Engine, Installing
Engine, Installing
Tightening specifications
• Torque 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%.
Tightening specifications => [ Assembly Mount, Overview ] Assembly Mount, Overview, => [ Crankshaft Assembly Overview ] Service and Repair.
Securing engine to transmission
Work procedure
Installation is in reverse order of removal, note the following:
• Replace bolts which have been tightened to torque.
• Replace self-locking nuts and bolts as well as sealing rings, seals and O-rings.
• Only replace torque converter bolts with original bolts.
• 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.
- Check whether alignment sleeves for centering engine and transmission in cylinder block are present, insert missing alignment sleeves.
CAUTION!
Risk of destroying ATF pump coupling plate by inserting torque converter incorrectly.
• Check torque converter installation dimension.
When torque converter is installed correctly, distance - a - between contact surface of threaded holes at torque converter and contact surface of bell housing on Automatic Transmission 09E is at least 19 mm.
- Before guiding engine and transmission together, rotate torque converter and drive plate so that holes and threaded holes are same height as opening on removed starter - arrow -.
CAUTION!
Risk of destroying automatic transmission.
• Keep checking whether the torque converter behind the drive plate can be turned before and during tightening of the bolts at engine/transmission connection. If the torque converter cannot be turned, it must be assumed that it is inserted incorrectly.
• Only secure torque converter to drive plate with new original bolts.
- Install ATF lines.
- Before installing an exchanged engine, check whether O-ring - arrow - is inserted in power steering pump input shaft.
- Install starter.
- Install right engine support => [ Right Engine Mount ] Right Engine Mount.
- Install exhaust manifold: Left => [ Left Exhaust Manifold with Catalytic Converter ] Left Exhaust Manifold with Catalytic Converter, right => [ Right Exhaust Manifold with Catalytic Converter ] Right Exhaust Manifold with Catalytic Converter.
- Install left coolant pipe => [ Left Coolant Pipe ] Left Coolant Pipe.
- Place oil dipstick guide tube in hole on upper part of oil pan.
- Install right coolant pipe => [ Right Coolant Pipe ] Right Coolant Pipe.
- Install secondary air injection air guide pipe => [ Secondary Air Injection System Assembly Overview ] Service and Repair.
- Always clean threaded driveshaft bores in transmission flanged shaft of locking fluid residue using a tap before installation.
- Turn spindle of left rear support element on engine downward.
- Remove left rear support element base plate from Scissor Lift Table (VAS 6131).
- Turn spindle of right rear support element on engine downward.
- Remove right rear support element base plate from Scissor Lift Table (VAS 6131).
• The support points for front of engine and transmission remain unchanged.
- Equip scissor lift platform (VAS 6131) 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).
- Using Scissor Lift Platform (VAS 6131), slowly guide engine/transmission unit with subframe into body from below.
- Lift engine/transmission subassembly using scissor lift platform (VAS 6131) until dimension - a - is reached.
• Dimension - a - = at least 100 mm.
- Install selector lever cable and check adjustment.
- Bring torque support into installation position.
- Raise engine/transmission assembly with subframe further using Scissor Lift Table (VAS 6131).
- Align subframe and engine mount plates according to markings applied on long members during removal.
- Tighten subframe and engine mount plate bolts only to specified torque, do not tighten further (only tighten bolts after axle alignment).
CAUTION!
Risk of accident due to loose connections.
• If the bolts in the subframe are not tightened to final torque, vehicle must not be driven.
- Tighten bolts - arrows - on tunnel cross member.
The rest of installation is in reverse order of removal, note the following:
- Install drive axles.
- Install guide control arm, control arm, stabilizer bar, connecting link, suspension strut and subframe crossmember.
- Install driveshaft.
- Install front muffler: left => [ Left Front Muffler ] Left Front Muffler, right => [ Right Front Muffler ] Right Front Muffler.
- Align exhaust system free of tension => [ Exhaust System, Installing ] Service and Repair.
- Install ATF lines.
- Install power steering pump hydraulic hose.
- Install torque support => [ Assembly Mount, Overview ] Assembly Mount, Overview.
- Install air filter housing
- Observe safety precautions after connecting battery.
CAUTION!
Risk of destroying control modules with excess voltage.
• Do not use a battery charger for starting assistance!
- Install dome brace.
- Install wiper arms and adjust
- Add engine oil and check oil level => [ Engine Oil Level, Checking ] Component Tests and General Diagnostics.
- 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 ] Cooling System, Draining and Filling.
• 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 plates.
- Perform axle alignment.
CAUTION!
Risk of accident due to loose connections.
• Tighten subframe bolts to final torque after axle alignment.
- Check ATF level.