Engine, Installing

WARNING: This page is about a different car, the 2015 Audi A6 Quattro and 2014 Audi A6 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

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 S TRONIC TRANSMISSION - GENERAL & TECHNICAL DATA or AUTOMATIC TRANSMISSION 0BK - GENERAL & TECHNICAL DATA .

Procedure

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 .

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

Secure the engine with the subframe on the Scissor Lift TableVAS6131B.
Engine secured with Articulated Joint SupportVAS6131/13-7.

-- 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:

Fig 1: Insert Assembly Aid T40169 into transmission housing

Courtesy of AUDI OF AMERICA, LLC

-- Insert the Clutch Module Assembly AidT40169 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 Clutch Module Transportation LockT40170 in the transmission housing from below and secure it on the flange shaft -1-.

Fig 2: Identifying Transportation Lock T40170

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

Fig 3: Identifying Locking Piece

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Vehicles with 8-Speed Automatic Transmission 0BK

Fig 4: 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.

-- 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 Subframe Crossbrace, Removing And Installing .

-- 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-.

Fig 5: Identifying Locking Piece
Courtesy of AUDI OF AMERICA, LLC

NOTE:

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

-- Install the starter, refer to STARTER (CPNB) .

-- Remove the Clutch Module Transportation LockT40170 and Clutch Module Assembly AidT40169.

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.

Fig 6: Pressing Torque Converter

Courtesy of AUDI OF AMERICA, LLC

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

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

Fig 7: Identifying Clutch Module First Bolt Installation Location

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Use the Torque Wrench 1332 Insert - Ring Wrench - 16mmVAG1332/14 to tighten the bolts.

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

-- Join the tools as illustrated.

Fig 8: Identifying Socket 21 mm

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Socket 21 mm for ¹ /₂ "-drive

Fig 9: Turning Crankshaft In Direction Of Engine Rotation -Arrow-

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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 .

-- Turn the crankshaft 60° farther and tighten the remaining five bolts to the tightening specification .

-- 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 Fastener Tightening Specifications .

-- Install the ATF lines, refer to AUTOMATIC TRANSMISSION FLUID .

-- 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 => List Item:Nut .

-- Lift the engine/transmission assembly with the Scissor Lift TableVAS6131B.

-- 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 Fastener Tightening Specifications .

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 Mount .

Install in reverse order of removal. Note the following:

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

-- Install the selector lever cable, refer to SELECTOR LEVER CABLE, REMOVING AND INSTALLING .

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

-- 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 Crossbrace, Removing And Installing and Stabilizer Bar, Removing And Installing .

-- Install the brake caliper, refer to 47 HYDRAULIC COMPONENTS .

-- Install the front lower longitudinal member, refer to LEFT LONGITUDINAL MEMBER HEAT SHIELD, REMOVING AND INSTALLING, VEHICLES WITH TDI ENGINE .

-- 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 SYSTEM WIRING DIAGRAM INFORMATION.

-- Install the cable Terminal 30 Wire Junction 2 -TV22- and the cover for the plenum chamber E-box, refer to PLENUM CHAMBER BULKHEAD, REMOVING AND INSTALLING .

-- Install the tower brace, refer to Tower Brace, Removing And Installing .

-- Install the refrigerant lines, refer to Refrigerant Lines With Inner Heat Exchanger, Removing And Installing .

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

-- Follow all steps after connecting the battery, refer to Battery -A-, 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 .

-- Fill the engine oil and check the oil level, refer to the appropriate FLUID CAPACITY TABLES informatoin .

-- Connect the coolant hoses with the connector coupling, refer to Fig 10.

Fig 10: Connecting Coolant Hose Coupling

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Do not reuse used coolant.

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

-- Bleed the fuel system, refer to FUEL SYSTEM, FILLING/BLEEDING .

-- Fill the refrigerant circuit, refer to REFRIGERANT R134A SERVICING (1 OF 2) or REFRIGERANT R134A SERVICING (2 OF 2) .

-- Install the wheel housing liners, refer to WHEEL HOUSING LINERS .

-- Install the front wheels, refer to WHEELS, TIRES & WHEEL ALIGNMENT .

-- 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.

-- Fill the ATF, refer to Filling ATF .

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