Audi Workshop Service and Repair Manuals

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  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: –  Check clutch release bearing for wear; renew if necessary. –  Lubricate splines of gearbox input shaft lightly with grease -G 000 100-. The guide sleeve for the release bearing should not be lubricated. –  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; install needle bearing if not already fitted → 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. All vehicles: –  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install dowel sleeves if necessary.

–  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 spindles of support bracket -10-222 A-. –  Lower engine, inserting studs of engine mountings into consoles for engine mountings as you do so.   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 manual gearbox

Item	Bolt	Nm
1, 4	M12x75	65
2	M12x90	65
3	M12x75	65 → Remark
5	M12x110	65 → Remark
6	M12x110	65
7 … 10	M10x45	45
11	M12x130	65
A	Dowel sleeves for centralising

1)  The wiring harness bracket is also secured with this bolt.

Securing engine to multitronic gearbox

Item	Bolt	Nm
1	M12x90	65 → Remark
2	M10x60	45 → Remark
3	M12x67	65 → Remark
4	M12x75	65 → Remark → Remark
5	M12x75	65 → Remark
6	M12x110	65 → Remark → Remark
7	M12x80	65 → Remark
8	M10x50	45 → Remark
9 … 11	M10x45	45 → Remark
A	Dowel sleeves for centralising

2)  Renew bolts. 3)  The wiring harness bracket is also secured with this bolt. All vehicles: 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.

–  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 bolts -arrows-. –  Install front bumper cover → General body repairs, exterior; Rep. gr.63. –  Secure the ATF lines → multitronic gearbox 01J, front-wheel drive; 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 → multitronic gearbox 01J, front-wheel drive; Rep. gr.37. –  Check headlight adjustment → Booklet803. 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
	M7	15
	M8	20
	M10	45
	M12	65
Except for the following:
Engine mounting to engine console		23
Engine mounting to engine support		23
Terminal B+ to starter		16
Drive shaft heat shield to gearbox		23
Fuel line to fuel rail		22
Stop for torque reaction support to lock carrier		28