Table of contents: Removal ↓ Installation ↓
Removal
Caution: Mark all wires and hoses when removing to facilitate subsequent reassembly.
Disconnect the wire from the negative battery terminal. Relieve the fuel pressure.
Open the heater control valve completely and drain the coolant.
Remove the fuel injector cooling fan motor and inlet hose.
On some models, remove the upper radiator cap, radiator grille, bumper trim. Disconnect the wiring harness in the bumper that goes to the turn signals and headlights. Remove the bumper.
Disconnect the plug from the fan. Remove the upper radiator hose from the engine. Remove the hose from the radiator to the expansion tank and the air bleed hose from the auxiliary radiator.
Disconnect the wire from the thermal switch. Remove the radiator mounting bolts, the right radiator cap and the lower radiator cap.
Remove the windshield washer reservoir from its mount and secure it to the side.
Caution: Be careful when discharging the air conditioning system to avoid injury.
Discharge the air conditioning system as required and disconnect the hoses from the air conditioning condenser.
Remove the radiator together with the air conditioner condenser. Remove the air conditioner compressor and its mounting bracket from the engine.
Remove the power steering pump drive belt from the pump. Remove the pump from its mount. Set it aside without disconnecting the hoses
Disconnect the coolant hose from the thermostat housing and disconnect the wires from the oil pressure sensor and temperature sensor. Disconnect the wires from the pressure regulator.
Remove the fuel pressure regulator from the engine without disconnecting the fuel lines. Secure it to the side.
Remove the throttle rod clamps and remove the rod from the engine. Remove the injector holder and remove the injectors from the cylinder head.
Disconnect the plug from the cold start valve and remove the valve from the intake manifold. Do not disconnect the fuel line.
At the throttle body, disconnect the plugs from the throttle valve switch and the intake air temperature switch.
Disconnect the air intake hoses. Disconnect the wire from the auxiliary air flow regulator. Remove the vacuum hoses and disconnect the breaker-distributor hose from the engine.
Remove and mark the vacuum hoses on the two-way valve. Remove the thermopneumatic valve. Without disconnecting the vacuum hoses, remove the engine speed sensor.
Disconnect the speedometer cable from the gearbox.
Remove the distributor from the engine.
Disconnect and mark the plugs of the thermal time switch and overheating warning lamp. Disconnect the heater hoses from the engine.
On the left engine mount, disconnect the brake booster and reservoir from the engine compartment bulkhead without disconnecting the pipes. On Quattro vehicles, disconnect the differential lock indicator light plug. Disconnect the reverse light switch wires.
Disconnect the steering rods from the steering rack. Disconnect the steering rods.
If the gearbox is manual, disconnect the clutch slave cylinder from the housing. Do not disconnect the tubes. Remove the bracket and rod under the gearbox bracket.
Disconnect the ground bus from the left engine mount. Disconnect the vacuum hose from the auxiliary air valve.
Disconnect the air duct from the intercooler (intercooler) and remove the intercooler.
Disconnect and label electrical connectors from alternator. Remove oil cooler. Do not disconnect tubes. Disconnect and label starter wires.
Disconnect the exhaust pipe from the turbocharger. Remove the plates covering the gearbox and the right-hand gearbox support. Disconnect the shafts from the gearbox. On Quattro vehicles, disconnect the propeller shaft from the rear of the gearbox.
On Quattro vehicles, disconnect the differential lock on the gearbox, remove the front and rear retaining rings and pull the boot back. Disconnect the cable.
Remove the left gearbox support bolt and the supports on both sides.
Remove the ball joint retaining bolts on both front wheels. Loosen the auxiliary frame mounting bolts and remove the auxiliary frame. Separate the ball joints from the steering knuckle.
Attach the hoist to the engine. Raise the engine slightly and remove the left and right engine mounts. Lower the engine and gearbox under the vehicle.
Raise the front of the vehicle and push the engine and gearbox assembly out from under the vehicle.
Separate the engine from the gearbox.
Installation
Install the engine assembly and temporarily secure the engine mounts.
Install the ball joints on the steering knuckles and tighten to 3 Nm. Install the ball joint lock bolts and tighten to 65 Nm.
0. Install the exhaust system retaining clips and, on all-wheel drive models, the differential lock, if equipped.
Connect the exhaust pipe to the turbocharger.
Install the axle shafts into the gearbox.
Install the gearbox ball joint and gearbox cover plates.
Connect the propeller shaft to the rear of the gearbox.
Lower the vehicle and connect all electrical plugs.
Install the oil radiator.
Install the intercooler assembly and duct.
Connect the ground bus of the left engine mount.
Install the clutch slave cylinder, if equipped.
Connect the steering rods to the toothed rack.
Install the brake booster and reservoir. On Quattro vehicles, connect the differential lock indicator light plug. Connect the reversing light wires.
Install the heater hoses.
Install the distributor.
Install the speedometer cable and all vacuum hoses.
Install the fuel injectors onto the cylinder head.
Connect the plugs to the throttle body, throttle linkage and fuel injector pressure regulator.
Install the power steering pump and all drive belts.
Install the radiator and air conditioner condenser. Connect the hoses.
Install the windshield washer reservoir.
On some models, it is necessary to install the upper radiator cap and radiator grilles. Connect the wiring harness to the bumper, turn signals and headlights. Install the bumper.
Install the fan motor and inlet hose to the engine.
Fill the cooling system and release air. Connect the wire to the negative terminal of the battery.
To reduce vibration, loosen all engine and subframe mounting bolts and then tighten them to 34 Nm with the engine idling.
Check the level of all operating fluids and test drive the vehicle.
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