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Home >> Audi >> 2007 >> A4 Base, 2D Convertible >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> 2.0L - Turbo Engine Mechanical, Engine Code(S): BPG, BWT >> 10 - Engine - Assembly >> Engine, removing and installing >> Engine, installing

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.
  • Hose connections and charge air system hoses must be free of oil and grease before installing.
  • Secure all hose connections using hose clamps .
  • During installation, all cable ties must be re-installed at the same location.

Vehicles with manual transmission: 

NOTE:
  • If clutch disc is not being replaced, the adjustment ring must not be turned back.
  • New SAC-pressure plates are already pre-adjusted and must not be reset.

If plastic ring of clutch release bearing is loose:

Fig 1: Servicing Release Bearing With Plastic Ring
GW00005259Courtesy of VOLKSWAGEN UNITED STATES, INC.

Vehicles with automatic transmission: 

All: 

Fig 2: Identifying Intermediate Plate Is Hooked In At Sealing Flange And Is Pushed Onto Alignment Sleeves
GW00010543Courtesy of VOLKSWAGEN UNITED STATES, INC.
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: Identifying Engine/Transmission Threaded Connections
GW00017463Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine/manual transmission, fastening 

Item Bolt Nm
1, 6 M12x105 65
2, 4 M12x80 65
3 M12x90 65
5, 7 M12x95 65
8 M10x50 45
9, 10, 11 M10x45 45
A Alignment sleeves for centering
Fig 4: Identifying Engine/Transmission Threaded Connections
GW00017463Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine/multitronic transmission, fastening 

Item Bolt Nm
1 M12x67 65
2 M10x70 45
3, 4, 5, 7 M12x75 65
6 M12x105 65
8 M10x60 45
9, 10, 11 M10x45 45
A Alignment sleeves for centering

All: 

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

Fig 5: Identifying Lock Carrier With Attachments
GW00017468Courtesy of VOLKSWAGEN UNITED STATES, INC.
CAUTION: Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.
NOTE:
  • Only reuse drained coolant if cylinder head or engine block was not replaced.
  • Dirty coolant must not be re-used.

Torque 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:  
Engine mount to engine plate 40
Engine mount to engine support 23
Electrical wiring to starter 16
Electrical wiring to generator 16
Heat shield for drive shaft to transmission 23
Torque support stop 28
Hose clamps 9 mm wide 3
Hose clamps 13 mm wide 5.5
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