Audi Workshop Service and Repair Manuals

Installing engine Procedure Installation is carried out in the reverse order; note the following:   Note t  Renew the bolts tightened with specified tightening angle. t  Renew self-locking nuts and bolts as well as seals, gaskets and O-rings. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly.

–  Before installing engine, check that brace -B- is still turned to one side in direction of -arrow- (brace is pivoted back down after installing engine). –  Before installing engine, tie electrical wiring to one side so that it cannot be trapped between engine and gearbox.

–  Check whether dowel sleeves -A- for centring engine and gearbox are fitted in cylinder block; install missing dowel sleeves. Vehicles with manual gearbox: –  Clean the 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 clutch release bearing for wear; renew if necessary. –  Check that the clutch plate is properly centralised (only necessary if you have carried out other work on the clutch). –  A needle bearing must be fitted in the flywheel on vehicles with manual gearbox. Install needle bearing if necessary → Chapter. Vehicles with automatic gearbox: –  Short engines are supplied without centring sleeve in crankshaft. Drive centring sleeve in before installing drive plate → Fig.. –  To secure torque converter on drive plate, use only new bolts (same as original equipment); refer to → Electronic parts catalogue. –  Tighten bolts for torque converter with special tool -V/175-.

Checking installation depth of torque converter: l  If the torque converter has been correctly installed, the distance between the bottom contact surfaces at the threaded holes on the torque converter and the contact surface on the torque converter bell housing (with automatic gearbox) is approx. 23 mm.   Caution Risk of damage to gearbox if torque converter is installed incorrectly. If the torque converter has not been fully inserted, this distance will be approx. 11 mm.

–  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 bolts (same as original equipment); refer to → Electronic parts catalogue.   Caution Risk of damage to gearbox if torque converter is installed incorrectly. t  Before and during tightening of bolts securing engine to gearbox, continually check that the torque converter behind the drive plate can be turned. t  If the torque converter cannot be turned, the drive lugs of the ATF pump and consequently the gearbox will be damaged when the bolts are finally tightened. –  Secure ATF lines to ATF cooler → Rep. Gr.37.

All vehicles (continued): –  Install engine mountings free of stress. To do so, shake engine before tightening engine mountings. –  Install air conditioner compressor and power steering pump. –  Check whether dowel sleeves -B- for centring air conditioner compressor have been fitted; insert missing dowel sleeves.

–  Bolt on power steering pump at holes -B- on bracket -A-.

–  Install poly V-belt pulley for power steering pump.

–  Secure viscous fan.

Tightening torque for viscous fan	Nm
Torque wrench -V.A.G 1331- together with open-end spanner -3312-	37
Torque wrench -V.A.G 1331- without open-end spanner -3312-	70

–  Install alternator → Rep. Gr.27. –  Install poly V-belt for power steering pump, alternator and viscous fan → Chapter. –  Install lock carrier → Chapter.

–  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support and tighten bolts -arrows- to 28 Nm. –  Fill up with coolant → Anchor.   Note t  Do not use drained coolant again if: t  the cylinder head or cylinder block have been renewed. t  the coolant is contaminated or dirty. –  Top up power steering fluid and bleed steering system → Rep. Gr.48. –  Align the exhaust system free of stress: vehicles with front-wheel drive → Chapter, vehicles with four-wheel drive → Chapter. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Observe notes on procedure for connecting the battery → Rep. Gr.27.   Caution Risk of damage to control units because of excessive voltage. Never use battery charging equipment for boost starting.   Caution Risk of irreparable damage to injection pump. Do not attempt to start the engine without first bleeding the fuel system! –  Bleed fuel system → Rep. Gr.20. –  Check engine oil level → Booklet802. –  Read out fault memory of engine control unit → Rep. Gr.01.   Note Faults will have been stored in the memory because connectors have been unplugged. Therefore interrogate and erase fault memory after installing engine. –  Adjust headlights → Rep. Gr.94. –  On vehicles with automatic gearbox: check ATF level → Rep. Gr.37. Tightening torque   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%.

Engine/gearbox connecting bolts (manual gearbox)

Item	Bolt	Nm
1	M12x80	65
2	M12x90	65
3	M10x50 1)	45
4	M10x45	45
5	M10x135	65
6	M12x110	65
7	M12x67	65
A	Dowel sleeves for centralising
l  1) Special bolt.

Engine/gearbox connecting bolts (automatic gearbox)

Item	Bolt	Nm
1	M12x80	65
2	M12x90	65
3	M10x60	45
4	M10x45	45
5	M10x80	65
6	M12x110	65
7	M12x67	65
A	Dowel sleeves for centralising

Component		Nm
Bolts/nuts	M6	10
	M8	20
	M10	45
	M12	65
Except for the following:
Engine support to cylinder block		45
Air cleaner housing to body		10
Tensioning roller for poly V-belt for A/C compressor to bracket		22
Front exhaust pipe to connection for turbocharger		25
Heat shield to turbocharger		10
Support for intermediate flange to intermediate flange		22
Drain plug to coolant drain pipe		10
Stop for torque reaction support to lock carrier		25
Drive plate to torque converter M10x1		85
Air conditioner compressor to bracket		22
Power steering pump to bracket for power steering pump and oil cooler		22
Underbody cross member to body		20
Poly V-belt pulley to power steering pump		22
Engine mounting to subframe		25