Audi Workshop Service and Repair Manuals

Installing engine   Note t  Renew self-locking nuts and bolts when performing assembly work. 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) → Electronic parts catalogue. t  To ensure that the charge air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing. t  Fit all cable ties in the original positions when installing. Vehicles with manual gearbox: –  When fitting a new clutch plate together with a used pressure plate (self-adjusting clutch), the adjuster ring in the pressure plate has to be reset by turning it back as far as it will go. If this is not done, the pressure plate will operate with reduced clamping force, causing clutch slip → Rep. Gr.30.   Note t  If the clutch plate is not being replaced, it is not necessary to reset the adjuster ring. t  New SAC pressure plates are already pre-set accordingly, and do not have to be reset. –  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. Do not lubricate guide sleeve. –  Check that the clutch plate is properly centralised (only necessary if you have carried out other work on the clutch). –  Check clutch release bearing for wear and make sure that plastic ring is securely seated; renew clutch release bearing if necessary → 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 multitronic gearbox: –  Clean input shaft splines and splines of damper unit on flywheel; remove corrosion and apply only a very thin coating of grease for clutch plate splines -G 000 100- to the splines. Remove any excess grease. All vehicles: –  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-. –  Push intermediate plate between engine and gearbox onto dowel sleeves. –  Attach engine to gearbox and screw in one bolt finger-tight. –  Release spindle of support bracket -10-222 A-. –  Lower engine, inserting studs of engine mountings into consoles for engine mountings as you do so.   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%.

Securing engine to manual gearbox

Item	Bolt	Nm
1, 6	M12x105	65
2, 4	M12x80	65
3	M12x90	65
5, 7	M12x95	65
8	M10x50	45
9, 10, 11	M10x45	45
A	Dowel sleeves for centralising

Securing engine to multitronic gearbox

Item	Bolt	Nm
1	M12x67	65
2	M10x70	45
3, 4, 5, 7	M12x75	65
6	M12x105	65
8	M10x60	45
9, 10, 11	M10x45	45
A	Dowel sleeves for centralising

All vehicles: Remaining installation steps are carried out in reverse sequence; note the following: –  Install exhaust system and align so it is free of stress: vehicles without particulate filter → Chapter, vehicles with particulate filter → Chapter. –  Install air conditioner compressor → Rep. Gr.87. –  Install power steering pump → Rep. Gr.48. –  Install poly V-belt → Chapter.

–  When installing air intake hoses with plug-in connectors, ensure that the securing clip -arrow- engages audibly on the retaining lug -A-.

–  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 nuts -arrows-. –  Install bumper cover (front) → Rep. Gr.63. Vehicles with multitronic gearbox: –  Secure ATF lines → Rep. Gr.37. All vehicles: –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Observe notes on procedures required after connecting 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 → Booklet803 or → Booklet805. –  Fill cooling system → 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 fluid level of power steering → Rep. Gr.48. Vehicles with multitronic 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	9
	M8	20
	M10	40
	M12	65
Except for the following:
Engine mounting to engine console		40
Engine mounting to engine support		23
Electrical wire to starter		16
Electrical wire to alternator		16
Drive shaft heat shield to gearbox		23
Stop for torque reaction support to lock carrier		28
Hose clips (9 mm wide)		3
Hose clips (13 mm wide)		5.5