Audi Workshop Service and Repair Manuals

Installing engine Special tools and workshop equipment required

t  Ring spanner insert AF 16 -V.A.G 1332/14-

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.

Earth stud at suspension turret - tightening torque –  Tighten earth stud -1- to 9 Nm.

Earth wiring at longitudinal member - tightening torque –  Tighten nut -arrow- to 9 Nm.

Engine to dual-clutch gearbox 0B5

Item	Bolt	Nm
1	M10x50 1)	65
2 … 6	M12x100 2)	30 + 90°
7	M12x125 2)	30 + 90°
8, 11	M10x60 2)	15 + 90°
9, 10	M10x95 2)	15 + 90°
A	Dowel sleeves for centralising
l  1) Property class 10.9. The steel bolt may be re-used as often as necessary. l  2) Aluminium bolts must not be used more often than twice → Anchor.

t  The aluminium bolts -2 … 11- 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 dual clutch gearbox 0B5, a needle bearing is fitted in the drive plate. Before installing, check that the needle bearing is fitted. Removing and installing needle bearing in drive plate (pressing in and out) → Chapter. t  Hose connections and air pipes and hoses 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 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 and engine mountings → Chapter. –  Install coolant pipe (bottom right) → Chapter. –  Hold ATF lines in installation position when joining engine and subframe. –  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 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 dowel sleeves -A- for centring engine and gearbox are fitted in cylinder block; install missing dowel sleeves. –  Check whether aluminium bolts securing engine to gearbox can be reused; if so, apply marking → Anchor. –  Bring gearbox into position on engine and tighten bolts -1 … 11-. –  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. –  Using assembly lever -1-, press clutch module -2- slightly against drive plate -3--arrow-.

–  Bolt clutch module onto drive plate as follows:   Note Use ring spanner insert AF 16 -V.A.G 1332/14- to tighten bolts. –  Hand-tighten first bolt -arrow- (2 Nm).

–  Insert guide pin of adapter -T40058- as follows: l  The larger-diameter section -arrow 1- faces towards the engine. l  The smaller-diameter section -arrow 2- faces the adapter.

–  Turn crankshaft 180° further in normal direction of engine rotation -arrow- with adapter -T40058-. –  Tighten bolt accessible in this crankshaft position to specified torque → Rep. gr.34. –  Turn crankshaft by 60° each time and tighten remaining 5 bolts to specified torque → Rep. gr.34. –  Install hydraulic fluid lines for power steering → Rep. gr.48. –  Install poly V-belt tensioner → Chapter. –  Bolt drive shafts (left and right) onto gearbox flange shafts → Rep. gr.40. –  Install ATF lines → Rep. gr.34. –  Install particulate filter → Chapter. –  Install heat shield for turbocharger → Chapter. –  Raise engine/gearbox assembly using scissor-type assembly platform -VAS 6131 A-. –  Align subframe and tunnel cross member on longitudinal members according to markings made before removal.

–  Tighten subframe bolts only to specified torque (do not turn further); the bolts are only to be fully tightened after performing the wheel alignment check → Rep. gr.40.   WARNING Risk of accident because of loose bolt connections. Do NOT drive the vehicle unless the subframe bolts have been finally tightened.

–  Tighten bolts for tunnel cross member → Rep. gr.34. Remaining installation steps are carried out in reverse sequence; note the following: –  Install propshaft → Rear final drive 0BC; Rep. gr.39 or → Rear final drive 0BD; Rep. gr.39. –  Install front exhaust pipe → Chapter. –  Align the exhaust system so it is free of stress → Chapter. –  Install front cross member → Rep. gr.66. –  Install selector lever cable → Rep. gr.34. –  Secure universal joint on steering box → Rep. gr.48. –  Install subframe cross brace, upper suspension links and anti-roll bar; secure suspension strut to track control link → Rep. gr.40. –  Install brake calipers → Rep. gr.46. –  Install struts for lock carrier → Rep. gr.50. –  Install engine control unit → Rep. gr.23. –  Electrical connections and routing → Current flow diagrams, Electrical fault finding and Fitting locations. –  Install electrical wiring, terminal 30 wiring junction 2 -TV22- and cover for electronics box in engine compartment → Fig., → Fig. and → Rep. gr.97. –  Plug in electrical connectors for exhaust gas temperature senders → Chapter. –  Install body brace → Rep. gr.40. –  Install filler neck for washer fluid reservoir → Electrical system; Rep. gr.92. –  Install refrigerant lines → Rep. gr.87. –  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 throttle valve module -J338-, exhaust gas pressure sensor 1 -G450- and air cleaner housing → Rep. gr.23. –  Fill up with engine oil and check oil level → Booklet811, → Booklet812 or → Booklet818. –  Before starting engine, top up hydraulic fluid in power steering reservoir → Rep. gr.48.   Note The power steering pump must not be run when dry.

–  Connect coolant hose and connection with plug-in connector → Fig.. –  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. –  Charge refrigerant system → Air conditioner with refrigerant R134a. –  Install wheel housing liners → Rep. gr.66. –  Fit front wheels and perform wheel alignment → Rep. gr.44.   WARNING Risk of accident because of loose bolt connections. Tighten subframe bolts to final setting after performing wheel alignment check. –  Fill up with ATF → Rep. gr.34. –  Install noise insulation panels → Rep. gr.66.