Audi Workshop Service and Repair Manuals

Installing engine 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. –  Check that dowel sleeves for centring engine and gearbox are fitted in the cylinder block; install missing dowel sleeves. –  Clean input shaft splines on gearbox 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. –  Press intermediate plate between engine and gearbox onto dowel sleeves. –  Secure gearbox to engine with new bolts.   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, 7	M10x115	65 1)
2	M12x130	65
3, 4, 5, 6	M12x110	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.

–  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.

–  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 -2- of selector lever cable onto selector shaft lever. –  Fit support bracket -1- to gearbox according to marking. –  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: –  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:
Terminal B+ to starter		16
Engine support to cylinder block		40
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