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, all cable ties must be re-installed at the same location.
- Make sure alignment sleeves for engine to transmission are installed in cylinder block. Install if necessary.
- Install intermediate plate between engine and transmission onto alignment bushings.
Installation dimension for torque converter, checking
When the torque converter is installed correctly, the distance - a - between contact surface of the torque converter threaded holes and contact surface of the bell housing on the automatic transmission 09E is at least 6 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 guiding the engine and transmission together, rotate the torque converter and engine drive plate so that the fastening locations are positioned at the height of opening of the removed starter.
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.
- 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
* Bolt class 10.9.
- To secure torque converter to drive plate, use new ribbed bolts.
- Hand-tighten 6 bolts - arrows - of torque converter in the opening of the removed starter (turn crankshaft 1/3 rotation in each case).
- Tighten torque converter bolts to the specification (turn the crankshaft 1/3 rotation).
The rest of the installation is in reverse order of removal, note the following.
- Install exhaust manifolds with catalytic converters: Left => [ Installing ] Left Exhaust Manifold With Catalytic Converters, right => [ Installing ] Right Exhaust Manifold With Catalytic Converters.
- Check routing of wiring on engine => [ Routing of Wiring on Engine ] Routing of Wiring on Engine.
- Always clean threaded bores in transmission flanged shaft for crankshaft of locking fluid residue using a tap before installation.
- Rotate spindles of support elements (VAS 6131/10-11) and (VAS 6131/10-12) downward at left of engine/transmission assembly.
- Remove both base plates for left support element on scissor lift platform (VAS 6131).
- Rotate spindles of support elements (VAS 6131/10-11) and (VAS 6131/10-13) downward at right of engine/transmission assembly.
- Remove both base plates for right support element on Scissor Lift Table (VAS 6131).
• 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:
* Support elements remain unchanged.
* Only install support elements after installing subframe.
- Position engine carrier on both support elements (VAS 6131/10-7).
- Rotate spindles of the support elements (VAS 6131/10-7) upward on both sides.
- Tighten base plates for support elements to 20 Nm on scissor lift platform (VAS 6131).
- Fasten bolts - arrows - for engine carrier on both sides.
• A second technician is required to position subframe onto support elements.
- Position subframe on both attachments (VAS 6131/10-8).
- Rotate spindles of the support elements (VAS 6131/10-8) upward on both sides.
- Tighten base plates for support elements to 20 Nm on scissor lift platform (VAS 6131).
- Fasten bolts - arrows - of left and right transmission mounts.
- Using scissor lift platform (VAS 6131), slowly guide engine/transmission assembly with subframe and engine carrier into body from below.
CAUTION!
Make sure that the selector lever cable is guided over the rear transmission mount so that it will not be pinched during installation.
- Raise the engine/transmission slightly so that the distance between subframe and body achieve dimension - a -.
• Dimension - a - = 80 mm.
- Attach selector lever cable to transmission.
- Align subframe according to the markings on the longitudinal members.
- Tighten bolts for subframe only to specified torque. Do not tighten further (tighten bolts only after axle alignment).
1. 50 Nm
2. 150 Nm
3. 150 Nm
CAUTION!
Vehicle must not be driven in this condition.
- Tighten bolts - 4 - for engine carrier.
- Tighten bolts - arrows - at tunnel cross member.
- Install driveshaft.
- Align exhaust system. Refer to=> [ Exhaust System, Installing ] Exhaust System, Installing.
- Install guide links, control arms and stabilizer bar.
- Install drive axles.
- Install refrigerant lines.
- Install intake manifold side part => [ Left Intake Manifold Side-Section ] Left Intake Manifold Side-Section and => [ Right Intake Manifold Side-Section ] Right Intake Manifold Side-Section.
- Install strut tower brace.
- Before tightening specifications support, adjust torque support mount.
- Turn adjustment ring - 1 - counter-clockwise until it comes into contact with torque support bracket.
- Then, turn adjustment ring one rotation clockwise again.
- Tighten bolt - arrow - on torque support mount.
- 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.
- Check oil level. Refer to => [ Oil Level, Checking ] Component Tests and General Diagnostics.
- Fill with coolant. Refer to => [ Filling ] Procedures.
• Only reuse drained coolant if cylinder head or engine block was not replaced.
• Dirty coolant must not be re-used.
- Fill with oil for power steering system and bleed steering system.
- Fill refrigerant circuit.
- Install and adjust wiper arms.
- Check adjustment of selector lever cable.
- Deactivate vehicle lifting mode.
- Perform axle alignment.
CAUTION!
After axle alignment, tighten subframe bolts to final torque.
- Inspect fuel system for leaks => [ Fuel System, Performing Leak Test ] Fuel System, Performing Leak Test.
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%.
* Replace bolts.