With Manual Transmission
Engine, Installing
• 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 with hose clamps appropriate for the model.
• 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).
• 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 replace if necessary.
- Check clutch release bearing for wear and loose plastic ring.
- 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.
• Tightening 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%.
Engine/transmission, fastening
Further installation is in reverse order of removal, noting the following.
- Install front exhaust pipes. Refer to: Left => [ Left Front Exhaust Pipe with Catalytic Converter ] Left Front Exhaust Pipe With Catalytic Converter; right => [ Right Front Exhaust Pipe with Catalytic Converter ] Right Front Exhaust Pipe With Catalytic Converter.
- Always clean threaded bores in transmission flanged shaft for driveshaft of locking fluid residue using a tap before installation.
- Rotate attachment spindles at left of engine/transmission assembly downward.
- Remove both base plates for left support element on scissor lift platform (VAS 6131 A).
- Rotate attachment spindles at right of engine/transmission assembly downward.
- Remove both base plates for right support element on Scissor Lift Table (VAS 6131 A).
• The support points for front of engine and tunnel cross member remain unchanged.
- Equip scissor lift platform (VAS 6131 A) with support set for Audi (VAS 6131/10) and (VAS 6131/11) as follows:
- 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 A).
- Carefully guide engine/transmission assembly from below into body using Scissor Lift Table (VAS 6131 A) far enough so distance between subframe and body is dimension - a -.
• Dimension - a - = 80 mm.
- Place torque support with torque support stop between lock carrier and engine.
- Tighten clutch slave cylinder with new bolt - arrow -, procedure.
- Install lever for selector shaft - arrow -.
- Install connecting rod - 2 - of shift rod.
- Screw in socket head bolt - 1 - of pivot rod.
- Loosely bolt guide control arm - 1 - and control arm - 2 - to subframe.
• Bolts must first be tightened once the vehicle is sitting on its wheels on the floor.
- Align subframe, engine bearing consoles and tunnel cross member according to markings applied on longmembers during removal.
- Tighten bolts for subframe, engine mount consoles as well as tunnel crossmember only to specified torque. Do not tighten further (tighten bolts only after axle alignment).
1. 65 Nm
2. 110 Nm
3. 110 Nm
4. 75 Nm
CAUTION!
Vehicle must not be driven in this condition.
Further installation is in reverse order of removal, noting the following:
- Install driveshaft.
- Align exhaust system free of tension. Refer to => [ Exhaust System, Installing ] Exhaust System, Installing.
- Install refrigerant lines.
- Install drive axles.
- Install guide control arm, control arm, stabilizer bar and suspension strut.
- Tighten bolts - arrows - for torque support.
- Place torque support on rubber buffer for torque support and tighten bolts - arrows -.
- Electrical connections and routing.
- Observe safety precautions after connecting battery.
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.
- Check oil level.
- Bleed fuel system.
- Remove old O-ring - 2 - in coolant hose - 3 -.
- Moisten new O-ring with coolant additive and install it in the coolant hose.
- Press coolant hose onto the radiator or coolant pipe - 1 - until it engages.
- Press coolant hose on again and pull to make sure the connection is engaged correctly.
- Fill with coolant => [ Filling ] Procedures.
• Only reuse drained coolant if cylinder head or engine block was not replaced.
• Dirty coolant must not be re-used.
- Fill power-steering system oil and bleed steering system.
- Align subframe and both engine mount bracket..
- Perform axle alignment.
CAUTION!
After axle alignment, tighten subframe bolts to final torque.
- Fill refrigerant circuit.
Tightening Specifications
• Tightening 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%.
