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 re-installed at the same location.
- When installing a new clutch disc in combination with a worn 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 worn clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of Lubricant (G 000 100) on splines. Do not grease the guide sleeve.
- If necessary, check centering of clutch drive plate.
- Check clutch release bearing for wear and loosen plastic ring.
- 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.
- 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 in reverse order of removal, note the following:
- Install exhaust manifold: Left => [ Left Exhaust Manifold ] Left Exhaust Manifold, right => [ Right Exhaust Manifold ] Right Exhaust Manifold.
- Install front exhaust pipe with pre- and main catalytic converter: Left => [ Left Front Exhaust Pipe with Primary and Main Catalytic Converters ] Left Front Exhaust Pipe With Primary and Main Catalytic Converters, right => [ Right Front Exhaust Pipe with Primary and Main Catalytic Converters ] Right Front Exhaust Pipe With Primary and Main Catalytic Converters.
- Always clean threaded driveshaft bores in transmission flanged shaft of locking fluid residue using a tap before installation.
- Rotate attachment spindles at left of engine/transmission assembly downward.
- Remove both base plates for left support element on Scissor Lift Platform (VAS 6131 A).
- Rotate attachment spindles at right of engine/transmission assembly downward.
- 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:
- 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 - = max. 100 mm.
- Secure coolant hose - arrow - to heat exchanger on rear coolant pipe.
- Tighten clutch slave cylinder with new bolt - arrow -, procedure
- Install the shift mechanism.
- Bring subframe into contact with body using Scissor Lift Table (VAS 6131 A).
- 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).
CAUTION!
Vehicle must not be driven in this condition.
- Install drive axles.
- Install guide control arm, control arm and suspension strut.
- Install driveshaft.
- Align exhaust system free of tension. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.
- Install the power steering hydraulic pressure line.
- Tighten the fuel supply line to the fuel rail.
- Install refrigerant lines.
- Install stabilizer bar.
- Install torque support. Refer to => [ Torque Support Bracket ] Torque Support Bracket.
- Install lock carrier with attachments. Refer to =>
Radiator Support Radiator Support
- 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.
- Install wiper arms and adjust.
- Fill the engine oil and check the level.
- Before starting engine for the first time, fill power steering vacuum reservoir with hydraulic oil.
• The 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 mount brackets.
- Install the front wheels and perform an alignment.
CAUTION!
After axle alignment, tighten subframe bolts to final torque.
- Check headlamp 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 tightening specifications ±15%.
