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.

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.

When installing a new clutch disc in combination with a used SAC clutch pressure plate (self-adjusting pressure plate), the adjustment ring of the pressure plate must be turned back to stop. Otherwise pressure plate works with decreased contact pressure (clutch slips) →
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
- 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
.

NOTE:

If clutch disc is not being replaced, the adjustment ring must not be turned back.
New SAC-pressure plates are already pre-adjusted and must not be reset.

Clean input shaft splines and (in case of used clutch plates) clean hub splines, remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Do not grease guide sleeve.
If necessary, check centering of clutch drive plate.
Check clutch release bearing for wear and replace if necessary.
Check clutch release bearing for wear and loose plastic ring →
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
- 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
.

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.

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 1: Identifying Engine/Transmission Threaded Connections

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine/transmission, fastening

Item	Bolt	Nm
1	M12x140	65
2	M12x155	65
3, 5	M12x110	65
4	M12x115	65
6	M12x125	65
7	M10x160	65 ¹⁾
8, 9, 10	M10x80	45
A	Alignment sleeves for centering
¹⁾ Bolt class 10.9.

Further installation is in reverse order of removal, note the following.

Install front exhaust pipes: Left → Left front exhaust pipe with catalytic converter (vehicles with manual transmission), removing and installing ; right → Right front exhaust pipe with catalytic converter (vehicles with manual transmission), removing and installing .
Always clean threaded drive shaft bores in transmission flanged shaft of locking fluid residue using a tap before installation.

Fig 2: Positioning/Removing Support Elements From VAS 6131/10 And VAS 6131/12 At Left On Engine

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Rotate attachment spindles at left of engine/transmission assembly downward.
Remove both base plates for left support element on scissor lift platform VAS 6131.

Fig 3: Positioning/Removing Support Elements From VAS 6131/10 And VAS 6131/11 At Right On Engine

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Rotate attachment spindles at right of engine/transmission assembly downward.
Remove both base plates for right support element on Scissor Lift Table VAS 6131.

NOTE:

The support points for front of engine and tunnel cross member remain unchanged.

Fig 4: Identifying Scissor Lift Platform VAS 6131

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Equip scissor lift platform VAS 6131 with support set for Audi VAS 6131/10 and VAS 6131/11 as follows:

Platform coordinates	Parts of support set for Audi VAS 6131/10 and VAS 6131/11
B4 ¹⁾	/10-1	/10-4	/10-5	/10-11
G4 ¹⁾	/10-1	/10-4	/10-5	/10-12
B10	/10-1	/10-2	/10-5	/10-8 ²⁾
G10	/10-1	/10-2	/10-5	/10-8 ²⁾
C15 ¹⁾	/10-1	/10-2	/10-5	/11-2
F15 ¹⁾	/10-1	/10-3	/10-5	/10-7
¹⁾ The support elements remain unchanged. ²⁾ Only install support elements after installing subframe.

Fig 5: Positioning Support Elements From VAS 6131/10 At Left/Right On Subframe

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Position subframe on both Attachments VAS 6131/10-8.
Twist spindles of support elements upward on both sides.
Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131.

Fig 6: 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 7: Slave Cylinder Bracket And Fastener

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Tighten clutch slave cylinder with new bolt - arrow - , procedure →
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 012/01W FRONT WHEEL DRIVE
- 30 CLUTCH for 5 SPD. MANUAL TRANSMISSION 01A ALL WHEEL DRIVE
- 30 CLUTCH for 6 SPD. MANUAL TRANSMISSION 01E ALL WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
- 30 CLUTCH for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
.

Fig 8: Removing/Installing Nut And Lever From Selector Shaft

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Install lever for selector shaft - arrow -.

Fig 9: Identifying Push Rod And Connecting Rod For Selector Rod

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Install connecting rod - 2 - of shift rod.
Install socket head bolt of pivot rod - 1 -.

Fig 10: Removing Nuts For Fastening Link And Guide Link

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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 11: Removing/Installing Bolts In Stages

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Align subframe, engine bearing plates and tunnel cross member according to markings applied on long members during removal.
Tighten bolts for subframe, engine mount plates as well as tunnel cross member 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.

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

Vehicles with all wheel drive: 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 drive shafts → 40 - FRONT SUSPENSION .

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

Fig 12: Removing/Installing Bolts For Torque Support

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Tighten bolts - arrows - for torque support.

Fig 13: 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 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 .
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:
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