audi Workshop Repair Guides

Audi Workshop Service and Repair Manuals

ABOUT US
Enginecrankshaft group, pistons > < Securing engine to assembly stand

A4 Cabriolet Mk2

Installing engine
Installing engine
  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, gaskets and O-rings.
t  Hose connections and hoses for charge air system 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) → Parts catalogue.
t  Fit all cable ties in the original positions when installing.
Vehicles with manual gearbox:
–  When fitting a new clutch plate together with a used pressure plate (self-adjusting clutch), the adjuster ring in the pressure plate has to be reset by turning it back as far as it will go. If this is not done, the pressure plate will operate with reduced clamping force, causing clutch slip → Rep. gr.30.
  Note
t  If the clutch plate is not being replaced, it is not necessary to reset the adjuster ring.
t  New SAC pressure plates are already pre-set accordingly, and do not have to be reset.
–  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. Do not lubricate guide sleeve.
–  Check that the clutch plate is properly centralised (only necessary if you have carried out other work on the clutch).
–  Check clutch release bearing for wear; renew if necessary.
If the plastic ring for release bearing is loose:
   
–  Bond the plastic ring for release bearing to bearing race using adhesive -AMV 195 KD1 01-.
l  Three square lugs -arrows- on the plastic ring engage in the recesses in the bearing race.
l  The release bearing must be renewed if it has scoring deeper than 0.5 mm.
–  A needle bearing must be fitted in the crankshaft on vehicles with manual gearbox. If necessary, install needle bearing → Chapter.
Vehicles with multitronic gearbox:
–  Clean input shaft splines and splines of damper unit on flywheel; remove corrosion and apply only a very thin coating of grease -G 000 100- to the splines. Remove any excess grease.
Vehicles with automatic gearbox 01V:
–  Engines for vehicles with automatic gearbox 01V must not be fitted with a needle bearing in the crankshaft. If necessary, remove needle bearing → Chapter.
–  To secure torque converter on drive plate, use only bolts of the correct type (same as original equipment) as specified in → Parts catalogue.
  N30-0285
Checking installation position of torque converter:
If the torque converter has been correctly installed, the distance between the bottom contact surfaces at the studs on the torque converter and the contact surface on the torque converter bell housing (with automatic gearbox) is approx. 23 mm.
  Caution
If the torque converter is not installed correctly, the drive lugs of the torque converter and the ATF pump will be seriously damaged when the gearbox is joined to the engine.
All vehicles:
–  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install dowel sleeves if necessary.
  V32-0069
–  Ensure that the intermediate plate is engaged on the sealing flange and pushed onto the dowel sleeves -arrows-.
–  Push intermediate plate between engine and gearbox onto dowel sleeves.
–  Attach engine to gearbox and screw in one bolt finger-tight.
–  Release spindle of support bracket -10-222 A-.
–  Lower engine, inserting studs of engine mountings into consoles for engine mountings as you do so.
Remaining installation steps are carried out in reverse sequence; note the following:
–  Install engine mountings free of stress. To do so, shake engine before tightening engine mountings.
–  Install exhaust system and align free of stress → Chapter.
–  Install air conditioner compressor → Air conditioning system; Rep. gr.87
–  Install power steering pump → Running gear, front-wheel drive and four-wheel drive; Rep. gr.48.
–  Install poly V-belt → Chapter.
  A13-0682
–  Install lock carrier with attachments → General body repairs, exterior; Rep. gr.50.
–  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight and tighten nuts -arrows-.
–  Install front bumper cover → General body repairs, exterior; Rep. gr.63.
–  Secure ATF lines → Rep. gr.37.
–  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations.
–  Observe notes on procedures required after connecting battery → Electrical system; 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.
–  Check power steering fluid level: → Running gear, front-wheel drive and four-wheel drive; Rep. gr.48.
–  Check ATF level → Rep. gr.37.
–  Check headlight adjustment → Booklet8E.
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 %.
  A10-10298
ComponentNm
Bolts/nutsM69
 M715
 M820
 M1045
 M1265
Except for the following: 
Engine to gearboxM1045 → Remark
 M1265 → Remark
Torque converter to drive plate85 → Remark
Engine mounting to engine console23
Engine mounting to engine support23
Terminal B+ to starter16
Drive shaft heat shield to gearbox23
Fuel line to fuel rail22
Stop for torque reaction support to lock carrier28
Hose clips (9 mm wide)3
Hose clips (13 mm wide)5.5

1)  Renew bolts on vehicles with multitronic gearbox.
2)  Use only genuine bolts → Parts catalogue
   

Enginecrankshaft group, pistons > < Securing engine to assembly stand