Engine, Installing
Engine, installing (vehicles with automatic transmission)
Note:
^ Replace self-locking nuts and bolts during assembly work.
^ Always replace bolts that are tightened to torque as well as sealing rings, gaskets and O-rings.
^ Secure all hose connections using hose clamps appropriate for the model type
^ During installation, reinstall all heat insulation sleeves at the same locations.
^ During installation, reinstall all cable ties at the same locations.
Checking installation dimension for torque converter
If torque converter is correctly installed, distance between contact surface of threaded holes at torque converter and contact surface of converter housing on 6 Spd. Automatic Transmission 09L All Wheel Drive is approximately 19 mm.
CAUTION: In case of an incorrectly inserted torque converter, the coupling plate of the torque converter or the ATF pump will be destroyed if the transmission is mated to the engine.
- Before connecting engine and transmission, rotate torque converter and engine drive plate so that one hole or one threaded hole stands at height of opening of the removed starter - arrow -.
- Secure torque converter to drive plate using new original ribbed bolts.
- Bolt transmission to engine.
CAUTION: Keep checking whether the torque converter behind the drive plate can be turned before and during tightening of the bolts at the engine/transmission flange. If the torque converter cannot be turned, it must be assumed that it has not been inserted properly and that the coupling plate of the ATF pump and therefore the transmission will be destroyed during final tightening of the bolts.
Note:
^ Tightening torques are valid only for nuts and bolts that are lightly greased, oiled, covered with a thin coat of phosphate or blackened.
^ Other lubricants are permitted, e.g. engine oil or transmission fluid, however they may not contain graphite.
^ Do not use degreased parts.
^ Tightening torque tolerance 15%.
Engine/transmission connections
The rest of the installation is performed in reverse order of removal, noting the following:
- Install front exhaust pipes with catalytic converters: Left Left front exhaust pipe with front and main catalytic converter, removing and installing (vehicles with manual transmission)
- Install ATF lines.
- Always clean threaded holes for driveshaft in transmission flange of locking fluid residue using a tap before installation.
- Twist down spindles of left support element at engine/transmission assembly.
- Unscrew both base plates for left support element on scissor lift platform VAS 6131.
- Twist down spindles of right support element at engine/transmission assembly.
- Unscrew both base plates for right support element on scissor lift platform VAS 6131.
Note: The support points for front of engine and rear of transmission remain unchanged.
- Equip scissor lift platform VAS 6131 with support set for Audi VAS 6131/10 as follows:
- Position subframe on both support elements VAS 6131/10-8.
- Twist spindles of support elements upward on both sides.
- Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131.
- Install left and right transmission mounts.
- Using scissor lift platform VAS 6131, slowly guide engine/transmission assembly with subframe into body from below.
- Align subframe and engine bearing consoles according to markings applied on longmembers during removal.
- Tighten bolts for subframe and engine bearing consoles only to tightening torque, do not tighten further (tighten bolts only after wheel alignment).
CAUTION: Vehicle must not be driven in this condition.
The rest of the installation is performed in reverse order of removal, noting the following:
- Install selector lever cable. Check adjustment if necessary.
- Install drive axles.
- Install guide control arm, control arm, stabilizer and suspension strut.
- Align exhaust system free of tension
- Install refrigerant lines.
- Secure fuel hose to connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head - 1 - and - 3 - and tighten union nut - 2 - to 22 Nm.
- Install lock carrier with attachments.
- Install ATF lines.
- Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
- Install front bumper cover.
- Reconnect harness connectors and check routing of wiring: Electrical Wiring Diagrams, Troubleshooting Component Locations.
- Observe safety precautions when connecting battery.
CAUTION: Do not use a battery charger for starting assistance! There is risk of damage at the vehicle control modules.
- Install and adjust wiper arms.
- Check engine oil level
- Before first engine start, fill power steering reservoir with hydraulic fluid.
Note: The power-steering pump must not run dry.
- Fill system with coolant.
Note:
^ Only reuse drained coolant if the cylinder head or engine block was not replaced.
^ Dirty coolant cannot be reused.
- Fill refrigerant circuit
- Align subframe and both engine bearing consoles.
- Perform wheel alignment.
CAUTION: After wheel alignment, tighten the subframe bolts to final torque.
- Check headlight adjustment.
Tightening torques
Note:
^ Tightening torques are valid only for nuts and bolts that are lightly greased, oiled, covered with a thin coat of phosphate or blackened.
^ Other lubricants are permitted, e.g. engine oil or transmission fluid, however they may not contain graphite.
^ Do not use degreased parts.
^ Tightening torque tolerance 15%.
