Engine, Installing

Special tools and workshop equipment required 

• Clutch Module Transportation Lock :T40170 
• Torque Wrench 1332 Insert - Ring Wrench - 16mm :VAG1332/14 
• Scissor Lift Table :VAS6131B 
• Chain Tensioner Lever
• Cleaning Solution :D 009 401 04 

Procedure 

• Replace the 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.
• The hose connections as well as air duct pipes and hoses must be free of oil and grease before installing.
• Secure all hose connections with hose clamps that match the ones used in series production. Refer to the 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 suspension threaded connections when vehicle is in curb weight position or in the control position.

-- Bring the starter into the installation position.

-- Install the engine supports and engine mount. Refer to OVERVIEW - SUBFRAME MOUNT .

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

-- The following preparations must be made before connecting the engine and transmission:

-- Clean the contact surface -1- on the lower cover for the timing chain and on the sealing piece -2- with Cleaning Solution :D 009 401 04  .

Courtesy of AUDI OF AMERICA, LLC

-- Bond the sealing piece with the lower timing chain cover.

-- Insert the :T40170  in the transmission housing from below and secure it on the flange shaft -1-.

-- Check if the alignment sleeves -A- for centering the engine and transmission in the cylinder block are installed.

-- Inspect the aluminum bolts used to connect the engine to the transmission to check if they can be used again and mark them if necessary. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

• When guiding together the engine and transmission make sure that the locking piece is seated correctly.

-- Place the transmission on the engine and at the same time turn the bolt -1- for the starter.

-- Install the bolts -2 to 11- all the way by hand.

-- Tighten the bolts -1 to 11-. Refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

-- Remove the :T40170  .

• The following step is necessary to make sure the torque converter rests on the drive plate evenly and is not tilted.
  Fig 3: Pressing Flywheel Slightly Against Drive Plate

  Courtesy of AUDI OF AMERICA, LLC

-- Press the torque converter -2- slightly in against the drive plate -3- in direction of -arrow- using an assembly lever -1-.

-- Attach the torque converter to the drive plate as follows:

-- Turn the torque converter so that hole next to the notch -arrow- is visible in the lower cut-out in the transmission housing.

TIP:

There is only one notch on the circumference, so rotate the torque converter as needed.

-- Tighten the bolts -arrow- for the torque converter -1- that are accessible in this position. Refer to OVERVIEW - TORQUE CONVERTER .

Courtesy of AUDI OF AMERICA, LLC

TIP:

Use the :VAG1332/14  to tighten the bolts.

-- Then turn the crankshaft 60° farther -arrow- and tighten the remaining five bolts to the tightening specification. Refer to OVERVIEW - TORQUE CONVERTER .

Courtesy of AUDI OF AMERICA, LLC

-- Install the plug for "TDC" hole. Refer to OVERVIEW - CRANKSHAFT .

-- Install the coolant pipes. Refer to COOLANT PIPES, REMOVING AND INSTALLING .

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

-- Install the ATF cooler. Refer to ATF COOLER, REMOVING AND INSTALLING .

-- Carefully guide the engine/transmission assembly into the body using the Scissor Lift Table :VAS 6131 B  .

-- Remove the locating pins and install the subframe. Refer to SUBFRAME, SECURING .

-- Tighten the tunnel crossmember bolts. Refer to OVERVIEW - ASSEMBLY MOUNTS .

Further installation is performed in reverse order of removal, while noting the following:

-- Install the parking lock emergency release cable. Refer to [For transmission(s) 0D5A] Selector Mechanism .

-- Install the A/C compressor. Refer to OVERVIEW - A/C COMPRESSOR .

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

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

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

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

-- Install the Engine Control Module -J623-. Refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

-- Wires and connections. Refer to COMPONENT LOCATION OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES and 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 heat shield and engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Install the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

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

-- Install the front lower longitudinal member. Refer to OVERVIEW - LOCK CARRIER (1 Of 2) / OVERVIEW - LOCK CARRIER (2 Of 2) .

-- Mount the front wheels. Refer to Wheels and Tires .

-- Install the lock carrier cover. Refer to LOCK CARRIER COVER, REMOVING AND INSTALLING (1 Of 2) / LOCK CARRIER COVER, REMOVING AND INSTALLING (2 Of 2) .

-- Fill the engine oil and check the oil level. Refer to ENGINE OIL LEVEL, CHECKING AND CORRECTING IF NECESSARY .

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

-- If the engine is replaced, perform the "01 - mechanical engine, functions" listed adaptation using the Vehicle Diagnostic Tester.

-- Connect the coolant hoses with the connector coupling. Refer to Fig 5.

-- Fill with coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Check the ATF level. Refer to ATF LEVEL, CHECKING .

-- Install the underbody trim panel. Refer to Underbody Trim Panel .

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

Tightening Specifications 

• The tightening specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts.
• Additional lubricants, such as engine or transmission oil are permitted, although lubricants containing graphite are not.
• Do not use any ungreased parts.
• Tightening specification tolerance: ±15%.

Component			Nm
Bolts and Nuts		M6	9
		M7	15
		M8	20
		M10	40
		M12	65

• Refer to OVERVIEW - SUBFRAME MOUNT 
• Engine to transmission. Refer to the appropriate service information .