Audi Workshop Service and Repair Manuals

Installing engine   Note t  Renew self-locking nuts and bolts. t  Renew bolts which are tightened to a specified angle as well as oil seals, gaskets and O-rings. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. 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. Vehicles with manual gearbox: –  Make sure that clutch plate is properly centred → Rep. Gr.30. –  Check clutch release bearing for wear; renew if necessary. –  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 -G 000 100- to the splines. Then move clutch plate back and forth on input shaft until the hub moves smoothly on the shaft. Remove any excess grease. Do not lubricate guide sleeve → Rep. Gr.30. –  A needle bearing must be fitted in the crankshaft on vehicles with manual gearbox; install needle bearing if not already fitted → Chapter. Vehicles with automatic gearbox: –  In vehicles with automatic gearbox, the needle bearing must NOT be fitted in the crankshaft; remove needle bearing if fitted → Chapter.

–  Checking installation depth of torque converter: l  If the torque converter has been correctly installed, the distance between the bottom contact surfaces at the studs on the torque converter and the contact surface on the torque converter bell housing (with automatic gearbox) is approx. 23 mm.   Caution If the torque converter is not installed correctly, the drive lugs of the torque converter and the ATF pump will be seriously damaged when the gearbox is joined to the engine. –  To secure torque converter on drive plate, only use new bolts (same as original equipment) as specified in → Parts catalogue.   Caution Before and during tightening of bolts on engine/gearbox flange, continually check that the torque converter behind the drive plate can be turned. If the converter cannot be turned, it must be assumed that it has not been installed correctly and the drive lugs of the ATF pump and consequently the gearbox will be damaged when the bolts are finally tightened.

All models: –  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install dowel sleeves if necessary. –  Ensure that the intermediate plate is engaged on the sealing flange and pushed onto the dowel sleeves -arrows-. –  Press intermediate plate between engine and gearbox onto dowel sleeves. –  Join engine onto gearbox and screw in one securing bolt (tighten hand-tight). –  Slacken spindle of support bracket -10 - 222 A-. –  Lower engine, inserting studs of engine mountings into consoles for engine mountings.

Securing engine to manual gearbox

Item	Bolt	Nm
1, 3, 4	M12x67	65
2, 6	M12x90	65
5 *), 11	M12x110	65
7 … 10	M10x45	45
A	Dowel sleeves for centralising
l  *) The wiring harness bracket is also secured with this bolt.

Securing engine to automatic gearbox

Item	Bolt	Nm
1, 8, 9, 10	M10x45	45
2, 3, 4, 11	M12x67	65
5 *)	M12x110	65
6	M12×90	65
7	M10x60	45
A	Dowel sleeves for centralising
l  *) The wiring harness bracket is also secured with this bolt.

Remaining installation steps are carried out in reverse sequence; note the following: –  Install engine mountings free of stress. To do so, shake engine before tightening engine mountings. –  Install air conditioner compressor → Rep. Gr.87. –  Install power steering pump → Rep. Gr.48. –  Install poly V-belt → Chapter. –  Align exhaust system so it is free of stress: vehicles with front-wheel drive → Chapter, vehicles with four-wheel drive → Chapter.

–  Install lock carrier with attachments → Rep. Gr.50. –  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight, and tighten bolts. Vehicles with automatic gearbox: –  Secure ATF pipes → Rep. Gr.37. All models: –  Install front bumper → Rep. Gr.63. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Observe notes on procedure for connecting the battery → Rep. Gr.27.   Caution Do not use a battery charger to boost starting. There is danger of damaging the vehicle's control units. –  Check oil level → Chapter. –  Fill up with coolant → 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. –  Check power-assisted steering fluid level → Rep. Gr.48. Vehicles with automatic gearbox: –  Check ATF level → Rep. Gr.37. Tightening torques   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 %.

Component		Nm
Bolts/nuts	M6	10
	M7	15
	M8	20
	M10	45
	M12	65
Except for the following:
Engine mounting to subframe		25
Engine support to engine mounting		25
Torque converter to drive plate		85
Catalytic converter to turbocharger		30
Bracket for ATF pipes		10
Power steering pump to bracket		23
Pulley to power steering pump		23
Viscous fan to bearing		45
A/C compressor to bracket		25
Stop for torque reaction support to sump		28
Hose clips for coolant hoses		2
Hose clips for air hoses		3.5