Engine, Installing: Procedure

WARNING: This page is about a different car, the 2015 Audi RS 5, 2014 Audi RS 5, and 2013 Audi RS 5. 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.

The hose connections as well as the air guide pipes and 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. Refer to the Parts Information.

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 semi-circular ring -arrow- is inserted in the power steering pump drive axle.

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 .

-- 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 Clutch Module Assembly Aid: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 Clutch Module Transportation Lock:T40170 in the transmission housing from below and secure it on the flange shaft -1-.

Fig 3: Identifying Transportation Lock T40170

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

-- 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 ENGINE, INSTALLING .

-- Position the transmission on the engine and tighten the bolts -1 through 10-.

-- Remove the Clutch Module Transportation Lock:T40170 and Clutch Module Assembly Aid:T40169 .

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

NOTE:

The following procedure is necessary to assure that the clutch module contacts the drive plate evenly and does not get bent.

Fig 5: Pressing Flywheel Slightly Against Drive Plate

Courtesy of AUDI OF AMERICA, LLC

-- Press the clutch module -2- slightly against the drive plate -3- using a pry bar -1- in direction of -arrow-.

-- 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 Torque Wrench 1332 Insert - Ring Wrench - 16mm:VAG1332/14 to tighten the bolts.

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

-- Position the Crankshaft Turning Tool:T40257 onto the Wrench - 21mm:T40263 .

Fig 7: Attaching T140257 To T140263

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-- Attach the Crankshaft Turning Tool:T40257 to the bolts on the vibration damper.

The semi-round countersink -arrow A- on the Crankshaft Turning Tool:T40257 must face the semi-round countersink -arrow B- on the vibration damper.

NOTE:

Ignore the notch on the Crankshaft Turning Tool:T40257 .

-- Turn the crankshaft 180° in the direction of engine rotation -arrow-.

-- Tighten the bolts accessible in this crankshaft position to the tightening specification. Refer to TRANSMISSION, DISASSEMBLING AND ASSEMBLING .

-- Turn the crankshaft 60° farther and tighten the remaining five bolts to the tightening specification. Refer to TRANSMISSION, DISASSEMBLING AND ASSEMBLING .

-- 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 DRIVE AXLE .

-- Install the selector lever cable. Refer to the appropriate Service Information .

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

-- Install the exhaust manifold and catalytic converters. Refer to OVERVIEW - MUFFLER .

-- Lift the engine/transmission assembly using the Scissor Lift Table: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 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 SUBFRAME .

Fig 9: Identifying Bolts & Tunnel Crossmember

Courtesy of AUDI OF AMERICA, LLC

-- Tighten the air guide to the tunnel crossmember. Refer to Figure.

Install in reverse order of removal. Note the following:

-- Attach the steering intermediate shaft to the steering gear. Refer to OVERVIEW - HYDRAULIC PIPES AND RESERVOIR .

-- Install the drive axle. Refer to DRIVE AXLE .

-- Install the exhaust system free of tension. Refer to EXHAUST SYSTEM, INSTALLING WITHOUT TENSION .

-- Install the subframe crossbrace and stabilizer bar. Refer to SUBFRAME .

-- Install the upper control arm and fasten the suspension strut on the control arm. Refer to UPPER CONTROL ARM, REMOVING AND INSTALLING .

-- Install the brake caliper. Refer to the appropriate Service Information .

-- Electrical connections and wiring routing. Refer to appropriate Wiring diagram.

-- Install the wires, Terminal 30 Wire Junction 2 - TV22- and engine compartment E-box cover. Refer to RELAY PANELS, FUSE PANELS AND E-BOXES .

-- Install the GND bolt. Refer to Figure.

-- Install the electric wires. Refer to Figure.

-- Install the oil lines. Refer to OVERVIEW - ENGINE OIL COOLER .

-- Install the tower brace. Refer to UPPER CONTROL ARM, REMOVING AND INSTALLING .

-- Install windshield wiper fluid reservoir filler tube. Refer to WINDSHIELD WASHER SYSTEM .

-- Install the refrigerant line. Refer to REFRIGERANT CIRCUIT .

-- Install the Secondary Air Injection (AIR) pipes. Refer to OVERVIEW - SECONDARY AIR INJECTION SYSTEM .

-- Install the lock carrier cover. Refer to FRONT BUMPER .

-- Install the air filter housing and air guide pipes. Refer to OVERVIEW - AIR FILTER HOUSING .

-- Fill the engine oil and check the level. Refer to oil capacity chart. .

-- Follow all steps after connecting the battery. Refer to BATTERY .

CAUTION:

There is a risk of destroying control modules with excess voltage.

Do not use a charger as a starting aid.

-- Before starting engine for the first time, fill the hydraulic oil in the power steering reservoir. Refer to POWER STEERING FLUID LEVEL, CHECKING .

NOTE:

The power steering pump must not run dry.

-- Connect the coolant hoses with the connector coupling. Refer to Fig 10.

Fig 10: Connecting Coolant Hose Coupling

Courtesy of AUDI OF AMERICA, LLC

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

NOTE:

Do not reuse used coolant.

-- Fill the refrigerant circuit. Refer to REFRIGERANT CIRCUIT .

-- Align the subframe. Refer to SUBFRAME .

-- Install the wheel housing liners. Refer to WHEEL HOUSING LINER .

-- Install the front wheels. Refer to WHEELS AND TIRES .

-- Perform an axle alignment. Refer to VEHICLE ALIGNMENT .

WARNING:

Risk of accident due to loose connections.

Tighten the subframe bolts to the specification after performing axle alignment.

-- Fill the ATF. Refer to the appropriate Service Information .

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