Engine, Installing: Procedure

WARNING: This page is about a different car, the 2015 Audi A7 Quattro, 2014 Audi A7 Quattro, 2013 Audi A7, and 2012 Audi A7. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Replace any bolts that were tightened with an additional turn.

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

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.

To mount the air guide hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing.

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

Secure the engine with the subframe on the Scissor Lift Table VAS 6131B.
Engine secured with articulated joint support VAS 6131/13-7.

-- 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.

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

Vehicles with 7-Speed DSG Transmission 0B5:

Fig 1: Insert Assembly Aid T40169 Into Transmission Housing

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-- Insert the Clutch Module Assembly Aid T40169 in the transmission housing between the dual mass flywheel and the transmission housing 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.

-- Install the Clutch Module Transportation Lock T40170 into the transmission housing and the dual mass flywheel from below and secure it to the flange shaft -1-.

Fig 2: Identifying Transportation Lock T40170

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-- 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, INSTALLING and TRANSMISSION TIGHTENING SPECIFICATIONS .

Fig 3: Checking If Alignment Sleeves For Centering Engine/Transmission Are In Cylinder Block

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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.

-- Attach the transmission to the engine and the tighten the bolts -1 and 6 through 10-.

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

Vehicles with 8-Speed Automatic Transmission 0BK:

Fig 4: Locating Hole Next To Notch

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-- Turn the torque converter so that hole next to the notch -arrow- is visible in the lower cut-out in the transmission housing as shown.

NOTE: There is only 1 notch on the circumference; rotate the torque converter as needed.

-- Insert the Clutch Module Transportation Lock T40170 in the transmission housing from below and secure it on the flange shaft -1-.

Fig 5: Identifying Transportation Lock T40170

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

Fig 6: Identifying Bolts

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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.

-- Position the transmission on the engine. Be careful of the starter.

-- Tighten bolts -1 to 11-.

-- Remove the Clutch Module Transportation Lock T40170.

Continuation for All Vehicles:

Fig 7: Pressing Torque Converter

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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.

-- Press the dual mass flywheel and / or the torque converter -2- in direction of -arrow- slightly against the drive plate -3- using a pry bar -1-.

-- Secure the dual mass flywheel and/or the torque converter to the drive plate as follows:

Fig 8: Identifying Clutch Module First Bolt Installation Location

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NOTE: Use the Torque Wrench 1332 Insert - Ring Wrench - 16 mm VAG 1332/14 to tighten the bolts.

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

-- Insert the crankshaft socket T40058 guide pins as follows:

Fig 9: Identifying Guide Pin And Adapter T40058

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The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

-- Rotate the crankshaft 180° further in direction of engine rotation in direction of -arrow- using the Crankshaft Socket T40058 and ring wrench.

Fig 10: Counter Hold Crankshaft Using Socket T40058

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-- Tighten the accessible bolts in this crankshaft position to the tightening specification, refer to TORQUE CONVERTER, REMOVING AND INSTALLING .

-- Turn the crankshaft 60° farther and tighten the remaining five bolts to the tightening specification, refer to TORQUE CONVERTER, REMOVING AND INSTALLING .

-- Install the ATF cooler, refer to AUTOMATIC TRANSMISSION FLUID (ATF) COOLER, REMOVING AND INSTALLING .

-- Install the drive axles and the driveaxle heat shield, refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Install the left (refer to LEFT CATALYTIC CONVERTER, REMOVING AND INSTALLING, VEHICLES WITH DSG TRANSMISSION ) and right (refer to RIGHT CATALYTIC CONVERTER, REMOVING AND INSTALLING, VEHICLES WITH DSG TRANSMISSION ) catalytic converters.

Vehicles with 7-Speed DSG Transmission 0B5:

Fig 11: Lower The Transmission

Courtesy of AUDI OF AMERICA, LLC

-- Next, raise engine/transmission subassembly high enough using Scissor Lift Table VAS 6131B until dimension -a- is reached between subframe and body.

Dimension -a- = minimum 100 mm

-- Install the selector lever cable and adjust if necessary, refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING and SELECTOR LEVER CABLE, CHECKING AND ADJUSTING .

-- Lift the engine/transmission assembly further using the Scissor Lift Table VAS 6131B.

Vehicles with 8-Speed Automatic Transmission 0BK:

-- Lift the engine/transmission assembly with the Scissor Lift Table VAS 6131B.

Continuation for All Vehicles:

-- Align the subframe and transmission carrier 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 OVERVIEW - 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 TUNNEL CROSSMEMBER, REMOVING AND INSTALLING .

Vehicles with 8-Speed Automatic Transmission 0BK:

-- Install the selector lever cable and adjust if necessary, refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING and SELECTOR LEVER CABLE, CHECKING AND ADJUSTING .

Continuation for All Vehicles:

Install in reverse order of removal. Note the following:

-- Attach the steering intermediate shaft to the steering gear, refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

-- Install the driveshaft, refer to REMOVAL AND INSTALLATION or REMOVAL AND INSTALLATION .

-- Install the front muffler, refer to OVERVIEW - MUFFLER .

-- Install the exhaust system free of tension, refer to EXHAUST SYSTEM, INSTALLING WITHOUT TENSION .

-- 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 OVERVIEW - SUBFRAME .

-- Install the brake caliper, refer to BRAKE SYSTEM - MECHANICAL COMPONENTS .

-- Install the front lower longitudinal member, refer to LOWER FRONT LONGITUDINAL MEMBER, REMOVING AND INSTALLING .

-- Install the engine control module, refer to ENGINE CONTROL MODULE -J623-, REMOVING AND INSTALLING .

-- Install windshield wiper fluid reservoir filler tube, refer to WASHER FLUID RESERVOIR FILLER NECK .

-- Electrical connections and wiring routing, refer to appropriate Wiring Diagram.

-- Install the cable Terminal 30 Wire Junction 2 -TV22- and the cover for the engine compartment E-box, refer to PLENUM CHAMBER E-BOX, WIRE JUNCTION, FUSE HOLDER AND BATTERY OVERVIEW .

-- Install the tower brace, refer to TOWER BRACE, 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 filter housing, refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Install the lock carrier cover, refer to LOCK CARRIER COVER, REMOVING AND INSTALLING .

-- Install the plenum chamber cover, refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Install the front lower longitudinal member, refer to LOWER FRONT LONGITUDINAL MEMBER, REMOVING AND INSTALLING .

-- Fill the engine oil and check the oil level, refer to => 411.

-- Connect the coolant hose to the coupling, refer to Fig 12.

Fig 12: Connecting Coolant Hose Coupling

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NOTE: Do not reuse used coolant.

-- Fill the coolant, refer to COOLANT, DRAINING AND FILLING .

-- Fill the refrigerant circuit, refer to Refrigerant System - with Refrigerant R134a.

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

-- Install the front wheels, refer to WHEELS AND TIRES .

-- Perform an axle alignment, refer to AXLE ALIGNMENT PROCEDURE .

WARNING:

Risk of accident due to loose connections.

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

-- Install the noise insulations, refer to NOISE INSULATION, REMOVING AND INSTALLING .