Engine, Installing: Procedure

WARNING: This page is about a different car, the 2016 Audi Q5, 2015 Audi Q5, and 2014 Audi Q5. 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.

Only remove the plugs or caps after installing the lines.

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.

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

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

-- Install the engine support and engine mount, refer to OVERVIEW - SUBFRAME MOUNT .

Vehicles with S tronic transmission:

Fig 1: Insert Assembly Aid T40169 Into Transmission Housing

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

-- Insert the Clutch Module Assembly Aid T40169 in the transmission housing and the flywheel from below as shown in the illustration.

The assembly aid must engage in the semicircular opening -1- and in the inspection hole -2-.

NOTE:

The inspection hole is only in one location on the circumference so rotate the flywheel as needed.

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

-- Insert the Clutch Module Transportation Lock T40170 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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-- Check if the alignment sleeves -A- for centering the engine/transmission are in the cylinder block and insert them if they are not.

Fig 4: Checking If Alignment Sleeves -A- For Centering Engine/Transmission Are In Cylinder Block

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-- Inspect the aluminum bolts used to connect the engine to the transmission to see if they can be used again and mark them, if necessary, refer to Figure.

-- Position the transmission on the engine and tighten the bolts -3 through 10-.

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

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

Fig 5: Identifying Locking Piece
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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 INSTALLING - Starter .

Vehicles with Automatic Transmission:

Fig 6: Locating Hole Next To Notch

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

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

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 7: Identifying Transportation Lock T40170

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

Fig 8: Identifying Locking Piece

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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.

Fig 9: Engine To Transmission Bolts

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-- Inspect the aluminum bolts used to connect the engine to the transmission to see if they can be used again and mark them, if necessary, refer to Figure.

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

-- Remove the Clutch Module Transportation Lock T40170.

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

Fig 10: Identifying Locking Piece
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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 INSTALLING - Starter .

All Vehicles:

Fig 11: Pressing Torque Converter

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NOTE:

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

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

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

Fig 12: Identifying Clutch Module First Bolt Installation Location

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NOTE:

Use the Torque Wrench 1332 Insert - Ring Wrench - 16mm VAG1332/14 to tighten the bolts.

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

-- Join the tools as illustrated.

Fig 13: Crankshaft Turning Tool, Wrench - 21 MM And Adapter

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Socket 21 mm for ¹ /₂ "-drive

Fig 14: Identifying Wrench - 21 MM T40263

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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 -arrow- in this crankshaft position to the tightening specification, refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

Fig 15: Identifying Clutch Module First Bolt Installation Location

Courtesy of AUDI OF AMERICA, LLC

-- Turn the crankshaft 60° farther and tighten the remaining five bolts to the tightening specification, refer to TRANSMISSION TIGHTENING SPECIFICATIONS .

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

-- Install the left and right drive axles on the transmission flange shafts, refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Install the ATF lines, refer to OVERVIEW - ATF CIRCUIT .

-- Install the ATF cooler, refer to OVERVIEW - ATF CIRCUIT .

-- Install the particulate filter, refer to PARTICULATE FILTER, REMOVING AND INSTALLING, VEHICLES WITH ENGINE CODE CDUD .

-- Install the selector lever cable, refer to INSTALLING - Cable.

-- Lift the engine/transmission assembly with the Scissor Lift Table - Q7 Set VAS6131A.

-- 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 OVERVIEW - SUBFRAME, CROSSBRACE, STABILIZER BAR, COUPLING ROD AND SUBFRAME SHIELD .

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 INSTALLING .

The rest of the installation is performed in reverse order of removal, noting the following:

-- Install the driveshaft, refer to DRIVESHAFT, REMOVING AND INSTALLING .

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

-- Subframe crossbrace, refer to OVERVIEW - SUBFRAME, CROSSBRACE, STABILIZER BAR, COUPLING ROD AND SUBFRAME SHIELD . Upper control arm, refer to UPPER CONTROL ARM, REMOVING AND INSTALLING . Stabilizer installing, refer to STABILIZER BAR, REMOVING AND INSTALLING . Tighten the suspension strut on the left and right control arms, refer to CONTROL ARM, REMOVING AND INSTALLING .

-- Install the brake caliper, refer to BRAKE CALIPER, REMOVING AND INSTALLING .

-- Install the Engine Control Module (ECM), refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

-- Install the tower brace, refer to TOWER BRACE, REMOVING AND INSTALLING .

-- Install the torque support, refer to TORQUE SUPPORT AND CROSSMEMBER, REMOVING AND INSTALLING .

-- Electrical connections and wiring routing, refer to the appropriate SYSTEM WIRING DIAGRAM.

-- Install the cable Terminal 30 Wire Junction 2 -TV22- and the cover for the engine compartment E-box, refer to OVERVIEW - RELAY PANELS, FUSE PANELS AND E-BOXES .

-- Install the refrigerant lines, refer to REFRIGERANT LINE WITH INNER HEAT EXCHANGER .

-- Install the windshield wiper fluid reservoir filler tube, refer to WASHER FLUID RESERVOIR, REMOVING AND INSTALLING .

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

-- Plenum chamber cover, refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING and install the lock carrier brace, refer to LOCK CARRIER BRACE, REMOVING AND INSTALLING .

-- Fill the engine oil and check the oil level, refer to ENGINE OIL LEVEL, FILLING AND CHECKING .

-- Connect the coolant hoses with the connector coupling, refer to Fig 16.

Fig 16: Connecting Coolant Hose Coupling

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-- Fill with coolant, refer to COOLANT, DRAINING AND FILLING => Check the coolant level. .

NOTE:

Do not reuse used coolant.

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

-- Install the engine cover, refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Fill the refrigerant circuit, refer to USING SERVICE STATION .

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

-- Install the front wheels, wheel bolt tightening specification: 140 Nm. .

-- Perform an axle alignment, refer to 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 ATF, DRAINING AND FILLING .

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