Table of contents: Tightening torques (Nm) ↓ Engine to DSG gearbox ↓
Tightening torques (Nm)
Note: Tightening torques apply to lightly greased, oiled, phosphated or oxidised nuts and bolts. The use of additional lubricants, such as motor or transmission oils, is permitted, except for graphite-containing ones. Do not use degreased parts. The tolerance of tightening torques is ±15%.
| Bolts and nuts | ||
| M6 | 9 | |
| M7 | 15 | |
| M8 | 20 | |
| M10 | 40 | |
| M12 | 65 | |
| Except: ground bolt to body near upper shock absorber support | 9 | |
| Nut for ground wire | 9 | |
Engine to DSG gearbox
| Pos. | Bolt | N·m |
| 1 | M10x50 (1) | 65 |
| 2...6 | M12X100 (2) | 30 + 90° |
| 7 | M12X125 (2) | 30 + 90° |
| 8 | M10x60(2) | 15 + 90° |
| 9,10 | M 10x95 (2) | 15 + 90° |
| A | Alignment bushings | |
(1) Bolt strength class 10.9. Steel bolt can be used repeatedly.
(2) Use bolts twice.
Aluminum bolts "2...10" are allowed to be used no more than 2 times. Therefore, after a single use of the bolts, 2 notches "X" "arrow" should be made. To avoid damage to the bolts, do not clamp them in a vice. Insert the bolt into the head by 14 mm with an extension of 1/2 inch, the other end of which is fixed in a hand vice (as shown in the picture). Bolts marked with "X" must not be reused.
Replace bolts that were tightened with additional turning. Replace self-locking nuts, lip seals, gaskets and sealing rings. On vehicles with DSG gearboxes, a needle bearing is installed in the driven disk. Before installing the disk, make sure that the needle bearing is installed. Press out the needle bearing from the driven disk. Hose nipples, air duct tubes 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 duct hoses to the nipples, treat the threaded connections of the already used clamps with a rust remover. During installation, all cable ties must be placed in their original places. Be sure to clean the threaded holes for fixing the power unit in the cylinder block with a tap before assembling the gearbox. Before securing the engine to the gearbox, do the following: Insert the mounting device "T40169" from below into the gearbox housing and install the clutch module as shown in the figure. The mounting device must enter the semicircular recess "1" and additionally into the inspection hole "2". In order to find the inspection hole, it is necessary to turn the dual-mass flywheel. Insert the mounting device bolts into the hole on the gearbox housing.
Insert the transport fastener "T40170" from below into the gearbox housing and secure it to the shaft with flange "1". When installing the engine on the subframe, hold the ATF lines in the installation position.
Install the engine mounts and engine mount. Install the right lower coolant pipe. Make sure that the installation bushings "A" for aligning the engine and gearbox in the cylinder block are present; if necessary, insert the missing bushings. If necessary, check the possibility of reusing the aluminum engine mounting bolts on the gearbox and mark them. Install the gearbox on the engine and tighten the bolts "1...10". Remove the transport fastener "T40170" and the mounting device "T40169". The next step is necessary to ensure that the clutch module fits evenly to the driven disk and does not warp. Lightly press the clutch module "2" with the mounting lever "1" to the driven clutch disk "3" "in the direction of the arrow".
Screw in the first bolt "arrow" manually (2 Nm).
Turn the crankshaft another 180° in the direction of engine rotation. In this position of the crankshaft, tighten the accessible bolt to the specified torque. Turn the crankshaft 60° and tighten the remaining 5 bolts to the specified tightening torque. Install the hydraulic lines of the power steering. Install the tensioner of the poly V-belt. Bolt the left and right drive shafts to the axle shafts with the gearbox flanges. Install the ATF lines. Install the diesel particulate filter. Install the heat shield of the turbocharger. Raise the power unit with 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 to the specified tightening torque, but do not tighten them at an angle (tightening only after measuring the wheel alignment angles). Risk of accident due to loose bolt connections. If the subframe bolts are not fully tightened, the car must not be moved.
Tighten the tunnel crossmember bolts.
Installation is in the reverse order, while observing the following. Install the propeller shaft. Install the selector cable. Install the exhaust pipe. Tighten the universal joint mounting bolts with the crosspiece on the steering gear. Install the subframe brace, upper suspension arm, stabilizer, tighten the shock absorber strut mounting bolts on the support arm. Install the brake caliper. Install the radiator frame cross members. Install the engine control unit. Electrical connectors and wiring. Install the wires, 2-terminal 30 "TV22" splitter and the cover of the engine compartment switching unit. Install the brace. Install the washer fluid reservoir filler neck. Install the refrigerant lines. Observe the instructions after connecting the battery terminals. Risk of damage to the control units due to overvoltage. Do not use a charger to start the engine! Install the throttle module "J338", the air filter housing and the exhaust pressure sensor 1 "G450". Fill with oil and check its level. Before starting the engine for the first time, fill the hydraulic oil in the expansion tank of the power steering. The vane pump should not run "dry". Fill with coolant. Fill the air conditioning system circuit. Install the front wheels and adjust the wheel alignment angles. Fill with ATF oil. Install noise insulation screens and mudguards.