Engine, Installing
Engine, Installing
• 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 using hose clamps appropriate for the model type.
• During installation, re-install all heat insulation sleeves at the same locations.
• During installation, all cable ties must be re-installed at the same location.
- When installing a new clutch disc in combination with a used SAC clutch pressure plate (self-adjusting pressure plate), the adjustment ring of the pressure plate must be turned back to impact. Otherwise the pressure plate works with decreased contact pressure (clutch slips).
• If clutch disc is not being replaced, the adjustment ring must not be turned back.
• New SAC-pressure plates are already pre-adjusted and must not be reset.
- 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. Refer to on splines. Do not grease the guide sleeve.
- If necessary, check centering of clutch drive plate.
- Check clutch release bearing for wear and replace if necessary.
If plastic ring of clutch release bearing is loose:
- Adhere clutch release bearing plastic ring to bearing ring, adhesive.
• 3 rectangular tabs - arrows - of the plastic ring reach into the cutouts of the bearing ring.
• If grooves with depth of more than 0.5 mm are present, the 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.
• 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
The rest of the installation is performed in reverse order of removal, noting the following:
- Install front exhaust pipes with catalytic converters. Refer to: Left => [ Left Front Exhaust Pipe with Primary and Main Catalytic Converter, Vehicles with Manual Transmission ] Left Front Exhaust Pipe With Primary and Main Catalytic Converter, Vehicles With Manual Transmission, right => [ Right Front Exhaust Pipe with Primary and Main Catalytic Converter, Vehicles with Automatic Transmission ] Right Front Exhaust Pipe With Primary and Main Catalytic Converter, Vehicles With Automatic Transmission.
- Always clean threaded bores in transmission flanged shaft for driveshaft of locking fluid residue using a tap before installation.
- Rotate spindles of support elements downward at left of engine/transmission assembly.
- Remove both base plates for left support element on scissor lift platform (VAS 6131 A).
- Rotate spindles of support elements downward at right of engine/transmission assembly.
- Remove both base plates for right support element on Scissor Lift Table (VAS 6131 A).
• The support points for front of engine and tunnel cross member remain unchanged.
- Equip scissor lift platform (VAS 6131 A) with support set for Audi (VAS 6131/10) as follows:
* Support elements remain unchanged.
* Only install support elements after installing subframe.
- 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.
- Lift engine/transmission subassembly using scissor lift platform (VAS 6131 A) until dimension - a - is reached.
• Dimension - a - = 100 mm.
- Secure clutch slave cylinder with a new bolt - arrow -.
- Install lever for selector shaft - arrow -.
- Install connecting rod - 2 - on shift rod.
- Install pivot rod socket head bolt - 1 -.
- Align subframe, engine bearing brackets and tunnel cross member according to markings applied on longmembers during removal.
- Tighten bolts for subframe, engine mount brackets as well as tunnel crossmember only to specified torque. Do not tighten further (tighten bolts only after axle alignment).
1. 65 Nm
2. 110 Nm
3. 110 Nm
4. 75 Nm
CAUTION!
Vehicle must not be driven in this condition.
- Install drive axles.
- Install guide control arm, control arm, stabilizer bar and suspension strut.
- Install driveshaft.
- Align exhaust system free of tension. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.
- 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. Refer to =>
Radiator Support Radiator Support
- Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
- Install front bumper cover.
- 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.
- Mount wiper arms and adjust.
- Check oil level. Refer to => [ Oil Level, Checking ] Testing and Inspection.
- Before starting engine for the first time, fill power steering vacuum reservoir with hydraulic oil.
• Power-steering pump must not run dry.
- 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 refrigerant circuit.
- Align subframe and both engine bearing brackets.
- Perform axle alignment.
CAUTION!
After axle alignment, tighten subframe bolts to final torque.
- Check headlight adjustment.
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 %.
* Insert using locking compound; locking compound.
* Replace bolt.