SUBFRAME MOUNT, ADJUSTING
Special tools and workshop equipment required
- Engine Support Bridge 10 - 222 A
- Shackle 10 - 222 A /12
- Special Hook 10 - 222 A /20
- Engine Sling 2024 A
- Adapter T40093/6 qty. 2
Procedure
- For the correct tightening specifications, refer to «ENGINE AND TRANSMISSION MOUNTS OVERVIEW»(ref-505811-S35405817822012100100000) .
Remove the engine cover -arrows-.
Scheme 950
Remove the bolts -arrows- and air guide.
Scheme 951
Remove the coolant hose by loosening the hose clamp -1-.
Scheme 952
Disconnect the connector -2- from the Mass Airflow (MAF) Sensor -G70-.
Detach upper section of the air filter housing -arrow- and remove air filter insert.
Remove the bolts -arrows- and the lower section of the air filter housing.
Scheme 953
Remove the bolts -arrows- and the air filter housing bracket.
Scheme 954
Remove the bolt and nut -arrows- and then push the front right coolant pipe to the side with the coolant hoses still connected.
Scheme 955
Place the 10 - 222 A on upper edge of web plates with the following tool parts
Scheme 956
- Engine brackets 10 - 222 A /1, quantity: 2
- Spindle 10 - 222 A /11; quantity: 2
- Shackle 10 - 222 A /12
- Adapter 10 - 222 A /20
- Engine sling 2024 A hook
- Adapter T40093/6 qty. 2
Engage the spindle 10 - 222 A /11 with 10 - 222 A /12 on the left transmission lifting eye.
Attach the 10 - 222 A /11, 10 - 222 A /20 and 2024 A hook to the transmission.
| WARNING | Risk of accident. Lifting hooks and alignment pins on lifting tackle must be secured with securing pins -arrows-. |
Tension engine/transmission subframe by evenly tightening the 2 spindles.
Remove the subframe bolts -arrows- on the engine side.
Scheme 957
Remove the subframe bolts -arrows- on the transmission side.
Scheme 958
Replace all 5 bolts in succession (if not already done when installing engine) hand tighten.
Loosen the 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 959
- Both bolt heads -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 bolts on the transmission side.
The edges on the support arm -1- and transmission mount -2- are parallel on the transmission side.
Scheme 960
- Dimension -x- same size on both sides of bracket.
Tighten subframe mount bolts on the engine side.
The rest of the installation is performed in reverse order of removal, noting the following
Note. The hose supports, air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model.
Tighten the bolts for front section of the longitudinal member. Refer to Removal and Installation .
Remove the 10 - 222 A.
Install the front right coolant pipe. Refer to RIGHT FRONT COOLANT PIPE .
Install the air filter housing and the air filter. Refer to Removal and Installation .
ENGINE, REMOVING
Special tools and workshop equipment required
- Drip Tray VAS 6208
- Engine/Transmission Jack V.A.G 1383 A
- Hose Clip Pliers V.A.G 1921
- Step Ladder VAS 5085
- Engine/Trans. Support T10012
- Pry Lever - Rmv Outside Mirror 80 - 200
- Ring Spanner 7-Piece Set 3337
- Locking Pin T10060A
- Puller T10369
- 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.
| WARNING | There 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 BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .
| CAUTION | Danger of causing damage to electrical components when disconnecting the battery. Complete the steps for disconnecting the battery. |
Remove luggage compartment floor covering.
If the battery negative post cover is under the rear cross panel trim, remove rear cross panel trim. Refer to Removal and Installation .
Scheme 961
Release retaining clips -arrows- and remove negative post cover.
Loosen nut a few turns and remove terminal clamp -arrow- on the ground (GND) cable from battery post.
Scheme 962
| WARNING | Risk of scalding due to hot steam and hot coolant. The coolant system is under pressure when the engine is warm. Reduce pressure by covering coolant reservoir cap with a cloth and carefully open. |
Open the coolant reservoir cap.
Remove both front wheels.
Remove the front noise insulation -1-. Refer to Removal and Installation .
Scheme 963
Remove left and right noise insulation -arrows-.
Scheme 964
Remove the noise insulation frame -arrow- and the rear noise insulation. Refer to Removal and Installation .
Scheme 965
Place the VAS 6208 under the engine.
Remove the lower coolant hose -arrow- from the radiator by lifting the clamp and let the coolant drain out.
Scheme 966
Remove lower coolant hose to after-run coolant pump -V51- -arrow- and allow coolant to drain.
Scheme 967
Remove the air guide hose by loosening hose clamps -1- and -2-.
Scheme 968
Disconnect the connector -2-.
Scheme 969
Remove the bolts -3-.
Remove the engine cover -arrows-.
Remove the coolant hoses -1- and -2-.
Scheme 970
| WARNING | Risk of injury from fuel. To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen. |
| CAUTION | Follow the guidelines for cleanliness when working on the fuel supply system. Refer to CLEAN WORKING CONDITIONS . |
Remove the protective boot -2- and disconnect the fuel hose by pressing the release ring.
Remove the hose -1-.
Release the EVAP canister -B arrow-, remove it upward -A arrow- and lay it aside.
Remove the bolts -arrows- and air guide.
Remove the bolts -1- and remove the fan shroud upward.
Remove the upper coolant hose -arrow- from the radiator by removing the retaining clip.
Scheme 971
Remove the bolts -arrows- on the rear side of the radiator.
Scheme 972
Remove the radiator downward.
Vehicles with Air Conditioning (A/C)
Scheme 973
| 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. |
Pivot the tensioner clockwise -arrow- to release the tension on the ribbed belt.
Secure the tensioning element with the T10060 A.
Scheme 974
Remove ribbed belt.
Remove the bolts -arrows- and remove the generator from the accessory assembly bracket.
Scheme 975
Note. If generator is stuck in its bracket, screw in mounting bolt again up to 2 rotations. Carefully strike on bolt heads using flat side of hammer - doing this loosens the bushings on the generator mount.
Move the generator, the electrical wires still connected, to the right side of the vehicle.
Disconnect the connector -2-.
Scheme 976
Remove the wire -1- and the clamp -3- from the generator.
Remove the generator upward.
Disconnect solenoid clutch electrical connector -1- on A/C compressor.
Scheme 977
| CAUTION | Risk of damaging refrigerant lines and hoses. Do not stretch, kink or bend refrigerant lines and hoses. |
Remove the bolts -arrows-.
Remove the A/C compressor from the accessory assembly bracket and tie it up on the right side.
All Vehicles
Remove the coolant pipe by loosening the hose clamp -1-.
Disconnect the connector -2- from the Mass Airflow (MAF) Sensor -G70-.
Detach upper section of the air filter housing -arrow- and remove air filter insert.
Remove the bolts -arrows- and the lower section of the air filter housing.
Remove the bolts -arrows- and the air filter housing bracket.
Remove the connector -arrow- for the Heated Oxygen Sensor (HO2S) -G39- from the bracket, disconnect it and free it up.
Scheme 978
Remove the heated oxygen sensor -arrow- with a socket taken from the 3337.
Scheme 979
Remove bolt -arrow-.
Scheme 980
Remove the hose clamp -1- and lay the air guide pipe with the hose still connected -2- on the engine.
Note. Ignore -3-.
Remove the bolts -arrows- and nuts -1- and then remove the heat shield.
Scheme 981
Remove the nuts -arrows- on the front exhaust pipe/turbocharger connection from the top.
Scheme 982
Remove the heat exchanger coolant hoses -arrows-.
Scheme 983
Remove the vacuum hose -1- from the non-return valve.
Scheme 984
Remove the non-return valve -arrow- from the brake booster.
Pry cover caps off windshield wiper arms with screwdriver.
Scheme 985
Loosen nuts -arrows- a few turns.
Position the puller for removing wiper arms T10369/1 on the windshield wiper arm -1- as illustrated.
Scheme 986
Mount the pressure piece -2- on the wiper axle.
Turn the bolt -3- clockwise until the wiper arm is pulled off the wiper axle.
Remove the nuts completely and remove wiper arms.
Remove gasket -1-.
Scheme 987
| CAUTION | The 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 rear engine wiring harness on plenum chamber partition.
Remove the Engine Control Module (ECM). Refer to Removal and Installation .
Disconnect the engine wiring harness electrical connector -1- -arrow-.
Scheme 988
Release the engine wiring harness feed -1- through and remove upward -arrow-.
Scheme 989
Remove E-box cover by slide both latches in direction of -arrow-.
Scheme 990
Open wiring router bracket -arrows-.
Scheme 991
Unclip electrical connector -1- from bracket and disconnect.
Scheme 992
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 the terminal 30 wire -arrow- at the engine compartment E-box and free it up.
Scheme 993
Note. To unclip spiral clip, use 80 - 200.
Cut off cable ties -arrow- for protective boot -1-.
Scheme 994
Disconnect the connector -2-.
Fold back protective boot and remove battery positive 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.
Disconnect the connector -1-.
Scheme 995
Note. Ignore -arrows-.
Remove the subframe bolts -arrows- on the engine side 2 turns.
Scheme 996
Remove the subframe bolts -arrows- on the transmission side 2 turns.
Mark position of flexible disc to bevel box flange for reinstallation.
Remove the driveshaft flexible disc bolts -arrows- from the bevel box while counterholding at the triangular flange with a lever.
Scheme 997
| CAUTION | The shaft seal -arrow- in the driveshaft flange could be damaged. Press driveshaft horizontally as far back and to the right side of vehicle as possible. |
Scheme 998
Remove the bolts -1- and -2- on the bracket for the oxygen sensor electrical connector under the vehicle floor. Remove the cover.
Scheme 999
Remove the bolt -3- and free up the electrical wire to the oxygen sensor.
Remove the connector coupling -arrow- from the bracket.
Scheme 1000
Disconnect the connector from the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and free it up.
Remove the bolts -arrows-, exhaust system bracket and tunnel brace.
Scheme 1001
| CAUTION | Risk of damaging decoupling elements. Do not bend decoupling element in front exhaust pipe by more than 10°. |
Loosen the nuts -arrows- at the clamping sleeve and separate the exhaust system.
Scheme 1002
Remove the front exhaust pipe with the catalytic converter and front muffler.
Remove bracket bolts -1-.
Scheme 1003
Remove locking washer -3- -arrow- and remove selector lever cable from the transmission.
Note. Ignore -2-.
| 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 1004
Disconnect the connector -1- from the oil level thermal sensor -G266-.
Scheme 1005
Unclip bracket -2- for electrical wiring to oil level thermal sensor from subframe.
Remove the right drive axle heat shield from bevel box -arrows-.
Scheme 1006
Remove the left drive axle from the transmission flange and the right drive axle from the bevel box flange.
Remove the air guide hose from the charge air cooler by loosening the hose clamp -arrow-.
Scheme 1007
Free up the coolant hose -2-.
Scheme 1008
Remove the bolts -4- and lay the after-run coolant pump -V51- with the coolant hoses still connected -arrows- to the side.
Note. Ignore -1 and 3-.
Fasten the T10012 to the cylinder block with bolt -1- and nut -2- to approximately 20 Nm.
Scheme 1009
Place the V.A.G 1383 A on the T10012 and raise engine/transmission assembly slightly.
Note. To remove subframe mounting bolts, use VAS 5085.
Remove the subframe bolts -arrows- on the engine side.
Remove the subframe bolts -arrows- on the transmission side.
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 the engine/transmission as far as possible to the front and left and slowly lower it while paying attention to the drive axles.
ENGINE AND S-TRONIC TRANSMISSION, SEPARATING
Special tools and workshop equipment required
- Special Hook 10 - 222 A /20
- Engine Sling 2024 A
- Shop Crane VAS 6100
- Engine/Trans. Support T10012
Procedure
- The engine/transmission assembly is removed and mounted on the T10012.
Free up the coolant hose -arrow-.
Scheme 1010
Free up the wiring harnesses -arrows- and the electrical connector -1- at the bracket.
Remove the bolts -1- and -2- and then remove the starter from the transmission.
Scheme 1011
Remove the coolant hoses -arrows- from the ATF cooler.
Scheme 1012
Loosen the bolts -1- and remove the bolts -2-.
Scheme 1013
Attach the 2024 A hooks to the transmission lifting eyes and secure it with the securing pin -arrow-.
Scheme 1014
Attach the VAS 6100 and 10 - 222 A /20 to the 2024 A hook.
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, SECURING TO ENGINE AND TRANSMISSION HOLDER
Special tools and workshop equipment required
- Engine Sling 2024 A
- Shop Crane VAS 6100
- Engine and Transmission Holder VAS 6095
Procedure
- Transmission separated from engine.
Engage the 2024 A on engine and on the VAS 6100 as shown in the illustration.
Scheme 1015
Note. To be aligned to the center of gravity on the engine assembly, the hole rails of the lifting hook must be inserted as shown in the illustration.
| WARNING | Loose 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 engine from the VAS 6100 using the T10012.
Secure the transmission side of the engine to the VAS 6095 as illustrated.
Scheme 1016
ENGINE, INSTALLING
Tightening Specifications
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%.
- For the correct tightening specifications, refer to «ENGINE AND TRANSMISSION MOUNTS OVERVIEW»(ref-505811-S35405817822012100100000) .
- Additional tightening specifications
| Component | Nm | |
|---|---|---|
| Bolts/nuts | M6 | 10 |
| M7 | 15 | |
| M8 | 22 | |
| M10 | 40 | |
| M12 | 65 | |
| Exceptions | ||
| Ground (GND) wire | 22 | |
Mounting, S-Tronic Transmission to Engine
| Item | Bolt | Nm |
|---|---|---|
| 1, 3 | M12x55 | 80 |
| 5 | M12x65 | 80 |
| 6 | M12x50 | 80 |
| 7, 8 | M10x50 | 40 |
| 9 | M12x70 | 80 |
| 10 | M12x55 | 80 |
| 2, 4 | Starter mounting, refer to [For transmission(s) 02E] Removal and Installation | |
| A | Alignment sleeves for centering | |
Procedure
Installation is done is reverse order, observe the following
Note. Replace self-locking nuts and bolts. Always replace bolts that are tightened to torque as well as O-rings and gaskets. The hose supports, air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model. To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing. 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.
If no needle bearing is installed in crankshaft, install needle bearing. Refer to NEEDLE BEARING ON CRANKSHAFT .
Attach transmission to engine.
Tighten the bevel box bracket. Refer to Removal and Installation .
Guide engine/transmission assembly into body.
First tighten the subframe bolts -arrows- on the engine side by hand.
First tighten the subframe bolts -arrows- on the transmission side by hand.
Note. Only tighten the bolts to the specification when installing the subframe mount. Refer to SUBFRAME MOUNT, ADJUSTING .
Remove the engine/trans. support T10012 from engine.
Tighten the pendulum support bolts -2- and -3- to the transmission. Refer to ENGINE AND TRANSMISSION MOUNTS OVERVIEW .
Install selector lever cable. Refer to Removal and Installation .
| CAUTION | The shaft seal -arrow- in the driveshaft flange could be damaged. Press the engine/transmission assembly toward bulkhead while carefully guiding bevel box pins into driveshaft flange. |
Tighten the pendulum support bolt -1- to the subframe. Refer to ENGINE AND TRANSMISSION MOUNTS OVERVIEW .
Tighten driveshaft with flexible disc on the bevel box. Refer to Removal and Installation .
The rest of the installation is performed in reverse order of removal, noting the following
Install the front exhaust pipe with the catalytic converter and front muffler. 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 the Heated Oxygen Sensor (HO2S) -G39-. Refer to Removal and Installation .
Install drive axles. Refer to Removal and Installation .
Install drive axle heat shield. Refer to Removal and Installation .
Install A/C compressor. Refer to Removal and Installation .
Install generator. Refer to [For transmission(s) 02E] Removal and Installation .
Install the ribbed belt. Refer to RIBBED BELT TENSIONER .
Install the radiator. Refer to RADIATOR .
Install fan shroud. Refer to FAN SHROUD .
Install starter. Refer to [For transmission(s) 02E] Removal and Installation .
Install the noise insulation frame and the noise insulation. Refer to Removal and Installation .
Adjust the subframe mount. Refer to SUBFRAME MOUNT, ADJUSTING .
Install Engine Control Module (ECM). Refer to Removal and Installation .
Electrical connections and routing. Refer to appropriate SYSTEM WIRING DIAGRAM.
Install wiper arms. Refer to [For transmission(s) 02E] Removal and Installation .
Follow measures after connecting battery. Refer to [For transmission(s) 02E] Removal and Installation .
Engine 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 1017
Special tools and workshop equipment required
- Engine Sling 2024 A
- Shop Crane VAS 6100
- Engine and Transmission Holder VAS 6095
Scheme 1018
Special tools and workshop equipment required
- Drip Tray VAS 6208
- Engine/Transmission Jack V.A.G 1383 A
- Hose Clip Pliers V.A.G 1921
- Step Ladder VAS 5085
- Engine/Trans. Support T10012
- Pry Lever - Rmv Outside Mirror 80 - 200
Scheme 1019
Special tools and workshop equipment required
- Engine Support Bridge 10 - 222 A
- Shackle 10 - 222 A /12
- Special Hook 10 - 222 A /20
- Engine Sling 2024 A
- Adapter T40093/6 qty. 2
Special tools and workshop equipment required
Scheme 1020
Scheme 1021
Scheme 1022
Scheme 1023
- Ring Spanner 7-Piece Set 3337
- Locking Pin T10060A
- Puller T10369
- Shop Crane VAS 6100
- Not illustrated
- Engine Bung Set VAS 6122