Note: Replace screws that are tightened to the specified angle. Replace self-locking nuts as well as lip seals, O-rings and gaskets. Use factory-installed clamps to secure all hoses. During assembly, install all cable ties in their original places.
Install intermediate plate. If the cylinder block does not have bushings -A- for centering the engine and gearbox, install them. Securely screw the gearbox to the engine at points -1, 2, 3, 6, 7, 8, 9-. Install gearbox support. Power unit is mounted on engine support bracket -T10497-. Insert the power unit into the body.
Screw in bolts -arrows- for engine support by hand, but do not tighten. First screw in bolts -arrows- for gearbox support by hand until they are in contact with the bearing surface.
Note: The screws are tightened when adjusting the subframe.
Remove bracket -T10497- from engine. Install starter. Install coolant bleeder pump -V51- after engine is switched off. Install air duct. Air duct installation.
Vehicles with manual gearbox
Install the clutch slave cylinder. Install cables with cable supports.
Vehicles with automatic transmission DSG
Install the subframe. Install the selector cable, connect the connector of the mechatronic unit and install all brackets on the gearbox.
All
Install downpipe with converter. Install drive shafts. Install the control arm, ball joint and stabilizer link. Install the air conditioner compressor. Install poly V-belt. Electrical connectors and cabling. Install engine control unit -J623-. Connect coolant hoses with quick coupling. Install the power unit lower support. Install the front fenders. Install front wheels. Adjust the support assembly of the unit.
Install battery with bracket. Install the air filter housing.
Carefully! Excessive voltage creates a risk of damage to the control units. Do not use the charger to start the engine!
Fill and bleed the cooling system. Install the engine cover. Install the plenum box cover. Interrogate the event recorders of all units and erase the errors resulting from the removal and installation of the engine. After erasing the errors in the event memory of the engine control unit, regenerate the readiness code.
Tightening torques
Other screws for fastening the gearbox to the engine, bolts for fastening the supports of the power unit.