Audi Workshop Service and Repair Manuals

Installing engine   Note t  On assembly, renew oil seals and gaskets as well as self-locking nuts and bolts that are tightened by turning through to a specified angle. 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. –  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install dowel sleeves if necessary.

–  Engage intermediate plate on sealing flange and slip onto dowel sleeves -arrows-. –  Check that clutch plate is correctly centred. –  Check clutch release bearing for wear, renew if necessary. –  Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with grease for clutch plate splines -G 000 100-.   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 %. –  Fit bracket for bevel box before fitting engine/gearbox securing bolts. –  Use new securing bolts.

Securing engine to gearbox

Item	Bolt 2	Nm
1, 2 1)	M12x55	80
3 1), 4 1)	M12x165	80
5	M10x105	40
6, 7	M10x50	40
8	M12x70	80
A	Dowel sleeves for centralising
l  1) Bolt with M8 stud l  2) Renew bolts.

–  Push in small cover plate -2- for flywheel behind bevel box in such a way that lug at bottom engages into cylinder block and secure with bolt -1-.

–  Fit bolts of bevel box bracket. Note tightening sequence:

1.  Initially tighten bolts -arrow 1- to 3 Nm. 2.  Tighten bolts -arrow 2- to 35 Nm. 3.  Tighten bolts -arrow 1- to 45 Nm.

–  Guide engine/gearbox assembly into the body. –  Tighten bolts securing engine mounting to engine support -arrows- initially hand-tight.

–  Tighten bolts securing gearbox mounting to gearbox support -arrows- initially hand-tight. –  Use new securing bolts.   Note The bolts are tightened to final torque only after adjusting the engine mountings → Chapter. –  Remove engine bracket -T10012- from engine. –  Bolt drive shafts to flange shafts of gearbox → Rep. Gr.40.   Note Drive shafts must be installed prior to further assembly. –  Secure coupling rod to anti-roll bar → Rep. Gr.40.

–  Secure pendulum support at gearbox -arrows B-. –  Use new securing bolts.

Caution Avoid damaging the seal -arrow- in the propshaft flange when installing. If a seal is damaged the propshaft must be renewed. –  Push engine/gearbox assembly towards bulkhead; the journal of the bevel box must be simultaneously inserted horizontally and carefully into the flange of the propshaft.

–  Secure pendulum support to subframe -arrows A-. –  Use new securing bolts.

–  Secure propshaft with flexible coupling to bevel box -arrows- → Rep. Gr.39. –  Install catalytic converter and front exhaust pipe → Chapter. –  Install exhaust system and align it free of stress → Chapter. –  Install cross piece; note marking “L” or “Links” for left side of vehicle. –  Use new securing bolts. –  Knock back bushes for securing bolts slightly to facilitate installation of power steering pump and air conditioner compressor. –  Install power steering pump → Rep. Gr.48. –  Install secondary air pump → Chapter. –  Install air conditioner compressor → Rep. Gr.87.

–  Push the hydraulic line -1- for clutch slave cylinder into the hose connector and lock it with the catch.   Caution The clutch pedal must not be depressed prior to bleeding the clutch system. –  Detach hose clamp -3094-. –  Bleed clutch hydraulics → Rep. Gr.30. Remaining installation steps are carried out in reverse sequence; note the following: –  Install cable support bracket and selector cables → Rep. Gr.34. –  Install poly V-belt → Chapter. –  Adjust assembly mountings → Chapter. –  Connect vacuum hoses → Chapter. –  Install cross piece for suspension strut → Rep. Gr.40. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations.   Note t  When the battery is reconnected, please ensure that the vehicle equipment (e.g. radio, radio/navigation system, clock, electric window lifters) is activated as described in the operating instructions. t  For further operations after reconnecting power supply, refer to → Rep. Gr.24. –  Check oil level → Chapter. –  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.   Caution Never use battery charging equipment for boost starting. There is danger of damaging the vehicle's control units. Tightening torques

Component			Nm
Bolts/nuts		M6	9
		M8	20
		M10	45
		M12	65
Except for the following:
Radiator cowl to radiator			10
Pendulum support to:	Gearbox		40 + 90° 1)2)
	Subframe		20 + 90° 1)2)
Drive shaft heat shield to bevel box			25
Rear cross piece to subframe			30 + 90° 1)2)3)
Connecting pipe for charge air coolers to longitudinal member			20
Hose clips for air hoses			3.5
l  1) Renew bolts. l  2) 90° = one quarter turn. l  3) Install using locking fluid; for locking fluid refer to → Parts catalogue.