Audi Workshop Service and Repair Manuals

Installing engine l  Engine installed on engine support -T40076- Installation is carried out in the reverse order; note the following:   Note t  Renew self-locking nuts and bolts when performing assembly work. t  Renew bolts which are tightened to a specified angle as well as oil seals and gaskets. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. Do NOT use lubricant. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. t  Fit all cable ties in the original positions when installing. –  Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splines to the splines. Do not lubricate guide sleeve → Rep. Gr.30. –  Check that clutch plate is correctly centred → Rep. Gr.30. –  Check clutch release bearing for wear, renew if necessary → Rep. Gr.30. –  Check whether dowel sleeves for centring the engine and the gearbox are fitted in the cylinder block; install missing dowel sleeves.

–  Ensure that the intermediate plate is engaged on the sealing flange and pushed onto the dowel sleeves -arrows-. –  Bolt gearbox to engine.   Note t  Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. t  Additional lubricant such as engine oil or gearbox oil may be used, but do not use lubricant containing graphite. t  Do not use degreased parts. t  Tolerance for tightening torques ± 15 %.

Securing engine to gearbox

Item	Bolt	Nm
1 1), 2	M12x55	80
3	M10x50	40
4 1)2)	M12x150	80
5 3)	M6x12	10
A, B	Dowel sleeves for centralising
l  1) Bolt with M8 stud l  2) Also for starter to gearbox. l  3) Cover for dual-mass flywheel.

–  Guide engine/gearbox assembly into the body.

–  Tighten bolts -1 and 2- of assembly mounting for engine initially hand-tight.   Note Disregard -item 3-.

–  Tighten bolts of assembly mounting for gearbox -arrows- initially hand-tight. –  Use new securing bolts. –  Remove engine support -T40076- from engine. –  Install drive shafts → Rep. Gr.40. –  Install swivel joint → Rep. Gr.40. –  Install catalytic converter → Chapter. –  Install pendulum support → Chapter. –  Install air conditioner compressor → Rep. Gr.87. –  Install starter → Rep. Gr.27. –  Install poly V-belt → Chapter.   Caution The clutch pedal must not be operated before installing slave cylinder. –  Install clutch slave cylinder → Rep. Gr.30. –  Attach and adjust selector mechanism at gearbox → Rep. Gr.34. –  Install transverse support → Rep. Gr.34. –  Install air pipes/hoses with plug-in connectors → Chapter. –  Install assembly mountings so they are free of stress → Chapter and → Rep. Gr.34. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Observe notes on procedures required after connecting battery → Rep. Gr.27. –  Install windscreen wiper arm → Rep. Gr.92. –  Check oil level → Chapter.   Caution Do not use a battery charger to boost starting. There is danger of damaging the vehicle's control units. –  Fill cooling system → 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. Tightening torques

Component			Nm
Bolts/nuts		M6	9
		M7	15
		M8	20
		M10	40
		M12	65
Except for the following:
Battery plus (+) cable to starter			16
Earth wire to gearbox			22
Bracket for wiring harness to coolant hose/pipe connection			10
Drive shaft heat shield to cylinder block			33
Air pipe to:	Turbocharger		8
	Sump		8
	Body		8
Engine cover panel to bracket			5.5