Engine, Installing, Vehicles With Manual Transmission: Procedure

WARNING: This page is about a different car, the 2012 Audi S5, 2011 Audi S5, 2010 Audi S5, 2009 Audi S5, and 2008 Audi S5. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Replace Any Bolts That Were Tightened With An Additional Turn.

Replace Self-Locking Nuts And Bolts And Seals, Gaskets And O-Rings.

There Is A Needled Bearing In The Drive Plate. Check If The Needle Bearing Is Inserted Before Installing. Remove Needle Bearing From Drive Plate And Install. Refer To NEEDLE BEARING IN DRIVE PLATE, REPLACING, VEHICLES WITH MANUAL TRANSMISSION .

Secure All Hose Connections With Hose Clamps Of The Same Type As Those Equipped By The Factory.

When Installing, Bring All Cable Ties Back To Same Positions.

-- Clean The Threaded Holes In The Cylinder Block For Connecting The Engine And Transmission Using A Thread Tap Before Installing The Transmission.

-- Before Installing A Replacement Engine, Make Sure The Semicircular Ring -Arrow- Is Inserted In The Power Steering Pump Driveshaft.

Fig 1: Checking Power Steering Pump Input Shaft O-Ring

Courtesy of AUDI OF AMERICA, LLC

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

-- Installing the lower left coolant pipe. Refer to LOWER LEFT COOLANT PIPE, REMOVING AND INSTALLING .

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

Fig 2: Insert Assembly Aid T40169 Into Transmission Housing

Courtesy of AUDI OF AMERICA, LLC

-- Insert The :T40169 In The Transmission Housing And The Clutch Module From Below As Shown In The Illustration.

The Assembly Aid Must Engage In The Semicircular Opening -1- And In The Inspection Hole -2-.

NOTE:

The Inspection Hole Is Only In One Location On The Circumference So Rotate The Clutch Module As Needed.

-- Install The Assembly Aid Bolt Into The Hole On The Transmission Housing.

-- Insert The :T40170 In The Transmission Housing From Below And Secure It On The Flange Shaft -1-.

Fig 3: Identifying Transportation Lock T40170

Courtesy of AUDI OF AMERICA, LLC

-- Check If The Alignment Sleeves -A- For Centering The Engine/Transmission Are In The Cylinder Block And Insert Them If They Are Not.

Fig 4: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

Courtesy of AUDI OF AMERICA, LLC

-- Inspect The Aluminum Bolts Used To Connect The Engine To The Transmission To See If They Can Be Used Again And Mark Them, If Necessary. Refer To FROM VIN 8T-9A-008000: THE ALUMINUM BOLTS -2 THROUGH 11- MAY BE USED TWICE. THEREFORE, THE BOLTS MUST BE MARKED WITH TWO NOTCHES "X" MADE BY A CHISEL AFTER THEY HAVE BE USED THE FIRST TIME -ARROW-.

-- Position The Transmission On The Engine And Tighten The Bolts -1 Through 11-.

-- Remove The :T40170 and :T40169 .

-- Tighten The Drive Axles On The Transmission Flange Shafts. Refer To DRIVE AXLE, REMOVING AND INSTALLING / OVERVIEW - DRIVE AXLE .

-- Install The Wheel Housing Liners. Refer To WHEEL HOUSING LINER .

-- Install The Front Wheels. Refer To WHEEL, CHANGING AND MOUNTING .

NOTE:

The Following Procedure Is Necessary To Assure That The Clutch Module Contacts The Drive Plate Evenly And Does Not Get Bent.

Fig 5: Locating Transmission Housing Check Hole

Courtesy of AUDI OF AMERICA, LLC

-- 4. Engage a gear and turn the front wheels in direction of travel until the clutch module is rotated one complete turn (360°).

The inspection hole -arrow- must be visible through the opening in the transmission housing.

-- Secure the clutch module to the drive plate as follows:

Fig 6: Identifying Clutch Module First Bolt Installation Location

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Use the :VAG1332/14 to tighten the bolts.

-- Install the first bolt -arrow- and tighten by hand (2 Nm).

-- Turn the front wheels in direction of travel until the clutch module is rotated one have turn (180°).

-- Tighten The Bolts That Are Accessible In This Position To The Tightening Specification. Refer To CLUTCH MODULE [0B2 AWD (COUPE) AS OF 09.2009] / CLUTCH MODULE [0B4 AWD (COUPE)] .

-- Turn The Front Wheels In Direction Of Travel Until The Clutch Module Is Rotated ¹ /₆ Turn (60°) And Tighten The Remaining Bolts To The Tightening Specification. Refer To DESCRIPTION AND OPERATION [0B2 AWD (COUPE) AS OF 09.2009] / DESCRIPTION AND OPERATION [0B4 AWD (COUPE)] .

-- Install The Power Steering Hydraulic Lines. Refer To OVERVIEW - HYDRAULIC PIPES AND RESERVOIR .

-- Install Secondary Air Injection Pipe. Refer To OVERVIEW - SECONDARY AIR INJECTION SYSTEM WITHOUT VACUUM CONTROL .

-- Install The Catalytic Converter. Refer To OVERVIEW - MUFFLER .

-- Next, Raise Engine/Transmission Subassembly High Enough Using :VAS6131B Until Dimension -A- Is Reached Between The Tunnel Crossmember And Body.

Fig 7: Engine And Gearbox Jack VAS 6931

Courtesy of AUDI OF AMERICA, LLC

Dimension -a- = minimum 100 mm

-- Install The Gearshift Rod And The Push Rod. Refer To SELECTOR MECHANISM OVERVIEW [0B4 AWD (COUPE] , SELECTOR MECHANISM OVERVIEW [0B2 (COUPE)] .

-- Lift The Engine/Transmission Assembly Further Using The :VAS6131B .

-- Align The Subframe And Tunnel Crossmember Using The Marks Made On The Longitudinal Members During Removal.

-- Tighten The Subframe Bolts Only To The Tightening Specifications, Do Not Tighten Them Further (Tighten The Bolts Only After Axle Alignment). Refer To OVERVIEW - DRIVE AXLE / OVERVIEW - SUBFRAME .

Fig 8: Identifying Subframe 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.

-- Tighten The Tunnel Crossmember Bolts -arrows-. Refer To TUNNEL CROSSMEMBER [0B2 COUPE] / TUNNEL CROSSMEMBER [0B4 AWD COUPE]TUNNEL CROSSMEMBER - AUTOMATIC .

Fig 9: Identifying Bolts & Tunnel Crossmember

Courtesy of AUDI OF AMERICA, LLC

Install In Reverse Order Of Removal. Note The Following:

-- Install The Clutch Slave Cylinder CLUTCH SLAVE CYLINDER [0B4 AWD (COUPE)] / CLUTCH MASTER CYLINDER [0B2 AWD (COUPE) AS OF 09.2009] .

-- Attach The Steering Intermediate Shaft To The Steering Gear. Refer To STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

-- Install the driveshaft. Refer to The Appropriate Service Information. .

-- Install The Front Muffler. Refer To FRONT MUFFLER, REMOVING AND INSTALLING .

-- Install The Exhaust System Free Of Tension. Refer To EXHAUST SYSTEM, INSTALLING WITHOUT TENSION .

-- Install The Front Crossmember. Refer To OVERVIEW - SUBFRAME .

-- Install The Subframe Crossbrace. Refer To OVERVIEW - SUBFRAME .

-- Install The Upper Control Arm. Refer To OVERVIEW - SUSPENSION STRUT AND UPPER CONTROL ARM .

-- Install The Stabilizer Bar. Refer To OVERVIEW - SUBFRAME .

-- Tighten The Suspension Strut To The Control Arm. Refer To OVERVIEW - LOWER CONTROL ARM AND BALL JOINT .

-- Install The Brake Caliper. Refer To the appropriate Service Information .

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

-- Electrical Connections And Wiring Routing. Refer to The Appropriate Wiring Diagram(s).

-- Install the cable Terminal 30 Wire Junction 2 -TV22- and the cover for the engine compartment E-box. Refer to TERMINAL 30 WIRE JUNCTION 2 -TV22-, REMOVING AND INSTALLING .

-- Install The Tower Brace. Refer To TOWER BRACE - REMOVING AND INSTALLING .

-- Install The Windshield Wiper Fluid Reservoir Filler Tube. Refer To WASHER FLUID RESERVOIR, REMOVING AND INSTALLING .

-- Install The Refrigerant Lines. Refer To REFRIGERANT LINES, DISCONNECTING AND CONNECTING AT A/C COMPRESSOR .

-- Follow All Steps After Connecting The Battery. Refer To BATTERY, DISCONNECTING AND CONNECTING .

CAUTION:

There Is A Risk Of Destroying Control Modules With Excess Voltage.

Do not use a charger as a starting aid.

-- Install and adjust the windshield wiper arms. Refer to WINDSHIELD WIPER ARMS, ADJUSTING .

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

-- Install The Lock Carrier Braces. Refer To LOCK CARRIER COVER, REMOVING AND INSTALLING .

-- Fill With Engine Oil And Check The Oil Level. Refer To ENGINE OIL (CHECK OIL LEVEL)

-- Before Starting Engine For The First Time, Fill The Hydraulic Oil In The Power Steering Reservoir. Refer To the appropriate Service Information .

NOTE:

The Power Steering Pump Must Not Run Dry.

-- Fill with coolant. Refer to COOLANT 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 The Refrigerant Circuit. Refer To REFRIGERANT CIRCUIT, CHARGING / REFRIGERANT CIRCUIT, CHARGING WITH A/C SERVICE STATION .

-- Align The Subframe. Refer To OVERVIEW - SUBFRAME .

-- Perform An Axle Alignment. Refer To AXLE ALIGNMENT INFORMATION / AXLE ALIGNMENT SPECIFIED VALUES / AXLE ALIGNMENT PROCEDURE .

WARNING:

Risk Of Accident Due To Loose Connections.

Tighten The Subframe Bolts To The Specification After Performing Axle Alignment.

-- Install The Noise Insulations. Refer To NOISE INSULATION, REMOVING AND INSTALLING .