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, gaskets and O-rings. 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. –  Install engine supports. –  When fitting a new clutch plate together with a used pressure plate (self-adjusting clutch), the adjuster ring in the pressure plate has to be reset by turning it back as far as it will go. If this is not done, the pressure plate will operate with reduced clamping force, causing clutch slip → Rep. gr.30.   Note t  If the clutch plate is not being replaced, it is not necessary to reset the adjuster ring. t  New SAC pressure plates are already pre-set accordingly, and do not have to be reset. –  Clean 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 for clutch plate splines -G 000 100- to the splines. Do not lubricate guide sleeve. –  Make sure that clutch plate is properly centred. –  Check clutch release bearing for wear and make sure that plastic ring is securely seated; renew clutch release bearing if necessary → Rep. gr.30. –  Check whether dowel sleeves for centring the engine/gearbox assembly are fitted in the cylinder block; install dowel sleeves if necessary. –  Press intermediate plate between engine and gearbox onto dowel sleeves. –  Bolt gearbox to engine.   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, 2	M12x135	65 1)
3, 4, 5	M12x105	65
6, 7	M12x120	65
8, 9, 10	M10x80	45
A	Dowel sleeves for centralising
l  1) Property class 10.9.

Remaining installation steps are carried out in reverse sequence; note the following: –  Install starter catalytic converter: vehicles without particulate filter → Chapter, vehicles with particulate filter → Chapter. –  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 tunnel cross member 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	/10-7
F15 1)	/10-1	/10-3	/10-5	/10-7
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-.

–  Slowly guide engine/gearbox assembly with subframe into body from below using scissor-type assembly platform -VAS 6131 A- until distance between subframe and body is -a-. l  Dimension -a- = max. 60 mm.

–  Secure slave cylinder with new bolt -arrow-; procedure → Rep. gr.30.

–  Install gearbox selector lever -arrow-.

–  Secure connecting rod -2- of selector rod. –  Screw in hexagon socket head bolt for push rod -1-.

–  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.

–  Raise subframe via scissor-type assembly platform -VAS 6131 A- until subframe makes contact with body. –  Adjust the subframe, consoles for engine mountings and tunnel cross member according to the markings made on the longitudinal members during removal. –  Only tighten bolts for subframe, consoles for engine mountings and tunnel cross member to specified torque (do not turn further); tighten bolts to final setting only after performing 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. Vehicles without particulate filter: –  Install front exhaust pipe together with catalytic converter → Chapter. –  Align exhaust system so it is free of stress → Chapter. Vehicles with particulate filter: –  Install particulate filter → Chapter. –  Install front exhaust pipe → Chapter. –  Align exhaust system so it is free of stress → Chapter. All vehicles (continued): –  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. –  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. –  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:
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 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