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  Reinstall all cable ties in the same locations when assembling. –  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install dowel sleeves if necessary. –  Press spacer plate or intermediate plate onto 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 to the splines. Do not lubricate guide sleeve. For grease refer to → Parts catalogue. –  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. All models: –  Guide engine/gearbox assembly carefully into body. –  Place engine down onto engine mountings. –  Bolt gearbox to engine → Anchor.

–  Attach support -T10062- at tapped holes for torque reaction support and tighten to 20 Nm. –  Using engine and gearbox jack -V.A.G 1383 A-, lift engine just far enough to fit bottom engine/gearbox securing bolts.

–  Tighten bottom engine/gearbox securing bolts -arrows-. –  Lower the engine back down. –  Align the exhaust system so it is free of stress → Chapter. –  Install starter → Electrical system; Rep. Gr.27. –  Install alternator → Electrical system; Rep. Gr.27 –  Install air conditioner compressor → Air conditioning system; Rep. Gr.87. –  Install poly V-belt → Anchor. –  Install lock carrier → Chapter. Vehicles with automatic gearbox 01J: –  Secure the ATF pipes → multitronic gearbox 01J, front-wheel drive; Rep. Gr.37. All models: –  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 Never use battery charging equipment for boost starting. There is danger of damaging the vehicle's control units. –  Check the oil level before starting engine → 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. –  Top up power steering fluid and bleed steering system: → Running gear, front-wheel drive and four-wheel drive; Rep. Gr.48 Vehicles with automatic gearbox 01J: –  Check ATF level → multitronic 01J, front-wheel drive; Rep. Gr.37. All models: –  Check headlight setting → Electrical system; Rep. Gr.94. 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%.

Engine/gearbox connecting bolts (manual gearbox)

Item	Bolt	Nm
1, 9, 10, 11	M10x45	45
2 → Note	M10x135	65
3	M12x130	65
4 … 6	M12x67	65
7	M12x90	65
8	M12x75	65
A	Dowel sleeves for centralising

1)  Property class 10.9

Engine/gearbox connecting bolts (automatic gearbox 01J)

Item	Bolt	Nm
1, 10, 11	M10x60	45
2 → Note	M10x90	65
3	M12x110	65
4	M12x80	65
5, 6	M12x75	65
7	M12x100	65
8	M12x75	65
9	M10x70	45
A	Dowel sleeves for centralising

2)  Property class 10.9

Component			Nm
Bolts/nuts		M6	10
		M8	20
		M10	45
		M12	65
Except for the following:
Torque reaction support to top section of sump			40
Engine mounting	Engine support		23
to:	Subframe		23
Drive shaft heat shield to gearbox			23
Oil cooler to sump (top section)			30
Pressure line for	Pressure hose		40
power steering to:	Coolant pipe		20
Air duct to intake manifold			10
Fuel supply line to fuel rail			23
Wiper arms to wiper shafts			21
ATF hose to ATF pipe			29