ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER
Special tools and workshop equipment required
- Lifting Tackle 3033
- Engine Support 3269
- Engine and Transmission Holder VAS 6095
- Shop Crane VAS 6100
Procedure
Engage 3033 on engine and on VAS 6100 as shown in illustration.
Scheme 720
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 721
Engine, engaging at sides
Secure sides of 3269 to cylinder block as shown in illustration.
Scheme 722
Secure engine to VAS 6095 with 3269.
Scheme 723
- Bolt Transmission support to transmission Tightening specifications, refer to «Description and Operation»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-roadster) or «Description and Operation»(/audi/tt/8j-2006-2010/remont/manual-trans/#controls-housing-manual-transmission-02q-awd-roadster)
- Bolts Pendulum supports to transmission Replace 40 Nm plus an additional 90° ( 1 / 4 ) turn.
- Engine Support
- Bolt Engine support to engine 45 Nm
- Engine Mount With support arm
- Bolt Engine mount to body Replace 40 Nm plus an additional 90° ( 1 / 4 ) turn.
- Bracket
- Bolt Bracket to engine mount Replace 20 Nm plus an additional 90° ( 1 / 4 ) turn.
- Bolt Bracket to body Replace 20 Nm plus an additional 90° ( 1 / 4 ) turn.
- Bolt Engine mount to body Replace 40 Nm plus an additional 90° ( 1 / 4 ) turn.
- Screws Engine mount to engine support Replace 60 Nm plus an additional 90° ( 1 / 4 ) turn.
- Pendulum Supports
- Bolt Pendulum supports to subframe Replace 100 Nm plus an additional 90° ( 1 / 4 ) turn.
- Bolt Transmission mount to transmission support Tightening specifications, refer to «Description and Operation»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-roadster) or «Description and Operation»(/audi/tt/8j-2006-2010/remont/manual-trans/#controls-housing-manual-transmission-02q-awd-roadster)
- Bolt Transmission mount to body Tightening specifications, refer to «Description and Operation»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-roadster) or «Description and Operation»(/audi/tt/8j-2006-2010/remont/manual-trans/#controls-housing-manual-transmission-02q-awd-roadster)
- Transmission Mount With support arm Illustration shows version for direct shift automatic transmission.
- Bolt Transmission support to transmission Tightening specifications, refer to «Description and Operation»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-roadster) or «Description and Operation»(/audi/tt/8j-2006-2010/remont/manual-trans/#controls-housing-manual-transmission-02q-awd-roadster)
- Bolt Transmission support to transmission Tightening specifications, refer to [ «Description and Operation»(/audi/tt/8j-2006-2010/remont/automatic-trans/#controls-housing-direct-shift-automatic-transmission-02e-awd-roadster) or «Description and Operation»(/audi/tt/8j-2006-2010/remont/manual-trans/#controls-housing-manual-transmission-02q-awd-roadster)
- Transmission Support
FASTENER TIGHTENING SPECIFICATIONS
| Component | Bolt Size | Nm |
|---|---|---|
| Bracket to Body | 20 + 90° (1) | |
| Engine Mount to Body | 40 + 90° (1) | |
| Engine Mount to Engine Support | 60 + 90° (1) | |
| Engine Support to Engine | 45 | |
| Pendulum Supports to Subframe | 100 + 90° (1) | |
| Pendulum Supports to Transmission | 40 + 90° (1) | |
| Bolts/Nuts | ||
| M6 | 10 | |
| M7 | 15 | |
| M8 | 22 | |
| M10 | 40 | |
| M12 | 65 | |
| Exceptions | ||
| Ground wire | 22 | |
| (1) Always replace | ||
| (1) | Always replace |
Manual transmission to engine fastener
Scheme 724
| Item | Bolt | Nm |
|---|---|---|
| 1 1) , 3 | M12x55 | 80 |
| 2 2) | M12x65 | 80 |
| 4, 5 2) | M10x50 | 40 |
| 6 2) | M12 x 80 | 80 |
| A | Alignment sleeves for centering | |
| 1) Bolt with threaded pin M8. 2) Install in transmission from engine side. | ||
Direct shift automatic transmission to engine mounting
Scheme 725
| Item | Bolt | Nm |
|---|---|---|
| 1, 3, 6 | M12x55 | 80 |
| 5 | M12x65 | 80 |
| 7, 8 | M10x50 | 40 |
| 9 | M10x45 | 40 |
| 10 | M12x70 | 80 |
| A | Alignment sleeves for centering | |
Note. Ignore -2 and 4-.
SUBFRAME MOUNT, CHECKING ADJUSTMENT
Procedure
Check dimensions on right mount for engine and transmission
Scheme 726
- Both bolt heads -2- must be parallel to edge of engine mount 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 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
- Engine Support Bridge 10 - 222 A
- Bracket With Spindle and Hook 10 - 222 A /10
- Shackle (1 Set=2 Pieces) 10 - 222 A /12
- Bracket T10338
- Engine Support Basic Set T40091
- Engine Support Supplement Set T40093 with T40093/3-2 and T40093/3-3
Adjusting
- Tightening specifications. Refer to «SUBFRAME MOUNT ASSEMBLY OVERVIEW»(/audi/tt/8j-2006-2010/remont/mechanical/#32l-engine-assembly-engine-codes-cbra-roadster) .
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 727
Remove EVAP canister bracket.
Remove resonance tube -2- from air guide hose.
Scheme 728
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 729
Remove lower section of air filter housing -arrows-.
Scheme 730
Remove air filter housing bracket -arrows-.
Scheme 731
Install T10338 on free threaded hold at left rear of engine.
Scheme 732
Place 10 - 222 A on upper edge of web plates with the following tool parts
Scheme 733
- Engine brackets 10 - 222 A /1 qty. 2
- Bracket With Spindle and Hook 10 - 222 A /10 (spindle faces back)
- Spindle 10 - 222 A /11 (spindle faces forward)
- Shackle 10 - 222 A /12
- 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 734
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 735
Slide connector T40093/4 onto square tube.
Scheme 736
Slide support T40091/2 into both connectors T40093/4 with slide T40093/5.
| WARNING | Risk 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 737
Remove subframe mount bolts on transmission -arrows-.
Scheme 738
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
- Both bolt -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 corresponding round stock.
Tighten subframe mount to transmission bolts.
On transmission side, edges of support arm -1- and transmission mount -2- are parallel.
Scheme 739
- 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
- Pry Lever - Rmv Outside Mirror 80 - 200
- Engine/Transmission Jack V.A.G 1383 A
- Step Ladder VAS 5085
- Drip Tray VAS 6208
- Locking Pin T10060 A
- Assembly Tool T10118
- Hose Clamps Up to 25 mm Dia. 3094
- Torque Wrench SAT 8010/3
- Engine mount T40074
- Qty. 1 M12 nut
- 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.
| CAUTION | Risk 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 740
Loosen nut a few turns and remove terminal clamp -arrow- on Ground (GND) cable from battery pole.
Scheme 741
| WARNING | Risk 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 742
Remove left and right noise insulation -arrows-.
Scheme 743
Remove noise insulation frame -arrow-.
Scheme 744
Disconnect electrical connector -1- on engine coolant temperature (ECT) sensor (on radiator) -G83-.
Scheme 745
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 746
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 747
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 748
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 749
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 750
Disconnect electrical connector -arrow- for body wiring harness -1-.
Scheme 751
Release engine wiring harness feed through -1- and remove upward -arrow-.
Scheme 752
Remove E-box cover by sliding both latches in direction of -arrow-.
Scheme 753
Open wiring router bracket -arrows-.
Scheme 754
Cut off cable ties -1-.
Unclip electrical connector -1- from bracket and disconnect.
Scheme 755
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 756
Note. To unclip spiral clip, use 80 - 200.
Manual Transmission
Cut off cable ties -arrow- for protective boot -3-.
Scheme 757
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 758
Unclip lock washer -1- from shift cable and lock washer -2- from selector cable.
Scheme 759
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 760
Pull fastener upward -arrow- and remove hose/line assembly -1- from clutch slave cylinder bleeder.
| CAUTION | Risk 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 761
Disconnect electrical connector -2-.
Fold back protective boot and remove B+ wire from starter solenoid.
Remove Ground (GND) wire -3-.
| CAUTION | Risk 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 762
Remove upper left coolant hose from radiator -arrow-.
Scheme 763
| WARNING | There 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 764
Vehicles with engine code CBRA
Disconnect the vacuum hoses from the intake manifold and free them up
Scheme 765
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 766
Note. Nuts -3 through 6- are removed at a later time.
Remove upper fan shroud bolts -top arrows-.
Scheme 767
| CAUTION | Risk 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 768
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 769
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 770
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 771
| WARNING | Risk 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 772
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 773
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 774
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 775
- For Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWO) -G130
- For Oxygen Sensor (O2S) Behind Three Way Catalytic Converter (TWO) -G131
Remove exhaust system bracket -arrows-.
Scheme 776
| CAUTION | Risk of damaging decoupling elements. Do not bend decoupling element in front exhaust pipe more than 10°. |
Disconnect exhaust system at clamping sleeve -1-.
Scheme 777
Remove front exhaust pipes with catalytic converters and front muffler.
Mark position of flexible disc to bevel box flange for reinstallation.
Scheme 778
Remove driveshaft flexible disc from bevel box -arrows- while counterholding on triangle flange with lever.
| CAUTION | Risk of damaging sealing ring -arrow- in driveshaft flange. Press driveshaft horizontally as far back and to right side of vehicle as possible. |
Scheme 779
Vehicles with DSG transmission
Remove bracket bolts -1-.
Scheme 780
Remove locking washer -3- -arrow- and remove selector lever cable from transmission.
Note. Ignore -2-.
All Vehicles
| CAUTION | Risk 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 781
Secure the T40074 to the cylinder block using one M12 nut and two M10 bolts -arrows- tightened to approximately 20 Nm.
Scheme 782
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
- Additional Hooks 10 - 222 A /2
- Shop Crane VAS 6100
- Transmission Lift Hook T40013
Procedure
- Engine/transmission assembly is removed and mounted on engine mount.
Remove bolts -1- and -2- and remove bevel box bracket -A-.
Scheme 783
Install T40013 at transmission and close locking device.
Scheme 784
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
- Additional Hooks10 - 222 A /2
- Shop Crane VAS 6100
- Bracket T10013
- M8x40 bolt with nut and washer, exterior diameter 25 mm
Procedure
- 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 785
Remove coolant hoses from transmission oil cooler and from coolant pipe to transmission oil cooler -arrows-.
Scheme 786
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 787
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
| Component | Nm | |
|---|---|---|
| Bolts/nuts | M6 | 10 |
| M7 | 15 | |
| M8 | 22 | |
| M10 | 40 | |
| M12 | 65 | |
| Exceptions | ||
| Ground wire | 22 | |
Manual transmission to engine fastener
| Item | Bolt | Nm |
|---|---|---|
| 1 (1) , 3 | M12x55 | 80 |
| 2 (2) | M12x65 | 80 |
| 4, 5 (2) | M10x50 | 40 |
| 6 (2) | M12 x 80 | 80 |
| A | Alignment 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
| Item | Bolt | Nm |
|---|---|---|
| 1, 3, 6 | M12x55 | 80 |
| 5 | M12x65 | 80 |
| 7, 8 | M10x50 | 40 |
| 9 | M10x45 | 40 |
| 10 | M12x70 | 80 |
| A | Alignment 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 Description and Operation .
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
| CAUTION | Risk 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 Description and Operation .
The rest of the installation is in reverse order of removal, note the following
Install front exhaust pipe. Refer to FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER .
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 Description and Operation .
Connect electrical connector on starter. Refer to [For transmission(s) 02E] Removal and Installation .
Manual Transmission
Selector mechanism, installing and adjusting. Refer to Removal and Installation .
| CAUTION | Risk 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 .
Install wiper arms. Refer to [For transmission(s) 02E] Removal and Installation .
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
| CAUTION | Risk 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 788
Special tools and workshop equipment required
- Additional Hooks 10 - 222 A /2
- Shop Crane VAS 6100
- Transmission Lift Hook T40013
Scheme 789
Special tools and workshop equipment required
- Engine Support Bridge 10 - 222 A
- Bracket With Spindle and Hook 10 - 222 A /10
- Shackle (1 Set=2 Pieces) 10 - 222 A /12
- Bracket T10338
- Engine Support Basic Set T40091
- Engine Support Supplement Set T40093 with T40093/3-2 and T40093/3-3
Scheme 790
Special tools and workshop equipment required
- Pry Lever - Rmv Outside Mirror 80-200
- Engine/Transmission Jack V.A.G 1383 A
- Step Ladder VAS 5085
- Drip Tray VAS 6208
- Locking Pin T10060 A
- Assembly Tool T10118
Scheme 791
Special tools and workshop equipment required
- Additional Hooks 10 - 222 A /2
- Shop Crane VAS 6100
- Bracket T10013
Scheme 792
Special tools and workshop equipment required
- Lifting Tackle 3033
- Engine Support 3269
- Engine and Transmission Holder VAS 6095
- Shop Crane VAS 6100
Special tools and workshop equipment required
Scheme 793
Scheme 794
- Hose Clamps Up to 25 mm Dia. 3094
- Torque Wrench SAT 8010/3
- Engine mount T40074
- qty. 1 M12 nut
- qty. 2 M10 bolts
See also:
• Description and Operation
• Description and Operation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• NEEDLE BEARING ON CRANKSHAFT
• REMOVAL AND INSTALLATION
• Description and Operation
• SECONDARY AIR INJECTION PUMP
• COOLANT PIPE TO TRANSMISSION OIL COOLER
• FRONT EXHAUST PIPE WITH CATALYTIC CONVERTERS AND FRONT MUFFLER
• EXHAUST SYSTEM, INSTALLING
• [For transmission(s) 02E] Removal and Installation
• REMOVAL AND INSTALLATION
• FAN SHROUD
• RIBBED BELT
• [For transmission(s) 02E] Removal and Installation
• OIL LEVEL, CHECKING
• COOLING SYSTEM, DRAINING AND FILLING => Filling
• SUBFRAME MOUNT, ADJUSTING
• SUBFRAME MOUNT ASSEMBLY OVERVIEW