and to right side of vehicle as possible.

All Vehicles

Scheme 317

Scheme 317

Remove the bolts -1 and 2- on the bracket for the oxygen sensor electrical connector under the underbody. Remove the cover.

Remove the bolt -3- and free up the electrical wire to the oxygen sensor.

Remove the connector coupling -arrow- from the bracket.

Scheme 318

Scheme 318

Disconnect the connector from the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and free it up.

Remove the rest of the nuts accessible from below that connect the front exhaust pipe to the turbocharger -arrows-.

Remove the bolts -arrows-, exhaust system bracket and cross brace.

Scheme 319

Scheme 319
CAUTIONRisk of damaging decoupling elements. Do not bent decoupling elements in front exhaust pipe more than 10°.

Loosen the nuts -arrows- at the clamping sleeve and separate the exhaust system.

Scheme 320

Scheme 320

Remove the front exhaust pipe with the catalytic converter and front muffler.

Remove bolts -1, 2, 3- and remove pendulum support.

Scheme 321

Scheme 321

Disconnect the connector -1- from the oil level thermal sensor -G266-.

Scheme 322

Scheme 322

Unclip bracket -2- for electrical wiring to oil level thermal sensor from subframe.

Remove the air guide hose -arrows-.

Scheme 323

Scheme 323

Loosen the subframe mount bolts -arrows- on the engine approximately two turns.

Loosen the subframe mount bolts -arrows- on the transmission approximately two turns.

Disconnect the Air Conditioning (A/C) compressor regulator valve -N280- -1- connector from the A/C compressor.

Scheme 324

Scheme 324
WARNINGRefrigerant can cause serious personal injury. Do not open the A/C refrigerant circuit.

Remove the A/C compressor bolts -arrows-.

CAUTIONRisk of damaging refrigerant lines and hoses. Do not stretch, kink or bend refrigerant lines and hoses.

Tie up the compressor with the refrigerant lines attached to the longitudinal member.

Attach the T10359 to the cylinder block with the bolt -1- to approximately 20 Nm.

Scheme 325

Scheme 325

Note. The threaded hole in the bolt -1- serves to secure the after-run coolant pump -V51-.

Mount the V.A.G 1383 A on the T10359.

Slightly lift the engine/transmission subassembly.

Note. Use VAS 5085 to remove bolts for assembly mounting.

Remove the subframe bolts -arrows- on the engine.

Remove the subframe bolts -arrows- on the transmission.

Note. Verify that all hose and line connections between engine, transmission and body have been disconnected. While lowering, carefully guide the engine/transmission assembly in order to prevent damages.

Pull the engine/transmission as far as possible to the front and left and slowly lower it.

ENGINE AND TRANSMISSION, SEPARATING

Special tools and workshop equipment required

  1. Engine Sling 2024 A
  2. Lifting Eyebolt 3368
  3. Engine Support T10359
  4. Shop Crane -Load Cap=700-1200 kg VAS 6100
  5. Self-locking collar nut M10

Procedure

Scheme 326

Scheme 326
  1. Engine/transmission assembly removed and mounted on the T10359.

Free up electrical wiring -arrows-.

Remove the coolant hoses from the transmission oil cooler -arrows-.

Scheme 327

Scheme 327

Note. To prevent dirt from entering, seal open lines and connections with clean plugs or protective caps.

Remove the bolts -1 and 2- and the starter.

Scheme 328

Scheme 328

AWD

Scheme 329

Scheme 329

Loosen the bolts -1- and remove the bolts -2-.

All Vehicles

Scheme 330

Scheme 330

Tighten the 3368 a few turns on the transmission bracket with an M10 self-locking collar nut -arrow-.

Engage the 2024 A on the VAS 6100 and on the transmission as shown in the illustration.

Scheme 331

Scheme 331

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.

WARNINGLoose engine support bridge components could cause an accident. Secure the mounting hooks and pins on the engine support bridge using securing pins -arrows-.

Raise the transmission slightly.

Remove engine to transmission connecting bolts -1, 3, 5, 6, 7, 8, 9, 10-.

Note. Ignore items -2, 4 and A-.

Remove transmission from engine.

ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER

Special tools and workshop equipment required

  1. Engine Sling 2024 A
  2. Engine/Transmission Jack V.A.G 1383 A
  3. Shop Crane -Load Cap=700-1200 kg VAS 6100
  4. Engine and Transmission Holder VAS 6095

Procedure

  1. The transmission is separated from the engine. Refer to «ENGINE AND TRANSMISSION, SEPARATING»(/audi/tt-rs/8j-2009-2014/remont/mechanical/#20l-engine-assembly-engine-codes-ceta-ccta-coupe__engine-and-transmission-separating) .

Hook the 2024 A to the engine and to the VAS 6100.

Scheme 332

Scheme 332

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.

WARNINGLoose engine support bridge components could cause an accident. Secure the mounting hooks and pins on the engine support bridge using securing pins -arrows-.

Lower the engine from the V.A.G 1383 A using the VAS 6100.

Secure the transmission side of the engine to the VAS 6095 as illustrated.

Scheme 333

Scheme 333

ENGINE, INSTALLING

Special tools and workshop equipment required

  1. Engine Support T10359

Tightening Specifications

Note. The tightening specifications apply only to lightly greased, oiled, phosphated or blackened nuts and bolts. Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant. Do not use any ungreased parts. Tightening specification tolerance +/- 15%.

For the correct tightening specifications, refer to SUBFRAME ASSEMBLY OVERVIEW .

Additional Tightening Specifications

ComponentNm
Bolts/nutsM610
M715
M822
M1040
M1265

Attaching the S-Tronic Transmission 02E to the engine

ItemBoltNm
1, 3, 10M12x5580
5, 9M12x7080
6, 7, 8M10x5040
AAlignment sleeves for centering
Bolts -2 and 4- : Attaching starter to transmission, refer to [For transmission(s) 02E] Removal and Installation .

Procedure

Installation is carried out in the reverse order while noting the following

  1. Engine mounted on T10359.

Note. Replace self-locking nuts and bolts. Always replace bolts that are tightened to torque as well as O-rings and gaskets. Secure all hose connections with hose clamps of the same type as those equipped by the factory. During installation, cable ties must be installed at the same location.

If no alignment sleeves for center the engine and transmission are present in cylinder block, insert sleeves.

Make sure the intermediate plate is engaged on the sealing flange and slid onto the guide sleeves -arrows-.

Scheme 334

Scheme 334

Attach transmission to engine.

Guide the engine/transmission subassembly into the body.

Then install engine mounting to engine support bolts -arrows- and tighten by hand.

Install the transmission mount bolts in the transmission bracket -arrows- and tighten them by hand.

Note. Only tighten the bolts to the specification when installing the subframe mount. Refer to FASTENER TIGHTENING SPECIFICATIONS .

Remove the T10359 from the engine.

Install the drive axle heat shield.

Install the control arms and drive axles. Refer to Removal and Installation .

Install the pendulum support. Refer to SUBFRAME ASSEMBLY OVERVIEW .

Installing the front exhaust pipe with catalytic converter. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER .

Install the exhaust system free of stress. Refer to EXHAUST SYSTEM, ALIGNING .

Install after-run coolant pump -V51-. Refer to After-Run Coolant Pump -V51 .

Install the Air Conditioning (A/C) compressor. Refer to Removal and Installation .

Install the fan shroud. Refer to FAN SHROUD .

Install the ribbed belt. Refer to RIBBED BELT .

Install the starter. Refer to [For transmission(s) 02E] Removal and Installation .

Install throttle valve control module -J338-. Refer to Removal and Installation .

Adjust the subframe mount. Refer to SUBFRAME MOUNT, ADJUSTING .

Electrical connectors and wiring routing. Refer to the appropriate SYSTEM WIRING DIAGRAMS information.

Be sure to follow the procedure for connecting the battery and afterwards. Refer to [For transmission(s) 02E] Removal and Installation .

Install the windshield wiper arms. Refer to [For transmission(s) 02E] Removal and Installation .

Check oil level.

CAUTIONThere is a risk of destroying control modules with excess voltage. Do not use a charger as a starting aid.

Fill the coolant. Refer to COOLANT, DRAINING AND FILLING .

Note. Do not use drained coolant in the following situations: If the cylinder head or cylinder block was replaced. If the coolant is contaminated.

Scheme 335

Scheme 335: SPECIAL TOOLS

Special tools and workshop equipment required

  1. Engine Sling 2024 A
  2. Shop Crane -Load Cap=700-1200 kg VAS 6100
  3. Engine and Transmission Holder VAS 6095

Scheme 336

Scheme 336

Special tools and workshop equipment required

  1. Pry Lever - Rmv Outside Mirror 80 - 200
  2. Engine Support T10359
  3. Engine/Transmission Jack V.A.G 1383 A
  4. Hose Clip Pliers V.A.G 1921
  5. Step Ladder VAS 5085
  6. Drip Tray for VAS6100 VAS 6208

Special tools and workshop equipment required

Scheme 337

Scheme 337

Scheme 338

Scheme 338

Scheme 339

Scheme 339

Scheme 340

Scheme 340

Scheme 341

Scheme 341

Scheme 342

Scheme 342

Scheme 343

Scheme 343

Scheme 344

Scheme 344
  1. Engine support bridge 10 - 222 A
  2. Special Hook 10 - 222 A /20
  3. Ring Spanner 7-Piece Set 3337
  4. Lifting Eyebolt 3368
  5. Locking Pin T10060A
  6. Puller T10369
  7. Adapter T40093/6 qty. 2
  8. Lifting Eyebolt 3368
  9. Engine Bung Set VAS 6122