Audi Workshop Service and Repair Manuals

Installing engine Tightening torques   Note t  Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. t  Additional lubricants such as engine or gearbox oil may be used, but do not use lubricants containing graphite. t  Do not use degreased parts. t  Tolerance for tightening torques: ± 15 %.

Component		Nm
Bolts/nuts	M6	9
	M7	15
	M8	22
	M10	40
	M12	65

Assembly mountings → Chapter „Assembly mountings - exploded view“.

Manual gearbox to engine

Item	Bolt	Nm
1	M12x65	80
2 1)	M12x140	80
3	M12x80	80
4	M10x50	40
A	Dowel sleeves for centralising
l  1) Also secures starter.

Procedure Installation is carried out in the reverse order; note the following:   Note t  Renew the bolts tightened with specified tightening angle. t  Renew self-locking nuts and bolts as well as seals, gaskets and O-rings. t  Hose connections and air pipes and hoses must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  To ensure that the air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing. t  Fit all cable ties in the original positions when installing.

–  Ensure that intermediate plate is engaged on sealing flange -arrow A- and pushed onto dowel sleeves -arrows B-.

–  If not already fitted, install dowel sleeves -A- for centring engine and gearbox in cylinder block. –  Renew clutch release bearing if worn → Rep. gr.30. –  Clean the input shaft splines and the hub splines. Remove corrosion and apply only a very thin coating of grease -G 000 100- to the splines. Remove any excess grease. –  Install flywheel → Chapter. –  Secure gearbox to engine. –  Install starter → Electrical system; Rep. gr.27. –  Guide engine/gearbox assembly into body.

–  Initially hand-tighten bolts -arrows- for support arm of engine mounting as far as stop.

–  Initially screw in bolts -arrows- for gearbox mounting by hand until they make contact. –  Detach engine support -T10416- from engine. –  Install drive shafts and swivel joint → Rep. gr.40. –  Install pendulum support → Rep. gr.34. –  Install catalytic converter → Chapter. –  Install air conditioner compressor → Rep. gr.87. –  Install poly V-belt → Chapter. –  Install engine mountings → Chapter. –  Install engine control unit → Rep. gr.24.   Caution Avoid damage to clutch slave cylinder. Do not operate clutch pedal with slave cylinder removed. –  Install clutch slave cylinder → Rep. gr.30. –  Install and adjust gear selector cable and gate selector cable → Rep. gr.34. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install battery mounting and battery → Electrical system; Rep. gr.27. –  Install air cleaner housing → Rep. gr.24. –  Install wheel housing liners → Rep. gr.66. –  Check oil level → Booklet819.   Caution Risk of irreparable damage to control units because of excessive voltage. Never use battery charging equipment for boost starting. –  Fill up with coolant → Anchor.   Note t  Drained-off coolant may only be used again if the original cylinder head and cylinder block are re-installed. t  Contaminated or dirty coolant must not be used again. –  Install noise insulation → Rep. gr.66.