Audi Workshop Service and Repair Manuals

Installing engine Special tools and workshop equipment required

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 gearbox 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
		M7	15
		M8	20
		M10	40
		M12	65

Assembly mountings → Chapter „Assembly mountings - exploded view“.

Engine to manual gearbox

Item	Bolt	Nm
1 1)	M10x50 2)	65
2 3)	M12x100 4)	30 +90°
3 5), 6	M12x75 4)	30 +90°
4, 5 5)	M12x120 4)	30 +90°
7…9	M10x75 4)	15 +90°
10	M12x50 4)	30 +90°
A	Dowel sleeves for centralising
l  1) Also secures starter l  2) Property class 10.9. The steel bolt may be re-used as often as necessary. l  3) Also secures starter, with additional spacer sleeve between starter and gearbox l  4) Bolts must not be used more often than twice → Anchor. l  5) Also secures wiring retainer

t  The aluminium bolts -2 … 10- must not be used more often than twice. After the first use, the bolts must therefore be identified with an „X“ made by two chisel marks -arrow-. t  To avoid damaging the bolts when making this mark, do not clamp them directly in a vice. Clamp a 14 mm socket with 1/2" drive in a vice and insert the bolt as shown. t  Bolts already marked with an „X“ must not be used again. 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  On vehicles with manual gearbox, a needle bearing must be fitted in the drive plate. Before installing, check whether a needle bearing is fitted. Press needle bearing into drive plate → Chapter. t  Secure all hose connections with the correct type of hose clips (same as original equipment) → Electronic parts catalogue. t  Fit all cable ties in the original positions when installing.

–  The following preparations are required before joining engine and gearbox. –  Insert assembly aid -T40169- into gearbox housing and dual-mass flywheel from below, as illustrated. l  The assembly aid 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 dual-mass flywheel accordingly. –  Insert pin of assembly aid into hole on gearbox housing.

–  Insert transport lock -T40170- into gearbox housing from below and clamp onto flange shaft -1-. –  Check whether aluminium bolts securing engine to gearbox can be reused; if so, apply marking → Anchor.

–  Check whether dowel sleeves -A- for centring engine and gearbox are fitted in cylinder block; install missing dowel sleeves. –  Bring engine into position on gearbox, fit bolts -2 … 6- and tighten.   Note

t  Bolt -2- secures the starter to the gearbox and is provided with an additional spacer sleeve -arrow-. t  The spacer sleeve must be fitted between starter and gearbox.

–  Slacken spindle -10 - 222 A /11-. –  Lower workshop hoist and place engine/gearbox assembly onto engine mountings. –  Secure engine mounting → Chapter. –  Detach workshop hoist -VAS 6100- and lifting tackle -2024 A-.

–  Tighten bolts -1, 7, 8, 9, 10- securing engine to gearbox. –  Remove transport lock -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. –  Install wheel housing liners → Rep. gr.66. –  Fit front wheels → Wheels and tyres; Rep. gr.44. –  Engage 4th gear and turn front wheels in direction of travel until clutch module is rotated by one complete turn (360°). l  The inspection hole -arrow- should be visible again in the recess on the gearbox housing.

–  Bolt clutch module onto drive plate as follows: –  Hand-tighten first bolt -arrow- (2 Nm). –  Turn front wheels in direction of travel until clutch module is rotated by 240°. –  Tighten bolt accessible in this position to specified torque → Rep. gr.30. –  Turn front wheels in direction of travel until clutch module is rotated by 120° each time and tighten remaining 2 bolts to specified torque → Rep. gr.30. Remaining installation steps are carried out in reverse sequence; note the following: –  Install particulate filter → Chapter. –  Install pressure differential sender -G505- → Rep. gr.23. –  Install alternator → Electrical system; Rep. gr.27. –  Install power steering pump → Rep. gr.48. –  Install air conditioner compressor → Rep. gr.87. –  Install poly V-belt → Chapter. –  Install cross member and torque reaction support → Chapter. –  Install lock carrier and plenum chamber partition panel → Rep. gr.50. –  Install air cleaner housing → Rep. gr.23. –  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 → Electrical system; Rep. gr.97. –  Install filler neck for washer fluid reservoir → Electrical system; Rep. gr.92. –  Observe notes on procedure for connecting the battery → Electrical system; 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 hoses with screw-type clips → Fig.. –  Check oil level → Booklet811 or → Booklet812. –  Bleed fuel system → Rep. gr.23. –  Connect coolant hoses with plug-in connector → Fig.. –  Fill up with coolant → Chapter.   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. –  Install noise insulation panels → Rep. gr.66.