Engine, Installing

Tightening Specifications

NOTE:

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

		85 ¹⁾
¹⁾ Replace bolts.

Subframe mount, refer to SUBFRAME OVERVIEW .

Fig 1: Battery Jump Start Terminal -U6- Pins

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the pins -1- for the battery jump start terminal -U6- to 15 Nm.

Ground Connection in the Right of the Plenum Chamber

-- Tighten the nut -2- to 9 Nm.

Fig 2: Engine Control Module (ECM) -J623- -1- And GND Wire Nut -2-

Courtesy of AUDI OF AMERICA, LLC

Fig 3: Identifying Ground (GND) Cable On Longmember

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the nut -1- to 15 Nm.

Engine/Transmission, Fastening

Fig 4: Identifying Alignment Sleeves -A- And Engine/Transmission Connecting Bolts

Courtesy of AUDI OF AMERICA, LLC

Item	Bolt	Nm
1, 2	M10x70	45
3 to 6	M12 x 80	80
7	M12x140	80
8	M12x70	80
9, 10	M12x50	80
A	Alignment sleeves for centering

Procedure

Installation is in reverse order of removal, note the following:

NOTE:

Replace bolts which have been tightened to torque.

Replace self-locking nuts and bolts as well as sealing rings, seals and O-rings.

Only remove the plugs or caps after installing the lines.

Secure all hose connections with hose clamps appropriate for the model.

During installation, all cable ties must be installed at the same location.

-- Install left and right engine supports.

-- 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.

Fig 5: Identifying Alignment Sleeves -A- And Engine/Transmission Connecting Bolts

Courtesy of AUDI OF AMERICA, LLC

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

Fig 6: Identifying Torque Converter Centering Bushing

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Risk of destroying ATF pump coupling plate by inserting torque converter incorrectly.

Check torque converter installation dimension.

Fig 7: Measuring Torque Converter Installed Dimension -A-

Courtesy of AUDI OF AMERICA, LLC

When torque converter is installed correctly, distance between lower contact surfaces of threaded holes at torque converter and contact surface of bell housing on Automatic Transmission 09D is approximately 22 mm.

If torque converter is not fully engaged, the distance is approximately 10 mm.

-- Before installing an exchanged engine, make sure the semi-circular ring -arrow- is inserted in the power steering pump input shaft.

Fig 8: Checking Power Steering Pump Input Shaft O-Ring

Courtesy of AUDI OF AMERICA, LLC

-- 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-.

Fig 9: Identifying Two Torque Converter Bolts Located Close To Each Other -Arrows-

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Risk of destroying automatic transmission.

Keep checking whether the torque converter behind the drive plate can be turned before and during tightening of the bolts at engine/transmission connection. If the torque converter cannot be turned, it must be assumed that it is inserted incorrectly.
Only secure torque converter to drive plate with new original bolts.

-- Bolt transmission to engine.

-- Tighten the torque converter. Refer to TORQUE CONVERTER .

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

-- Install power steering pressure line. Refer to LINES AND HOSES ASSEMBLY OVERVIEW (VEHICLES WITH V8 TDI ENGINE) .

-- Install starter. Refer to STARTER, REMOVING AND INSTALLING .

-- Install ATF lines. Refer to ATF LINES AND ATF COOLER .

-- Install right rear coolant pipe REAR RIGHT COOLANT PIPE .

-- Install left rear coolant pipe. Refer to REAR LEFT COOLANT PIPES .

-- Install the front driveshaft on the transfer case. Refer to FRONT DRIVESHAFT, REMOVING AND INSTALLING .

-- Install primary catalytic converter. Refer to LEFT PRIMARY CATALYTIC CONVERTER , RIGHT PRIMARY CATALYTIC CONVERTER .

-- Using VAS 6131, slowly guide engine/transmission unit with subframe into body from below.

-- Align subframe, engine carrier and transmission carrier according to markings applied on longitudinal members during removal.

-- Only tighten the subframe, engine carrier and transmission carrier bolts to the specification and only after the vehicle alignment is complete. Refer to SUBFRAME, STABILIZER BAR AND COUPLING ROD .

Fig 10: Subframe, Engine Carrier, Crossmember And Bolts

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Risk of accident due to loose connections.

If the bolts in the subframe are not tightened to final torque, vehicle must not be driven.

-- Install universal joint on steering gear. Refer to STEERING GEAR .

-- Install selector lever cable and check adjustment if necessary. Refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING .

-- Align exhaust system free of tension. Refer to EXHAUST SYSTEM, INSTALLING .

-- Install the rear driveshaft on the transfer case. Refer to REAR DRIVESHAFT .

-- Install stabilizer bar. Refer to SUBFRAME, STABILIZER BAR, COUPLING ROD AND STONE DEFLECTOR OVERVIEW .

-- Install brake caliper. Refer to BRAKE CALIPER, REMOVING AND INSTALLING .

-- Install the suspension struts and control arms. Refer to LOWER CONTROL ARM, LEVEL CONTROL SYSTEM SENSOR, UPPER FRONT AND UPPER REAR CONTROL ARMS AND TIE ROD OVERVIEW .

-- Install Engine Control Module (ECM). Refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

-- Remove the plenum chamber E-box cover. Refer to DRIVER SIDE E-BOX PLENUM CHAMBER, REMOVING AND INSTALLING .

-- Install refrigerant lines. Refer to Removal and Installation .

-- Tighten the battery jump start point -U6- pins. Refer to Fig 1.

-- Tighten the ground connection on the right longitudinal member. Refer to Fig 3.

-- Electrical connections and routing. Refer to the applicable SYSTEM WIRING DIAGRAM.

-- Observe safety precautions after connecting battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

CAUTION:

Risk of destroying control modules with excess voltage.

Do not use a battery charger for starting assistance!

-- Install wiper arms and adjust. Refer to WINDSHIELD WIPER ARM, REMOVING AND INSTALLING & WINDSHIELD WIPER ARMS, ADJUSTING .

-- Fill the engine oil and check the oil level.

-- Before starting engine for the first time, check the fluid level in power steering reservoir. Refer to POWER STEERING PUMP, HYDRAULIC PIPES AND RESERVOIR OVERVIEW .

NOTE:

Power-steering pump must not run dry.

-- Connect the coolant hoses with the connector coupling. Refer to Fig 11.

Fig 11: Connecting Coolant Hose Coupling

Courtesy of AUDI OF AMERICA, LLC

Fig 12: Connecting Coolant Hose Coupling

Courtesy of AUDI OF AMERICA, LLC

-- Fill with coolant, refer to COOLING SYSTEM, DRAINING AND FILLING .

NOTE:

Do not use drained coolant in the following situations:

If the cylinder head or cylinder block was replaced.

If the coolant is contaminated.

-- Fill refrigerant circuit.

-- Align subframe and engine carrier. Refer to SUBFRAME, SECURING Front & SUBFRAME, SECURING Rear .

-- Align transmission carrier and tighten it. Refer to TRANSMISSION CARRIER AND CONSOLE .

-- Install the front wheels and perform an alignment. Refer to VEHICLE ALIGNMENT TEST REQUIREMENTS .

WARNING:

Risk of accident due to loose connections.

Tighten subframe bolts to final torque after axle alignment.

-- Install the noise insulation bracket and the noise insulation. Refer to NOISE INSULATION, REMOVING AND INSTALLING .

-- On a vehicle with air suspension, deactivate vehicle lift mode. Refer to VEHICLE LIFT MODE .