Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Depth measurement (vehicles with automatic gearbox)

Procedure

• ● Engine installed on engine bracket T10012.

Installation is carried out in the reverse order to removal, noting the following:

Notes:

• ◆ When performing installation procedures always replace self-locking nuts and bolts.
• ◆ Replace seals, gaskets, and bolts which have a specified tightening angle.
• ◆ Hose connections and hoses for charge air system must be free of oil and grease before assembly.

• ‒ Check whether the dowel sleeves for centralising engine/gearbox are in the cylinder block, install if necessary.

• ‒ → Engage intermediate plate on sealing flange and slide onto dowel sleeves -arrows-.

Vehicles with manual gearbox

• ‒ If necessary, check that clutch plate is properly centralised.
• ‒ Check clutch release bearing for wear, renew if necessary.
• ‒ Lightly lubricate clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000 100.
• ‒ Attach gearbox to engine.

Notes:

• ◆ The tightening torques listed on this page apply only to lightly greased, oiled, phosphated, or black finished nuts and bolts.
• ◆ Additional lubricant such as engine or gearbox oil may be used, but do not use graphite lubricant.
• ◆ Do not use degreased parts.
• ◆ Tightening torque tolerance ±15%.

→ Engine/gearbox mountings (manual gearbox)

    1)    Bolt with threaded pin M8

A: Centring sleeves

• ‒ → Push in splash plate -2- in so that the lower lug engages into the cylinder block and secure at top with bolt -1-.

Vehicles with automatic gearbox:

• ‒ To secure the torque converter on the drive plate only use the correct nuts as specified in the parts catalogue.

=> Parts List

→ If the torque converter is correctly installed, the depth between the contact surfaces at the bottom of the studs on the torque converter and the contact surface of the torque converter bell housing is about 22 mm.

If the torque converter has not been completely inserted, this distance will be approx. 10 mm.

• ‒ Before installing engine, rotate torque converter and drive plate so that one hole and one stud are level with the aperture for the starter motor.

• ‒ Attach gearbox to engine.
• ‒ Secure nuts of torque converter with special tool Matra V/175.

Notes:

• ◆ The tightening torques listed on this page apply only to lightly greased, oiled, phosphated, or black finished nuts and bolts.
• ◆ Additional lubricant such as engine or gearbox oil may be used, but do not use graphite lubricant.
• ◆ Do not use degreased parts.
• ◆ Tightening torque tolerance ±15%.

→ Securing engine to gearbox in vehicles with automatic gearbox

    1)    Bolt with threaded pin M8

A: Centring sleeves

All models:

• ‒ Guide engine/gearbox assembly into the body.
• ‒ → Insert bolts -arrows- for engine support to engine console...

• ‒ → ... and gearbox support to gearbox console handtight.
• ‒ Only use new bolts to secure.

Note:

The bolts are tightened to final torque only after adjusting the engine mountings .

• ‒ Remove engine bracket T10012 from engine.
• ‒ Install drive shafts.

=> Running Gear; Repair group 40; Removing and installing drive shaft

Note:

Before further assembly carry out the installation of the drive shafts.

• ‒ Install the connecting rod.

=> Running Gear; Repair group 40; Removing and installing stabiliser bar

• ‒ → Bolt pendulum support to gearbox -arrows B-.
• ‒ Only use new bolts to secure.

• ‒ → Bolt pendulum support to subframe -arrows A-.
• ‒ Only use new bolts to secure.

Vehicles with air conditioning:

• ‒ → To facilitate the attachment of the air conditioner compressor drive back bush -B- for securing bolt -A- slightly.

Vehicles with manual gearbox

• ‒ Install hydraulic clutch slave cylinder:

=> 5-speed Manual Gearbox 02J; Repair group 30; Servicing clutch release mechanism

• ‒ Attach selector cables to gearbox and adjust:

=> 5-speed Manual Gearbox 02J; Repair group 34; Servicing shift mechanism; Removing and installing selector cables

The remaining installation steps are carried out in the reverse sequence.

• ‒ Install ribbed belt=> Page 13-10.
• ‒ Adjust engine mountings => Page 10-41.
• ‒ Install vacuum hoses =>as of Page 21-19.

• ‒ Electrical connections and routing:

=> Current Flow Diagrams, Electrical Fault-finding and Fitting Locations binder

Note:

If the battery is reconnected, please ensure that the vehicle equipment (radio, radio/navigation system, clock, electric window lifters) is activated as described in the operating instructions.

• ‒ Top up coolant => Page 19-7.

Notes:

• ◆ Drained coolant may only be used again if the original cylinder head and cylinder block are re installed.
• ◆ Coolant must not be used again if it is dirty.

• ‒ Check oil level before starting engine.

Tightening torques

    1)    Stretch bolts, replace

    2)    90°corresponds to a quarter of a turn