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 gear oil may be used, but do not use lubricants 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	40
		M12	65
Except for the following:
Underbody cross member (front) to body			23

Assembly mountings → Chapter „Assembly mountings - exploded view“.

Securing manual gearbox to engine

Item	Bolt	Nm
1 1)	M12x55	80
2 1)	M12x165	80
3	M10x105	40
4	M10x50	40
5 2)	M12x65	80
A	Dowel sleeves for centralising
l  1) Bolt with M8 threaded pin l  2) Screwed into gearbox from engine side

Securing dual-clutch gearbox to engine

Item	Bolt	Nm
1, 3, 10	M12x55	80
5	M12x65	80
6, 7, 8	M10x50	40
9	M12x70	80
2, 4	Securing starter → Electrical system; Rep. gr.27
A	Dowel sleeves for centralising

Heat shield for drive shaft (right-side) - tightening torque   Note Illustration shows heat shield on vehicles with front-wheel drive as an example. –  Tighten bolts -arrows- to 35 Nm. Procedure Installation is carried out in the reverse order; note the following:   Note t  Renew the bolts tightened with specified tightening angle. t  Renew self-locking nuts and bolts as well as seals, gaskets and O-rings. t  Hose connections and air pipes and hoses 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  Fit all cable ties in the original positions when installing. –  Install intermediate plate → Fig..

Vehicles with manual gearbox: –  If not already fitted, install dowel sleeves -A- for centring engine and gearbox in cylinder block. –  Remove needle bearing in crankshaft if fitted → Chapter. –  Renew clutch release bearing if worn → Rep. gr.30. –  Lubricate splines of gearbox input shaft lightly with grease for clutch plate splines → Electronic parts catalogue. –  Make sure that clutch plate is properly centred.

Vehicles with dual clutch gearbox: –  If not already fitted, install dowel sleeves -A- for centring engine and gearbox in cylinder block. –  Install needle bearing if not fitted in crankshaft → Chapter. All vehicles (continued): –  Secure gearbox to engine. –  Install gearbox support → Rep. gr.34. –  Attach engine/gearbox assembly to engine bracket -T10012-. Vehicles with four-wheel drive: –  Install bracket for bevel box → Rep. gr.34. All vehicles (continued): –  Guide engine/gearbox assembly into body.

–  Initially screw in bolts -arrows- for engine mounting by hand until they make contact.

–  Initially screw in bolts -arrows- for gearbox mounting by hand until they make contact.   Note The bolts are tightened to final torque only after adjusting the assembly mountings → Chapter. –  Remove engine support -T10012- from engine. –  Install starter → Electrical system; Rep. gr.27. –  Install pump for exhaust gas recirculation cooler -V400- → Chapter. –  Install air pipe → Chapter. –  Install intake connecting pipe → Chapter. –  Install air hoses with screw-type clips → Fig.. Vehicles with dual clutch gearbox: –  Install and adjust selector lever cable → Rep. gr.34. All vehicles (continued): –  Install particulate filter → Chapter. –  Install drive shafts, wishbones and coupling rod → Rep. gr.40. –  Install heat shield for drive shaft (right-side) → Fig.. –  Install air conditioner compressor → Rep. gr.87. –  Install poly V-belt: t  → Chapter „Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioner“. t  → Chapter „Removing and installing poly V-belt - vehicles with air conditioner compressor and tensioning roller“. –  Install front sections of wheel housing liner → Rep. gr.66. –  Fit front wheels → Wheels and tyres; Rep. gr.44. –  Install engine control unit → Rep. gr.23. –  Install radiator → Chapter. –  Connect coolant hoses with plug-in connectors to heat exchanger for heater → Fig.. –  Install supplementary fuel pump -V393- → Rep. gr.20. –  Install pressure differential sender -G505- → Rep. gr.23. –  Install filler pipe with filler neck for washer fluid reservoir → Electrical system; Rep. gr.92. Vehicles with manual gearbox: –  Connect clutch slave cylinder and bleed clutch hydraulics → Rep. gr.30. –  Install cables with cable support bracket → Rep. gr.34. All vehicles (continued): –  Install pendulum support → Rep. gr.34. –  Adjust assembly mountings → Chapter. –  Install battery mounting and battery → Electrical system; Rep. gr.27. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Connect vacuum hoses → Chapter. –  Install plenum chamber partition panel → Rep. gr.55. –  Install and adjust wiper arms → Electrical system; Rep. gr.92. –  Install air cleaner housing → Rep. gr.23. –  Check oil level → Booklet808.   Caution Risk of irreparable damage to control units because of excessive voltage. Never use battery charging equipment for boost starting. –  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. –  Install noise insulation frame (if fitted) and noise insulation panels → Rep. gr.50.