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3.2l - Engine Assembly - Engine Code(s): Cbra (coupe) Audi TT 8J

Mechanical 75 illustrations ~3512 words

ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER

Special tools and workshop equipment required

  1. Lifting Tackle 3033
  2. Engine Support 3269
  3. Engine and Transmission Holder VAS 6095
  4. Shop Crane VAS 6100

Procedure

Engage 3033 on engine and on VAS 6100 as shown in illustration.

Scheme 281

Scheme 281
Scheme 281

Raise the engine from the VAS 6100 using the T40074.

Engine, engaging on transmission side

Secure transmission side of VAS 6095 on cylinder block as shown in illustration.

Scheme 282

Scheme 282
Scheme 282

Engine, engaging at sides

Secure sides of 3269 to cylinder block as shown in illustration.

Scheme 283

Scheme 283
Scheme 283

Secure engine to VAS 6095 with 3269.

Scheme 284

Scheme 284: SUBFRAME MOUNT ASSEMBLY OVERVIEW
Scheme 284: SUBFRAME MOUNT ASSEMBLY OVERVIEW
  1. Bolt Transmission support to transmission Tightening specifications, refer to «[For transmission(s) 02E] Description and Operation»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-fwd-coupe) or «Description and Operation»(/audi/tt/8j-2006-2010/remont/manual-trans/#controls-housing-manual-transmission-02q-awd-coupe)
  2. Bolts Pendulum supports to transmission Replace 40 Nm plus an additional 90° ( 1 / 4 ) turn.
  3. Engine Support
  4. Bolt Engine support to engine 45 Nm
  5. Engine Mount With support arm
  6. Bolt Engine mount to body Replace 40 Nm plus an additional 90° ( 1 / 4 ) turn.
  7. Bracket
  8. Bolt Bracket to engine mount Replace 20 Nm plus an additional 90° ( 1 / 4 ) turn.
  9. Bolt Bracket to body Replace 20 Nm plus an additional 90° ( 1 / 4 ) turn.
  10. Bolt Engine mount to body Replace 40 Nm plus an additional 90° ( 1 / 4 ) turn.
  11. Screws Engine mount to engine support Replace 60 Nm plus an additional 90° ( 1 / 4 ) turn.
  12. Pendulum Supports
  13. Bolt Pendulum supports to subframe Replace 100 Nm plus an additional 90° ( 1 / 4 ) turn.
  14. Bolt Transmission mount to transmission support Tightening specifications, refer to «[For transmission(s) 02E] Description and Operation»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-fwd-coupe) or «Description and Operation»(/audi/tt/8j-2006-2010/remont/manual-trans/#controls-housing-manual-transmission-02q-awd-coupe)
  15. Bolt Transmission mount to body Tightening specifications, refer to «[For transmission(s) 02E] Description and Operation»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-fwd-coupe) or «Description and Operation»(/audi/tt/8j-2006-2010/remont/manual-trans/#controls-housing-manual-transmission-02q-awd-coupe)
  16. Transmission Mount With support arm Illustration shows version for direct shift automatic transmission.
  17. Bolt Transmission support to transmission Tightening specifications, refer to «[For transmission(s) 02E] Description and Operation»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-fwd-coupe) or «Description and Operation»(/audi/tt/8j-2006-2010/remont/manual-trans/#controls-housing-manual-transmission-02q-awd-coupe)
  18. Bolt Transmission support to transmission Tightening specifications, refer to «[For transmission(s) 02E] Description and Operation»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-fwd-coupe) or «Description and Operation»(/audi/tt/8j-2006-2010/remont/manual-trans/#controls-housing-manual-transmission-02q-awd-coupe)
  19. Transmission Support

FASTENER TIGHTENING SPECIFICATIONS

ComponentBolt SizeNm
Bracket to Body20 + 90° (1)
Engine Mount to Body40 + 90° (1)
Engine Mount to Engine Support60 + 90° (1)
Engine Support to Engine45
Pendulum Supports to Subframe100 + 90° (1)
Pendulum Supports to Transmission40 + 90° (1)
Bolts/Nuts
M610
M715
M822
M1040
M1265
Exceptions
Ground wire22
(1) Always replace
(1)Always replace

Manual transmission to engine fastener

Scheme 285

Scheme 285
Scheme 285
ItemBoltNm
1 (1) , 3M12x5580
2 (2)M12x6580
4, 5 (2)M10x5040
6 (2)M12 x 8080
AAlignment sleeves for centering
(1) Bolt with threaded pin M8. (2) Install in transmission from engine side.
(1)Bolt with threaded pin M8.
(2)Install in transmission from engine side.

Direct shift automatic transmission to engine mounting

Scheme 286

Scheme 286
Scheme 286
ItemBoltNm
1, 3, 6M12x5580
5M12x6580
7, 8M10x5040
9M10x4540
10M12x7080
AAlignment sleeves for centering

Note. Ignore -2 and 4-.

SUBFRAME MOUNT, CHECKING ADJUSTMENT

Procedure

Check dimensions on right mount for engine and transmission

Scheme 287

Scheme 287: SUBFRAME MOUNT, CHECKING ADJUSTMENT
Scheme 287: SUBFRAME MOUNT, CHECKING ADJUSTMENT
  1. Both bolt heads -2- must be parallel to edge of 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.

If distance is too small or too large, subframe mount must be adjusted. Refer to SUBFRAME MOUNT, ADJUSTING .

SUBFRAME MOUNT, ADJUSTING

Special tools and workshop equipment required

  1. Engine Support Bridge 10-222 A
  2. Bracket With Spindle and Hook 10-222 A /10
  3. Shackle (1 Set=2 Pieces) 10-222 A /12
  4. Bracket T10338
  5. Engine Support Basic Set T40091
  6. Engine Support Supplement Set T40093 with T40093/3-2 and T40093/3-3

Adjusting

  1. Tightening specifications. Refer to «SUBFRAME MOUNT ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-engine-assembly-engine-codes-cbra-coupe) .

Pull the EVAP canister in the engine compartment together with the connected hoses upward out of the bracket -arrow- and lay it to the side.

Scheme 288

Scheme 288
Scheme 288

Remove EVAP canister bracket.

Remove resonance tube -2- from air guide hose.

Scheme 289

Scheme 289
Scheme 289

Remove air guide hose -1- from throttle valve control module -J338-.

Disconnect the electrical connector -3- for the mass air flow sensor -G70-.

Detach upper section of air filter housing -arrow- and remove air filter insert.

Remove bolts -arrows- and remove air duct.

Scheme 290

Scheme 290
Scheme 290

Remove lower section of air filter housing -arrows-.

Scheme 291

Scheme 291
Scheme 291

Remove air filter housing bracket -arrows-.

Scheme 292

Scheme 292
Scheme 292

Install T10338 on free threaded hold at left rear of engine.

Scheme 293

Scheme 293
Scheme 293

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

Scheme 294

Scheme 294
Scheme 294
  1. Engine brackets 10-222 A /1 qty. 2
  2. Bracket With Spindle and Hook 10-222 A /10 (spindle faces back)
  3. Spindle 10-222 A /11 (spindle faces forward)
  4. Shackle 10-222 A /12
  5. Connectors T40091/3 qty. 2

Engage 10-222 A /11 with 10-222 A /12 on right engine lifting eye.

Engage 10-222 A /10 on T10338.

Tension engine/transmission subframe slightly with spindles.

Install T40093/3-2 (left) and T40093/3-3 (right) on T40093/3.

Scheme 295

Scheme 295
Scheme 295

Remove ground line from left longitudinal member.

Remove left and right connecting bolts for front part of longitudinal member.

Attach adapters with one M8x30 bolt each to longitudinal members -arrow-.

Note. The illustration shows the left side of the vehicle.

Insert square tube T40091/1 in connector T40091/3 and supports T40093/3 as shown in illustration.

Scheme 296

Scheme 296
Scheme 296

Slide connector T40093/4 onto square tube.

Scheme 297

Scheme 297
Scheme 297

Slide support T40091/2 into both connectors T40093/4 with slide T40093/5.

WARNINGRisk of accident due to loose engine support bridge spindles. Secure T40091/2 with connector pins and T40093/4. Secure connector and supports with clamping screws.

Install 10-222 A /11 on slider and on engine lifting eye.

Tension engine/transmission subframe by evenly tightening the 3 spindles.

Remove subframe mount bolts on engine -arrows-.

Scheme 298

Scheme 298
Scheme 298

Remove subframe mount bolts on transmission -arrows-.

Scheme 299

Scheme 299
Scheme 299

Replace all 5 bolts in succession (if not already done when installing engine) and hand tighten.

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

  1. Both bolt -2- must be parallel to edge of 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.

On transmission side, edges of support arm -1- and transmission mount -2- are parallel.

Scheme 300

Scheme 300
Scheme 300
  1. Dimension -x- same size on both sides of bracket.

Tighten subframe mount bolts.

The rest of the installation is in reverse order of removal, note the following

Tighten bolts for front part of longitudinal member. Refer to Removal and Installation .

Install air filter housing. Refer to Removal and Installation .

Install air filter insert. Refer to Removal and Installation .

ENGINE, REMOVING

Special tools and workshop equipment required

  1. Pry Lever - Rmv Outside Mirror 80 - 200
  2. Engine/Transmission Jack V.A.G 1383 A
  3. Step Ladder VAS 5085
  4. Drip Tray VAS 6208
  5. Locking Pin T10060 A
  6. Assembly Tool T10118
  7. Hose Clamps Up to 25 mm Dia. 3094
  8. Torque Wrench SAT 8010/3
  9. Engine mount T40074
  10. Qty. 1 M12 nut
  11. Qty. 2 M10 bolts

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.

CAUTIONRisk of destroying electrical components when battery is disconnected. Observe measures when disconnecting battery.

Remove luggage compartment floor covering.

If the battery negative pole cover is under the rear cross panel trim, remove rear cross panel trim. Refer to Removal and Installation .

Release retaining clips -arrows- and remove negative pole cover.

Scheme 301

Scheme 301
Scheme 301

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

Scheme 302

Scheme 302
Scheme 302
WARNINGRisk of scalding due to hot steam and hot coolant. When the engine is warm the cooling system is under pressure. Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.

Open coolant reservoir cap.

Remove both front wheels.

Remove noise insulation in center by loosening mounting sections -1 through 4-.

Scheme 303

Scheme 303
Scheme 303

Remove left and right noise insulation -arrows-.

Scheme 304

Scheme 304
Scheme 304

Remove noise insulation frame -arrow-.

Scheme 305

Scheme 305
Scheme 305

Disconnect electrical connector -1- on engine coolant temperature (ECT) sensor (on radiator) -G83-.

Scheme 306

Scheme 306
Scheme 306

Place VAS 6208 under engine.

Remove coolant hose downward from radiator -arrow- and allow coolant to drain.

Remove lower coolant hose to after-run coolant pump -V51- -arrow- and allow coolant to drain.

Scheme 307

Scheme 307
Scheme 307

Note. The illustration shows the coolant hose on a vehicle with direct shift automatic transmission (DSG).

Remove resonance tube -2- from air guide hose.

Remove air guide hose -1- from throttle valve control module -J338-.

Disconnect the electrical connector -3- for the mass air flow sensor -G70-.

Detach upper section of air filter housing -arrow- and remove air filter insert.

Remove bolts -arrows- and remove air duct.

Remove lower section of air filter housing -arrows-.

Remove air filter housing bracket -arrows-.

Disconnect electrical connector -1- for heated oxygen sensor (HO2S) 2 -G108- and electrical connector -2- for heated oxygen sensor (HO2S) -G39-.

Scheme 308

Scheme 308
Scheme 308

Disconnect electrical connector -3- for brake fluid level warning switch -F34-.

Free up electrical wires to oxygen sensors.

Pry cover caps off windshield wiper arms with screwdriver.

Scheme 309

Scheme 309
Scheme 309

Loosen nuts -arrows- a few turns.

Loosen wiper arms in succession by tilting wiper axles slightly.

Remove nuts completely and remove wiper arms.

Note. If wiper arms cannot be removed in this way, use a standard puller.

Remove rubber seal -1-.

Scheme 310

Scheme 310
Scheme 310

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

Free up rear engine wiring harness on plenum chamber partition.

Remove bolt -arrow- and remove engine control module from bracket.

Scheme 311

Scheme 311
Scheme 311

Disconnect electrical connector -arrow- for body wiring harness -1-.

Scheme 312

Scheme 312
Scheme 312

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

Scheme 313

Scheme 313
Scheme 313

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

Scheme 314

Scheme 314
Scheme 314

Open wiring router bracket -arrows-.

Scheme 315

Scheme 315
Scheme 315

Cut off cable ties -1-.

Unclip electrical connector -1- from bracket and disconnect.

Scheme 316

Scheme 316
Scheme 316

Open wiring router bracket below.

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

Place engine wiring harness with engine control module on engine.

Secure engine control module against falling down.

Unclip electrical connector -2- from bracket and disconnect.

Remove terminal 30 wiring -arrow- from engine compartment E-box and free up.

Scheme 317

Scheme 317
Scheme 317

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

Manual Transmission

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

Scheme 318

Scheme 318
Scheme 318

Disconnect electrical connector -2-.

Fold back protective boot and remove B+ wire from starter solenoid.

Remove Ground (GND) cable -1-.

Remove upper starter bolt.

Remove cable bracket from transmission -arrows-.

Scheme 319

Scheme 319
Scheme 319

Unclip lock washer -1- from shift cable and lock washer -2- from selector cable.

Scheme 320

Scheme 320
Scheme 320

Remove cable retainers with cables from selector shaft lever or relay lever.

Tie cables with cable bracket off to side.

Clamp off pressure line to clutch slave cylinder with 3094.

Scheme 321

Scheme 321
Scheme 321

Pull fastener upward -arrow- and remove hose/line assembly -1- from clutch slave cylinder bleeder.

CAUTIONRisk of contamination from escaping brake fluid. If the hose/line assembly is disconnected from the clutch slave cylinder breather, do not press clutch pedal.

Vehicles with DSG transmission

Cut off cable ties -arrow- for protective boot -1-.

Scheme 322

Scheme 322
Scheme 322

Disconnect electrical connector -2-.

Fold back protective boot and remove B+ wire from starter solenoid.

Remove Ground (GND) wire -3-.

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.

All Vehicles

Remove coolant hoses to heater core from bulkhead -arrows-.

Scheme 323

Scheme 323
Scheme 323

Remove upper left coolant hose from radiator -arrow-.

Scheme 324

Scheme 324
Scheme 324
WARNINGThere is a risk of injury because the fuel is under high pressure. Before opening the fuel system, lay a clean cloth around the connection point and carefully loosen it, which lowers the pressure.

Disconnect fuel supply hose -4- by pressing release ring.

Free up fuel supply hose.

Remove the coolant hoses -2- and -3-.

Remove vacuum hose to brake booster -arrow-.

Scheme 325

Scheme 325
Scheme 325

Vehicles with engine code CBRA

Disconnect the vacuum hoses from the intake manifold and free them up

Scheme 326

Scheme 326
Scheme 326

2 - To Leak detection pump (LDP) -V144

4 - To Evaporative emission (EVAP) canister purge regulator valve -N80

Remove the evaporative emission (EVAP) canister purge regulator valve -N80- from the bracket and lay it to the side.

Note. Ignore -1 and 3- and -arrows-.

All Vehicles

Remove nuts -1- and -2- (accessible from top) from front exhaust pipe to exhaust manifold connection.

Scheme 327

Scheme 327
Scheme 327

Note. Nuts -3 through 6- are removed at a later time.

Remove upper fan shroud bolts -top arrows-.

Scheme 328

Scheme 328
Scheme 328
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 329

Scheme 329
Scheme 329

Secure tensioner with T10060 A.

Remove ribbed belt.

Loosen subframe mounts bolts on engine -arrows- approximately 2 turns.

Loosen subframe mounts bolts on transmission -arrows- approximately 2 turns.

Manual Transmission

Disconnect electrical connector -2- on back-up light switch -F4-.

Scheme 330

Scheme 330
Scheme 330

Remove nut -1- and bracket with electrical wires from lower starter bolt.

All Vehicles

Disconnect electrical connector -1- at secondary air injection (AIR) pump motor -V101- and free up electrical wiring.

Scheme 331

Scheme 331
Scheme 331

Note. Ignore -2, 3 and arrows-.

Free up coolant hose on bottom of fan shroud.

Disconnect electrical connectors -1- for coolant fan on bottom of fan shroud.

Remove fan shroud lower bolts -bottom arrows-.

Remove fan shroud downward with both coolant fans.

Disconnect solenoid clutch electrical connector -1- on A/C compressor.

Scheme 332

Scheme 332
Scheme 332
WARNINGRisk of injury from refrigerant. The air conditioning refrigerant circuit must not be opened.

Remove A/C compressor bolts -arrows-.

Secure A/C compressor with connected refrigerant hoses on front of longitudinal member.

Disconnect electrical connector -1- on oil level thermal sensor -G266-.

Scheme 333

Scheme 333
Scheme 333

Unclip bracket -2- for electrical wiring to oil level thermal sensor -G266- from subframe.

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

Scheme 334

Scheme 334
Scheme 334

Remove right drive axle. Refer to Removal and Installation .

Remove left drive axle from transmission flange shaft.

Remove front exhaust pipe to exhaust manifold connecting nuts -3 through 6-.

Note. Nuts -1 and 2- were already removed.

Remove nuts -1- and -2- under vehicle floor.

Scheme 335

Scheme 335
Scheme 335

Remove cover from oxygen sensor electrical connector bracket.

Remove bolt -3- and free up electrical wiring to oxygen sensors.

Remove electrical connectors from bracket and disconnect

Scheme 336

Scheme 336
Scheme 336
  1. For Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWO) -G130
  2. For Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWO) -G131

Remove exhaust system bracket -arrows-.

Scheme 337

Scheme 337
Scheme 337
CAUTIONRisk of damaging decoupling elements. Do not bend decoupling element in front exhaust pipe more than 10°.

Disconnect exhaust system at clamping sleeve -1-.

Scheme 338

Scheme 338
Scheme 338

Remove front exhaust pipes with catalytic converters and front muffler.

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

Scheme 339

Scheme 339
Scheme 339

Remove driveshaft flexible disc from bevel box -arrows- while counterholding on triangle flange with lever.

CAUTIONRisk of damaging sealing ring -arrow- in driveshaft flange. Press driveshaft horizontally as far back and to right side of vehicle as possible.

Scheme 340

Scheme 340
Scheme 340

Vehicles with DSG transmission

Remove bracket bolts -1-.

Scheme 341

Scheme 341
Scheme 341

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

Note. Ignore -2-.

All Vehicles

CAUTIONRisk of damaging sealing ring in driveshaft flange. Engine/transmission swings forward slightly when pendulum support/subframe bolts are loosened.

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

Scheme 342

Scheme 342
Scheme 342

Secure the T40074 to the cylinder block using one M12 nut and two M10 bolts -arrows- tightened to approximately 20 Nm.

Scheme 343

Scheme 343
Scheme 343

Place V.A.G 1383 A on T40074 and raise engine/transmission assembly slightly.

Note. To remove subframe mounting bolts, use VAS 5085.

Remove subframe mount bolts on engine -arrows-.

Remove subframe mount bolts on transmission -arrows-.

Note. Verify that all hose and line connections between engine, transmission and body have been disconnected. To prevent damage, carefully guide engine/transmission assembly when lowering.

Pull engine/transmission assembly as far forward as possible and slowly lower it.

ENGINE AND MANUAL TRANSMISSION, SEPARATING

Special tools and workshop equipment required

  1. Additional Hooks 10-222 A /2
  2. Shop Crane VAS 6100
  3. Transmission Lift Hook T40013

Procedure

  1. Engine/transmission assembly is removed and mounted on engine mount.

Remove bolts -1- and -2- and remove bevel box bracket -A-.

Scheme 344

Scheme 344
Scheme 344

Install T40013 at transmission and close locking device.

Scheme 345

Scheme 345
Scheme 345

Engage VAS 6100 with 10-222 A /2 on lifting tackle.

Remove bolts -1 through 6- on engine/transmission flange.

Remove transmission from engine.

ENGINE AND DSG TRANSMISSION, SEPARATING

Special tools and workshop equipment required

  1. Additional Hooks10-222 A /2
  2. Shop Crane VAS 6100
  3. BracketT10013
  4. M8x40 bolt with nut and washer, exterior diameter 25 mm

Procedure

  1. Engine/transmission assembly is removed and mounted on engine mount.

Remove bolts -1- and -2- and remove bevel box bracket -A-.

Free up electrical wiring -arrows-.

Scheme 346

Scheme 346
Scheme 346

Remove coolant hoses from transmission oil cooler and from coolant pipe to transmission oil cooler -arrows-.

Scheme 347

Scheme 347
Scheme 347

Remove bolts -1- and -2- and remove coolant pipe -A-.

Disconnect air guide hose -arrow-.

Remove bolts -3-.

Loosen bolt -2- and remove Secondary Air Injection (AIR) pump with bracket.

Note. Ignore -1-.

Remove threaded pins from T10013 by releasing securing ring.

Scheme 348

Scheme 348
Scheme 348

Secure T10013 on transmission lifting eye using M8x40 bolt, nut and 25 mm exterior diameter washer.

Engage VAS 6100 with 10-222 A /2 on T10013.

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

Note. Ignore -2, 4 and A-.

Remove transmission from engine.

ENGINE, INSTALLING

Tightening Specifications

Note. Tightening specifications only apply to lightly greased, oiled, phosphated 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 torque specifications ±15%.

Tightening specifications SUBFRAME MOUNT ASSEMBLY OVERVIEW .

Additional tightening specifications

ComponentNm
Bolts/nutsM610
M715
M822
M1040
M1265
Exceptions
Ground wire22

Manual transmission to engine fastener

ItemBoltNm
1 (1) , 3M12x5580
2 (2)M12x6580
4, 5 (2)M10x5040
6 (2)M12 x 8080
AAlignment sleeves for centering
(1) Bolt with threaded pin M8. (2) Install in transmission from engine side.
(1)Bolt with threaded pin M8.
(2)Install in transmission from engine side.

Direct shift automatic transmission to engine mounting

ItemBoltNm
1, 3, 6M12x5580
5M12x6580
7, 8M10x5040
9M10x4540
10M12x7080
AAlignment sleeves for centering

Note. Ignore -2 and 4-.

Procedure

Installation is in reverse order of removal, note the following

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 appropriate for the model. During installation, cable ties must be installed at the same location.

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

Manual Transmission

If a needle bearing is installed in crankshaft, remove needle bearing. Refer to NEEDLE BEARING ON CRANKSHAFT .

If clutch release bearing is worn, replace it. Refer to REMOVAL AND INSTALLATION .

Lightly lubricate transmission input shaft splines with clutch disc connection lubricating grease.

Check clutch drive plate centering.

Vehicles with DSG transmission

If no needle bearing is installed in crankshaft, install needle bearing. Refer to NEEDLE BEARING ON CRANKSHAFT .

All Vehicles

Attach transmission to engine.

Secure bevel box bracket -A-. Refer to SPECIFICATIONS .

Vehicles with DSG transmission

Install secondary air injection (AIR) pump. Refer to SECONDARY AIR INJECTION PUMP .

Install coolant hose to transmission oil cooler. Refer to COOLANT PIPE TO TRANSMISSION OIL COOLER .

All Vehicles

Guide engine/transmission assembly into body.

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

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

Note. Bolts are only tightened to final torque when installing subframe mount. Refer to SUBFRAME MOUNT ASSEMBLY OVERVIEW .

Remove T40074 from engine.

Tighten pendulum support on transmission. Refer to SUBFRAME MOUNT ASSEMBLY OVERVIEW .

Vehicles with DSG transmission

Install selector lever cable. Refer to REMOVAL AND INSTALLATION .

All Vehicles

CAUTIONRisk of damaging sealing ring -arrow- in driveshaft flange. Press engine/transmission assembly toward bulkhead while carefully guiding bevel box pins into driveshaft flange.

Tighten pendulum support on subframe. Refer to SUBFRAME MOUNT ASSEMBLY OVERVIEW .

Tighten driveshaft with flexible disc on bevel box -arrows-. Refer to REMOVAL AND INSTALLATION .

The rest of the installation is in reverse order of removal, note the following

Install exhaust system and align it free of stress. Refer to EXHAUST SYSTEM, INSTALLING .

Install drive axles. Refer to Removal and Installation .

Install driveshaft heat shield. Refer to SPECIFICATIONS .

Connect electrical connector on starter. Refer to REMOVAL AND INSTALLATION .

Manual Transmission

Selector mechanism, installing and adjusting. Refer to REMOVAL AND INSTALLATION .

CAUTIONRisk of contamination from escaping brake fluid. If hose/line assembly is not yet connected to clutch slave cylinder breather, do not press clutch cylinder.

Connect hose/line assembly to clutch slave cylinder breather and bleed clutch system. Refer to General Information .

All Vehicles

Install A/C compressor. Refer to REMOVAL AND INSTALLATION .

Install fan shroud. Refer to FAN SHROUD .

Install ribbed belt. Refer to RIBBED BELT .

Adjust subframe mount. Refer to SUBFRAME MOUNT, ADJUSTING .

Electrical connections and routing.

Follow measures after connecting battery. Refer to [For transmission(s) 02E] Removal and Installation .

Check oil level. Refer to OIL LEVEL, CHECKING

CAUTIONRisk of destroying control modules with excess voltage. Do not use a battery charger for starting assistance!

Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING => 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 349

Scheme 349: SPECIAL TOOLS
Scheme 349: SPECIAL TOOLS

Special tools and workshop equipment required

  1. Additional Hooks 10-222 A /2
  2. Shop Crane VAS 6100
  3. Transmission Lift Hook T40013

Scheme 350

Scheme 350
Scheme 350

Special tools and workshop equipment required

  1. Engine Support Bridge 10-222 A
  2. Bracket With Spindle and Hook 10-222 A /10
  3. Shackle (1 Set=2 Pieces) 10-222 A /12
  4. Bracket T10338
  5. Engine Support Basic Set T40091
  6. Engine Support Supplement Set T40093 with T40093/3-2 and T40093/3-3

Scheme 351

Scheme 351
Scheme 351

Special tools and workshop equipment required

  1. Pry Lever - Rmv Outside Mirror 80-200
  2. Engine/Transmission Jack V.A.G 1383 A
  3. Step Ladder VAS 5085
  4. Drip Tray VAS 6208
  5. Locking Pin T10060 A
  6. Assembly Tool T10118

Scheme 352

Scheme 352
Scheme 352

Special tools and workshop equipment required

  1. Additional Hooks 10-222 A /2
  2. Shop Crane VAS 6100
  3. Bracket T10013

Scheme 353

Scheme 353
Scheme 353

Special tools and workshop equipment required

  1. Lifting Tackle 3033
  2. Engine Support 3269
  3. Engine and Transmission Holder VAS 6095
  4. Shop Crane VAS 6100

Special tools and workshop equipment required

Scheme 354

Scheme 354
Scheme 354

Scheme 355

Scheme 355
Scheme 355
  1. Hose Clamps Up to 25 mm Dia. 3094
  2. Torque Wrench SAT 8010/3
  3. Engine mount T40074
  4. qty. 1 M12 nut
  5. qty. 2 M10 bolts

See also:
• [For transmission(s) 02E] Description and Operation
• Description and Operation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• NEEDLE BEARING ON CRANKSHAFT
• SPECIFICATIONS
• SECONDARY AIR INJECTION PUMP
• COOLANT PIPE TO TRANSMISSION OIL COOLER
• REMOVAL AND INSTALLATION
• REMOVAL AND INSTALLATION
• FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER
• EXHAUST SYSTEM, INSTALLING
• REMOVAL AND INSTALLATION
• REMOVAL AND INSTALLATION
• FAN SHROUD
• RIBBED BELT
• [For transmission(s) 02E] Removal and Installation
• [For transmission(s) 02E] Removal and Installation
• OIL LEVEL, CHECKING
• COOLING SYSTEM, DRAINING AND FILLING => Filling
• SUBFRAME MOUNT, ADJUSTING
• SUBFRAME MOUNT ASSEMBLY OVERVIEW

More articles — Engine