Tightening torques (Nm)
Note: The tightening torques apply to lightly lubricated, oiled, phosphated or oxidized nuts and bolts. It is allowed to use additional lubricants, such as motor or transmission oils, except those containing graphite. Do not use degreased parts. The tightening torque tolerance is±15%.
Bolts and nuts | ||
M6 | 9 | |
M7 | 15 | |
M8 | 20 | |
M10 | 40 | |
M12 | 65 | |
Except: ground bolt to body near upper shock mount | 9 | |
Nut for ground wire | 9 |
Engine to DSG gearbox
Pos. | Bolt | Nm |
1 | M10x50 (1) | 65 |
2...6 | М12Х100 (2) | 30 + 90° |
7 | М12Х125 (2) | 30 + 90° |
8 | M10x60 (2) | 15 + 90° |
9,10 | M 10x95 (2) | 15 + 90° |
A | Alignment sleeves |
(1) Bolt strength class 10.9. The steel bolt can be reused many times.
(2) Use bolts twice.
Aluminum bolts -2...10- may not be used more than 2 times. Therefore, after using the bolts once, 2 notches should be made "X" -arrow-. To avoid damaging the bolts, do not clamp them in a vice. Insert a 14 mm bolt into the head with a 1/2 extension", the other end of which is fixed in a hand vice (as shown in the picture). Bolts marked "X", must not be reused.
Replace bolts that were overtightened. Replace self-locking nuts, lip seals, gaskets and seals. rings. On vehicles with a DSG gearbox, a needle bearing is installed in the driven disk. Before installing the disc, make sure the needle bearing is installed. Press out the needle bearing from the driven disk. Hose fittings, air pipes and hoses must be cleaned of oil and grease before installation. Secure all hose connections with hose clamps of the appropriate series. To ensure reliable fastening of the air hoses to the fittings, the threaded connections of already used clamps should be treated with a rust remover. During installation, all cable ties should be placed in the same places. Be sure to clean the threaded holes for fixing the power unit in the cylinder block before assembling the gearbox with a tap. Before securing the engine to the gearbox, do the following: Insert mounting tool -T40169- into the gearbox housing from below and install the clutch module as shown in the illustration. The mounting device must fit into the semicircular recess -1- and additionally into the inspection hole -2-. In order to find the inspection hole, you need to turn the dual-mass flywheel. Insert the bolts of the mounting device into the hole on the gearbox housing.
Insert the transport securing device -T40170- into the gearbox housing from below and secure it to the flange shaft -1 -. When installing the engine on the subframe, keep the ATF lines in the mounting position.
Install the engine mounts and engine mount. Install the right lower coolant pipe. Make sure that the installation bushings -A- are present for aligning the engine and gearbox in the cylinder block; if necessary, insert the missing bushings. If necessary, check the possibility of reusing the aluminum engine mounting bolts on the gearbox and mark them. Place the gearbox on the engine and tighten bolts -1...10-. Remove transport securing device -T40170- and mounting device -T40169-. The next step is necessary to ensure that the clutch module is evenly adjacent to the driven disc and does not warp. Lightly press the clutch module -2- using the mounting lever -1 - onto the clutch driven plate -3- -in the direction of the arrow-.
Screw in the first bolt -arrow- by hand (2 Nm).
Rotate the crankshaft again another 180°in the direction of engine rotation. In this position of the crankshaft, tighten the accessible bolt to the specified torque. Rotate the crankshaft 60°and tighten the remaining 5 bolts to the specified torque. Install the power steering hydraulic lines. Install the poly V-belt tensioner. Screw the left and right drive shafts to the axle shafts with gearbox flanges. Install ATF lines. Install the particulate filter. Install the turbocharger heat shield. Raise the power unit using the lifting table -VAS 6131 A-. Align the subframe and tunnel cross member in accordance with the markings made on the side members during dismantling. Tighten the subframe bolts to the specified torque, but do not tighten them at an angle (tightening only after measuring the wheel alignment angles). Risk of accident due to loose bolted connections. If the subframe bolts are not completely tightened, the vehicle cannot be moved.
Tighten the tunnel cross member bolts.
Installation is in reverse order, observing the following. Install the driveshaft. Install the selector cable. Install the exhaust pipe. Tighten the bolts securing the cardan joint to the crosspiece on the steering gear. Install the subframe extension, upper suspension arm, stabilizer, tighten the bolts securing the shock absorber strut to the support arm. Install the brake. caliper Install the radiator frame cross members. Install the engine control unit. Electrical connectors and wiring. Install wires, splitter 2 cells. 30 -TV22- and the engine switch box cover. compartment Install a stretcher. Install the filler neck of the washer fluid reservoir. Install the refrigerant lines. Follow the instructions after connecting the battery terminals. Risk of damage to control units due to overvoltage. Do not use a charger to start the engine! Install throttle valve module -J338-, air housing. filter and exhaust pressure sensor 1-G450-. Add oil and check its level. Before starting the engine for the first time, fill hydraulic oil into the expansion tank. power steering reservoir. The vane pump should not be running "dry". Fill with coolant. Fill the air conditioning circuit. Install the front wheels and adjust the wheel alignment angles. Fill with ATF oil. Install soundproofing screens and fender liners.
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