Tightening torques (Nm)
| Bolts and nuts | M6 | 9 |
| M7 | 15 | |
| M8 | 20 | |
| M10 | 40 | |
| M12 | 65 |
Ground bolt to the body near the shock absorber cup
Tighten ground bolt "1" to 9 Nm.
Ground wires to the side members
Tighten the arrow nut to a torque of 9 Nm.
Engine for the multitronic 0AW gearbox
| Pos. | Bolt | Nm |
| 1 | M10x50(1) | 65 |
| 2...6 | M12x100 (2), (3) | 30 + 90° |
| 7 | M12x125 (2), (3) | 30 + 90° |
| 8, 11 | M 10x60 (2), (3) | 15 + 90° |
| 9, 10 | M10x95 (2), (3) | 15 + 90° |
| A | Centering bushings | |
(1) Bolt strength class 10.9. Steel bolt can be used repeatedly.
(2) Up to identification number 8K-9-066499: Replace aluminum bolts.
(3) From ID number 8K-9-066500: Aluminum bolts are used twice.
Aluminum bolts "2...11" may be used no more than 2 times. Therefore, after the first use, mark such bolts with 2 notches "X" "arrow". To avoid damaging the bolts when making the notches, do not clamp them in a vice. Insert the bolt as shown in the illustration into the 14 mm socket using a 1/2-inch drive, which can then be clamped in a vice. Bolts marked with "X" must not be reused.
Note: Bolts tightened with a tightening angle must be replaced. Replace self-locking nuts, lip seals, gaskets and seals. rings. On vehicles with the multitronic OAW transmission, a needle bearing is installed in the driven disk. Before dismantling, make sure the needle bearing is installed. Pressing in and pressing out a needle bearing from a driven disk. Hose fittings, air tubes and hoses must be cleaned of oil and grease before installation. To secure all hose connections, use clamps of the appropriate series. To ensure reliable fastening of the air duct hoses to the fittings, all cable ties should be placed in their original locations during installation.
Install the engine mounts and engine cushion. Install the right lower coolant pipe. When installing the engine on the subframe, hold the ATF lines in the mounting position. Be sure to clean the threaded holes for securing the power unit in the cylinder block with a tap before assembling the transmission. Before connecting the engine and transmission, perform the following preparatory steps. Install mont. device "T40169" from below under the gearbox housing and dual-mass flywheel, as shown in the figure. The mounting fixture should fit into the semicircular groove "1" and additionally into the inspection hole "2." To locate the inspection hole, it is necessary to rotate the dual-mass flywheel. Insert mounting bolts. devices into the hole on the gearbox housing.
Install the "T40170" transport protection from below under the gearbox housing and attach it to the shaft with flange "1".
Check the presence of centering bushings "A" for the engine and gearbox in the cylinder block; insert the bushings if necessary. Check the aluminum engine-to-gearbox bolts for reuse and mark them if necessary. Install the gearbox onto the engine and tighten bolts 1...11. Remove transport lock "T40170" and mounting tool "T40169." This step ensures that the clutch module fits evenly on the driven disc and does not warp. Lightly press the dual mass flywheel "2" using the mounting. lever "1" to the driven clutch disc "3" "in the direction of the arrow".
Secure the dual mass flywheel to the driven disk as follows. To tighten the bolts use a ring spanner SW 16 "VAG 1332/14". Screw in the first "arrow" bolt by hand (2 Nm).
Insert the guide pins of the adapter "T40058" as shown below: the large diameter "arrow 1" faces the engine, the small diameter "arrow 2" faces the adapter.
Turn the crankshaft using the adapter "T40058" 180° in the direction of engine rotation "arrow". In this crankshaft position, tighten the accessible bolt to the specified torque. Turn the crankshaft 60° and tighten the remaining 5 bolts to the specified tightening torque.
Install power steering lines. Install the tensioner element of the poly V-belt. Bolt the left and right drive shafts to the axle shafts with the transmission flanges. Install the ATF lines. Install the diesel particulate filter. Install the turbocharger heat shield. Raise the power unit using the lifting table -VAS 6131 A-. Align the subframe and tunnel crossmember in accordance with the markings made on the side members during dismantling.
Tighten the subframe bolts only with a light torque, do not tighten at an angle (tighten the bolts only after checking the wheel alignment angles). Tighten the tunnel crossmember bolts. Installation in reverse order. Install the exhaust system inlet pipe. Align the system. exhaust gas release without mechanical stress. Install the front cross member. Install the selector cable. Tighten the universal joint mounting bolts to the steering gear. Install the subframe brace, upper suspension arm, stabilizer, tighten the shock absorber strut mounting bolts on the support arm. Install brake. support. Install the radiator frame crossbars. Install the engine control unit. Electrical connections and wiring. Install the wires, the 2-way splitter 30 "W22" and the cover of the motorcycle junction box. compartment.
Connect the exhaust gas temperature sensor connectors. Install the stretcher. Install the washer reservoir filler neck. Install refrigerant lines. Consider the measures taken after connecting the battery. Install the throttle module "J338", exhaust gas pressure sensor 1 "G450" and the air intake housing. filter. Fill with oil and check its level. Before starting the engine for the first time, fill the power steering expansion tank with hydraulic oil. The vane pump must not run dry. Connect the connecting pipe and coolant hose to the nipple connector. Fill with coolant.
Fill the air conditioning circuit. Install wheel arches. Install the front wheels and adjust the wheel alignment angles. Fill with ATF. Install noise insulation screens.