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. 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	40
A	Dowel sleeves for centralising
l  1) Also for starter to gearbox

Securing dual-clutch gearbox 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 attached to engine support -T40075-   Note t  Renew seals, gaskets and self-locking nuts and bolts. t  Renew the bolts tightened with specified tightening angle. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  Fit cable ties in the original positions when installing.

–  Ensure that intermediate plate is engaged on sealing flange -arrow A- and pushed onto dowel sleeves -arrows B-. –  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. –  Install clutch plate → 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.

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. Vehicles with dual clutch gearbox: –  Guide selector lever cable into cable support bracket when lifting engine/gearbox assembly.   Note Take care not to bend or kink selector lever cable. All vehicles (continued): –  Guide engine/gearbox assembly into body. –  Tighten bolts -arrows- securing engine mounting to engine support initially hand-tight.

Vehicles with manual gearbox: –  Tighten bolts -arrows- securing gearbox mounting to gearbox support initially hand-tight.

Vehicles with dual clutch gearbox: –  Tighten bolts -arrows- securing gearbox mounting to gearbox support -1- initially hand-tight. All vehicles (continued):   Note The bolts are tightened to final torque only after adjusting the assembly mountings → Chapter. –  Remove engine support -T40075- from engine. –  Install coolant circulation pump -V50- → Chapter. –  Install drive shafts, swivel joints and anti-roll bar → Rep. Gr.40. –  Install radiator cowl → Chapter.

–  Install pendulum support → Chapter. –  Install exhaust system and align free of stress → 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 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): –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install battery tray and battery → Electrical system; Rep. Gr.27. –  Install air cleaner housing → Rep. Gr.24. –  Check oil level → Booklet808.   Caution Risk of 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 → Rep. Gr.44. –  Install noise insulation panels → Rep. Gr.66.