AUDI A4 1996 B5 / 1.G AFC Engine Assembly User Guide

10-8

- Unbolt hydraulic pump from mounting bracket.

CAUTION!

Hydraulic lines should remain connected.

- Unscrew bolts and secure A/C compressor to
one side with wire.

CAUTION!

Disconnect at mounting points only.
DO NOT open the air conditioning refrigerant
circuit.
Set the A/C compressor aside carefully.
Refrigerant lines kink easily.
The A/C refrigerant circuit must only be
opened by specially trained technicians
using the proper tools and equipment.

- Remove bolts securing exhaust manifold and
front exhaust pipe at top.

- Disconnect battery positive (B+) cable from
starter at right of engine below exhaust manifold.
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- Remove starter, take off insulator at starter
positive (B+) connection, unbolt fixture at engine
block, disconnect ground wire from engine
support.

- Unscrew four engine mounting bolts.
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10-9

- Support weight of transmission using engine
support bridge 10-222A.

- Attach engine support adapter 3147 to bolt hole of transmission bell
housing.
(Adapter installation shown with engine removed)

CAUTION!
The mounting hooks and pins on the lifting device must be secured
with locking pins. - Attach engine sling 2024A to engine and workshop crane 1202A.
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10-10

Mounting engine cylinder block on assembly
stand

CAUTION!
DO NOT have the cylinder block mounted to the assembly stand
while measuring the cylinder bores (Repair Group 13). The cylinder
block is deformed by its own weight under these conditions and
such stress will result in false measurements that are not accurate
after the tension has been relieved. - Mount engine to stand using holding fixture VW 540 along with VW
540/2.
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10-11

Installing

The engine is installed in the reverse order of
removal, with the addition of the following special
conditions and steps:

WARNING!

Do not re-use any fasteners that are worn or
deformed in normal use. Many fasteners are
designed to be used only once and become
unreliable and may fail when used a second
time. This includes, but is not limited to, nuts,
bolts, washers, self-locking nuts or bolts,
circlips and cotter pins. Always follow
recommendations given in this publication.
Always replace these fasteners with new
parts.

- Check that alignment sleeves for centering
engine and transmission are properly installed in
cylinder block. Install sleeves if necessary.

- Always install new seals and gaskets.

- Check centering of clutch disc, if necessary.

- Check clutch release bearing for wear and
replace if necessary.

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- Clean transmission input shaft splines. Lightly
lubricate clutch release bearing and
transmission input shaft splines with G 000 100
grease. Do not grease guide sleeve for release
bearing.

- Install engine mounts free of stress. To do so,
align engine by shaking before tightening engine
mounts.
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10-12

- Allow stop of torque support to move down onto
rubber block under its own weight; tighten bolts
to 45 Nm (33 ft lb).

- Align exhaust system free of stress Repair
Group 26.
- Adjust accelerator pedal cable Repair Group
20.
- Re-fill engine cooling system Repair Group
19.
- Drained coolant may only be re-used provided
the cylinder block or the cylinder head was not
replaced.

- Check oil level before starting engine.

- Short blocks are supplied without bushing in
crankshaft. For vehicles with automatic
transmission, tap bushing into place before
installing drive plate.

- Check reconditioned engines with manual
gearbox to determine whether needle bearing is
installed in crankshaft; install if necessary.
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- Observe tightening torque specifications.
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10-13

Tightening torques


Notes:

The tightening torques apply only to lightly
greased, oiled, plated or specially treated nuts
and bolts.
It is permissible to use additional lubricants
such as engine or gear oils, but do not use
Molykote and do not use degreased parts.
Permissible tolerance for tightening torques
15%.

Bolts, nuts M6 10
Nm (7 ft
lb)
M8 20
Nm (15 ft
lb)
M10 45
Nm (33 ft
lb)
M12 60
Nm (44 ft
lb)

Exhaust pipe to manifold M8 25
Nm (18 ft
lb)
AC compressor to bracket M8 25 (18 ft
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Nm lb)
Torque converter to drive
plate M8 35
Nm (26 ft
lb)
Engine support to engine
mount M10 45
Nm
Viscous coupling to
bracket M10 45
Nm (33 ft
lb)
Hydraulic pump to bracket M8 25
Nm (18 ft
lb)
Generator to mounting
bracket M8 35
Nm (28 ft
lb)
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