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Enginecrankshaft group, pistons > < Securing engine to engine and gearbox support

A4 Cabriolet Mk2

Installing engine
Installing engine
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  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) → Electronic parts catalogue.
t  To ensure that the charge air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing.
t  Fit all cable ties in the original positions when installing.
Vehicles with self-adjusting clutch (SAC):
–  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 for clutch plate splines -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 and make sure that plastic ring is securely seated; renew clutch release bearing if necessary → Rep. Gr.30.
–  A needle bearing must be fitted in the crankshaft on vehicles with manual gearbox; install needle bearing if not yet fitted: Open version → Chapter, closed version → 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 for clutch plate splines -G 000 100- to the splines. Remove any excess grease.
   
All vehicles:
–  Check whether both 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-.
–  If fitted, push intermediate plate between engine and gearbox onto dowel sleeves.
–  Attach engine to gearbox and screw in one bolt finger-tight.
–  Fit engine mounting (left-side).
–  Release spindle of support bracket -10 - 222 A-.
–  Lower engine, inserting studs of engine mountings into consoles for engine mountings as you do so.
–  Before securing engine mountings, align engine so that mountings are free of stress by shaking back and forth.
–  Screw in securing bolts for engine/gearbox, noting different bolt lengths as you do so.
The remaining installation steps are carried out in the reverse sequence.
Vehicles with engine codes AVB, AVF, AWX, BKE:
–  Install catalytic converter together with front exhaust pipe → Chapter.
–  Align exhaust system so it is free of stress → Chapter.
Vehicles with engine codes BPW, BRB, BRC:
–  Install particulate filter → Chapter.
–  Install front exhaust pipe: vehicles with manual gearbox → Chapter; vehicles with multitronic gearbox → Chapter.
–  Align exhaust system so it is free of stress → Chapter.
All vehicles:
–  Install air conditioner compressor → Rep. Gr.87.
–  Install power steering pump → Rep. Gr.48.
–  Install poly V-belt: vehicles up to 05.2003 → Anchor, vehicles from 06.2003 onwards → Anchor.
  A10-0129
–  When installing air intake hoses with plug-in connectors, ensure that the securing clip -arrow- engages audibly on the retaining lug -A-.
–  Install lock carrier with attachments → Rep. Gr.50.
Vehicles with multitronic gearbox:
–  Secure ATF lines → Rep. Gr.37.
All vehicles:
–  Install bumper cover (front) → Rep. Gr.63.
–  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.
–  Install and adjust wiper arms → Electrical system; Rep. Gr.92.
–  Check oil level → Booklet803 or → Booklet805.
–  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.
–  Top up power steering fluid and bleed steering system → Rep. Gr.48.
Vehicles with multitronic gearbox:
–  Check ATF level → Rep. Gr.37.
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%.
  N21-0184
ComponentNm
Bolts/nuts M610
  M820
  M1045
  M1265
Except for the following: 
Engine to gearbox M1045 1)
  M1265 1)
Engine mounting to:Console for engine mounting40
 Engine support23
Electrical wire to starter16
Hose clipsWidth 9 mm3
Width 13 mm5.5
l  1) Renew bolts on vehicles with multitronic gearbox.

   

Enginecrankshaft group, pistons > < Securing engine to engine and gearbox support