Audi Workshop Service and Repair Manuals

Installing engine Special tools and workshop equipment required

t  Transport lock -T40170- t  Adapter -T40257- t  Socket -T40263- 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“.

Air duct on tunnel cross member - tightening torques –  Tighten bolts -arrows- to 3 Nm.

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 1)	M10x50 2)	65
2 1), 3, 4, 5, 6	M12x100 3)	30 +90°
7	M12x175 3)	30 +90°
8, 9, 10	M10x60 3)	15 +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) 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  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  Fit all cable ties in the original positions when installing. –  Before installing gearbox, remove residue from threaded holes for engine/gearbox bolts in cylinder block using a thread tap.

–  Before installing an exchange engine, check whether flat-section O-ring -arrow- is fitted in drive shaft of power steering pump. –  Install engine supports and engine mountings → Chapter.

–  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 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 pin of assembly aid into hole on gearbox housing.

–  Insert transport lock -T40170- into gearbox housing from below and clamp onto flange shaft -1-. –  Hold ATF lines in installation position when joining engine and subframe.

–  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 … 10-. –  Remove transport lock -T40170- and assembly aid -T40169-. –  Install engine supports and engine mountings → Chapter.   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-.

–  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).

–  Fit adapter -T40257- onto wrench -T40263-. –  Position adapter on bolts of vibration damper. l  The semi-circular recess -arrow A- on the adapter -T40257- must point to the semi-circular recess -arrow B- on the vibration damper.   Note Disregard notch on adapter -T40257-. –  Turn crankshaft 180° in direction of engine rotation -arrow-. –  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 lines for power steering → Rep. gr.48. –  Bolt drive shafts (left and right) onto gearbox flange shafts → Rep. gr.40. –  Install selector lever cable → Rep. gr.34. –  Install ATF lines → Rep. gr.34. –  Install exhaust manifolds with catalytic converters → 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 -arrows- for tunnel cross member → Rep. gr.34. –  Secure air duct on tunnel cross member → Fig.. Remaining installation steps are carried out in reverse sequence; note the following: –  Secure intermediate steering shaft on steering box → Rep. gr.48. –  Install propshaft → Rear final drive 0BF; Rep. gr.39. –  Align the exhaust system so it is free of stress → Chapter. –  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. –  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 → Electrical system; Rep. gr.97. –  Install earth stud → Fig.. –  Install electrical wiring → Fig.. –  Install oil pipes → 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. –  Install secondary air pipes → Chapter. –  Install lock carrier cover → Rep. gr.63. –  Install air pipes and air cleaner housing → Rep. gr.24. –  Fill with engine oil and check oil level → Booklet811. –  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. –  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 hoses 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. –  Align subframe → Rep. gr.40. –  Install wheel housing liners → Rep. gr.66. –  Fit front wheels → Wheels and tyres; Rep. gr.44. –  Perform wheel alignment check → 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.