Withdrawal
1. Park your vehicle on a firm, level surface.
2. See Section 11 and remove the hood. On models with 5-cylinder engines, this is not necessary, because. the radiator and the upper cross member of its frame will be removed and the engine will only need to be lifted slightly to separate it from the underframe.
3. Disconnect the negative cable from the battery and take it away from the terminal (see Section 4A).
Note: If your car's radio is coded, make sure you have the key code before disconnecting the battery.
4. Do the following:
- a) If the engine needs to be disassembled, drain the engine oil.
- b) Drain the liquid from the cooling system.
5. Apply the handbrake, then jack up the front of the vehicle and place it on axle stands.
6. Turn off screws and remove the bottom guard of the engine.
7. Remove the front bumper and the upper cross member of the radiator frame (see Section 11). Remove also the thermoviscous fan assembly (Section 2).
8. On models without air conditioning, remove the radiator (see section 2). To do this, detach the transmission fluid cooler from it, move it to the side and tie it to the body with a piece of twine.
9. On air-conditioned models, pry off the trim from the right side of the radiator, then remove the radiator mounting bolts. Loosen the bolts on the right radiator bracket. Remove the mounting bolts and move the radiator forward. There is a special Audi bracket designed to hold the radiator away from the engine, but a metal strip or block of wood is a suitable replacement.
10. Working under the vehicle, remove the bolts from the undershield support cross member located under the rear of the transmission on some models. On 3D engines, remove the front suspension and torque arm bolts as described in Section 1A.
11. Working at the rear of the engine, remove the fuel pump drive belt cover bolts.
12. Remove the air filter assembly as described in Section 3A.
13. Remove the air hoses going between the air cooler and the intake manifold and between the air cooler and the turbogenerator.
14. Disconnect the vacuum hoses from the EGR valve (EGR) and intake manifold.
15. Separate the ground strap from the right engine mount bracket. Label this belt so you don't confuse it with the starter cable (see illustration).
16. Remove the fuel filter bracket bolts from the left engine mount. The front bolt only needs to be loosened, since the bracket in this place does not have a hole, but a slot (see illustrations).
17. Remove the front suspension torque rod and its limiter from the engine and cross member as described in Section 1A (see illustration).
18. Disconnect the cooling system hoses from the radiator, expansion tank and cylinder head.
19. Disconnect the wiring from the generator and separate the ground strap.
20. Note how the engine wiring runs, then methodically disconnect the wires, marking the attachment point of each (see illustrations). It is necessary to disconnect the wiring going to the following components (note that depending on the reason for removing the engine, part of the wiring may remain connected (in the partition on the right):
- a) Exhaust gas recirculation valve;
- b) Air flow meter;
- c) Boost pressure control valve;
- d) Intake manifold temperature sensor;
- e) glow plugs.
21. Disconnect the supply and return fuel hoses from the fuel pump and plug the ends of the hoses and the holes opened in the pump.
22. Disconnect the gas pedal cable as described in Section 3A.
23. Disconnect the vacuum hoses (including the brake booster vacuum hose, which must be separated from the vacuum pump), by marking them.
24. Disconnect the hoses from the heater matrix in the bulkhead.
25. On manual transmission models, disconnect the reversing light switch wiring on the transmission. Also disconnect the wiring from the speedometer sensor.
26. Remove auxiliary drive belts.
27. On models equipped with an air conditioner, remove the compressor from the engine without disconnecting the coolant-carrying tubes. Move the compressor to the side and tie it to the wall of the engine compartment.
28. Remove the power steering pump from the engine without disconnecting the hydraulic pipes (see Section 10). Move the pump to the side and tie it to the wall of the engine compartment (see illustrations).
29. On models with automatic transmission, unscrew the bolts of the bracket that secures the transmission fluid tubes to the oil pan, and move them to the side.
30. Remove the starter as described in Section 4A.
31. On models with automatic transmission, unscrew the three bolts securing the torque converter to the drive plate, turning the crankshaft so as to bring the bolts into the starter opening one by one.
32. Where available, remove the cover from the right drive shaft. Disconnect the exhaust pipe and catalytic converter from the exhaust manifold. Loosen the bolts and separate the outlet pipe from the transmission bracket.
33. Remove the bolts securing the transmission to the engine, but for now leave the top bolt in position, only loosening it so that it can be unscrewed by hand. Note that on some models, the top left bolt also secures the wiring bracket (see illustration).
34. Attach a winch to the engine and raise it slightly to transfer the weight of the engine from the hangers to the lifting device. Keep the engine in a horizontal position, which is very important to separate it from the transmission.
35. Unscrew the nuts of the left and right engine mounts (see illustrations).
36. Support the transmission with a jack, laying a piece of board between them.
37. Remove the remaining transmission mounting bolt, then have an assistant move the engine forward, keeping it horizontal the whole time, and lower it to the ground (see illustration). On automatic transmission models, make sure the torque converter remains in the transmission fully engaged with the input shaft. Remove the dowel pins from the rear of the cylinder block if they are loose.
38. On manual transmission models, remove the clutch as described in Section 5.
Installation
39. Install in reverse order. On manual transmission models, pre-lubricate the input shaft grooves with a small amount of high temperature grease. Lightly lubricate the contact surface of the release bearing, but do not apply grease to its guide sleeve. Make sure all engine and transmission brackets are installed straight and tighten all nuts and bolts to specification. Install and, where necessary, adjust all components and systems associated with the engine as described in the relevant Sections. Make sure the engine is filled with oil and that the cooling system is refilled before starting the engine.
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