Removing and installing stiffening frame: Audi 1.8 (AJP)

Notes:

The following section describes how to remove and install the stiffening frame with the engine installed in the vehicle.
If the stiffening frame is removed with the engine removed from the vehicle, the oil pump can remain installed, but the suction pipe has to be unbolted from the oil pump.

Special tools, testers and auxiliary items

Socket 3249
Workshop crane V.A.G 1202 A
Electric drill with plastic brush attachment
Silicone sealant D 176 404 A2

Removing

Pull out oil dipstick.
Remove sump => Page
17-11
.
Remove oil pump=>Page
17-17
.

Cut through cable ties -arrows-. Open retainer for starter cable and take out the cable.

Support subframe with workshop crane V.A.G 1202 A.

Unscrew and remove lower nuts on engine mountings.

First remove front subframe bolts -2- and -3- (left and right). Then unscrew bolts -1-.

Note:

The subframe should be detached and lowered only at the front, otherwise it will be necessary to check wheel alignment.

Lower subframe slowly using workshop crane 1202 A.
Take out workshop crane 1202 A; pivot anti-roll bar downwards.

Unbolt support for intake manifold from stiffening frame.
Remove bolts securing gearbox to stiffening frame.
Unscrew M10 bolts -arrows-.
Slacken bolts -1 ... 13- in diagonal sequence.

Notes:

On vehicles with a manual gearbox, the two rear bolts on the stiffening frame are accessible through the recess -arrow- on the flywheel. Turn the flywheel to the appropriate position.
Use socket attachment 3249 to unscrew rear bolts on stiffening frame.

Take off stiffening frame: if necessary loosen it by striking lightly with a rubber hammer.

Carefully remove any remains of sealant from cylinder block.

Remove remaining sealant from stiffening frame (with rotating plastic brush or similar).

Warning!
Wear eye protection
Clean sealing surfaces: they must be free of oil and grease.

Installing

Note:

The stiffening frame must be installed within 5 minutes after applying the silicone sealant.

Cut off nozzle on tube at front marking (nozzle dia. approx. 3 mm).

Make sure that sealing surface is clean, then apply silicone sealant to sealing surface of stiffening frame as illustrated.
Thickness of sealant bead: 2 ... 3 mm

Notes:

The bead of sealant must not be thicker than 3 mm. Excess sealant can otherwise enter the sump and obstruct the filter screen in the oil intake pipe.
Apply the sealant particularly carefully around the rear sealing flange. There are two drillings in the cylinder block at the points marked with arrows.

Fit stiffening frame together with oil return connection immediately and tighten bolts in the sequence shown:

Tighten bolts -1 ... 4- and -7 ... 13- (M7 x 55) in diagonal sequence to an initial torque of 5 Nm.
Tighten bolts -5 and 6- (M7 x 28) to an initial torque of 5 Nm.
Tighten bolts securing stiffening frame to gearbox to 40 Nm.
Tighten bolts M10 -arrows- to 45 Nm.
Tighten bolts -1 ... 13- to 15 Nm in diagonal sequence.

Then install oil pump (=>Page
17-15
) immediately, so that stiffening frame is pressed uniformly onto sealing surface.

Notes:

When installing the stiffening frame with the engine out of the vehicle, ensure that the stiffening frame is aligned flush with the intermediate plate at the flywheel end, i.e. the stiffening frame should protrude 0.8 mm beyond the cylinder block.
After installing the stiffening frame, wait for about 30 minutes for the sealant to dry before putting in engine oil.

Installing subframe

=> Running gear, front-wheel drive and four-wheel drive; Repair group 40; Removing and installing subframe
Running gear, front-wheel drive and four-wheel drive
Removing and installing subframe

Tightening torques

Component · Nm
Stiffening frame to cylinder block · M7 · 15
M10 · 40
Stiffening frame to gearbox · 45
Support for intake manifold to stiffening frame · 20