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 %. Assembly mountings → Chapter „Assembly mountings - exploded view“. Further tightening torques

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

Securing manual gearbox to engine

Item	Bolt	Nm
1	M12x65	80
2 1)	M12x135	80
3 1)	M12x150	80
4	M12x80	80
5	M10x50	→ Rep. gr.34
A	Dowel sleeves for centralising
l  1) Also for starter to gearbox

Securing dual-clutch gearbox to engine

Item	Bolt	Nm
1, 8	M10x50	→ Rep. gr.34
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 attached to engine support -T10416-.   Note t  Renew self-locking nuts and bolts. t  Renew bolts which are tightened to a specified angle as well as seals and gaskets. 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.. –  Install flywheel → Chapter.

Vehicles with manual gearbox: –  If not already fitted, install dowel sleeves -A- for centring engine and gearbox in cylinder block. –  Remove needle bearing in crankshaft if fitted → Chapter. –  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. –  Make sure that clutch plate is properly centred.

Vehicles with dual clutch gearbox: –  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. –  Install starter → Electrical system; Rep. gr.27. –  Guide engine/gearbox assembly into body. –  Initially screw in bolts -arrows- for engine mounting by hand until they make contact.

Vehicles with manual gearbox: –  Initially screw in bolts -arrows 1- for gearbox mounting by hand until they make contact.   Note Disregard -arrows 2-.

Vehicles with dual clutch gearbox: –  Initially screw in bolts -arrows- for gearbox mounting -1- by hand until they make contact. All vehicles (continued):   Note The bolts are tightened to final torque only after adjusting the assembly mountings → Chapter. –  Detach engine support -T10416- from engine. –  Install drive shafts and swivel joint → Rep. gr.40. –  Install pendulum support → Rep. gr.34. –  Install front exhaust pipe → Chapter. –  Install air conditioner compressor → Rep. gr.87. –  Install poly V-belt → Chapter. –  Adjust assembly mountings → Chapter. –  Install engine control unit → Rep. gr.24. –  Install plenum chamber partition panel → Rep. gr.50. –  Install wiper arms → Electrical system; Rep. gr.92. Vehicles with manual gearbox:   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. Vehicles with dual clutch gearbox: –  Install selector lever cable → Rep. gr.34. All vehicles (continued): –  Install radiator cowl → Chapter. –  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. –  Check oil level → Booklet808.   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  Do not use drained coolant again if: t  the cylinder head or cylinder block have been renewed. t  the coolant is contaminated or dirty. –  Install wheel housing liners → Rep. gr.66. –  Fit front wheels → Wheels and tyres; Rep. gr.44. –  Install noise insulation → Rep. gr.50.