Table of contents: Tightening torques (Nm) ↓ Engine to manual transmission ↓
Tightening torques (Nm)
| Bolts and nuts | |
| Mb | 9 |
| M7 | 15 |
| M8 | 20 |
| M10 | 40 |
| M12 | 65 |
| except: | |
| Nut for ground wire | 9 |
Engine to manual transmission
| Pos. | Bolt | N·m |
| 1 | M10x50 | 65 |
| 2 | M12x100 | 30 + 90° |
| 3,6 | M12x75 | 30 + 90° |
| 4,5 | M12X120 | 30 + 90° |
| 7...9 | M10x75 | 15 + 90° |
| 10 | M12x50 | 30 + 90° |
| a | Centering bushings |
Aluminum bolts "2...10" are allowed to be used no more than 2 times. Therefore, after the first use, mark such bolts with two notches "X" "arrow" with a cutter. In order not to damage the bolts when notching, do not fix them in a vice. Insert the bolt into the head by 14 mm with an extension of 1/2 inch, the other end of which is fixed in a hand vice (as shown in the picture). Do not reuse bolts marked with "X".
Replace the bolts tightened with a tightening angle. Replace the self-locking nuts and bolts, lip seals, gaskets and sealing rings. On vehicles with a manual transmission, a needle bearing must be installed in the driven disk. Before installing the disk, make sure that the needle bearing is already installed. Press the needle bearing into the driven disk. Hose nipples, air duct tubes and hoses must be cleaned of oil and grease before installation. To ensure reliable fastening of the air duct hoses to the nipples, treat the threaded connections of the already used clamps with a rust remover. When installing, all cable ties must be placed in their original places. Be sure to clean the threaded holes for fixing the power unit in the cylinder block with a tap before assembling the gearbox. Before connecting the engine and gearbox, perform the following preparatory actions: Install the mounting device "T40169" from below under the gearbox housing and dual-mass flywheel, as shown in the figure. The mounting device must fit into the semicircular groove "1" and additionally into the control hole "2".
There is only 1 inspection hole, it is necessary to rotate the dual mass flywheel accordingly. Insert the mounting device bolts into the hole on the gearbox housing. Install the "T40170" transport protection from below under the gearbox housing and attach it to the shaft with flange "1". Check the aluminum engine-gearbox connection bolts for reuse and, if necessary, mark them.
Check the presence of centering bushings "A" of the engine and gearbox in the cylinder block, insert the bushings if necessary. Install the engine on the gearbox, screw in and tighten bolts "2...6". Bolt "2" secures the starter to the gearbox and has an additional spacer sleeve "arrow". The spacer sleeve should be located between the starter and the gearbox. Unload the spindle "10-222 A/11". Lower the crane and place the engine with the gearbox on the engine mounts. Install the engine mount. Remove the service crane "VAS 6100" and the hanging device "2024 A". Tighten the bolts "1, 7, 8, 9, 10" engine and gearbox connections. Remove the transport fastener "T40170" and the mounting device "T40169". The next step is necessary to ensure that the clutch module fits evenly against the driven disk and does not warp. Install the front wheels. 4. Engage the gear and rotate the front wheels in the direction of travel until the clutch module has made a full revolution. The inspection hole "arrow" should again be visible in the recess of the gearbox housing.
Tighten the clutch module bolts on the driven disk as follows: Screw in the first bolt "arrow" by hand (2 Nm). Turn the front wheels in the direction of travel so that the clutch module rotates by 240°. Tighten the accessible bolt in this position to the specified torque. Turn the front wheels in the direction of travel so that the clutch module rotates by 120°, and tighten the remaining 2 bolts to the tightening torque. Install in the reverse order, while observing the following: Install the particulate filter. Install the exhaust pipe.
Align the exhaust system without mechanical stress. Install the torsional vibration damper. Install the intermediate roller and tension roller. Install the generator. Install the vane pump. Install the compressor. Electrical connectors and wiring. Install the engine control unit. Install the wires, the 2-terminal 30 "TV22" splitter and the cover of the engine compartment switching unit. Install the stretcher. Install the windshield washer reservoir filler pipe. Pay attention to the work on installing the battery. Do not use a charger to start the engine. Install the air filter housing. Check the oil level. Fill with coolant. Do not use the drained coolant in the following cases: When replacing the cylinder head or cylinder block. If the coolant is contaminated. Install the mudguards and sound insulation.
(The text is based on materials from the website AudiManual)