Table of contents: Tightening torques (Nm) ↓ Engine to manual transmission ↓ Engine to dual clutch gearbox 0B5 ↓ All ↓ All ↓ All ↓
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 |
Engine to manual transmission
| Pos. | Bolt | N·m |
| 1(1) | M 10x50 (2) | 65 |
| 2(3) | M12x100 (4) | 30 + 90° |
| 3(5), 6 | M 12x75 (4) | 30 + 90° |
| 4,5(5) | M12x120 (4) | 30 + 90° |
| 7...9 | M10x75(4) | 15 + 90° |
| 10 | M 12x50 (4) | 30 + 90° |
| A | Alignment bushings | |
- (1) Additionally secures the starter.
- (2) The bolt strength class is 10.9, the steel bolt can be used repeatedly.
- (3) Additionally secures the starter; with an additional spacer sleeve between the starter and gearbox.
- (4) Bolts can be used twice.
- (5) Additionally secures the wire holder.
Engine to dual clutch gearbox 0B5
| Pos. | Bolt | N·m |
| 1(1) | M10x50 (2) | 65 |
| 2(3) | M12x100 (4) | 30 + 90° |
| 3(5), 6 | Ml 2x75 (4) | 30 + 90° |
| 4,5 | M12x120 (4) | 30 + 90° |
| 7,8 | Ml0x40 (4) | 15 + 90° |
| 9 | M12x50 (4) | 30 + 90° |
| A | Alignment bushings | |
- (1) Additionally secures the starter.
- (2) The bolt strength class is 10.9, the steel bolt can be used repeatedly.
- (3) Additionally secures the starter; with an additional spacer sleeve between the starter and gearbox.
- (4) Bolts can be used twice.
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Aluminum bolts can be used twice. Therefore, after using the bolts once, make 2 notches "X" "arrow". To avoid damaging 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 O-rings. On vehicles with a manual transmission, a needle bearing must be installed in the driven disk. Before installing the disk, make sure that the needle bearing is installed. Press the needle bearing into the driven disk. Secure all hose connections with hose clamps of the appropriate series. During installation, all cable ties must be placed in their original places. Before securing the engine to the gearbox, do the following. Insert the "T40169" installation tool into the gearbox housing from below and install the dual-mass flywheel as shown in the figure. The installation device must enter the semicircular recess "1" and additionally into the inspection hole "2". There is only 1 inspection hole, it is necessary to turn the dual-mass flywheel accordingly. Insert the bolts of the installation device 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". If necessary, check the possibility of reusing the aluminum engine mounting bolts on the gearbox and mark them.
Cars with manual transmission: Make sure that there are mounting bushings "A" for aligning the engine and gearbox in the cylinder block; if necessary, insert missing bushings. Install the engine on the gearbox, screw in and tighten bolts "2...6". Bolt "2" secures the starter to the gearbox and additionally has a spacer sleeve "arrow". The spacer sleeve must be inserted between the starter and the gearbox. Remove the load from the hook "10 - 222 A/10". Lower the crane and place the engine with the gearbox on the engine mounts. Install the engine mount. Dismantle the crane "VAS 6100" and the hanging device "2024 A". Tighten the bolts "1,7,8,9,10" engine and gearbox connections. Remove the transport fastener "T40170" and the mounting device "T40169".
Cars with dual-clutch gearbox 0B5: 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. Bolt "2" secures the starter to the gearbox and additionally has a spacer sleeve "arrow". The spacer sleeve must be inserted between the starter and the gearbox. Unload the spindle "10-222 A/11". Lower the crane and place the engine with the gearbox on the engine mounts. Install the engine mount. Dismantle the "VAS 6100" crane and the "2024 A" suspension device.
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The next step is necessary so that the clutch module fits evenly on the driven disk and does not warp. Install the wheel arches. Install the front wheels. Engage 4th gear and rotate the front wheels in the direction of travel until the clutch module makes a full revolution. The inspection hole arrow - should again be visible in the recess of the gearbox housing.
Secure the clutch module to the driven disk as follows. Screw in the first bolt "arrow" by hand (2 Nm). Rotate the front wheels in the direction of travel until the clutch module has rotated 240°. Tighten the accessible bolt in this position to the specified torque. Rotate the front wheels in the direction of travel until the clutch module has rotated 120°, respectively, and tighten the remaining 2 bolts to the tightening torque.
Installation is in reverse order, taking into account the following. Install the particulate filter. Install the injector for the reducing agent "N474". Install the differential pressure sensor "G505". Install the vibration damper. Install the intermediate roller and tension roller. Install the generator. Install the vane pump. Install the ATF lines. Install the compressor. Install the poly V-belt.
Front-wheel drive vehicles: Install the counter support and crossmember. Install the lock mounting beam.
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Electrical connections and gasket. Install the engine control unit. Install the electrical wires, distributor 2 for terminal 30 "TV22" and the cover of the switching unit in the engine compartment. Install the tensioner. Install the filler neck of the washer reservoir. Observe the measures after connecting the battery. Risk of damage to the control units due to overvoltage. Do not use a charger to start the engine! Install the air filter housing. Connect the air duct hose using threaded clamps. Check the oil level. Bleed the fuel system. Connect the coolant hoses using clamps. Fill with coolant. Install soundproofing screens.