Audi Workshop Service and Repair Manuals

Procedure

• ● Engine installed on engine bracket T10012.

Installation is carried out in the reverse order; note 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.
• ◆ Secure all hose connections with the correct hose clamps (same as original equipment):

=> Parts List

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

• ‒ → Engage intermediate plate on sealing flange and push onto dowel sleeves -arrows-.
• ‒ If necessary, check that clutch plate is properly centred.
• ‒ 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.
• ‒ Bolt gearbox to engine, use new bolts to fasten.

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%.

Vehicles with manual gearbox 02M:

→ Fastening engine to gearbox

    1)    Bolt with threaded pin M8

    2)    Replace bolts

A: Centring sleeves

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

• ‒ → Install angle drive mounting, observe the following installation sequence:
• ‒ Fit bolts -4 ... 6- loosely.
• ‒ Initially tighten bolts -1 ... 3- to 3 Nm.
• ‒ Then tighten bolts -4- and -6- to 45 Nm.
• ‒ Tighten bolt -5- to 22 Nm.
• ‒ Tighten bolts -1 ... 3- to 45 Nm.

• ‒ Guide engine/gearbox assembly into the chassis.
• ‒ → Unscrew bolts -arrows- engine mounting from engine console...

• ‒ → ...and gearbox mounting on gearbox console hand tight.
• ‒ Only use new bolts to secure.

Note:

The bolts are tightened to final torque only after adjusting the engine mounting => Page 10-85.

• ‒ Remove engine mounting T10012 from engine.

• ‒ → Push mechanical engine/gearbox units against bulkhead; the lug of the angle drive must be inserted horizontally and carefully into the flange of the propshaft.

• ‒ → Bolt on propshaft with drive disc to the flange of the angle drive
  -arrows-. Tightening torques:

=> 5 and 6-speed Manual Gearbox-02M Four-wheel Drive/Final Drives; Repair group 39

• ‒ Fit front exhaust pipe to turbocharger and secure with nut.
• ‒ Installing subframe

=> Running Gear, FWD and 4WD; Repair group 40

• ‒ → First attach pendulum support to gearbox -arrows B- and then to subframe -arrows A-.
• ‒ Only use new bolts to secure.
• ‒ Install drive shafts.

=> Running Gear, FWD and 4WD; Repair group 40

• ‒ To facilitate the attachment of the alternator, vane pump and air conditioner slightly push back the bush for the securing bolt.

• ‒ → Push the pressure line -1- into the hose connector and lock it with the catch.

• ‒ Remove hose clamp -3094-.
• ‒ Bleeding clutch hydraulic system:

=> 5 and 6-speed Manual Gearbox 02M Four-wheel Drive/Gearbox; Repair group 30; Servicing clutch mechanism

• ‒ Attach selector cables to gearbox and adjust:

=> 5 and 6-speed Manual Gearbox 02M Four-wheel Drive/Gearbox; Repair group 34; Servicing clutch mechanism

• ‒ Install exhaust system and align it stress-free => Page 26-35.
• ‒ Install ribbed belt =>Page 13-12.
• ‒ Adjust engine mounting => Page 10-85.

• ‒ → When installing air duct pipes with connectors, ensure that the securing clip -arrow- engages audibly in the retaining lug -A-.
• ‒ Install vacuum hoses =>as of Page 21-21.
• ‒ Electrical connections and routing:

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

Notes:

• ◆ 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.
• ◆ Deactivate the service mode of the telematics control unit.

=> Radio, Telephone and Navigation System; Repair group 91

• ‒ Check oil level => Page 17-23.

• ‒ Top up coolant => Page 19-10.

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.

Tightening torques

    1)    Stretch bolts, replace

    2)    90°corresponds to a quarter of a turn