ENGINE, SECURING TO ENGINE STAND
Special tools and workshop equipment required
- Engine Sling 2024 A
- Shop Crane VAS 6100
- Engine and Transmission Holder VAS 6095
- Counter Hold Tool 10 - 201
Procedure
Insert the 10 - 201 to loosen the bolts.
Scheme 49
| CAUTION | The outer surface of the bearing flange at the drive plate could be damaged. Use a multipoint socket wrench with a shaft at least 40 mm long to loosen and tighten the drive plate bolts. |
Remove the bolts and remove the drive plate.
| WARNING | Loose engine support bridge components could cause an accident. Secure the mounting hooks and pins on the engine support bridge using securing pins -arrows-. |
Hook the 2024 A to engine and to the VAS 6100.
Scheme 50
Note. To be aligned to the center of gravity of the engine assembly, the hole rails of the lifting hook must be inserted as shown in the illustration.
Secure the engine on the VAS 6095 during assembly work.
ENGINE, SUPPORT WITH ENGINE SUPPORT BRIDGE
Special tools and workshop equipment required
- Engine Support Bridge 10 - 222 A
Supporting
Remove the engine cover -arrows-.
Scheme 51
Install the 10 - 222 A with adapters 10 - 222 A /3 on the left and right strut towers, as shown in the illustration.
Scheme 52
Engage the spindles 10 - 222 A /11 to the engine lifting eyes.
Lightly pretension engine with spindles.
Scheme 53
- Not installed
- Bolt 20 Nm
- Retaining Plate For the engine mount If the engine mount is faulty, replace the retaining plate Check the retaining plate on the opposite side; replace if necessary
- Bracket For the hydraulic line
- Nut 9 Nm
- Bolt 40 Nm
- Engine Support
- Bolt 10 Nm
- Heat Shield
- Bolt Replace 90 Nm + 90° turn
- Engine Mount With the left electrohydraulic engine mount solenoid valve -N144- (left side only) Removing and installing, refer to «ENGINE MOUNT»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-engine-assembly-engine-codes-caeb-sedan__engine-mount) Replace in pairs only
- Subframe
- Bolt 55 Nm
FASTENER TIGHTENING SPECIFICATIONS
| Component | Bolt Size | Nm |
|---|---|---|
| Bolts and nuts | ||
| M6 | 9 | |
| M8 | 20 | |
| M10 | 40 | |
| M12 | 60 | |
| Bracket for the hydraulic line, nut | 9 | |
| Engine mount 1 | 90 + 90° | |
| Engine support | 40 | |
| Heat shield | 10 | |
| Retaining plate for the engine mount | 20 | |
| Subframe | 65 | |
| 1 Always replace | ||
Manual Transmission to Engine Fasteners
Scheme 54
| Item | Bolt | Nm |
|---|---|---|
| 1 3) | M10 x 50 1) | 65 |
| 2 3) , 7 | M12 x 100 2) | 30 + 90° |
| 3 4) , 6 | M12 x 75 2) | 30 + 90° |
| 4 and 5 4) | M12 x 120 2) | 30 + 90° |
| 8 to 10 | M10 x 75 2) | 15 + 90° |
| 11 | M12 x 50 2) | 30 + 90° |
| A | Alignment sleeves for centering | |
| 1) Steel bolt - not replaced 2) Replace bolts 3) Also secures the starter. 4) Attached the cable bracket as well | ||
ENGINE, REMOVING
Special tools and workshop equipment required
- Pry Lever - Rmv Outside Mirror 80 - 200
- Hose Clip Pliers V.A.G 1921
- Drip Tray VAS 6208
- Locking Tool T40098
- Engine Support Bridge 10 - 222 A
- Shackle 10-222 A/12
- Shop Crane VAS 6100
- Engine Sling 2024 A
- Engine-/Gearbox Jack V.A.G 1383 A
- Gearbox Support T10337
- Release Tool f/ Rev. Light Switch Conn.T40138
Removing
| WARNING | Risk of vehicle tipping over with engine removed. Secure vehicle. Luggage compartment must be empty for this. |
Note. Remove the engine without the transmission upward. Collect escaping coolant in a clean container for disposal or reuse. During installation, all cable ties must be installed at the same location. In order to be able to turn the driveshaft on an All Wheel Drive (AWD) vehicle to remove it, release the electro-mechanical parking brake before disconnecting the battery.
| CAUTION | Danger of causing damage to electrical components when disconnecting the battery. Follow the instructions when disconnecting the battery. Refer to Removal and Installation . |
Disconnect the battery. Refer to Removal and Installation .
Remove the left and right front wheels.
Remove left and right front wheel housing liners. Refer to Removal and Installation .
Remove the noise insulation. Refer to Description and Operation .
Install the lock carrier in service position. Refer to Description and Operation .
Remove the front exhaust pipe/front muffler. Refer to FRONT EXHAUST PIPE AND FRONT MUFFLER .
Disconnect the connector -1- from the Mass Airflow (MAF) Sensor -G70-.
Scheme 55
Loosen the air intake hose -2-.
Remove the air filter housing upward -arrows-.
Remove the engine cover -arrows-.
Remove the seal -arrow-.
Scheme 56
Unclip the plenum chamber covers -1, 2 and 3- and remove it.
Remove the left and right foam block -1- upward -arrows-.
Scheme 57
Release the retainer -arrow A- and open the cover -arrow B-.
Scheme 58
Remove the nuts -1 through 3- for the electrical wires.
Scheme 59
Remove the electrical connector -4- from the bracket and disconnect it.
Remove the bolt -5- and remove the wire junction from the tower brace -arrow-.
Release the retainers from the wheel housing side using a 5.5 mm open end wrench -1- and remove the wiring bushing -2- upward.
Scheme 60
Open the wiring duct by opening the release -arrow B-, pull the wiring duct forward -arrow A- and free up the wires.
Scheme 61
Remove the nut -1- and tilt the washer fluid filler neck upward -arrow A-.
Scheme 62
Remove the filler neck -2- with the filler tube from the washer fluid reservoir and the opening in the body -arrow B-.
Remove the bolts -1- and nuts -2- and the tower brace -3-.
Scheme 63
Remove the bolts -arrows- and the engine compartment E-box cover.
Scheme 64
Remove the nut -1- and free up the wire.
Release the retainers -A arrows- and remove the engine control module -arrow B-.
Scheme 65
Disconnect the electrical connectors -4- and remove the nut -3- for the electrical wire.
Scheme 66
Disconnect the electrical connector -2- if applicable.
Release the retainers -arrow- and remove the relay carrier with the fuse holder -1-.
Release the retainers -A arrows- and remove the wiring bushing -1- upward -arrow B-.
Scheme 67
Disengage the engine wiring harness at the engine compartment E-box and free it up.
Lay the wiring harness on the engine and secure the engine control module so that it cannot fall.
| WARNING | Risk of scalding due to hot steam and hot coolant. The coolant system is under pressure when the engine is warm. Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system. |
Open the coolant reservoir cap.
Place the VAS 6208 under the engine.
Open the drain -1- and let the coolant drain out and then remove the connection -2- from the radiator.
Scheme 68
Remove the left and right nuts -3- and remove the longitudinal braces -2-.
Scheme 69
Loosen the hose clamp -arrow-, pull off the air guide hose and move it to the side.
Scheme 70
Remove the nut -1- on the right longitudinal member and free up the ground (GND) wires.
Scheme 71
Remove the nut -2- for the bracket with the electrical wires on the right side of the vehicle.
Disconnect the coolant fan electrical connector -1- by sliding the retainer back -arrow- and pressing the release down.
Scheme 72
Lay the wiring harness on the engine and secure it from falling down.
Disconnect the vacuum connection -2- from the plenum chamber bulkhead by removing the vacuum hose -3- on the back side -arrow-.
Scheme 73
Remove the nut -5-.
Scheme 74
Remove the coolant hoses -1- through -4- and remove the plenum chamber bulkhead.
Remove the bolts -2 to 6-.
Note. The bolt -2- attaches the starter to the transmission and has an additional spacer sleeve -arrow-. Pay attention to the spacer sleeve while removing or installing the engine -arrow-. The spacer sleeve must be inserted between the starter and the transmission.
Remove the coolant hose -2- and the permanent ventilation -1-.
Scheme 75
Remove the permanent ventilation -1- and coolant hose -2- from the coolant reservoir.
Scheme 76
Loosen the hose clamps -arrows- and remove the air guide hose.
Scheme 77
Disconnect the charge air pressure sensor -G31- -1- connector and free it up.
Remove the catalytic converter. Refer to CATALYTIC CONVERTER .
| CAUTION | Risk of destroying due to reversed running direction on a used ribbed belt. Before removing the ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later. |
To release ribbed belt tension, rotate tensioner in direction of -arrow-.
Scheme 78
Secure the tensioner with the T40098.
Remove ribbed belt.
Disconnect solenoid clutch electrical connector -1- on the Air Conditioning (A/C) compressor.
Scheme 79
| WARNING | Refrigerant can cause serious personal injury. Do not open the air conditioning refrigerant circuit. |
Remove A/C compressor bolts -arrows-.
| CAUTION | Risk of damaging refrigerant lines and hoses. Do not stretch, kink or bend refrigerant lines and hoses. |
Tie up the A/C compressor with the refrigerant lines attached to the longitudinal member.
Note. The power steering pump hydraulic lines remain connected.
Remove the bolts -1- from the front through the belt pulley and then remove the bolt -2- from the back.
Scheme 80
Note. The power steering pump is shown in the illustration without the belt pulley and without the hydraulic lines.
Remove the power steering pump with the hydraulic lines connected to the longitudinal.
| CAUTION | Follow cleanliness precautions when working on the fuel supply system. |
Disconnect the fuel supply hose -1- and return hose -2-.
Scheme 81
Support the transmission with the V.A.G 1383 A and T10337.
Scheme 82
Remove the bolts -arrows- on the tunnel crossmember.
Scheme 83
Lower the transmission with the V.A.G 1383 A to dimension -a-.
Scheme 84
- Dimension -a- = 80 mm maximum.
Disconnect the connector -1- on the back-up lamp switch -F4- using the release tool f/ rev. light switch conn.T40138 and free it up.
Scheme 85
Unclip the wire -A- from the transmission and disconnect the connector -C-.
Scheme 86
Lift the transmission with the V.A.G 1383 A and install the bolts -arrows- for the tunnel crossmember.
Remove the bottom cover -1- from the transmission -arrow-.
Scheme 87
Remove the 3 drive plate bolts -arrow-. Turn the crankshaft an additional 120° in the direction of engine rotation.
Scheme 88
Remove the bolt on the starter -1- from the engine side.
Remove the starter from the transmission and leave it in the installation position
Remove the remaining bolts -7 through 10- connecting the engine to the transmission.
Install the 10 - 222 A with adapter 10 - 222 A /8 on the left and right strut towers, as shown in the illustration.
Scheme 89
Attach the transmission and spindle with the shackle 10-222 A/12.
Note. To improve clarity, the removed engine is shown.
Gently pretension the spindle by the 10-222 A.
Engage the 2024 A on the engine and on the VAS 6100 as shown in illustration.
Scheme 90
| WARNING | Lifting hooks and alignment pins on the engine sling must be secured with securing pins. |
Remove the left and right engine mount bolts -1-.
Scheme 91
Note. Ignore -arrow-.
Lift the engine until the engine mount is free.
Turn the 10-222 A spindles.
| CAUTION | Risk of damaging hose and wiring connections as well as engine compartment. Make sure all the hoses and lines between the engine, transmission, subframe and body have been disconnected. Carefully lift and guide the engine out of the engine compartment. |
Remove the engine from the transmission and lift it out of the engine compartment.
ENGINE, INSTALLING
Special tools and workshop equipment required
- Counter Hold Tool T10355 for vehicles with a DSG transmission
- Assembly Aid T40169
- Transportation Lock T40170
- Engine Support Bridge 10-222 A
- Drip Tray for VAS 6100 VAS 6208
Tightening Specifications
Note. Tightening specifications only apply to lightly greased, oiled, phosphate 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 tightening specifications +/- 15%.
For the correct tightening specifications, refer to SUBFRAME MOUNT OVERVIEW .
Additional Tightening Specifications
| Component | Nm | ||
|---|---|---|---|
| Bolts and nuts | M6 | 9 | |
| M8 | 20 | ||
| M10 | 40 | ||
| M12 | 65 | ||
Manual Transmission To Engine Fastener
| Item | Bolt | Nm |
|---|---|---|
| 1 3) | M10 x 50 1) | 65 |
| 2 3) , 7 | M12 x 100 2) | 30 + 90° |
| 3 4) , 6 | M12 x 75 2) | 30 + 90° |
| 4 and 5 4) | M12 x 120 2) | 30 + 90° |
| 8 to 10 | M10 x 75 2) | 15 + 90° |
| 11 | M12 x 50 2) | 30 + 90° |
| A | Alignment sleeves for centering | |
| 1) Steel bolt - not replaced 2) Replace bolts 3) Also secures the starter. 4) Attached the cable bracket as well | ||
Procedure
Note. Replace bolts which have been tightened to an additional torque. Replace self-locking nuts and bolts as well as sealing rings, seals and O-rings. The hose connections and charge air system hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps appropriate for the model. Refer to the Parts Information. To mount the charge hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing. During installation, all cable ties must be installed at the same location.
Check whether alignment sleeves for centering engine and transmission in cylinder block are present, insert missing alignment sleeves.
Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.
Complete the following steps before connecting the engine and transmission
Make sure the intermediate plate is engaged on the sealing flange and slide onto the guide sleeves -arrows-.
Scheme 92
Insert the T40169 into the transmission housing and clutch module from underneath as illustrated.
Scheme 93
- The T40169 must engage in the semi-circular opening -1- and in the inspection hole -2-.
Note. The inspection hole is only in one location on the circumference so rotate the clutch module as needed.
Insert the T40170 in the transmission housing from below and clamp it onto the flange shaft -1-.
Scheme 94
Note. The following step is necessary only if there is a drive plate with mounting pins -2- installed.
Align the drive plate to the clutch module so the mounting pins -2- (if equipped) on the drive plate can engage in the large holes -1- on the clutch module.
| CAUTION | The clutch will not function properly if it is installed incorrectly. If the drive plate mounting bolts -2- are not in the clutch module hole -1-, the clutch will not function properly. |
Note. The bolt -2- attaches the starter to the transmission and has an additional spacer sleeve -arrow-. Pay attention to the spacer sleeve -arrow- with removing or installing the engine. The spacer sleeve must be inserted between the starter and the transmission.
Attach the transmission to the engine and tighten the bolts -7 through 11-. For the correct tightening specifications, refer to ENGINE, INSTALLING .
Release the tension on the 10-222 A spindles.
Lower the VAS 6100 and mount the engine and transmission onto the engine mount.
Install the left and right engine mount bolts -1-.
Remove the VAS 6100 and 2024 A.
Install and tighten the engine/transmission bolts -1 through 6-.
Note. Ignore -A-.
Remove the T40170 and the T40169.
Scheme 95
Note. The following procedure is necessary to assure that the clutch module contacts the drive plate evenly and does not get bent.
Press the clutch module -2- slightly against the drive plate -3- using a pry bar -1- in direction of -arrow-.
Tightening Sequence - Clutch Module to the Drive Plate
Install the first bolt -arrow- hand-tight.
Turn the crankshaft another 120° in the direction of engine rotation and install the second bolt hand-tight.
Turn the crankshaft again 120° in the direction of engine rotation.
Tighten the third bolt to the tightening specification. Refer to Description and Operation .
Tighten the remaining bolts to the tightening specification.
Further installation is performed in reverse order.
Install the starter. Refer to Removal and Installation .
Install the catalytic converter. Refer to CATALYTIC CONVERTER .
Install the front exhaust pipe/front muffler. Refer to FRONT EXHAUST PIPE AND FRONT MUFFLER .
Install exhaust system free of stress. Refer to EXHAUST SYSTEM, ALIGNING .
Install A/C compressor. Refer to Removal and Installation .
Install the ribbed belt. Refer to RIBBED BELT .
Electrical connections and routing. Refer to Wiring Diagram.
Install Engine Control Module (ECM). Refer to Removal and Installation .
Install the electrical wires, terminal 30 wire junction 2 -TV22- and the engine compartment E-box cover. Refer to Removal and Installation .
Install the tower brace. Refer to Removal and Installation .
Install the washer fluid reservoir filler tube. Refer to Removal and Installation .
Follow procedures after connecting the battery. Refer to Removal and Installation .
| CAUTION | Risk of destroying control modules with excess voltage. Do not use a battery charger for starting assistance! |
Install the air filter housing. Refer to Removal and Installation .
Install the lock carrier in service position. Refer to Description and Operation .
Check the oil level. Refer to MAINTENANCE PROCEDURES .
Fill with coolant. Refer to Filling .
Note. Do not use drained coolant in the following situations: If the cylinder head or cylinder block was replaced. If the coolant is contaminated.
Install the noise insulation and the wheel housing liners. Refer to Removal and Installation .
ENGINE MOUNT
Note. The following describes the work procedure on the engine mount.
Note. Only replace engine mounts in pairs on the left and right. The retaining plates for them must also be replaced.
Special tools and workshop equipment required
- Engine Support Bridge 10 - 222 A
Removing
Remove the engine cover -arrows-.
Remove the strut tower brace. Refer to Removal and Installation .
Position the 10 - 222 A on the left and right suspension strut tower as shown in the illustration.
Scheme 96
Engage the spindle 10 - 222 A /11 on the rear engine lifting eye.
Lightly pretension the engine using the spindle.
Remove the left front wheel.
Scheme 97
Remove the front noise insulation -1-. Refer to Description and Operation .
Remove the left front wheel housing liner. Refer to Removal and Installation .
Remove the nut -2- and free up the bracket -1-.
Scheme 98
Disconnect and free up the connector -3- for the left electron-hydraulic engine mount solenoid valve -N144-.
Scheme 99
Remove the engine mount bolts -1, 4 and 5-.
Move the engine mount retaining plate -2- to the side.
Remove the engine mount.
Installing
- For the correct tightening specifications, refer to «SUBFRAME MOUNT OVERVIEW»(/audi/a4/b8-2007-2012/remont/mechanical/#20l-engine-assembly-engine-codes-caeb-sedan) .
Install in reverse order of removal. Note the following
Note. Replace bolts which have been tightened to an additional torque.
Install the wheel housing liner and noise insulation. Refer to Removal and Installation .
Mount the front wheel. Refer to Removal and Installation .
Install the tower brace. Refer to Removal and Installation .
Scheme 100
Special tools and workshop equipment required
- Engine Sling 2024 A
- Shop Crane VAS 6100
- Engine and Transmission Holder VAS 6095
Special tools and workshop equipment required
Scheme 101
Scheme 102
Scheme 103
Scheme 104
Scheme 105
Scheme 106
Scheme 107
Scheme 108
Scheme 109
Scheme 110
- Counter Hold Tool 10 - 201
- Engine Support Bridge 10 - 222 A
- Shackle 10-222 A/12
- Pry Lever - Rmv Outside Mirror 80 - 200
- Counter Hold Tool T10355 for vehicles with a DSG transmission
- Locking Tool T40098
- Assembly Aid T40169
- Transportation Lock T40170
- Hose Clip Pliers V.A.G 1921
- Drip Tray for VAS 6100 VAS 6208
- Not illustrated
- Gearbox Support T10337
- Release Tool f/ Rev. Light Switch Conn. T40138
- Engine-/Gearbox Jack V.A.G 1383 A
See also:
• Removal and Installation
• Removal and Installation
• Description and Operation
• FRONT EXHAUST PIPE AND FRONT MUFFLER
• CATALYTIC CONVERTER
• Description and Operation
• EXHAUST SYSTEM, ALIGNING
• Removal and Installation
• RIBBED BELT
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• MAINTENANCE PROCEDURES
• Filling
• Removal and Installation
• ENGINE MOUNT
• SUBFRAME MOUNT OVERVIEW
• ENGINE, INSTALLING