Engine, Installing
Special tools and workshop equipment required
- Depth Gauge VAS 6082
Procedure
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. Refer to parts .
During installation, all cable ties must be re-installed at the same location.
-- Install the engine supports and mounts. Refer to SUBFRAME MOUNT ASSEMBLY OVERVIEW .
-- Check the torque converter installation dimension: When torque converter is installed correctly, distance between contact surface of threaded holes at torque converter and contact surface of converter housing on Automatic Transmission 09L is minimum 19 mm.
If torque converter is incorrectly installed, torque converter coupling and ATF pump could be damaged when transmission and engine are flanged together.
-- Before connecting engine and transmission, rotate torque converter and engine drive plate so that one hole or one threaded hole stands at height of opening of the removed starter -arrow-.
-- To secure torque converter to drive plate, use new original ribbed bolts. Refer to parts.
-- 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.
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.
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
| Item | Bolt | Nm |
|---|---|---|
| 1 | M10x100 | 65 1) |
| 2, 6 | M12x120 | 65 |
| 3, 4, 5 | M12x105 | 65 |
| 7 | M12x130 | 65 |
| 8, 9, 10 | M10x80 | 45 |
| A | Alignment sleeves for centering | |
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Further installation is in reverse order of removal, note the following.
-- Fasten the ATF lines. Refer to ATF PIPES, ATF COOLER AND ATF ADDITIONAL FILTER OVERVIEW .
-- Install front exhaust pipes. Refer to: Left LEFT FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER , right RIGHT EXHAUST PIPE WITH CATALYTIC CONVERTER .
-- Always clean threaded bores in transmission flanged shaft for crankshaft of locking fluid residue using a tap before installation.
-- Turn spindle of left support element on engine downward.
-- Remove the base plate for left support element on Scissor Lift Platform VAS 6131 A.
-- Turn spindle of right support element on engine downward.
-- Remove the base plate for right support element on Scissor Lift Platform VAS 6131 A.
Support points for front of engine, transmission and tunnel cross member remain unchanged.
-- Equip Scissor Lift Platform VAS 6131 A with Support Set for Audi VAS 6131/10 as follows:
| Platform coordinates | Parts of Support Set for Audi VAS 6131/10 | |||
|---|---|---|---|---|
| B5 1) | /10-1 | /10-4 | /10-5 | /10-11 |
| F5 1) | /10-1 | /10-4 | /10-5 | /10-12 |
| B11 | /10-1 | /10-2 | /10-5 | /10-8 2) |
| G11 | /10-1 | /10-2 | /10-5 | /10-8 2) |
| E9 1) | /10-1 | /10-3 | /10-5 | /11-3 |
| D10 1) | /10-1 | /10-2 | /10-5 | /12-1 |
| G14 1) | /10-1 | /10-4 | /10-5 | /10-13 |
| D16 1) | /10-1 | /10-3 | /10-5 | /10-6 |
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A second technician is required to position subframe onto support elements.
-- 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 bracket 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). Refer to Installing .
Vehicle must not be driven in this condition.
-- Tighten the tunnel crossmember bolts -arrow-. Refer to TUNNEL CROSSMEMBER .
Further installation is in reverse order of removal, note the following:
-- Install selector lever cable, adjust if necessary. Refer to SELECTOR LEVER CABLE .
-- Install drive axles. Refer to DRIVE AXLE .
-- Install guide control arm, control arm, stabilizer bar and suspension strut. Refer to REMOVAL AND INSTALLATION .
-- Install subframe cross member. Refer to SUBFRAME .
-- Install front cross member. Refer to CROSSMEMBER .
-- Install driveshaft. Refer to DRIVESHAFT .
-- Align exhaust system free of tension. Refer to EXHAUST SYSTEM, INSTALLING .
-- Tighten the hydraulic pressure line to the power steering pump. Refer to POWER STEERING PUMP .
-- Install A/C compressor. Refer to COMPRESSOR WITH PULLEY, REMOVING AND INSTALLING AT BRACKET .
-- Install ribbed belt. Refer to RIBBED BELT .
-- Install the torque support. Refer to TORQUE SUPPORT, REMOVING AND INSTALLING .
-- Electrical connections and routing. Refer to appropriate SYSTEM WIRING DIAGRAM.
-- Observe safety precautions after connecting battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .
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. Refer to WIPER ARM .
-- Install dome brace. Refer to Removing .
-- Check oil level. Refer to OIL LEVEL, CHECKING .
-- Bleed fuel system. .
-- Fill with coolant 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 the power steering fluid and bleed the steering system. Refer to POWER STEERING FLUID, CHECKING .
-- Check ATF level. Refer to ATF LEVEL, CHECKING AND CORRECTING .
-- Align subframe and both engine bearing brackets. Refer to SUBFRAME
-- Perform axle alignment. Refer to AXLE ALIGNMENT CONTROL POSITION, WITH AIR SPRING SUSPENSION, CHECKING .
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%.
| Component | Nm | |
|---|---|---|
| Bolts/nuts | M6 | 9 |
| M8 | 20 | |
| M10 | 40 | |
| M12 | 65 | |
| Exceptions: | ||
| Drive plate to torque converter | 85 1) | |
| B+ terminal to starter | 16 | |
| Fuel hose to fuel line | 22 | |
| Hose clamps 9 mm wide | 3 | |
| Hose clamps 13 mm wide | 5.5 | |
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