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.
- 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 the starter.
- 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.
- Always clean threaded bores in transmission flanged shaft for driveshaft of locking fluid residue using a tap before installation.
- Turn spindle of left support element on engine/transmission assembly downward.
- Remove left support element base plate from Scissor Lift Table (VAS 6131 A).
- Turn spindle of right support element on engine/transmission assembly downward.
- Remove right support element base plate from Scissor Lift Table (VAS 6131 A).
• The support points for front of engine and 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 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.
- Install selector lever cable and check adjustment if necessary.
- Raise engine/transmission assembly with subframe further using Scissor Lift Table (VAS 6131 A).
- Align subframe and engine mount brackets according to markings applied on long members during removal.
- Tighten subframe and engine mount bracket bolts only to specified torque, do not tighten further (only tighten bolts after axle alignment).
CAUTION!
Vehicle must not be driven in this condition.
- Tighten the tunnel crossmember bolts - arrow -.
The rest of the installation is performed in reverse order of removal, noting the following:
- Install drive axles.
- Install guide control arm, control arm, stabilizer bar, connecting link, suspension strut and subframe crossmember.
- Install driveshaft.
- Align exhaust system free of tension. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.
- Install refrigerant lines.
- Install left and right air filter housing.
- 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 suspension strut cross member.
- Install wiper arms and adjust.
- Check oil 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 consoles.
- 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 tightening specifications ±15%.
