Engine, Installing

NOTE:

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 using hose clamps appropriate for the model type .
During installation, reinstall all heat insulation sleeves and heat shields at the same locations.
During installation, all cable ties must be reinstalled at the same location.

Install left and right engine supports.
Make sure alignment sleeves for engine to transmission are installed in cylinder block. Install if necessary.

Bushing for torque converter

Fig 1: Torque Converter Centering Bushing

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On a vehicle with automatic transmission, check whether bearing bushing - arrow - is inserted at rear of crankshaft. Drive in bushing if necessary.

Fig 2: Removing Torque Converter Bolts In Opening On Removed Starter

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Before guiding engine and transmission together, rotate torque converter and drive plate so that holes or threaded holes are same height as opening on removed starter - arrows -.
To secure torque converter to drive plate, use new original ribbed bolts .
Bolt transmission to engine.

NOTE:

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%.

Fig 3: Removing Engine/Transmission Connecting Bolts

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Engine/transmission, fastening

Pos.	Bolt	Nm
1	M10x40	45
2	M10x135 1)	65
3	M12x105	65
4, 5	M12x100	65
6, 8, 9, 10, 11	M12x75	65
7	M12x155	65
A	Alignment sleeves for centering
1) Bolt class 10.9.

Fig 4: Checking Whether O-Ring Is Inserted In Power Steering Pump Input Shaft

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Before installing an exchanged engine, check whether O-ring - arrow - is inserted in power steering pump input shaft.
Install starter → 27 - STARTER, GENERATOR, CRUISE CONTROL .
Install left exhaust system tract → Left Exhaust System Tract, Removing and Installing .
Install right exhaust system tract → Right Exhaust System Tract, Removing and Installing .

Install left coolant pipe → Left Coolant Pipe, Removing and Installing .
Install right coolant pipe → Right Coolant Pipe, Removing and Installing .
Always clean threaded bores in transmission flanged shaft for crankshaft of locking fluid residue using a tap before installation.

Fig 5: Positioning/Removing Support Elements From VAS 6131/10 At Left On Engine

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Turn spindle of left support element on engine/transmission assembly downward.
Remove left support element base plate from Scissor Lift Table VAS 6131.
Turn spindle of right support element on engine/transmission assembly downward.

Fig 6: Positioning/Removing Support Elements From VAS 6131/10 At Right On Engine

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Remove right support element base plate from Scissor Lift Table VAS 6131.

NOTE:

The support points for front of engine and transmission remain unchanged.

Fig 7: Identifying Scissor Lift Platform VAS 6131

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Equip scissor lift platform VAS 6131 with support set for Audi VAS 6131/10 as follows:

Platform coordinates	Parts from Support Set VAS 6131/10
B3 1)	/10-1	/10-4	/10-5	/10-11
G3 1)	/10-1	/10-4	/10-5	/10-11
A11	/10-1	/10-2 2)	/10-5 2)	/10-8 2)
H11	/10-1	/10-2 2)	/10-5 2)	/10-8 2)
F10 1)	/10-1	/10-3	/10-5	/10-13
D11 1)	/10-1	/10-3	/10-5	/10-12
D16 1)	/10-1	/10-2	/10-5	/10-12
1) The support elements remain unchanged. 2) Only install support elements after installing subframe.

Fig 8: Positioning Support Elements From VAS 6131/10 At Left/Right On Subframe

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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.

Fig 9: Lowering Engine/Transmission Assembly Using Scissor Lift Platform VAS 6131 Only Approx. By Dimension

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Lift engine/transmission subassembly using scissor lift platform VAS 6131 until dimension - a - is reached.

Dimension - a - = max. 100 mm.

Install selector lever cable and check adjustment if necessary →
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE
- 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, ALL WHEEL DRIVE
.
Raise engine/transmission assembly with subframe further using Scissor Lift Table VAS 6131.

Fig 10: Removing/Installing Bolts In Stages

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Align subframe and engine mount consoles according to markings applied on longmembers during removal.
Tighten subframe and engine bearing plate bolts only to specified torque, do not tighten further (only tighten bolts after axle alignment).

55 Nm
110 Nm
110 Nm
75 Nm

CAUTION: Vehicle must not be driven in this condition.

Fig 11: Removing/Installing Bolts On Tunnel Cross Member

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Tighten bolts - arrows - at tunnel cross member.

The rest of the installation is in reverse order of removal, note the following:

Install drive axles → 40 - FRONT SUSPENSION .
Install guide control arm, control arm, stabilizer bar, connecting link, suspension strut and subframe crossmember → 40 - FRONT SUSPENSION
Install driveshaft → 39 FINAL DRIVE, REAR DIFFERENTIAL .
Align exhaust system → Exhaust System, Installing .

Install refrigerant lines → 87 - AIR CONDITIONING .
Install left and right air filter housing → 24 - MULTIPORT FUEL INJECTION (MFI) .
Electrical connections and routing → Electrical Wiring Diagrams, Troubleshooting and Component Locations , tightening torques → 97 - WIRES .
Observe safety precautions after connecting battery → 27 - STARTER, GENERATOR, CRUISE CONTROL .

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 → 40 - FRONT SUSPENSION .
Mount wiper arms and adjust → 92 - WINDSHIELD WIPER AND WASHER SYSTEM .
Add engine oil and check oil level → Oil Level, Checking .
Before starting engine for the first time, fill power steering vacuum reservoir with hydraulic oil → 48 - STEERING .

NOTE:

Power-steering pump must not run dry.

Fill with coolant → Cooling System, Draining and Filling .

NOTE:

Only reuse drained coolant if cylinder head or engine block was not replaced.
Dirty coolant must not be re-used.

Fill refrigerant circuit → Refrigerant R134a - Servicing.
Align subframe and both engine mount consoles → 40 - FRONT SUSPENSION .
Perform axle alignment → 44 - WHEELS, TIRES, WHEEL ALIGNMENT .

CAUTION: After axle alignment, tighten subframe bolts to final torque.

Tightening Specifications

NOTE:

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%.

Component		Nm
Bolts/nuts	M6	9
	M8	20
	M10	40
	M12	65
Exceptions:
Drive plate to torque converter		85 1)
Clamp B+ to starter		16
Engine support to cylinder block		40
Heat shield for drive axle to transmission		23
Engine mount console to longitudinal member		75
Tunnel cross member to body		50
Fuel supply line to distribution piece		25
1) Replace bolts.