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 using hose clamps appropriate for the model type.
• During installation, re-install all heat insulation sleeves at the same locations.
• During installation, all cable ties must be re-installed at the same location.
Installation dimension for torque converter, checking
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.
CAUTION!
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.
- Bolt transmission to engine.
CAUTION!
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
The rest of the installation is in reverse order of removal, note the following:
- Install front exhaust pipes with catalytic converters. Refer to: Left => [ Left Front Exhaust Pipe with Primary and Main Catalytic Converter, Vehicles with Manual Transmission ] Left Front Exhaust Pipe With Primary and Main Catalytic Converter, Vehicles With Manual Transmission, right => [ Right Front Exhaust Pipe with Primary and Main Catalytic Converter, Vehicles with Automatic Transmission ] Right Front Exhaust Pipe With Primary and Main Catalytic Converter, Vehicles With Automatic Transmission.
- Install ATF lines.
- Always clean threaded bores in transmission flanged shaft for driveshaft of locking fluid residue using a tap before installation.
- Rotate spindles of support elements downward at left of engine/transmission assembly.
- Remove both base plates for left support element on scissor lift platform (VAS 6131 A).
- Rotate spindles of support elements downward at right of engine/transmission assembly.
- Remove both base plates for right support element on Scissor Lift Table (VAS 6131 A).
• The support points for front of engine and rear of transmission remain unchanged.
- Equip scissor lift platform (VAS 6131 A) with support set for Audi (VAS 6131/10) as follows:
* Support elements remain unchanged.
* Only install support elements after installing subframe.
- 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).
- Install left and right transmission mounts.
- Using scissor lift platform (VAS 6131 A), slowly guide engine/transmission unit with subframe into body from below.
- Align subframe and engine bearing brackets according to markings applied on longmembers during removal.
- Tighten bolts for subframe and engine mount brackets only to specified torque. Do not tighten further (tighten bolts only after axle alignment).
1. 65 Nm
2. 110 Nm
3. 110 Nm
4. 75 Nm
CAUTION!
Vehicle must not be driven in this condition.
The rest of the installation is in reverse order of removal, note the following:
- Install selector lever cable, adjust if necessary.
- Install drive axle.
- 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 refrigerant lines.
- Secure fuel hose to connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head - 1 - and - 3 - and tighten union nut - 2 - to 22 Nm.
- Install lock carrier with attachments. Refer to =>
Radiator Support Radiator Support
- Install ATF lines.
- Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
- Install front bumper cover.
- 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.
- Mount wiper arms and adjust.
- Check oil level. Refer to => [ Oil Level, Checking ] Testing and Inspection.
- 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 ] 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 brackets..
- Perform axle alignment.
CAUTION!
After axle alignment, tighten subframe bolts to final torque.
- Check headlight adjustment.
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 %.
* Replace bolts.
* Insert bolts with locking fluid.