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 gear 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	20
		M10	40
		M12	65
Except for the following:
Drive shaft heat shield to cylinder block			35

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

Manual gearbox to engine

Item	Bolt	Nm
1	M12x55	80
2 1)	M12x150	80
3	M10x50	40
4	M12x60	80
5 2)	M6x8	10
A	Dowel sleeves for centralising
l  1) Also secures starter. l  2) Cover for flywheel.

7-speed dual clutch gearbox 0AM to engine:

Item	Bolt	Nm
1, 8	M10x50	40
2, 6, 7	M12x65	80
3, 4, 5	M12x55	80
A	Dowel sleeves for centralising

Procedure Installation is carried out in the reverse order; note the following: l  Engine/gearbox assembly attached to engine bracket -T10012-.   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  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  Fit all cable ties in the original positions when installing. –  Install intermediate plate → Fig..

Vehicles with manual gearbox: –  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. –  Lubricate splines of gearbox input shaft lightly with grease for clutch plate splines → Electronic parts catalogue. –  Make sure that clutch plate is properly centred.

Vehicles with 7-speed dual clutch gearbox 0AM: –  If not already fitted, install dowel sleeves -A- for centring engine and gearbox in cylinder block. –  Install needle bearing if not fitted in crankshaft → Chapter.

All vehicles (continued): –  Secure gearbox to engine. –  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. –  Remove engine support -T10012- from engine. –  Install clutch slave cylinder → Rep. gr.30. –  Install starter → Electrical system; Rep. gr.27. –  Install pump for exhaust gas recirculation cooler -V400- → Chapter. –  Install pendulum support → Rep. gr.34. –  Install drive shafts, wishbones and coupling rod → Rep. gr.40. –  Install heat shield for drive shaft → Anchor. –  Install alternator → Electrical system; Rep. gr.27. –  Install air conditioner compressor → Rep. gr.87. –  Install poly V-belt: t  → Chapter „Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioner“. t  → Chapter „Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioning roller“. Vehicles with manual gearbox: –  Install cables with cable support bracket → Rep. gr.30. Vehicles with 7-speed dual clutch gearbox 0AM: –  Install and adjust selector lever cable → Rep. gr.34. All vehicles (continued): –  Install engine control unit → Rep. gr.23. –  Install electronics box → Rep. gr.97. –  Install support arm of engine mounting → Chapter. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install particulate filter → Chapter. –  Connect coolant hoses with plug-in connector → Fig.. –  Install air pipe with connection → Chapter. –  Install air pipe → Chapter. –  Install air hoses with screw-type clips → Fig.. –  Install radiator cowl → Chapter. –  Observe notes on procedure for connecting the battery → Electrical system; Rep. gr.27. –  Install and adjust wiper arms → Electrical system; Rep. gr.92. –  Install air cleaner housing → Rep. gr.23. –  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.