Engine, Installing

WARNING: This page is about a different car, the 2016 Audi A7 Quattro. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Torque Wrench 1332 Insert - Ring Wrench - 16mm :VAG1332/14
Clutch Module Assembly Aid :T40169
Clutch Module Transportation Lock :T40170
Scissor Lift Table :VAS6131B .
Articulated Joint Support :VAS6131/13-7 .

Tightening Specifications

NOTE:

The tightening specifications apply only 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 ungreased parts.

Tightening specification tolerance: ± 15%.

Component	Nm
Bolts and nuts	M6	9
	M7	15
	M8	20
	M10	40
	M12	65

Assembly mounts. Refer to OVERVIEW - SUBFRAME MOUNT .
Engine to the transmission. Refer to TRANSMISSION, TRANSPORTING .

NOTE:

Replace the bolts that were tightened with an additional turn.

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

Only remove the plugs or caps after installing the lines.

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. Refer to the Parts information.

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

Secure the engine with the subframe on the :VAS6131B .
Engine secured with :VAS6131/13-7 .

-- Install the engine supports and engine mount. Refer to OVERVIEW - SUBFRAME MOUNT .

-- Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.

-- If applicable, tighten torque support with stop into its installed position.

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

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-- Insert the :T40169 in the transmission housing and the dual mass flywheel / torque converter 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/torque converter as needed.

-- Install the assembly aid bolt into the hole on the transmission housing.

-- Insert the :T40170 in the transmission housing from below and secure it on the flange shaft -1-.

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-- Bring the starter and if equipped the locking piece -1- into the installation position:

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Vehicles with S tronic Tansmission 0CK

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

-- 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, TRANSPORTING \.

-- Position the transmission on the engine and tighten the bolts -3 through 9-.

Vehicles with 8-Speed Automatic Transmission 0BK

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

-- 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.

-- Position the transmission on the engine and tighten the bolts -3 through 11-.

The locking piece -1- must be installed correctly before installing the starter -arrows-.

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NOTE:

If you have difficulty installing the starter, apply a small amount of lubricant to the locking ring.

-- Install the starter. Refer to BATTERY, STARTER, GENERATOR, CRUISE CONTROL STARTER .

-- Remove the :T40170 and :T40169 .

NOTE:

The following procedure is necessary to assure that the dual mass flywheel and/or the torque converter contacts the drive plate evenly and does not get bent.

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-- Press the dual mass flywheel/torque converter -2- against the drive plate -3- slightly in against the drive plate in direction of -arrow- using an assembly lever -1-.

-- Attach the dual mass flywheel/torque converter to the drive plate as follows:

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NOTE:

Use the :VAG1332/14 to tighten the bolts.

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

-- Join the tools as illustrated.

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Socket 21 mm for ¹ /₂ "-drive

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CAUTION:

Components could be destroyed by the camshaft timing chains jump off.

Turn crankshaft only in direction of engine rotation -arrow-.

-- Turn the crankshaft 180° in the direction of engine rotation.

-- Tighten the accessible bolts in this crankshaft position to the tightening specification. Refer to Overview - Flywheel And Dual Clutch (7-Speed DSG Transmission 0B5 (S tronic))Overview - Flywheel And Dual Clutch (7-Speed Dual Clutch Transmission 0B5 (S tronic)) or Overview - Torque Converter

-- Turn the crankshaft 60° farther and tighten the remaining five bolts to the tightening specification. Refer to Overview - Flywheel And Dual Clutch (7-Speed DSG Transmission 0B5 (S tronic))Overview - Flywheel And Dual Clutch (7-Speed Dual Clutch Transmission 0B5 (S tronic)) or Overview - Torque Converter .

-- When jointing the engine and subframe, hold the ATF lines in their installation position.

-- Tighten the left and right drive axles on the transmission flange shafts. Refer to 40 FRONT SUSPENSION .

-- Install the ATF lines.

-- Install the particulate filter:

Vehicles with Front Wheel Drive (FWD). Refer to PARTICULATE FILTER, REMOVING AND INSTALLING, VEHICLES WITH FWD .
Vehicles with All Wheel Drive (AWD). Refer to PARTICULATE FILTER, REMOVING AND INSTALLING, VEHICLES WITH AWD .

-- Secure the wire to the Catalytic Converter Heater 1 -Z119- /Catalytic Converter Heater 2 -Z120- -item 5- OVERVIEW - HEATED OXYGEN SENSOR, VEHICLES WITH TWO TURBOCHARGERS WITH SELECTIVE CATALYTIC REDUCTION SYSTEM .

-- Lift the engine/transmission assembly with the :VAS6131B .

-- Align the subframe and tunnel crossmember using the marks made on the longitudinal members during removal.

-- Tighten the subframe bolts only to the tightening specifications, do not tighten them further (tighten the bolts only after axle alignment). Refer to SUBFRAME . .

WARNING:

Risk of accident due to loose connections.

If the bolts in the subframe are not tightened to final torque, vehicle must not be driven.

-- Tighten the bolts for the tunnel cross member. Refer to SUBFRAME

Install in reverse order of removal. Note the following:

-- Install the driveshaft. Refer to FINAL DRIVE, DIFFERENTIAL 39 - FINAL DRIVE, DIFFERENTIAL FINAL DRIVE, DIFFERENTIAL (8-Speed Automatic Transmission 0BK AWD)FINAL DRIVE, DIFFERENTIAL .

-- Install the selector lever cable.

-- Attach the steering intermediate shaft to the steering gear. Refer to 48 STEERING .

-- Install the upper control arm and suspension strut. Refer to Suspension Strut And Upper Control Arm .

-- Install the subframe crossbrace and stabilizer bar. Refer to SUBFRAME .

-- Install the brake caliper. Refer to FRONT BRAKES .

-- Install the front lower longitudinal member.

-- Install the engine control module. Refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

-- Install windshield wiper fluid reservoir filler tube. Refer to WIPER/WASHER SYSTEMS .

-- Electrical connections and wiring routing. Refer to the Appropriate Wiring Diagram.

-- Install the cable Terminal 30 Wire Junction 2 -TV22- and the cover for the plenum chamber E-box.

-- Install the tower brace. Refer to Suspension Strut And Upper Control Arm .

-- Install the refrigerant lines. Refer to REFRIGERANT CIRCUIT .

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

-- Follow all steps after connecting the battery. Refer to BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

CAUTION:

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

Do not use a charger as a starting aid.

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

-- Install the lock carrier cover. Refer to FRONT BUMPER . .

-- Install the plenum chamber cover. Refer to BULKHEAD . .

-- Fill with engine oil and check the oil level.

-- Connect the coolant hoses with the connector coupling. Refer to Fig 1.

Fig 1: Coolant Hoses Connector Coupling

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NOTE:

Do not reuse used coolant.

-- Fill with coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Fill the refrigerant circuit. Refer to REFRIGERANT CIRCUIT .

-- Install the wheel housing liners. Refer to WHEEL HOUSING LINER . .

-- Install the front wheels. Refer to WHEELS/TIRES/TIRE PRESSURE MONITORING ASSEMBLY . .

-- Perform an axle alignment. Refer to WHEELS, TIRES, WHEEL ALIGNMENT .

WARNING:

Risk of accident due to loose connections.

Tighten the subframe bolts to the specification after performing axle alignment.

-- Depending on the transmission version, fill the ATF. .

-- Install the noise insulations. Refer to NOISE INSULATION . .

Fuel System, Bleeding and Checking for Leaks

-- Let the engine run a few minutes at idle without pressing the accelerator pedal and then stop the engine. The fuel system bleeds itself.

-- Check the entire fuel supply system for leaks.

Replace any leaking components.

-- Perform a road test where the accelerator pedal is fully depressed at least one time. Then check the high pressure area again for leaks.