Audi Workshop Service and Repair Manuals

Installing engine Special tools and workshop equipment required

t  Counterhold tool -T10355- for vehicles with dual clutch gearbox

t  Assembly aid -T40169-

t  Transport lock -T40170- 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 gear oil may be used, but do not use lubricants containing graphite. t  Do not use degreased parts. t  Tolerance for tightening torques: ± 15 %. Tightening torques → Chapter „Assembly mountings - exploded view“ Further tightening torques

Component			Nm
Bolts/nuts		M6	9
		M8	20
		M10	40
		M12	65

Securing engine to manual gearbox

Item	Bolt	Nm
1 3)	M10 x 50 1)	65
2 3), 7	M12 x 100 2)	30 + 90°
3 4), 6	M12 x 75 2)	30 + 90°
4 ... 5 4)	M12 x 120 2)	30 + 90°
8 ... 10	M10 x 75 2)	15 + 90°
11	M12 x 50 2)	30 + 90°
A	Dowel sleeves for centralising
l  1) Steel bolt - is not renewed l  2) Renew bolts l  3) Also secures starter l  4) Also secures cable retainer

Procedure   Note t  Renew the bolts tightened with specified tightening angle. t  Renew self-locking nuts and bolts 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 secure the charge air hoses at their connections, spray rust remover onto the worm thread of the used hose clips before installing. 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. –  Before installing gearbox, remove residue from threaded holes for engine/gearbox bolts in cylinder block using a thread tap. –  The following preparations are required before joining engine and gearbox.

–  Ensure that intermediate plate is engaged on sealing flange and pushed onto dowel sleeves -arrows-.

–  Insert assembly aid -T40169- into gearbox housing and clutch module from below, as illustrated. l  The assembly aid -T40169- must engage in the semi-circular recess -1- and in the inspection hole -2-.   Note There is only one inspection hole on the circumference; turn the clutch module accordingly.

–  Insert retainer -T40170- into gearbox housing from below and clamp onto flange shaft -1-.   Note

The next work step is only required if a drive plate with locating pins -2- is fitted. –  In addition, align drive plate relative to clutch module so that locating pins -2- (if fitted) on drive plate are in position to engage in large holes -1- in clutch module.   Caution Incorrect installation will cause the clutch mechanism to malfunction. If the locating pins of the drive plate -2- do not engage in the holes in the clutch module -1-, this can cause serious malfunctioning of the clutch mechanism.   Note t  Bolt -2- secures the starter to the gearbox and is provided with a spacer sleeve -arrow-.

t  Pay attention to the spacer sleeve -arrow- when removing and installing the engine. The spacer sleeve must be fitted between starter and gearbox.

–  Bring gearbox into position on engine and tighten bolts -7 … 11- securing engine to gearbox. Tightening torques → Anchor

–  Release spindle of support bracket -10-222 A-. –  Lower workshop hoist and place engine/gearbox assembly onto engine mounting.

–  Fit bolts -1- for left and right engine mountings. –  Detach workshop hoist -VAS 6100- and lifting tackle -2024 A-.

–  Screw in bolts -1 ... 6- of engine/gearbox assembly and tighten.   Note Disregard -item A-.

–  Remove retainer -T40170- and assembly aid -T40169-.   Note The following step is necessary to ensure that the clutch module is straight and that it makes even contact with the drive plate. –  Use assembly lever -1- to press clutch module -2- slightly against drive plate -3- in direction of -arrow-.

Tightening sequence - clutch module to drive plate –  Screw in first bolt -arrow- hand-tight. –  Turn crankshaft by 120° in direction of engine rotation and fit second bolt hand-tight. –  Turn crankshaft by 120° in direction of engine rotation once again. –  Then tighten third bolt to final torque → Rep. gr.30. –  Then tighten remaining bolts to final torque. The remaining installation steps are carried out in the reverse sequence. –  Install starter → Rep. gr.27 –  Install catalytic converter → Chapter. –  Install front exhaust pipe/front silencer → Chapter. –  Align the exhaust system so it is free of stress → Chapter. –  Install air conditioner compressor → Rep. gr.87. –  Install poly V-belt → Chapter. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install engine control unit → Rep. gr.23. –  Install electrical wiring, terminal 30 wiring junction 2 -TV22- and cover for electronics box in engine compartment → Rep. gr.97. –  Install body brace → Rep. gr.40. –  Install filler neck for washer fluid reservoir → Rep. gr.92. –  Observe notes on procedure for connecting the battery → Rep. gr.27.   Caution Risk of irreparable damage to control units because of excessive voltage. Never use battery charging equipment for boost starting. –  Install air cleaner housing → Rep. gr.23. –  Reset service position → Rep. gr.50. Check oil level; A4 → Booklet812, A5 → Booklet811 –  Fill up with coolant → Anchor.   Note t  Do not use drained coolant again if: t  the cylinder head or cylinder block have been renewed. t  the coolant is contaminated or dirty. –  Install noise insulation and wheel housing liners → Rep. gr.66.