Engine, Installing: Notes

Special tools and workshop equipment required 

• All special tools listed when removing.

Procedure 

• Replace bolts that were tightened with an additional turn after removing them.
• Replace the self-locking nuts and bolts, gaskets, seals and O-rings after removing.
• Only remove the plugs or caps just before installing the respective lines.
• Wear safety gloves during procedures at the exhaust system.
• Secure all hose connections with hose clamps that match the ones used in series production. Refer to the Parts Information.
• The securing components for the wires must correspond to the production series. Refer to Parts Information.
• Check the vacuum hoses for damage before the assembly and replace if necessary.
• During installation, all cable ties must be installed at the same location.
• Bonded rubber bushings have a limited range of rotation. Only tighten the threaded connections for the suspension when the vehicle is in the control position.
• If a new or replacement engine is installed, then a residual amount of the test cycle oil from the factory is still in the engine. Before starting the engine for the first time, bleed the test cycle oil and fill with engine oil. 

• Secure the engine with the subframe on the :VAS6131B  .

-- Check the sensor wheel for engine speed sensor. Refer to Crankshaft ; check the sensor wheel.

-- Install the engine supports and engine mount. Refer to OVERVIEW - ASSEMBLY MOUNTS .

-- Install the transmission on the engine. Refer to the appropriate service information .

-- Install the transmission mount. Refer to TRANSMISSION MOUNT, REMOVING AND INSTALLING .

-- Bring the subframe into the installation position.

-- Carefully guide the engine/transmission assembly into the body using the :VAS6131B  .

-- Tighten the tunnel crossmember bolts. Refer to the appropriate service information .

-- Remove the subframe. Refer to SUBFRAME, SECURING .

Install in reverse order of removal. Note the following:

-- Install the Transmission Fluid Cooling Valve -N509-. Refer to OVERVIEW - COOLANT VALVES .

-- Install the High Temperature Circuit Coolant Pump -V467-. Refer to OVERVIEW - ELECTRIC COOLANT PUMP .

-- Install the ribbed belt tensioner for the A/C compressor. Refer to RIBBED BELT TENSIONER, REMOVING AND INSTALLING .

-- Install the starter generator. Refer to GENERATOR, REMOVING AND INSTALLING .

-- Install the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Install the parking lock emergency release cable. Refer to the appropriate service information .

-- Install the steering intermediate shaft. Refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

-- Install the coupling rod. Refer to OVERVIEW - SUBFRAME .

-- Tighten the drive axles. Refer to OVERVIEW - DRIVE AXLE .

-- Install the lower control arm. Refer to OVERVIEW - LOWER CONTROL ARM AND BALL JOINT .

-- Install the steering gear boot. Refer to BOOT, REMOVING AND INSTALLING .

-- Install the tie rod end. Refer to OVERVIEW - STEERING GEAR .

-- Install the subframe crossbrace and shield. Refer to OVERVIEW - SUBFRAME .

-- If removed, install the refrigerant lines. Refer to Refrigerant Circuit .

-- Install the A/C compressor. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING FROM BRACKET or A/C COMPRESSOR, REMOVING AND INSTALLING .

-- Install the ribbed belt. Refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Install the parking/auxiliary heater bracket. Refer to the appropriate service information ; Overview - Parking/Auxiliary Heater Components.

-- Wires and connections. Refer to COMPONENT LOCATION OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES and the appropriate Wiring Diagram.

-- Connect the fuel hoses. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

-- Install the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Install the charge air hose connections. Refer to OVERVIEW - CHARGE AIR HOSE CONNECTIONS .

-- Install the catalytic converters. Refer to OVERVIEW - EMISSIONS CONTROL SYSTEM [CXYA] .

-- Install the heat shield and engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Install the coolant pipes. Refer to OVERVIEW - COOLANT PIPES .

-- Install the driveshaft. Refer to the appropriate service information .

-- Install the exhaust system. Refer to OVERVIEW - MUFFLER .

-- Install the wheel spoiler and wheel housing liner. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

-- Mount the front wheels. Refer to WHEELS AND TIRES .

-- Install the braces, longitudinal member and the mount. Refer to OVERVIEW - LOCK CARRIER .

-- If necessary, bleed the test cycle oil. Refer to ENGINE, INSTALLING - If a new or replacement engine is installed, then a residual amount of the test cycle oil from the factory is still in the engine. Before starting the engine for the first time, bleed the test cycle oil and fill with engine oil. .

-- Add engine oil (refer to ENGINE OIL, FILLING ) and check the oil level (refer to ENGINE OIL LEVEL, CHECKING AND CORRECTING IF NECESSARY ).

-- Bring the ground wire into the installation position and tighten the nuts -1, 2 and 3-. Refer to the appropriate Wiring Diagram. (Depending on the version the ground wires -1 and 3- can also only be installed with a ground connection).

Courtesy of AUDI OF AMERICA, LLC

-- Check the ground wires are installed correctly.

-- Follow all steps after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Install the plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- After replacing the engine, perform the "0001 - mechanical engine, functions" listed adaptation using the Vehicle Diagnostic Tester.

-- Connect the coolant hoses/coolant ventilation line with the connector coupling. Refer to Fig 1.

-- Fill the coolant. Refer to Coolant, Filling .

-- Install the noise insulation. Refer to OVERVIEW - NOISE INSULATION .