Audi Workshop Service and Repair Manuals

Installing engine Procedure l  Engine installed on 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  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  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 -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. –  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install if necessary.

–  Ensure that the intermediate plate is engaged on the sealing flange and pushed onto the dowel sleeves -arrows-. –  Check that clutch plate is correctly centred → Rep. Gr.30. –  Check clutch release bearing for wear, renew if necessary. –  Bolt gearbox to engine.   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 %.

Securing engine to gearbox

Item	Bolt	Nm
1, 2 1), 8	M12x55	80
3 1), 4 1)	M12x150	80
5 … 7	M10x50	45
A	Dowel sleeves for centralising
l  1) Bolt with M8 stud

–  Guide engine/gearbox assembly into the body.

–  Tighten bolts of assembly mounting on engine -arrows- initially finger-tight.

–  Tighten bolts of assembly mounting on gearbox -arrows- initially finger-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.

–  Secure pendulum support with bolts -1 ... 3- to gearbox and subframe. –  Use new securing bolts. –  Install exhaust system and align it free of stress → Chapter. –  Install air conditioner compressor → Rep. Gr.87. –  Install radiator → Chapter. –  Install alternator → Rep. Gr.27. –  Install poly V-belt → Chapter. –  Install slave cylinder for hydraulic clutch mechanism → Rep. Gr.30.   Caution The clutch pedal must not be operated before installing slave cylinder. –  Attach and adjust selector mechanism at gearbox → Rep. Gr.34. –  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.   Caution Do not use a battery charger to boost starting. There is danger of damaging the vehicle's control units. –  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. Tightening torques   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 %.

Component		Nm
Bolts/nuts	M6	10
	M7	15
	M8	20
	M10	40
	M12	65
Except for the following:
Gearbox support to gearbox		60 + 90° 1)2)
Air intake pipe (left-side) to sump		10
Pendulum support to gearbox		40 + 90° 1)2)
Pendulum support to subframe		100 + 90° 1)2)
Terminal B+ to starter		16
Earth wire to gearbox		22
l  1) Renew bolts. l  2) 90° = one quarter turn.