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 with hose clamps appropriate for the model.
• During installation, reinstall all heat insulation sleeves and heat shields at the same locations.
• During installation, all cable ties must be installed at the same location.
- Install the left and right engine supports. Refer to => [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview.
- 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.
- Make sure the rear torque converter centering bushing - arrow - is installed into the crankshaft. Install a missing centering bushing.
- Before guiding the engine and transmission together, rotate the torque converter and drive plate so that the holes and threaded holes are the same height as the opening on the removed starter - arrows -.
- To secure torque converter to drive plate, use new original ribbed bolts.
- 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 tightening specifications ±15%.
Engine/Transmission, Fastening
- Before installing an exchanged engine, make sure the semi-circular ring - arrow - is inserted in the power steering pump input shaft.
- Install starter.
- Always clean threaded bores in transmission flanged shaft for driveshaft of locking fluid residue using a tap before installation.
- Rotate attachment spindles at left of engine/transmission assembly downward.
- Remove both left support element base plates from scissor lift table (VAS 6131 A).
- Rotate attachment spindles at right of engine/transmission assembly downward.
- Remove both right support element base plates from (VAS 6131 A).
• The support points for front of engine and rear of transmission remain unchanged.
- Equip scissor lift platform (VAS 6131 A) with support set for Audi (VAS 6131/10) as follows:
- 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 (VAS 6131 A).
- Tighten left and right transmission mount bolts - arrows -.
- Remove additional support element (VAS 6131/10-10) with (VAS 6131/10-4) on right rear of transmission.
- Install wiring harness and coolant hose system on engine/transmission assembly.
- Install left driveshaft heat shield.
- Install left exhaust system tract. Refer to => [ Left Exhaust System Tract ] Left Exhaust System Tract.
- Install right exhaust system tract. Refer to => [ Right Exhaust System Tract ] Right Exhaust System Tract.
- Install left coolant pipe. Refer to => [ Left Coolant Pipe ] Left Coolant Pipe.
- Install right coolant pipe. Refer to => [ Right Coolant Pipe ] Right Coolant Pipe.
- Using (VAS 6131 A), slowly guide engine/transmission unit with subframe into body from below.
- Lift engine/transmission subassembly using (VAS 6131 A) until dimension - a - is reached.
• Dimension - a - = max. 300 mm.
- Install selector lever cable and check adjustment if necessary.
CAUTION!
Ensure selector lever cable is not pinched in left rear transmission support during installation.
- Align the subframe according to the markings on the longitudinal members.
- Tighten the subframe bolts to the tightening specification. Do not tighten any further (tighten bolts only after axle alignment).
CAUTION!
Vehicle must not be driven in this condition.
- Tighten the engine carrier bolts - 4 -. Refer to => [ Subframe Mount Assembly Overview ] Subframe Mount Assembly Overview.
- Tighten the tunnel crossmember bolts - arrow -.
The rest of installation is in reverse order of removal, note the following:
- Install driveshaft.
- Align exhaust system free of tension. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.
- Install driveshafts.
- Install guide control arm, control arm and stabilizer.
- Install refrigerant lines.
- Install right cylinder head cover. Refer to => [ Right Cylinder Head Cover ] Right Cylinder Head Cover.
- Install suspension strut cross member.
- Install and adjust the torque support bracket. Refer to => [ Torque Support Bracket, Removing and Installing and Adjusting ] Torque Support Bracket, Removing and Installing and Adjusting.
- Electrical connections and routing.
- Observe safety precautions after connecting battery.
- Install wiper arms and adjust.
CAUTION!
Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.
- Before starting engine for the first time, fill power steering vacuum reservoir with hydraulic oil.
• The power steering pump must not run dry.
- Check oil level.
- Fill with coolant => [ Filling ] Procedures.
• Only reuse drained coolant if cylinder head or engine block was not replaced.
• Dirty coolant may not be used again.
- Fill refrigerant circuit.
- Install the front wheels and perform an 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 %.
