Engine, installing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Special tools, testers and auxiliary items required

Depth gauge

Work procedure

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.
Secure all hose connections using hose clamps appropriate for the model type .
During installation, all cable ties must be re-installed at the same location.

Fig 1: Checking Torque Converter Is Correctly Positioned

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Installation dimension for torque converter, checking

When torque converter is installed correctly, distance between contact surface of threaded holes at torque converter and contact surface of converter housing on Automatic Transmission 09L is approx. 19 mm.

CAUTION: If torque converter is incorrectly installed, torque converter coupling and ATF pump could be damaged when transmission and engine are flanged together.

Fig 2: Torque Converter Bolts

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Before connecting engine and transmission, rotate torque converter and engine drive plate so that one hole or one threaded hole stands at height of opening of removed starter - arrow -.
To secure torque converter to drive plate, use new original ribbed bolts .
Make sure centering sleeves for engine to transmission are installed in cylinder block. Install if necessary.
Install intermediate plate between engine and transmission onto alignment bushings.

Bolt transmission to engine.

CAUTION: Keep checking whether the torque converter behind the drive plate can be turned before and during tightening of the bolts at engine/transmission flange. If the torque converter cannot be turned, it must be assumed that it has not been inserted properly and that the coupling plate of the ATF pump and therefore the transmission will be destroyed during final tightening of the bolts.

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

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine/transmission, fastening

Item	Bolt	Nm
1	M10x115	65 ¹⁾
2, 6	M12x125	65
3, 5	M12x110	65
4	M12x115	65
7	M12x140	65
8, 9, 10	M10x80	45
A	Alignment sleeves for centering
¹⁾ Bolt class 10.9.

Fasten ATF lines →
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING
- 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE
.
Install front exhaust pipes: Left → Left front exhaust pipe with catalytic converter (vehicles with automatic transmission 09L), removing and installing ; right → Right front exhaust pipe with catalytic converter (vehicles with automatic transmission 09L), removing and installing .
Vehicles with all wheel drive: Always clean threaded drive shaft bores in transmission flanged shaft of locking fluid residue using a tap before installation.
Rotate attachment spindles at left of engine/transmission assembly downward.

Fig 4: Positioning/Removing Support Elements From VAS 6131/10 And VAS 6131/12 At Left On Engine

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove base plate for left support element on scissor lift platform VAS 6131.

Fig 5: Removing Base Plate For Right Support Element On Scissor Lift Platform VAS 6131

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Rotate attachment spindles at right of engine/transmission assembly downward.
Turn spindle of right support element on engine downward.
Remove base plate for right support element on scissor lift platform VAS 6131.

NOTE:

The support points for front of engine and rear of transmission remain unchanged.

Fig 6: Identifying Scissor Lift Platform VAS 6131

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Equip scissor lift platform VAS 6131 with support set for Audi VAS 6131/10 as follows:

Platform coordinates	Parts of support set for Audi VAS 6131/10
B4 ¹⁾	/10-1	/10-4	/10-5	/10-11
G4 ¹⁾	/10-1	/10-4	/10-5	/10-12
B11	/10-1	/10-2	/10-5	/10-8 ²⁾
G11	/10-1	/10-2	/10-5	/11-8 ²⁾
D15 ¹⁾	/10-1	/10-3	/10-5	/10-12
F15 ¹⁾	/10-1	/10-3	/10-5	/10-12
¹⁾ The support elements remain unchanged. ²⁾ Only install support elements after installing subframe.

Fig 7: Positioning Support Elements From VAS 6131/10 At Left/Right On Subframe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position subframe on both attachments VAS 6131/10-8.
Twist spindles of support elements upward on both sides.

Fig 8: Removing Bolts For Left/Right Transmission Mount

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fasten transmission mount to subframe - arrows -.

Fig 9: Lowering Engine/Transmission Assembly Using Scissor Lift Platform VAS 6131 Only Approx. By Dimension

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Carefully guide engine/transmission assembly from below into body using Scissor Lift Table VAS 6131 far enough so distance between subframe and body is dimension - a -.

Dimension - a - = 80 mm.

Place torque support with torque support stop between lock carrier and engine.

Fig 10: Pressing Ball Socket Of Selector Lever Cable From Selector Shaft Lever & Removing Bracket On Transmission

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Press ball socket - 1 - of selector lever cable onto selector shaft lever.
Install mounting bracket according to marking on transmission - arrows -.
Insert drive axles into spines of left and right wheel bearing housings.

Fig 11: Removing Nuts For Fastening Link And Guide Link

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosely bolt guide link - 1 - and link - 2 - to subframe.

NOTE:

Bolts must first be tightened once the vehicle is sitting on its wheels on the floor.

Fig 12: Removing/Installing Bolts In Stages

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Align subframe according to markings on longitudinal members made during removal.
Tighten bolts for subframe and engine mount plates only to specified torque. Do not tighten further (tighten bolts only after axle alignment).

65 Nm
110 Nm
110 Nm
75 Nm

CAUTION: Vehicle must not be driven in this condition.

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

Install drive shaft →
- 39 - FINAL DRIVE, DIFFERENTIAL for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING
- 39 FINAL DRIVE, DIFFERENTIAL for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
- 39 FINAL DRIVE, DIFFERENTIAL for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
- 39F - FRONT FINAL DRIVE, DIFFERENTIAL for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE, INTERNAL COMPONENT SERVICING
- 39 FINAL DRIVE, DIFFERENTIAL for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
.
Align exhaust system free of tension → Exhaust system, installing free of tension .
Install refrigerant lines → 87 AIR CONDITIONING .
Install vacuum pump for brake booster → Vacuum pump for brake booster, removing and installing .

Install drive axles → 40 - FRONT SUSPENSION .
Install guide link, stabilizer bar and suspension strut → 40 - FRONT SUSPENSION .

Fig 13: Removing/Installing Bolts For Torque Support

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten bolts - arrows - for torque support.

Fig 14: Removing/Installing Bolts At Torque Support Stop

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
Electrical connections and routing → Electrical Wiring Diagrams, Troubleshooting and Component Locations.
Observe safety precautions after connecting battery → 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

CAUTION: Do not use a battery charger for starting assistance! There is the risk that the vehicle control modules could be damaged.

Mount wiper arms and adjust → 92 WINDSHIELD WIPER WASHER SYSTEM .
Check selector lever cable adjustment →
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING
- 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE
.
Check oil level → Oil level, checking .
Bleed fuel system → 24 - FUEL INJECTION SYSTEM .

Fill with coolant → Cooling system, draining and filling .

NOTE:

Only reuse drained coolant if cylinder head or engine block was not replaced.
Dirty coolant must not be re-used.

Fill power steering system oil and bleed steering system → 48 - STEERING .
Check ATF level →
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING
- 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE
.
Align subframe and both engine mount plates → 40 - FRONT SUSPENSION .
Perform axle alignment → 44 - WHEELS, TIRES, VEHICLE ALIGNMENT .

CAUTION: After axle alignment, tighten subframe bolts to final torque.

Fill refrigerant circuit Refrigerant R134a - Servicing.

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:
Drive plate to torque converter		85 ¹⁾
Clamp B+ to starter		16
Engine support to cylinder block		40
Transmission mount to subframe		23
Engine mount plate to longitudinal member		75
Engine mount to engine mount plate		23
Heat shield for drive axle to transmission		23
Torque bracket to engine		40
Torque support stop to lock carrier		28
Hydraulic pressure line to power steering pump		47
Fuel hose to fuel line		22
Hose clamps 9 mm wide		3
¹⁾ Replace bolts.