Engine, Installing
Engine, installing (vehicles with manual 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.
^ When installing a new clutch disc in combination with a used SAC (self-adjusting clutch) pressure plate, the adjustment ring of the pressure plate must be turned back to impact. If this is not done the pressure plate works with decreased contact pressure (clutch slips).
^ If the clutch disc is not replaced, the adjustment ring does not have to be turned back.
^ New SAC pressure plates are already pre-adjusted and must not be turned back.
- Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Do not grease guide sleeve.
- Check centering of clutch disc.
- Check clutch release bearing for wear and replace if necessary.
If plastic ring of clutch release bearing is loose:
- Use adhesive AMV 195 KD1 01 to glue plastic ring of clutch release bearing to bearing ring.
^ 3 rectangular tabs - arrows - of plastic ring reach into cutouts of bearing ring.
^ If grooves with depth of more than 0.5 mm are present, release bearing must be replaced.
- Make sure centering sleeves for engine to transmission are installed in cylinder block. Install if necessary.
- Install intermediate plate between engine and transmission onto alignment bushings.
- Bolt transmission to engine.
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.
- Always clean threaded holes for driveshaft in transmission flange of locking fluid residue using a tap before installation.
- Turn down spindles of left support element at engine/transmission assembly.
- Unscrew both base plates for left support element on scissor lift platform VAS 6131.
- Turn 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 tunnel crossmember remain unchanged.
- Equip scissor lift platform VAS 6131 with support set for Audi VAS 6131/10 as follows:
^ These support elements remain unchanged.
^ Only install support elements after installing subframe.
- Position subframe on both support elements VAS 6131/10-8.
- Turn spindles of support elements upward on both sides.
- Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131.
- Using scissor lift platform VAS 6131, slowly guide engine/transmission unit with subframe into body from below.
- Lift engine/transmission subassembly using scissor lift platform VAS 6131 until dimension - a - is reached.
^ Dimension - a - = 100 mm.
- Secure clutch slave cylinder with a new bolt - arrow -.
- Install lever for shift lever shaft - arrow -.
- Screw on connecting rod - 2 - of shift rod.
- Screw in socket head bolt of pivot rod - 1 -.
- Align subframe, engine bearing consoles and tunnel crossmember according to markings applied on longmembers during removal.
- Tighten bolts for subframe, engine bearing consoles and tunnel crossmember only to tightening torque, do not tighten further (tighten bolts only after wheel alignment).
CAUTION: Vehicle must not be driven in this condition.
- Install drive axles.
- Install guide control arm, control arm, stabilizer and suspension strut.
- Install driveshaft.
- 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.
- 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: Power-steering pump must not run dry.
- Fill system with coolant.
Note:
^ Only reuse drained coolant if 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 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%.
