Audi Workshop Service and Repair Manuals

Installing engine l  Engine/gearbox assembly 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  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.

–  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-. Vehicles with manual gearbox: –  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.

–  Renew O-ring -1- on stub shaft of gearbox (right-side) and lubricate splines -2- with universal grease → Electronic parts catalogue. Vehicles with direct shift gearbox: –  Clean input shaft splines on gearbox and splines 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 direct shift gearbox; install needle bearing if not yet fitted → Chapter. All vehicles (continued): –  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 manual gearbox

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

Securing engine to direct shift gearbox

Item	Bolt	Nm
1 1), 3 1), 10 1)	M12x55	80
5 1), 9 1)	M12x70	80
6 … 8 1)	M10x50	40
A	Dowel sleeves for centralising
l  1) Renew bolts.

–  Secure starter using bolts -2- and -4-. Vehicles with four-wheel drive: –  Install bracket for bevel box → Rep. Gr.34. –  Install flange shaft (right-side) → Rep. Gr.39.

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. –  Install drive shafts → Rep. Gr.40. Vehicles with engine codes AZV, BKD and direct shift gearbox: –  Install wishbone (right-side) → Rep. Gr.40. –  Install coupling rod (right-side) → Rep. Gr.40. –  Install radiator → Anchor. –  Install oil pressure switch → Chapter. Vehicles with four-wheel drive: –  Install propshaft → Rep. Gr.39.

All vehicles (continued): –  Secure pendulum support with bolts -1 ... 3- to gearbox and subframe. –  Use new securing bolts. Vehicles with engine codes AZV, BKD: –  Install front exhaust pipe → Chapter. Vehicles with engine codes BMN, BUY: –  Install particulate filter → Chapter. –  Install exhaust system and align it free of stress → Chapter. –  Install air conditioner compressor → Rep. Gr.87. –  To facilitate positioning of alternator, drive back bushes for securing bolts slightly. –  Install alternator → Rep. Gr.27. –  Install poly V-belt → 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.   WARNING 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 direct shift gearbox: –  Fit selector lever cable and adjust → Rep. Gr.34. All vehicles (continued): –  Adhere to the instructions for installing air pipes and hoses with plug-in connectors → Chapter. –  Install air pipes: vehicles with engine codes AZV, BKD → Chapter, vehicles with engine codes BMN, BUY → Chapter. Vehicles with four-wheel drive: –  Install crash sensor → Rep. Gr.69. All vehicles (continued): –  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 → 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.   WARNING Never use battery charging equipment for boost starting. There is danger of damaging the vehicle's control units. –  Check headlight adjustment → Booklet808. Tightening torques

Component			Nm
Bolts/nuts		M6	10
		M7	15
		M8	20
		M10	40
		M12	65
Except for the following:
Direct shift gearbox: Starter to gearbox			40
Manual gearbox: Gearbox support to gearbox			60 + 90° 1)2)
Pendulum support to:	Gearbox / subframe		Manual gearbox → Rep. Gr.34, automatic gearbox → Rep. Gr.37
Lock carrier to body			10
Terminal B+ to starter			16
Earth wire to gearbox			22
Air cleaner housing to bracket			10
Drive shaft heat shield to cylinder block			35
Underbody cross member (front) to body			23
l  1) Renew bolts. l  2) 90° = one quarter turn.