Audi Workshop Service and Repair Manuals

Installing engine l  Engine/gearbox unit 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 seals and gaskets. 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.

Vehicles with manual gearbox: –  If not already fitted, install dowel sleeves -A- for centring engine and gearbox in cylinder block. –  Check that clutch plate is correctly centred → Rep. gr.30. –  Check clutch release bearing for wear; renew slave cylinder with release bearing if necessary. –  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.

Vehicles with dual clutch gearbox: –  If not already fitted, install dowel sleeves -A- for centring engine and gearbox in cylinder block. –  Clean input shaft splines on gearbox 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. –  A needle bearing must be fitted in the crankshaft on vehicles with dual clutch gearbox; install needle bearing if not already fitted → Chapter.

All vehicles (continued): –  Ensure that the intermediate plate is engaged on the sealing flange and pushed onto the dowel sleeves -arrows-. –  Bolt gearbox to engine. Vehicles with four-wheel drive: –  Install bracket for bevel box → Rep. gr.34. All vehicles (continued): –  Install gearbox support → Rep. gr.34.   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 %.

Securing engine to manual gearbox

Item	Bolt	Nm
1, 2	M12x55 1)2)	80
3, 4	M12x165 1)	80
5	M12x105 2)	80
6, 7	M10x50 2)	40
8	M10x70 2)	40
A	Dowel sleeves for centralising
l  1) Bolt with M8 threaded pin l  2) Renew bolt.

Securing engine to dual clutch gearbox

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.

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 engine mountings → Chapter. –  Remove engine bracket -T10012- from engine. –  Install drive shafts → Rep. gr.40. –  Install wishbone (right-side) → Rep. gr.40.

Vehicles with four-wheel drive:   Caution Make sure not to damage the seal -arrow- in the propshaft flange. Push propshaft with flexible coupling horizontally onto centring pin and secure to bevel box flange → Rear final drive 02D, 0AV and 0BR; Rep. gr.39.

All vehicles (continued): –  Secure pendulum support → Rep. gr.34. –  Install particulate filter → Chapter. –  Align exhaust system so it is free of stress → Chapter. Vehicles with auxiliary heater: –  Install exhaust pipe for auxiliary heater → Rep. gr.82. All vehicles (continued): –  Install air conditioner compressor → Rep. gr.87. –  Install radiator cowl → Chapter. –  To facilitate positioning of alternator, drive back bushes for securing bolts slightly. –  Install alternator → Rep. gr.27. –  Install poly V-belt: vehicles with tensioner → Chapter, vehicles without tensioner → Chapter.

Vehicles with manual gearbox: –  Insert pipe/hose assembly -4- for clutch mechanism with a new O-ring -3- into bleeder connection -1- until securing clip -2- audibly locks into place. –  Pull on pipe/hose assembly as a check.   Caution The clutch pedal must not be operated before the clutch system has been bled. –  Detach hose clamp -3094-. –  Bleed clutch hydraulics → Rep. gr.30. –  Attach and adjust selector mechanism at gearbox → Rep. gr.34. Vehicles with dual clutch gearbox: –  Fit selector lever cable and adjust → Rep. gr.34. All vehicles (continued): –  Connect coolant hose to radiator → Fig.. –  Install air pipes/hoses with plug-in connectors → Chapter. –  Adjust assembly mountings → Chapter. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install battery → Rep. gr.27. –  Check oil level → Booklet808.   Caution Never use battery charging equipment for boost starting. There is danger of damaging the vehicle's control units. –  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. Tightening torques

Component			Nm
Bolts/nuts		M6	10
		M7	15
		M8	20
		M10	40
		M12	65
Except for the following:
Starter to dual-clutch gearbox			40
Underbody cross member to body			23
Charge pressure solenoid valve -N75- to bracket			8
Terminal B+ to starter			16
Earth cable			22
Oil pressure switch to oil filter bracket			20
Air pipe (left-side) to bracket			8
Air cleaner housing to bracket			10
Air pipe (right-side) to bracket			8
Heat shield to cylinder block			35