Audi Workshop Service and Repair Manuals

Installing engine Installation is carried out in the reverse order; note the following:   Note t  On assembly, renew oil seals and gaskets as well as self-locking nuts and bolts that are tightened by turning through to a specified angle. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. –  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install dowel sleeves if necessary. Vehicles with manual gearbox: –  There should be no needle bearing fitted in the crankshaft on vehicles with manual gearbox; remove needle bearing if fitted → Chapter. –  Check clutch release bearing for wear; renew if necessary. –  Lubricate splines of gearbox input shaft lightly with grease for clutch plate splines -G 000 100-. –  Check that the clutch plate is properly centralised (only necessary if you have carried out other work on the clutch). Vehicles with direct shift gearbox: –  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. –  Use new securing bolts.   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%.

Securing engine to manual gearbox

Item	Bolt	Nm
1 → Note, 3	M12x55	80
2 → Note	M12x65	80
4, 5 → Note → Note	M10x50	40
6 → Note	M12x80	80
A	Dowel sleeves for centralising

1)  Bolt with M8 stud 2)  Screwed into gearbox from engine side. 3)  Retaining clip for bolt must be fitted in sump.

Securing engine to direct shift gearbox

Item	Bolt	Nm
1	M12x55	80
2 → Note → Note	M10x40	40
3 → Note, 6	M12x55	80
4 → Note, 9	M10x45	40
5	M12x65	80
7, 8	M10x50	40
10	M12x70	80
A	Dowel sleeves for centralising

4)  Bolt with M8 stud 5)  Bolt is only used to secure starter to gearbox.

–  Install the bracket -A- for bevel box; note the following procedure: 1.  Initially tighten bolts -1- to 3 Nm. 2.  Tighten bolts -2- to 35 Nm. 3.  Then tighten bolts -1- to 45 Nm. –  Guide engine/gearbox assembly into the body.

–  Tighten bolts securing engine support to engine mounting -arrows- initially hand-tight.

–  Tighten bolts securing gearbox mounting to gearbox support -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 support from engine. –  Install drive shafts → Rep. Gr.40.   Note Drive shafts must be installed prior to further assembly.

–  Secure pendulum support to gearbox with new bolts -Item 2- and -Item 3-.

–  Push engine/gearbox assembly towards bulkhead; the journal of the bevel box must be simultaneously inserted horizontally and carefully into the flange of the propshaft.   Caution The oil seal -arrow- in the flange of propshaft must not be damaged when installing the engine/gearbox assembly. The propshaft must be renewed if oil seal is damaged.

–  Secure pendulum support to subframe using new bolt -item 1-.

–  Secure propshaft with flexible coupling to the flange of the bevel box -arrows-. Perform further installation in reverse order, paying attention to the following: –  Install exhaust system and align free of stress → Chapter. Vehicles with manual gearbox: –  Installing and adjusting selector mechanism → Rep. Gr.34. –  Connect pipe/hose to bleeder connection on clutch slave cylinder and bleed clutch system → Rep. Gr.30.   Caution The clutch pedal must not be depressed prior to bleeding the clutch system. Vehicles with direct shift gearbox: –  Install selector lever cable → Rep. Gr.37. All vehicles (continued): –  Install bracket for ancillary units → Chapter –  To facilitate positioning of alternator, drive back bushes for securing bolts slightly. –  Install alternator → Rep. Gr.27. –  Install air conditioner compressor. –  Install radiator cowl → Chapter „Removing and installing radiator fan -V7- and radiator fan 2 -V177-“. –  Install secondary air pump → Chapter. –  Install poly V-belt → Chapter. –  Adjust engine mountings → Chapter. –  Install windscreen wiper arms → Rep. Gr.92. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Connect earth strap to battery → Rep. Gr.27. –  Check oil level → Chapter.   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:
Pendulum support to gearbox		40 + 90° → Note → Note
Pendulum support to subframe		100 + 90° → Note → Note
Flexible coupling to flange		60
Front exhaust pipe to exhaust manifold		40 → Note
Drive shaft heat shield to bevel box		23
Terminal B+ to starter		16
Earth wire to gearbox		22

6)  Renew nuts and bolts. 7)  90° = a quarter of a turn.