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 seals and gaskets. t  Hose connections and hoses for charge air system must be free of oil and grease before assembly. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  To ensure that the charge air hoses can be properly secured at their connections, spray rust remover onto the worm thread of used hose clips before installing. t  Fit all cable ties in the original positions when installing.

–  Before installing an exchange engine in a vehicle with automatic gearbox, check whether the centralising bush -arrow- for the torque converter is fitted at the rear of the crankshaft.

Checking installation depth of torque converter If the torque converter has been correctly installed, the distance -a- between the contact surfaces at the threaded holes in the torque converter and the joint surface on the torque converter bellhousing for 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 → Electronic parts catalogue.   Caution Do not rotate crankshaft in opposite direction of engine rotation. –  Tighten 3 bolts for torque converter through opening for starter motor (turn crankshaft 1/3 turn each time). –  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 lubricants such as engine or gearbox oil may be used, but do not use lubricants containing graphite. t  Do not use degreased parts. t  Tolerance for tightening torques: ± 15%.

Securing engine to gearbox

Item	Bolt	Nm
1	M10x80	65 1)
2	M10x100	65 1)
3	M12x100	65
4, 5	M12x110	65
6, 7	M12x120	65
8, 9, 10	M10x80	45
A	Dowel sleeves for centralising
l  1) Property class 10.9.

Installation is carried out in the reverse order; note the following: –  Secure ATF lines → Rep. gr.37. Vehicles without particulate filter: –  Install starter catalytic converter with catalytic converter → Chapter. Vehicles with particulate filter: –  Install starter catalytic converter with particulate filter → Chapter. All vehicles (continued): –  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 spindles of support elements on left side of engine/gearbox assembly. –  Unscrew both base plates for support elements (left-side) at scissor-type assembly platform -VAS 6131 A-.

–  Screw down spindles of support elements on right side of 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 from support set for Audi -VAS 6131/10-
B3 1)	/10-1	/10-4	/10-5	/10-11
F3 1)	/10-1	/10-4	/10-5	/10-11
B10	/10-1	/10-2	/10-5	/10-8 2)
G10	/10-1	/10-2	/10-5	/10-8 2)
C15 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. –  Tighten base plates for support elements to 20 Nm on scissor-type assembly platform -VAS 6131 A-.

–  Secure gearbox mountings to subframe -arrows-.

–  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- = 60 mm.

–  Push ball socket -1- of selector lever cable onto gearbox selector lever. –  Attach cable support bracket to gearbox according to markings -arrows-.

–  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. –  Tighten bolts for subframe and consoles for engine mountings only to specified torque (do not turn further); the bolts are only fully tightened after performing the wheel alignment check. 1 -  65 Nm 2 -  115 Nm 3 -  115 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 propshaft → Rear final drive 01R and 0AR; Rep. gr.39. –  Align exhaust system so it is free of stress: vehicles without particulate filter → Chapter, vehicles with particulate filter → Chapter. –  Install refrigerant lines → Rep. gr.87. –  Install drive shafts → Rep. gr.40. –  Install guide links, track control links, anti-roll bar and suspension struts → Rep. gr.40.

–  Install stop for torque reaction support and torque reaction support. –  Allow stop for torque reaction support to rest on rubber buffer for torque reaction support under its own weight and tighten nuts -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. –  Install selector lever cable and check adjustment if necessary → Rep. gr.37. –  Check oil level → Booklet803 or → Booklet805.

–  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 -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. –  Before starting engine, top up hydraulic fluid in power steering reservoir and bleed steering system → Rep. gr.48.   Note The power steering pump must not be run when dry. –  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. –  Check fuel system for leaks → Chapter. Tightening torques   Note t  Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. t  Additional lubricants such as engine or gearbox oil may be used, but do not use lubricants 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 1)
Terminal B+ to starter		16
Engine support to cylinder block		40
Gearbox mounting to subframe		23
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 pipe to power steering pump		47
Throttle valve module -J338- to intake manifold		9
Hose clips (9 mm wide)		3
Hose clips (13 mm wide)		5.5
l  1) Renew bolts.