Withdrawal
Attention: Mark all wires and hoses when removing for easy reassembly.
Disconnect the wire from the minus AB. Relieve fuel pressure.
Fully open the heater control valve and drain the coolant.
Remove the fuel injector cooling fan motor and intake hose.
On some models, remove the top radiator cap. grille, bumper cover. Disconnect the wiring harness in the bumper going to the turn signals and headlights. Remove 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 outlet hose from the additional radiator.
Disconnect the wire from the thermal switch. Remove the radiator mounting bolts, right radiator cap and 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 personal injury.
Discharge the air conditioning system properly and disconnect the hoses from the air conditioning condenser.
Remove the radiator together with the air conditioning condenser. Remove the A/C compressor and its mounting bracket from the engine.
Remove the power steering pump drive belt from the pump. Remove pump from 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. Pin it to the side.
Remove the throttle rod clamps and remove the throttle 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 intake air temperature switch.
Disconnect air intake hoses. Disconnect the wire from the auxiliary airflow regulator. Remove the vacuum hoses and disconnect the breaker-distributor hose from the engine.
On the two-way valve, remove and mark the vacuum hoses. Remove thermopneumatic valve. Without disconnecting the vacuum hoses, remove the engine speed sensor.
Disconnect the speedometer cable from the transmission.
Remove distributor from engine.
Disconnect and tag the plugs of the thermal switch and the overtemperature warning light. Disconnect heater hoses from engine.
On the left engine support, disconnect the brake booster and reservoir from the bulkhead of the engine compartment without disconnecting the pipes. On Quattro vehicles, disconnect the differential lock warning light plug. Disconnect the reversing light switch wires.
Disconnect the tie rods from the steering rack. Disconnect tie rods.
If the transmission is manual, disconnect the clutch slave cylinder from the casing. Do not disconnect tubes. Remove bracket and rod under transmission bracket.
Disconnect the ground strap on 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 tag the electrical plugs from the generator. Remove oil cooler. Do not disconnect tubes. Disconnect and tag starter wires.
Disconnect exhaust pipes from turbocharger. Remove the plates covering the gearbox and the right gearbox support. Disconnect the shafts from the gearbox. On Quattro vehicles, disconnect the propeller shaft from the rear of the gearbox.
On Quattro vehicles, at the gearbox, disconnect the differential lock, remove the front and rear circlips and pull the cover back. Disconnect cable.
Remove the bolt of the left gearbox support and support on both sides.
On both front wheels, remove the ball joint lock bolts. Loosen the subframe mounting bolts and remove the subframe. Separate the ball joints from the steering knuckle.
Connect the lift to the engine. Raise the engine slightly and remove the left and right engine mounts. Lower the engine together with the gearbox under the vehicle.
Raise the front of the vehicle and push the engine/gearbox assembly out from under the vehicle.
Separate the engine from the gearbox.
Installation
Install the engine assembly and temporarily secure the engine mounts.
Fit ball joints to steering knuckles and tighten to 3Nm. Install ball joint retaining bolts and tighten to 65 Nm.
0. Install the exhaust retaining clips and, on 4WD models, the differential lock, if equipped.
Connect the exhaust pipe to the turbocharger.
Install the axle shafts in the gearbox.
Install the gearbox ball joint and gearbox cover plates.
Connect the driveshaft to the rear of the gearbox.
Lower the vehicle and connect all electrical connectors.
Install oil cooler.
Install the intercooler assembly and air duct.
Connect the ground bus on the left engine mount.
Install clutch slave cylinder, if applicable.
Connect the tie rods to the gear rack.
Install the brake booster and reservoir. On Quattro vehicles, connect the differential lock warning light plug. Connect the reversing light wires.
Install heater hoses.
Install distributor.
Install speedometer cable and all vacuum hoses.
Install the fuel injectors to the cylinder head.
Connect the connectors 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 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 bumper.
Install the fan motor and intake hose to the motor.
Fill the cooling system and bleed air. Connect the wire to the minus AB.
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 the vehicle in motion.
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