Engine, installing

WARNING: This page is about a different car, the 2008 Audi RS 4 and 2007 Audi RS 4. 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 and heat shields 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 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 the guide sleeve.
If necessary, check centering of clutch drive plate.
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 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 1: Identifying Engine/Transmission Threaded Connections

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Engine/transmission, fastening

Pos.	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 the installation is performed in reverse order of removal, note the following:

Install exhaust manifold: Left → Left exhaust manifold, removing and installing , right → Right exhaust manifold, removing and installing .
Install front exhaust pipe with pre- and main catalytic converter: Left → Left front exhaust pipe with primary and main catalytic converter, removing and installing , right → Right front exhaust pipe with primary and main catalytic converter, removing and installing .
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 2: Removing Both Base Plates For Left Support Element On Scissor Lift Platform VAS 6131

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

Fig 3: Removing Both Base Plates For Right Support Element On Scissor Lift Table VAS 6131

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

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 from Support Set VAS 6131/10
B4 ¹⁾	/10-1	/10-4	/10-5	/10-12
G3 ¹⁾	/10-1	/10-4	/10-5	/10-6
B10	/10-1	/10-2	/10-5	/10-8 ²⁾
G10	/10-1	/10-2	/10-5	/10-8 ²⁾
C14 ¹⁾	/10-1	/10-3	/10-5	/10-7
E14 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.
Using Scissor Lift Platform VAS 6131 , slowly guide engine/transmission unit with subframe into body from below.

Fig 6: Lowering/Lifting Engine/Transmission Assembly Using Scissor Lift Platform VAS 6131 Only Approx. By Dimension

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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

Dimension - a - = max. 100 mm.

Fig 7: Removing/Installing Coolant Hose To Heater Core On Rear Coolant Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Secure coolant hose - arrow - to heat exchanger on rear coolant pipe.

Fig 8: Slave Cylinder Bracket And Fastener

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 9: Removing/Installing Nut And Lever From/To Selector Shaft

Courtesy of VOLKSWAGEN UNITED STATES, INC.

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 pivot rod socket head bolt - 1 -.

Fig 11: Removing/Installing Bolts In Stages

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Bring subframe into contact with body using Scissor Lift Table VAS 6131.
Align subframe, engine bearing plates and tunnel cross member according to markings applied on long members during removal.
Tighten bolts for subframe, engine mount consoles as well as tunnel cross member only to specified torque. Do not tighten further (tighten bolts only after axle alignment).

65 Nm
115 Nm
115 Nm
75 Nm

CAUTION: Vehicle must not be driven in this condition.

Install drive axles → 40 - FRONT SUSPENSION .
Install guide link, link and suspension strut → 40 - FRONT SUSPENSION .
Install drive shaft →
- 39 FINAL DRIVE, DIFFERENTIAL
- 39 - FINAL DRIVE, DIFFERENTIAL for REAR FINAL DRIVE 0AR
.
Align exhaust system free of tension → Exhaust system, installing free of tension .

Install refrigerant lines → 87 AIR CONDITIONING .
Install stabilizer bar → 40 - FRONT SUSPENSION .
Install torque support.

Fig 12: Identifying Torque Support Bracket, Long Member & Correcting Shims

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Even up the gap between torque support bracket - 3 - and long member - 1 - using correcting shims - 2 - in an appropriate strength .

NOTE:

2 shims may also be used.

Install lock carrier with attachments →
- 50 BODY, FRONT
- 50 - BODY - FRONT for BODY EXTERIOR - CABRIOLET
.
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
.
Add engine oil and check oil level → Oil level, checking .
Before starting engine for the first time, fill power steering vacuum 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 Refrigerant R134a - Servicing.
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 803 or 805.

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 de-greased parts.
Tolerance for torque specifications ± 15%.

Component			Nm
Bolts/nuts		M6	9
		M8	20
		M10	40
		M12	65
Exceptions:
Engine support to engine			42 ¹⁾
Engine mount to engine mount plate			23
Clutch slave cylinder to transmission			23 ²⁾
Selector shaft lever to transmission			23
Pivot rod on transmission			40
Shift rod connecting rod on transmission			23
Heat shield for drive axle to transmission			23
Hydraulic pressure line			40
Fuel supply line to fuel rail			25
Torque support bracket to	Bearing		40
Long member	M8	30
		M10	50 + 90 ° ²⁾³⁾
Oil cooler oil lines to upper part of oil pan			8
¹⁾ Insert with locking compound; locking compound . ²⁾ Replace bolt. ³⁾ 90 ° corresponds to a quarter turn.