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

Component		Nm
Bolts/nuts	M6	10
	M7	15
	M8	22
	M10	40
	M12	65

Securing manual gearbox to engine

Item	Bolt	Nm
1, 2	M12x65	80
3 1)2)	M12x150	80
4 1)2)	M12x165	80
5	M10x50	40
6	M12x85	80
A	Dowel sleeves for centralising
l  1) Bolt with M8 stud l  2) Also for starter to gearbox

Securing dual-clutch gearbox to engine

Item	Bolt	Nm
1, 3, 10	M12x55	80
5, 9	M12x70	80
6, 7, 8	M10x50	40
A	Dowel sleeves for centralising
l  Bolts -2 and 4- secure starter to gearbox → Rep. Gr.27.

Procedure Installation is carried out in the reverse order; note the following: l  Engine installed on engine bracket -T10359-.   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 cable ties in the original positions when installing. –  If not already fitted, install dowel sleeves for centring engine and gearbox in cylinder block.

–  Ensure that intermediate plate is engaged on sealing flange and pushed onto dowel sleeves -arrows-. –  Secure gearbox to engine. –  Guide engine/gearbox assembly into body.

–  Tighten bolts securing engine mounting to engine support -arrows- initially hand-tight.

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

Vehicles with dual clutch gearbox: –  Tighten bolts securing gearbox mounting to gearbox bracket -arrows- initially hand-tight. All vehicles:   Note The bolts are tightened to final torque only after adjusting the assembly mountings → Chapter. –  Detach engine bracket -T10359- from engine. –  Install drive shafts → Rep. Gr.40. –  Install heat shield for drive shaft → Rep. Gr.39. –  Install swivel joints → Rep. Gr.40.

–  Install pendulum support → Chapter. Vehicles with manual gearbox: –  Installing and adjusting selector mechanism → Rep. Gr.34.   Caution Avoid damage to clutch slave cylinder. Do not operate clutch pedal with slave cylinder removed. –  Install clutch slave cylinder → Rep. Gr.30. Vehicles with dual clutch gearbox: –  Install selector lever cable → Rep. Gr.34. Vehicles with auxiliary heater: –  Install coolant pipes and exhaust silencer → Rep. Gr.82. All vehicles: –  Install front exhaust pipe with catalytic converter → Chapter. –  Align the exhaust system so it is free of stress → Chapter. –  Install continued coolant circulation pump -V51- → Chapter. –  Install air conditioner compressor → Rep. Gr.87. –  Install radiator cowl → Chapter. –  Install poly V-belt → Chapter. –  Install starter → Rep. Gr.27 –  Install throttle valve module -J338- → Rep. Gr.24. –  Adjust assembly mountings → Chapter. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install battery → Rep. Gr.27. –  Install wiper arms → Rep. Gr.92. –  Check oil level → Booklet808.   Caution Risk of damage to control units because of excessive voltage. Never use battery charging equipment for boost starting.

–  Connect coolant hose with plug-in connector → Fig.. –  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.