Engine (vehicles with manual transmission), installing

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2009 Audi S4, 2008 Audi S4, 2007 Audi S4, 2006 Audi S4, and 2005 Audi S4. 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, re-install all heat insulation sleeves at the same locations.
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 impact. Otherwise the pressure plate works with decreased contact pressure (clutch slips) → 30 CLUTCH .

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 on splines. Do not grease the guide sleeve.
If necessary, check centering of clutch drive plate.
Check clutch release bearing for wear and replace if necessary.

If plastic ring of clutch release bearing is loose:

Fig 1: Servicing Release Bearing With Plastic Ring

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Adhere clutch release bearing plastic ring to bearing ring, adhesive

3 rectangular tabs - arrows - of plastic ring reach into cutouts of bearing ring.
If grooves with depth of more than 0.5 mm are present, the release bearing must be replaced.

Make sure alignment 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 2: Identifying Engine/Transmission Threaded Connections

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Engine/transmission, fastening

Item	Bolt	Nm
1, 2	M12x120	65
3	M12x110	65
4, 5	M12x105	65
6	M12x130	65
7	M12x170	65
8, 9, 10	M10x60	45
A	Alignment sleeves for centering

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

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

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

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

Fig 4: Positioning Support Elements From VAS 6131/10 And VAS 6131/11 At Right On Engine/Transmission

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

NOTE:

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

Fig 5: Identifying Scissor Lift Platform VAS 6131

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

Platform coordinates	Parts of support set for Audi VAS 6131/10
B4 * See note	/10-1	/10-4	/10-5	/10-11
G3 * See note	/10-1	/10-4	/10-5	/10-11
B10	/10-1	/10-2	/10-5	/10-8 * See note
G10	/10-1	/10-2	/10-5	/10-8 * See note
C14 * See note	/10-1	/10-3	/10-5	/10-7
E14 * See note	/10-1	/10-3	/10-5	/10-7

*Support elements remain unchanged.

*Only install support elements after installing subframe.

Fig 6: 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.
Turn spindles of support elements upward on both sides.
Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131 A.
Using scissor lift platform VAS 6131 A , slowly guide engine/transmission unit with subframe into body from below.

Fig 7: Lowering Engine/Transmission Assembly Using Scissor Lift Platform VAS 6131 Only Approx. By Dimension

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Lift engine/transmission subassembly using scissor lift platform VAS 6131 A until dimension - a - is reached.

Dimension - a - = 100 mm.

Fig 8: Slave Cylinder Bracket And Fastener

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Secure clutch slave cylinder with a new bolt - arrow -.

Fig 9: Installing Lever For Selector Shaft

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Install lever for selector shaft - arrow -.

Fig 10: 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 11: Removing/Installing Bolts In Stages

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Align subframe, engine bearing plated 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.

Install driveshafts → 40 - FRONT SUSPENSION .
Install guide control arm, control arm, stabilizer bar and suspension strut → 40 - FRONT SUSPENSION .
Install driveshaft →
- 39 - FINAL DRIVE, DIFFERENTIAL for 5 SPD. AUTOMATIC TRANSMISSION 01V
- 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 012/01W FRONT WHEEL DRIVE
- 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
- 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 .

Fig 12: Installing/Removing Fuel Hose To/From Connection On Fuel Rail Line

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Secure fuel hose to connection on fuel rail line. To do so, counter hold using an open-end wrench at each hex head - 1 - and - 3 - and tighten union nut - 2 - to 22 Nm.
Install lock carrier with attachments →
- 50 BODY, FRONT
- 50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET
.

Fig 13: Placing Torque Support On Rubber Buffer For Torque Support

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Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
Install front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.
Electrical connections and routing → Electrical Wiring Diagrams, Troubleshooting and Component Locations.
Observe safety precautions after connecting battery →
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
- 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET
.

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
- 92 WINDSHIELD WIPER & WASHER SYSTEM for ELECTRICAL EQUIPMENT, CABRIOLET
.
Check oil level → Oil level, checking .
Before starting engine for the first time, fill power steering reservoir with hydraulic oil → 48 - STEERING .

NOTE:

Power-steering pump must not run dry.

Fill with coolant Filling .

NOTE:

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

Fill refrigerant circuit → 87 - AIR CONDITIONING .
Align subframe and both engine bearing plates → 40 - FRONT SUSPENSION
Perform axle alignment → 44 - WHEELS, TIRES, VEHICLE ALIGNMENT .

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

Check headlight adjustment →
- 01 - MAINTENANCE
- 01 - MAINTENANCE for MAINTENANCE PROCEDURES - CABRIOLET
.

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 engine		42 * See note
Clutch slave cylinder to transmission		23 * See note
Selector shaft lever to transmission		23
Pivot rod on transmission		40
Shift rod connecting rod on transmission		23
Heat shield for drive shaft to transmission		23
Hydraulic pressure line		40
Torque support stop to lock carrier		28
Fuel hose to fuel line		22

* Insert using locking compound; locking compound .

*Replace screw.