Engine, Installing, Vehicles With Automatic 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 The Bolts Which Are Being Tightened With An Additional Turn.

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

The Hose Connections And Charge Air System Hoses Must Be Free Of Oil And Grease Before Installing.

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

In Order To Be Able To Securely Mount The Air Guide Hoses On Their Connectors, Spray The Screws On The Previously Used Clamps With A Rust Remover.

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

-- Install Secondary Air Injection (AIR) pipe. Refer to OVERVIEW - SECONDARY AIR INJECTION SYSTEM WITHOUT VACUUM CONTROL .

-- 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

-- The Following Preparations Must Be Made Before Connecting The Engine And Transmission:

Fig 2: Locating Hole Next To Notch

Courtesy of AUDI OF AMERICA, LLC

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

NOTE:

There Is Only 1 Notch On The Circumference; Rotate The Torque Converter As Needed.

-- 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

-- When jointing the engine and subframe, hold the ATF lines in their installation position.

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

-- 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. Be careful of the starter.

-- Tighten bolts -1 to 11-.

-- Remove the :T40170 .

NOTE:

The Following Step Is Necessary To Make Sure The Torque Converter Rests On The Drive Plate Evenly And Is Not Tilted.

Fig 5: Pressing Flywheel Slightly Against Drive Plate

Courtesy of AUDI OF AMERICA, LLC

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

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

Fig 6: Identifying Clutch Module First Bolt Installation Location

Courtesy of AUDI OF AMERICA, LLC

-- Position The :T40257 Onto The :T40263 .

Fig 7: Identifying Notch -Arrow A- On T40257 Must Face Color Dash -Arrow B- On Vibration Damper

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-- Attach the :T40257 to the bolts on the vibration damper.

-- Turn The Crankshaft 180° In The Direction Of Engine Rotation -arrow-.

-- Tighten The Accessible Bolts In This Crankshaft Position To The Tightening Specification. Refer To TRANSMISSION - REMOVING AND INSTALLING [0B4] , TRANSMISSION, ASSEMBLY SEQUENCE [0B2 AWD] .

-- Turn The Crankshaft 60° Farther And Tighten The Remaining Five Bolts To The Tightening Specification. Refer To TRANSMISSION - REMOVING AND INSTALLING [0B4] , TRANSMISSION, ASSEMBLY SEQUENCE [0B2 AWD] .

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

-- Tighten The Left And Right Drive Axles On The Transmission Flange Shafts. Refer To OVERVIEW - DRIVE AXLE or The Appropriate Service Information. .

-- Installing The Lower Left Coolant Pipe. Refer To LOWER LEFT COOLANT PIPE, REMOVING AND INSTALLING .

-- Install The Selector Lever Cable. Refer To the appropriate Service Information .

-- Install the ATF lines. Refer to the appropriate Service Information .

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

-- Lift The Engine/Transmission Assembly 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 - 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 Tunnel Crossmember

Courtesy of AUDI OF AMERICA, LLC

Install In Reverse Order Of Removal. Note The Following:

-- 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 TUNNEL CROSSMEMBER [0B2 COUPE] / TUNNEL CROSSMEMBER [0B4 AWD COUPE]TUNNEL CROSSMEMBER - AUTOMATIC / OVERVIEW - SUBFRAME .

-- Install The Subframe Crossbrace. Refer to SUBFRAME CROSSBRACE, COUPE AND SPORTBACK and SUBFRAME CROSSBRACE, CABRIOLET / OVERVIEW - SUBFRAME .

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

-- Install The Stabilizer Bar. Refer To SUBFRAME, CROSSBRACE, STABILIZER BAR AND COUPLING ROD OVERVIEW, THROUGH 08.2007 / 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 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 and E-BOX RELAY AND FUSE PANELS, 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, REMOVING AND INSTALLING 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 .

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

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

-- 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.

-- Fill With ATF. Refer To the appropriate Service Information .

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