Audi Workshop Service and Repair Manuals

Installing engine Procedure l  Engine attached to engine bracket -T10012- Installation is carried out in the reverse order; note the following:   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 and gaskets. t  Reinstall all cable ties in the same locations when assembling. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  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. 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 %. –  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install if necessary.

–  Make sure that intermediate plate is engaged on sealing flange -arrow A- and pushed onto dowel sleeves -arrows B-. Vehicles with manual gearbox: –  Check that clutch plate is correctly centred → Rep. gr.30. –  Check clutch release bearing for wear; renew if necessary. –  Bolt gearbox to engine.

Securing engine to manual gearbox

Item	Bolt	Nm
1, 2	M12x65	80
3 1), 4 1)	M12x135	80
5 … 7	M10x60	40
8	M12x90	65
A	Dowel sleeves for centralising
l  1) Bolt with M8 threaded pin

–  Push in deflector plate -2- in such a way that the lower lug engages into the cylinder block and secure on top with bolt -1-.   Note Shown in illustration with gearbox removed.

Vehicles with automatic gearbox: Checking installation depth of torque converter: If the torque converter has been correctly installed, the distance between the contact surfaces at the bottom of the studs on the torque converter and the joint surface on the torque converter bell housing (with automatic gearbox) -a- is at least 19.5 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.

Securing engine to automatic gearbox

Item	Bolt	Nm
1, 2	M12x55	80
3 1)2), 4 1)2)	M12x165	80
5	M10x65	40
6, 7	M10x55	40
8	M12x100	65
A	Dowel sleeves for centralising
l  1) Bolt with M8 threaded pin l  2) Bolt also secures starter to gearbox

–  To secure torque converter on drive plate, use only new nuts -arrow- of the correct type (same as original equipment), as specified in → Electronic parts catalogue.   Note Disregard -item 1-.

Securing engine to dual clutch gearbox

Item	Bolt	Nm
1, 3	M12x55	80
2	M12x170	80
4	M12x80	80
5, 6, 7	M10x50	40
8	M12x90	65
A	Dowel sleeves for centralising

All vehicles (continued): –  Guide engine/gearbox assembly into the body. –  Tighten bolts -arrows- of assembly mounting for engine initially hand-tight.

–  Tighten bolts of assembly mounting for gearbox -arrows- initially hand-tight. –  Use new securing bolts.   Note The bolts are tightened to final torque only after adjusting the assembly mountings → Chapter. –  Remove engine bracket -T10012- from engine.

–  Apply locking fluid to sealing plug -arrow- and insert plug. t  Locking fluid → Electronic parts catalogue

–  Secure pendulum support with bolts -1 ... 3- to gearbox and subframe. –  Install drive shafts → Rep. gr.40. –  Install front exhaust pipe with catalytic converter: vehicles with engine codes BGU, BSE, BSF, CCSA → Chapter. –  Install front exhaust pipe with catalytic converter: vehicles with engine code CMXA → Chapter. –  Align the exhaust system so it is free of stress → Chapter. –  Install air conditioner compressor → Rep. gr.87. –  Install slave cylinder for hydraulic clutch mechanism → Rep. gr.30. –  Attach and adjust selector mechanism at manual gearbox → Rep. gr.34. –  Attach and adjust selector lever cable → Rep. gr.34 or → Rep. gr.37. –  To facilitate positioning of alternator, drive back bushes for securing bolts slightly. –  Install alternator → Rep. gr.27. –  Install poly V-belt → Chapter. –  Adjust engine 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. –  Bleed fuel system → Rep. gr.24. –  Check engine oil level → Booklet808. –  Connect coolant hose with plug-in connector to radiator → Fig.. –  Fill cooling system → Anchor.   Note t  Drained coolant may not be used again if the cylinder head or cylinder block have been renewed. 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. –  Check ATF level of automatic gearbox → Rep. gr.37. Tightening torques

Component			Nm
Bolts/nuts		M6	10
		M7	15
		M8	20
		M10	40
		M12	65
Except for the following:
Torque converter to drive plate			57 1)
Sealing plug in cylinder block			10 2)
Pendulum support to:	Gearbox		40 + 90° 1)3)
	Subframe		100 + 90° 1)3)
Air-conditioner compressor to bracket for ancillaries			25
Terminal B+ to starter			16
Earth wire to gearbox			23
l  1) Renew nuts/bolts. l  2) Apply locking fluid when installing; refer to → Electronic parts catalogue for locking fluid. l  3) 90° = one quarter turn.