Audi Workshop Service and Repair Manuals

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  Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. t  Fit all heat insulation sleeves in the original position when installing. t  Fit all cable ties in the original positions when installing.

Checking installation position 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 → Parts catalogue. –  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	M12×80	65
2, 4, 5	M12×105	65
3	M12×110	65
6	M12×130	65
7	M12×170	65
8, 9, 10	M10x60	45
A	Dowel sleeves for centralising

Remaining installation steps are carried out in reverse sequence; note the following: –  Install front exhaust pipes together with catalytic converters: left-side → Chapter, right-side → Chapter. –  Install ATF pipes → Rep. Gr.37. –  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 the spindles for support elements (left-side) at engine/gearbox assembly. –  Unscrew both base plates for support elements (left-side) at scissor-type assembly platform -VAS 6131 A-.

–  Screw down the spindles for support elements (right-side) at engine/gearbox assembly. –  Unscrew both base plates for support elements (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 → Note	/10-1	/10-4	/10-5	/10-11
G3 → Note	/10-1	/10-4	/10-5	/10-11
B10	/10-1	/10-2	/10-5	/10-8 → Note
G10	/10-1	/10-2	/10-5	/10-8 → Note
C15 → Note	/10-1	/10-3	/10-5	/10-12
F15 → Note	/10-1	/10-3	/10-5	/10-12

1)  Support elements remain unchanged. 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. –  Tighten base plates for support elements to 20 Nm on scissor-type assembly platform -VAS 6131 A-. –  Install left and right gearbox mountings → Rep. Gr.37. –  Slowly guide engine gearbox assembly together with subframe into the body from below using scissor-type assembly platform -VAS 6131 A-.

–  Adjust the subframe and consoles for engine mountings 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 selector lever cable and check adjustment if necessary → Rep. Gr.37. –  Install drive shafts → Rep. Gr.40. –  Install guide links, track control links, anti-roll bar and suspension struts → Rep. Gr.40. –  Align exhaust system so it is free of stress → Chapter. –  Install refrigerant lines → Rep. Gr.87.

USA vehicles: –  Secure fuel hose at connection for fuel rail pipe. To do so, counterhold at hexagon flats -1- and -3- with open-end spanners and tighten union nut -2-: tightening torque 22 Nm. All models: –  Install lock carrier with attachments → Rep. Gr.50. –  Install ATF pipes → Rep. Gr.37.

–  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight and tighten bolts -arrows-. –  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 → 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 oil level → Chapter. –  Before starting engine, top up hydraulic fluid in power steering reservoir → Rep. Gr.48.   Note The power steering pump must not be run when dry. –  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. –  Charge the refrigerant system → Air conditioner system - with refrigerant R134a. –  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. –  Check headlight adjustment → Booklet803 or → Booklet805. 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 → Note
Terminal B+ to starter		16
Engine support to engine		42 → Note
Drive shaft heat shield to gearbox		23
Hydraulic pressure pipe		40
Stop for torque reaction support to lock carrier		28
Fuel hose to fuel line		22

3)  Renew bolts. 4)  Apply locking fluid when fitting bolts.