Audi Workshop Service and Repair Manuals

Installing engine 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 de-greased parts. t  Tolerance for tightening torques: ± 15 %.

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 4)	M12 x 100 2)	30 + 90°
3 5), 6	M12 x 75 2)	30 + 90°
4…5 5)	M12 x 120 2)	30 + 90°
7…9	M10 x 75 2)	15 + 90°
10	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 starter, with additional spacer sleeve between starter and gearbox l  5) 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.

–  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 an additional spacer sleeve -arrow-.

t  Pay attention to the spacer sleeve -arrow- when removing and installing the engine. The spacer sleeve must be fitted between the starter and the gearbox. –  Place starter in engine support and secure to prevent it from dropping out.   Note After the engine has been joined to the gearbox, the starter can no longer be installed without removing the engine support.

–  Join engine onto gearbox, screw in bolts -2 … 6- and tighten.

–  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 bolt -1- and bolts -7 … 10- 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 –  Hand-tighten first bolt -arrow- (2 Nm). –  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. –  Now tighten remaining bolts securing clutch module to drive plate to final torque. The remaining installation steps are carried out in the reverse sequence. Note the following: –  Install starter → Rep. gr.27. –  Install particulate filter → Chapter. –  Install front exhaust pipe → Chapter. –  Install torque reaction support and cross member → Chapter. –  Align the exhaust system so it is free of stress → Chapter. –  Observe 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. Checking oil level (Audi A4) → Booklet812 Checking oil level (Audi A5) → Booklet811 –  Fill up with coolant → Chapter.   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.