Engine, Installing, Non-Hybrid Vehicles

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Special tools and workshop equipment required

Counterhold - Vibration Damper T10355 for vehicles with a S tronic transmission
Clutch Module Assembly Aid T40169
Clutch Module Transportation Lock T40170

Tightening Specifications

NOTE:

The tightening specifications apply only to lightly greased, oiled, phosphated or blackened nuts and bolts.

Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant.

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

Refer to OVERVIEW - SUBFRAME, ENGINE MOUNT
Engine to transmission, refer to TRANSMISSION, REMOVING AND INSTALLING for 0BW, or TRANSMISSION, REMOVING AND INSTALLING for 0BK .

Procedure

NOTE:

Replace any bolts that were tightened with an additional turn.

Remove the subframe bolts one after the other and replace them.

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

In vehicles with manual transmissions, the drive plate must have a needle bearing in it. Check if a needle bearing is inserted before installing. Install the needle bearing into the drive plate, refer to NEEDLE BEARING IN DRIVE PLATE, REPLACING .

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 .

In order to be able to securely mount the air guide hoses on their connectors, spray the screws on the previously used clamps with a rust remover.

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

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

Fig 1: 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 dual mass flywheel from below as shown in the illustration.

The assembly aid must engage in the semicircular opening -1- and in the inspection hole -2-.

NOTE:

There is only 1 inspection opening on the circumference; rotate the dual mass flywheel 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 2: Identifying Transportation Lock T40170

Courtesy of AUDI OF AMERICA, LLC

NOTE:

The bolt -2- attaches the starter to the transmission and has an additional spacer sleeve -arrow-.

Fig 3: Identifying Bolt & Spacer Sleeve

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The spacer sleeve must be inserted between the starter and the transmission.

Vehicles with S tronic Transmission

Fig 4: Starter, Locking Piece, Wedge And Installed Position

Courtesy of AUDI OF AMERICA, LLC

-- Bring the starter -1- and the locking piece -2- into the installed position:

-- Secure the starter with a plastic wedge -4- on the engine support -3-.

Continuation for All Vehicles

-- Inspect the aluminum bolts used to connect the engine to the transmission to check if they can be used again and mark them, if necessary, refer to TRANSMISSION, REMOVING AND INSTALLING for 0BW, or TRANSMISSION, REMOVING AND INSTALLING for 0BK .

Vehicles with A Manual Transmission

Fig 5: Engine To Transmission Bolts

Courtesy of AUDI OF AMERICA, LLC

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

-- Position the transmission on the engine and tighten the bolts -2 through 5-.

Vehicles with S tronic Transmission

Fig 6: Transmission To Engine Bolts

Courtesy of AUDI OF AMERICA, LLC

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

-- Position the transmission on the engine and tighten the bolts -2 through 5-.

Continuation for All Vehicles

Fig 7: Installing T40013 On Transmission

Courtesy of AUDI OF AMERICA, LLC

-- Release the tension on the spindle.

-- Lower the shop crane and mount the engine and transmission onto the engine mount.

-- Install the engine mount, refer to OVERVIEW - SUBFRAME, ENGINE MOUNT .

-- Remove the Shop Crane VAS6100 and lifting tackle.

-- Tighten the remaining engine/transmission bolts.

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

Vehicles with a S tronic transmission the locking piece -1- must be in position before installing the starter -arrow-.

Fig 8: Identifying Locking Piece
Courtesy of AUDI OF AMERICA, LLC

-- Install the starter, refer to STARTER, REMOVING AND INSTALLING, VEHICLES WITH 2.0L TFSI ENGINE .

NOTE:

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

Fig 9: Pressing Torque Converter

Courtesy of AUDI OF AMERICA, LLC

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

Vehicles with A Manual Transmission

Fig 10: Locating Transmission Housing Check Hole

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-- Install the front wheel, wheel bolt tightening specification: 140 Nm. Refer to WHEEL BOLT TIGHTENING SPECIFICATIONS .

-- 4. Engage a gear and turn the front wheels in direction of travel until the flywheel is rotated one complete turn (360°).

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

-- Secure the flywheel module to the drive plate as follows:

Fig 11: Identifying Clutch Module First Bolt Installation Location

Courtesy of AUDI OF AMERICA, LLC

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

-- Turn the front wheels in direction of travel until the flywheel module is rotated ² /₃ turn (240°).

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

-- Turn the front wheels in direction of travel until the flywheel module is rotated ¹ /₃ turn (120°) and tighten the remaining two bolts to the tightening specification .

-- Install the push rod .

Vehicles with S tronic Transmission

Fig 12: Identifying Clutch Module First Bolt Installation Location

Courtesy of AUDI OF AMERICA, LLC

-- Secure the flywheel module to the drive plate as follows:

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

-- Continue turning the crankshaft on the vibration damper 240° in direction of engine rotation using the Counterhold - Vibration Damper T10355.

Fig 13: Identifying Vibration Damper "TDC" Position With Special Tool T10355

Courtesy of AUDI OF AMERICA, LLC

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

-- Continue turning the crankshaft 120° and tighten the remaining two bolts to the tightening specification .

NOTE:

Ignore -arrow-.

-- Install the ATF lines, refer to ATF CIRCUIT for 0BW, ATF CIRCUIT for 0BK, or ATF CIRCUIT for 0B6 .

Continuation for All Vehicles

-- Install the catalytic converter, refer to CATALYTIC CONVERTER, REMOVING AND INSTALLING, NON-HYBRID VEHICLES .

-- Install the front muffler, refer to FRONT MUFFLER, REMOVING AND INSTALLING, NON-HYBRID VEHICLES .

-- Install the plenum chamber bulkhead, refer to OVERVIEW - BULKHEAD .

-- Install front coolant pipe, refer to OVERVIEW - COOLANT PIPES, NON-HYBRID VEHICLES .

-- Install the After-Run Coolant Pump -V51-, refer to OVERVIEW - COOLANT PIPES, NON-HYBRID VEHICLES .

-- Connect the coolant hoses with the connector coupling, refer to Fig 14.

Fig 14: Connecting Coolant Hose Coupling

Courtesy of AUDI OF AMERICA, LLC

-- Install the power steering pump, refer to POWER STEERING PUMP, REMOVING AND INSTALLING .

-- Install the Air Conditioning (A/C) compressor, refer to A/C COMPRESSOR, REMOVING AND INSTALLING, MECHANICALLY-DRIVEN A/C COMPRESSOR .

-- Install the ribbed belt, refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Electrical connections and wiring routing, refer to appropriate SYSTEM WIRING DIAGRAM.

-- Install the ECM, refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

-- Install the tunnel crossmember, refer to OVERVIEW - SUBFRAME MOUNT for 0BW, or OVERVIEW - SUBFRAME MOUNT for 0BK .

-- Install the cables Terminal 30 Wire Junction 2 -TV22- and the cover for the engine compartment E-box, refer to OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES and appropriate SYSTEM WIRING DIAGRAM.

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

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

-- Follow all steps after connecting the battery, refer to BATTERY, DISCONNECTING AND CONNECTING .

CAUTION:

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

Do not use a charger as a starting aid.

-- Install the air guide hoses, refer to OVERVIEW - CHARGE AIR SYSTEM .

-- Install the air filter housing, refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Install the engine cover, refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Check the oil level, refer to => 817.

NOTE:

Do not reuse used coolant.

-- Fill the coolant, refer to COOLANT, DRAINING AND FILLING, NON-HYBRID VEHICLES => Filling .

-- Install the wheel housing liners, refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Install the noise insulations, refer to OVERVIEW - NOISE INSULATION .

-- The combustion misfire adaptations must be adjusted after replacing the engine. Select 01 Reset Combustion Misfire Adaptation in Guided Fault Finding on the Vehicle Diagnostic Tester.