Engine, Installing

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

Special tools and workshop equipment required

Ring Spanner Insert AF 16 V.A.G 1332/14
Assembly Aid T40169
Transportation Lock T40170
Scissor-Type Assembly Platform VAS 6131 A

Tightening Specifications

NOTE:

The tightening specifications apply only 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 parts that have had the lubrication removed.

Tightening specification tolerance +/- 15%.

Component		Nm
Bolts and nuts	M6	9
	M7	15
	M8	20
	M10	40
	M12	65

Subframe mount, refer to SUBFRAME MOUNT OVERVIEW .

Fig 1: Disengaging Catches -Arrows A- And Remove Upper Part Of Line Pass-Through -2- Upward -Arrow B-

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-- Tighten the ground bolt -1- to 9 Nm.

Fig 2: Disconnecting Ground Wires -Arrow- From Right Longitudinal Member

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

Engine to Manual Transmission

Fig 3: Mounting Transmission To Engine

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Item

Bolt

M10 x 50 ¹⁾

2 through 6

M12 x 100 ²⁾

30 + 90°

M12 x 125 ²⁾

30 + 90°

8, 11

M10 x 60 ²⁾

15 + 90°

9, 10

M10 x 95 ²⁾

15 + 90°

Alignment sleeves for centering

¹⁾ Bolt class 10.9, the steel bolt may be used again unlimited number of times.
²⁾ The aluminum bolts can be used 2 times ENGINE, INSTALLING .

⁽¹⁾	To prevent damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt using a 14 mm socket with a /₂ drive, which is inserted in to the vise, as illustrated.

The aluminum bolts -2 through 11- may be used two times. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have been used the first time -arrow-.

Fig 4: Identifying Bolts Marked With An "X" May Not Be Used Again
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Bolts marked with an "X" may not be used again.

Procedure

NOTE:

Replace the bolts which are being tightened with an additional turn.

Replace self-locking nuts and bolts and seals, gaskets and O-rings.

In vehicles with manual transmissions, there is a needle bearing in the drive plate. Check if the needle bearing is inserted before installing. Needle bearing, removing from and installing on drive plate. Refer to NEEDLE BEARING ON DRIVE PLATE .

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.

To mount the air guide hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.

When installing, bring all cable ties back to the same positions.

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

-- Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.

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

Fig 5: Inserting Assembly Aid T40169 Into Transmission Housing & Clutch Module From Below

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-- Insert the T40169 into the transmission housing and clutch module from underneath as illustrated.

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 6: Identifying Transportation Lock T40170

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-- Check if the alignment sleeves -A- for centering the engine/transmission are in the cylinder block and insert them if they are not.

Fig 7: Ensuring Alignment Sleeves -A- For Centering Engine And Transmission In Cylinder Block Are Present

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-- 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 ENGINE, INSTALLING .

-- Position the transmission on the engine and tighten the bolts -1 through 11-.

-- Remove the T40170 and T40169.

NOTE:

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

Fig 8: Identifying Guide Pin And Adapter T40058

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-- Insert the T40058 guide pins as follows:

The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

-- Turn the crankshaft further one complete turn (360°) in direction of engine rotation -arrow- using the T40058 and ring wrench.

Fig 9: Rotating Crankshaft Using Socket T40058

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

Fig 10: Locating Transmission Housing Check Hole
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-- Secure the clutch module to the drive plate as follows:

Fig 11: Identifying Clutch Module First Bolt Installation Location

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NOTE:

Tighten the bolt with the V.A.G 1332/14.

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

-- Rotate the crankshaft with the T40058 180° in direction of engine rotation.

-- Tighten the bolts that are accessible in this position to the tightening specification. Refer to SPECIFICATIONS .

-- Turn the crankshaft 60° further and tighten the remaining 5 bolts to the tightening specification. Refer to SPECIFICATIONS .

-- Install the power steering hydraulic oil lines. Refer to POWER STEERING HYDRAULICS .

-- Install the left and right drive axles on the transmission flange shafts. Refer to OVERVIEW - DRIVE AXLE .

-- Install the catalytic converters: for the left one, refer to LEFT CATALYTIC CONVERTER and for the right one, refer to RIGHT CATALYTIC CONVERTER .

-- Next, raise engine/transmission subassembly high enough using VAS 6131 A until dimension -a- is reached between the subframe and body.

Fig 12: Raising Transmission

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-a- = minimum 100 mm

-- Install the shift rod and pivot rod. Refer to Description and Operation .

-- Continue raising the engine/transmission subassembly using the VAS 6131 A.

-- Align the subframe and transmission carrier 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 13: Identifying Subframe Bolts (Tighten To Specifications)

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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 -arrow-. Refer to Specifications .

Fig 14: Identifying Bolts & Tunnel Crossmember

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Install in reverse order of removal paying attention to the following:

-- Install the clutch slave cylinder. Refer to Removal and Installation .

-- 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 .

-- Install exhaust system free of stress. Refer to EXHAUST SYSTEM, INSTALLING .

-- Install the front crossmember. Refer to the appropriate Service Information .

-- Install the subframe cross brace, upper control arm and stabilizer bar and tighten the suspension strut on the control arm. Refer to OVERVIEW - DRIVE AXLE .

-- Install diagonal braces. Refer to the appropriate Service Information .

-- Install brake caliper. Refer to OVERVIEW - FRONT BRAKES .

-- Install the Engine Control Module (ECM). Refer to Removal and Installation .

-- Electrical connectors and wiring routing. Refer to appropriate SYSTEM WIRING DIAGRAM.

-- Install the wires, terminal 30, wire junction 2 -TV22- and the engine compartment E-box cover. Refer to Fig 1, Fig 2 and the appropriate Service Information .

-- Install the tower brace. Refer to TOWER BRACE, REMOVING AND INSTALLING .

-- Install the windshield wiper fluid reservoir filler tube. Refer to WINDSHIELD WASHER FLUID RESERVOIR, REMOVING AND INSTALLING .

-- Install refrigerant lines. Refer to REFRIGERANT LINES, DISCONNECTING AND CONNECTING AT A/C COMPRESSOR .

-- Be sure to follow the procedure for connecting the battery and afterwards. Refer to BATTERY .

CAUTION:

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

Do not use a charger as a starting aid.

-- Install the fuel supply hose and air filter housing. Refer to Removal and Installation .

-- Install the lock carrier braces. Refer to OVERVIEW - LOCK CARRIER .

-- Fill the engine oil and check the level.

-- Before starting the engine for the first time, check the fluid level in the power steering reservoir. Refer to GENERAL INFORMATION .

NOTE:

The power steering pump must not run dry.

-- Connect the coolant hose to the coupling. Refer to Fig 15.

Fig 15: Connecting Coolant Hose To Coupling

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Fig 16: Connecting Coolant Hose To Coupling

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-- Fill the coolant. Refer to COOLANT, 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 the refrigerant circuit. Refer to the appropriate service information .

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

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

-- Perform 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.

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