Engine, Installing
Engine, Installing
Special tools, testers and auxiliary items required
• Depth Gauge (VAS 6082)
Procedure
• During assembly, replace self-locking nuts and bolts.
• Always replace bolts that are tightened to torque as well as sealing rings, gaskets and O-rings.
• Secure all hose connections with hose clamps appropriate for the model.
• During installation, all cable ties must be re-installed at the same location.
- Install the engine supports and mounts. Refer to => [ Subframe Mount Assembly Overview ] .
- Check the torque converter installation dimension: When torque converter is installed correctly, distance between contact surface of threaded holes at torque converter and contact surface of converter housing on Automatic Transmission 09L is minimum 19 mm.
CAUTION!
If torque converter is incorrectly installed, torque converter coupling and ATF pump could be damaged when transmission and engine are flanged together.
- 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 -.
- To secure torque converter to drive plate, use new original ribbed bolts.
- Make sure the alignment sleeves - A - for centering the engine and transmission in the cylinder block are present. Insert the alignment sleeves if they are missing.
- Install intermediate plate between engine and transmission onto alignment bushings.
- 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 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.
• Tightening specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
• Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not.
• Do not use any degreased parts.
• Tolerance for torque specifications ±15%.
Engine/transmission, fastening
Further installation is in reverse order of removal, note the following.
- Fasten the ATF lines.
- Install front exhaust pipes. Refer to: Left => [ Left Front Exhaust Pipe with Catalytic Converter ] Left Front Exhaust Pipe with Catalytic Converter, right => [ Right Exhaust Pipe with Catalytic Converter ] Right Exhaust Pipe with Catalytic Converter.
- Always clean threaded bores in transmission flanged shaft for crankshaft of locking fluid residue using a tap before installation.
- Turn spindle of left support element on engine downward.
- Remove the base plate for left support element on Scissor Lift Platform (VAS 6131 A).
- Turn spindle of right support element on engine downward.
- Remove the base plate for right support element on Scissor Lift Platform (VAS 6131 A).
• Support points for front of engine, transmission and tunnel cross member remain unchanged.
- Equip Scissor Lift Platform (VAS 6131 A) with Support Set for Audi (VAS 6131/10) as follows:
• A second technician is required to position subframe onto support elements.
- Position subframe on both Attachments (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 A).
- Using Scissor Lift Platform (VAS 6131 A), slowly guide engine/transmission unit with subframe into body from below.
- Align subframe and engine bearing bracket according to markings applied on longitudinal members during removal.
- Tighten bolts for subframe and engine mount brackets only to specified torque. Do not tighten further (tighten bolts only after axle alignment).
CAUTION!
Vehicle must not be driven in this condition.
- Tighten the tunnel crossmember bolts - arrow -.
Further installation is in reverse order of removal, note the following:
- Install selector lever cable, adjust if necessary.
- Install drive axles.
- Install guide control arm, control arm, stabilizer bar and suspension strut.
- Install subframe cross member.
- Install front cross member.
- Install driveshaft.
- Align exhaust system free of tension. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.
- Tighten the hydraulic pressure line to the power steering pump.
- Install A/C compressor.
- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Install the torque support. Refer to => [ Torque Support, Removing and Installing ] .
- Electrical connections and routing.
- Observe safety precautions after connecting battery.
CAUTION!
Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.
- Install wiper arms and adjust.
- Install dome brace.
- Check oil level.
- Bleed fuel system.
- Fill with coolant => [ Filling ] Procedures.
• Only reuse drained coolant if cylinder head or engine block was not replaced.
• Dirty coolant must not be re-used.
- Fill the power steering fluid and bleed the steering system.
- Check ATF level.
- Align subframe and both engine bearing brackets.
- Perform axle alignment.
CAUTION!
After axle alignment, tighten subframe bolts to final torque.
Tightening Specifications
• Tightening specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
• Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not.
• Do not use any degreased parts.
• Tolerance for torque specifications ±15%.
