Audi Workshop Service and Repair Manuals

Installing engine Special tools and workshop equipment required t  Depth gauge Procedure   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  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.

Checking installation depth of torque converter If the torque converter has been correctly installed, the distance between the contact surfaces at the threaded holes in the torque converter and the contact surface on the torque converter bell housing (with automatic gearbox 09L) is at least 19 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.

–  Before bringing engine and gearbox together, turn torque converter and drive plate on engine so that the holes for one securing bolt are in line with the opening for the starter motor -arrow-. –  To secure torque converter on drive plate, use only new ribbed bolts of the correct type (same as original equipment) as specified in → Electronic parts catalogue. –  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install dowel sleeves if necessary. –  Press intermediate plate between engine and gearbox onto dowel sleeves. –  Bolt gearbox to engine.   Caution Before and during tightening of bolts on engine/gearbox flange, continually check that the torque converter behind the drive plate can be turned. If the converter cannot be turned, it must be assumed that it has not been installed correctly and the drive lugs of the ATF pump and consequently the gearbox will be damaged when the bolts are finally tightened.   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 gearbox

Item	Bolt	Nm
1	M10x115	65 1)
2, 6	M12x125	65
3, 5	M12x110	65
4	M12x115	65
7	M12x140	65
8, 9, 10	M10x80	45
A	Dowel sleeves for centralising
l  1) Bolt strength rating 10.9

–  Secure ATF lines → Rep. Gr.37. –  Install front exhaust pipes: left-side → Chapter; right-side → Chapter. –  The threaded holes in the flange shaft for the propshaft on the gearbox must be cleaned of remaining locking fluid with a thread tap before assembling.

–  Screw down spindles of support elements on left side of engine/gearbox assembly. –  Unscrew base plate for support element (left-side) at scissor-type assembly platform -VAS 6131 A-.

–  Screw down spindles of support elements on right side of engine/gearbox assembly. –  Screw spindle for support element (right-side) at engine downwards. –  Unscrew base plates for support element (right-side) at scissor-type assembly platform -VAS 6131 A-.   Note The mounting points for engine (front) and gearbox (rear) remain unchanged.

–  Set up scissor-type assembly platform -VAS 6131 A- with support set for Audi -VAS 6131/10- as follows:

Platform coordinates	Parts of support set for Audi -VAS 6131/10-
B4 1)	/10-1	/10-4	/10-5	/10-11
G4 1)	/10-1	/10-4	/10-5	/10-12
B11	/10-1	/10-2	/10-5	/10-8 2)
G11	/10-1	/10-2	/10-5	/11-8 2)
D15 1)	/10-1	/10-3	/10-5	/10-12
F15 1)	/10-1	/10-3	/10-5	/10-12
l  1) Support elements remain unchanged. l  2) Secure support elements only after installing the subframe.

–  Fit subframe onto the two support elements -VAS 6131/10-8-. –  Screw up the spindles for support elements on both sides.

–  Secure gearbox mountings to subframe -arrows-.

–  Slowly guide engine/gearbox assembly into body from below using scissor-type assembly platform -VAS 6131 A- until distance between subframe and body is -a-. l  Distance -a- = 80 mm. –  Bring torque reaction support with stop for torque reaction support into position between lock carrier and engine.

–  Push ball socket -1- of selector lever cable onto selector shaft lever. –  Fit support bracket to gearbox according to markings -arrows-. –  Insert drive shafts in splines of wheel bearing housing (left and right).

–  Bolt guide link -1- and track control link -2- loosely onto subframe.   Note Wait until vehicle is standing on ground before tightening bolts to final setting.

–  Adjust the subframe according to the markings made on the longitudinal members during removal. –  Only tighten bolts for subframe and consoles for engine mountings to the specified torque (do not turn further); tighten bolts only after performing wheel alignment check. 1 -  65 Nm 2 -  110 Nm 3 -  110 Nm 4 -  75 Nm   WARNING The vehicle must not be driven at this stage. Remaining installation steps are carried out in reverse sequence; note the following: –  Install propshaft → Rear final drive 01R; Rep. Gr.39. –  Align exhaust system so it is free of stress → Chapter. –  Install refrigerant lines → Rep. Gr.87. –  Install exhauster pump for brake servo → Chapter. –  Install drive shafts → Rep. Gr.40. –  Install guide links, track control links, anti-roll bar and suspension struts → Rep. Gr.40.

–  Tighten bolts -arrows- for torque reaction support.

–  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight and tighten bolts -arrows-. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Observe notes on procedures required after connecting battery → 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 → Rep. Gr.92. –  Check adjustment of selector lever cable → Rep. Gr.37. –  Check oil level → Booklet803 or → Booklet805. –  Bleed fuel system → Rep. Gr.24.

–  Remove old O-ring -2- from coolant hose -3-. –  Lubricate new O-ring with coolant additive and fit O-ring in coolant hose. –  Press coolant hose onto radiator or coolant pipe -1- until it engages with a click. –  Press coolant hose in again and then pull to check that plug-in connector is correctly engaged. –  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. –  Check ATF level → Rep. Gr.37. –  Adjust subframe and the two consoles for engine mountings → Rep. Gr.40. –  Perform wheel alignment check → Rep. Gr.44.   WARNING Tighten bolts for subframe to final setting after performing wheel alignment check. –  Charge the refrigerant system → Air conditioner system - with refrigerant R134a. 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	9
	M8	20
	M10	40
	M12	65
Except for the following:
Drive plate to torque converter		85 1)
Terminal B+ to starter		16
Engine support to cylinder block		40
Gearbox mounting to subframe		23
Console for engine mounting to longitudinal member		75
Engine mounting to console for engine mounting		23
Drive shaft heat shield to gearbox		23
Torque reaction support to engine		40
Stop for torque reaction support to lock carrier		28
Hydraulic pressure line to power steering pump		47
Fuel hose to fuel line		22
Hose clips (9 mm wide)		3
l  1) Renew bolts.