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, all cable ties must be re-installed at the same location.
• Clean the transmission input shaft splines and the splines of the damper unit on the flywheel, remove corrosion and apply only a very thin coating of Lubricant (G 000 100) on splines. Remove all excess grease.
- Install the engine supports and mounts. 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.
- Attach transmission to engine with new bolts.
• 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
Further installation is in reverse order of removal, note the following.
- Install front exhaust pipes with catalytic converter. Refer to: Left => [ Left Front Exhaust Pipe with Catalytic Converter ] Left Front Exhaust Pipe with Catalytic Converter, right => [ Right Exhaust Pipe with Catalytic Converter ] Right Exhaust Pipe with Catalytic Converter.
- Fasten the ATF lines.
- 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.
- Align subframe and engine bearing consoles according to markings applied on longitudinal members during removal.
- Tighten bolts for subframe and engine mount brackets only to specified torque. Do not tighten further (tighten bolts only after axle alignment).
CAUTION!
Vehicle must not be driven in this condition.
- Tighten the tunnel crossmember bolts - arrow -.
Further installation is in reverse order of removal, note the following:
- Install selector lever cable, adjust if necessary.
- Install drive axles.
- Install guide control arm, control arm, stabilizer bar and suspension strut.
- Align exhaust system free of tension. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.
- Install front cross member.
- Install subframe front cross member.
- Tighten the hydraulic pressure line to the power steering pump.
- Install A/C compressor.
- Install ribbed belt. Refer to => [ Ribbed Belt ] Ribbed Belt.
- Install the torque support. Refer to => [ Torque Support, Removing and Installing ] Torque Support, Removing and Installing.
- 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.
- Check oil level.
- Bleed fuel system.
- 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 the power steering fluid and bleed the steering system.
- Check ATF level.
- Align subframe and both engine bearing brackets.
- Perform axle 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 %.
