Diesel engines
1. Disconnect the wire terminal «masses» (-) from the battery.
2. Remove the two-piece engine mudguard.
3. Remove the hood.
4. Drain the coolant into a suitable container.
5. Disconnect the electrical wires from the radiator fans.
6. Disconnect the radiator fan thermal switch plug.
7. Turn out bolts of fastening of a box of the fan of an obduv of a radiator and take it from a motor compartment, giving up.
8. Disconnect all hoses from the radiator on a car with air conditioning, and remove the radiator fan box from the engine compartment by moving it to the left and up.
Only TDI engines
9. Disconnect the three plugs located behind the vacuum brake booster: the black 8-pole plug of the injection pump, the 3-pole plug of the engine speed sensor, also black, the brown 2-pole plug of the injector needle stroke sensor.
10. Disconnect the plug holders.
11. Set wires and plugs away from work area.
12. Disconnect the plugs of the power wires of the injection advance solenoid valve, fuel cut-off valve (located behind the fuel pump), glow plugs, coolant temperature sensor on the outlet pipe.
Only TD engines
13. Disconnect the plug of the power cable for the fuel cut-off valve and the fuel injection pump partial load sensor, as well as the electric water pump.
14. Disconnect fastening of wires of food of glow plugs of the fourth cylinder.
15. Pull out the wiring harness by pulling it back and set it aside from the work area.
16. Cut the transmission wiring harness clamp.
17. Disconnect the cable from the injection pump «gas» and cold start accelerator cable.
18. All engines. Disconnect the plugs of the oil pressure sensor and the coolant temperature sensor at the outlet pipe.
19. Disconnect the coolant supply hoses to the heater radiator located near the rear wall of the engine compartment.
20. Disconnect hoses from the fuel filter.
21. Disconnect the hose from the vacuum brake booster.
22. Disconnect the coolant hose located on the left side of the engine.
23. Remove the hose from the EGR valve.
24. Disconnect the air supply hose from the air filter housing to the turbocharger or to the volume/mass air flow meter.
Only TD engines
25. Disconnect the coolant supply hose from the electric water pump.
26. Press out the six clips on the air filter housing and remove the top and replaceable filter element.
27. Label the oil supply and return hoses on the oil cooler and disconnect them from the oil filter.
28. Secure the oil lines in the engine compartment so as to prevent oil leakage.
29. Disconnect the coolant line from the electric water pump to the right of the engine and from the heater radiator hoses. To do this, unscrew the two bolts on the flange of the gearbox to the engine and disconnect the hose mount on the rear of the cylinder head.
Only TDI engines
30. Disconnect the air supply hose from the turbocharger.
31. Disconnect the volume/mass air flow meter plug.
32. Disconnect the small diameter hoses from the rear of the air filter housing.
33. Wring out the clamping brackets on the air filter housing and remove the top of the filter along with the air volume / mass flow meter and the replaceable filter element.
34. Disconnect the plug of the intake air temperature sensor.
35. Disconnect the air supply hose to the intercooler on the turbocharger.
36. Disconnect the hose from the boost air pressure regulator chamber.
37. Disconnect the thin hose at the front of the turbocharger.
38. Disconnect the coolant hose from the oil cooler.
39. Disconnect the coolant line from the left side of the engine.
All engines
40. Disconnect the lower part of the air filter housing.
41. Turn away on flange connection of a reception pipe and a turbocharger four nuts on 12.
42. Remove the nuts securing the left and right engine mounts.
43. Turn out the top bolts of fastening of a transmission to the engine. Loosen one bolt, but do not remove.
44. Disconnect the wire from the generator.
45. Loosen the clamps and disconnect the wires from the starter.
46. Remove the starter.
On vehicles with air conditioning, remove the upper coolant hose holders.
Attention: Be careful. The hoses are kink sensitive. Do not open the coolant circuit!
47. Remove the ribbed belt.
48. Remove the lower holders of the coolant circulation hoses.
49. Remove the generator.
50. Disconnect the AC compressor plug.
51. Turn out bolts of fastening of the compressor of the conditioner and remove it. Lower the compressor without disconnecting the coolant hoses and secure it to the body.
On vehicles with automatic transmission, remove the three torque converter mounting bolts in the hole of the removed starter. To do this, rotate the engine ⅓ of a turn each time.
52. Turn out the bottom bolts on a flange of fastening of a transmission to the engine.
53. Remove the protective casing of the right drive shaft.
54. Remove the power steering hydraulic pump and fix it in the engine compartment without disconnecting the pipelines.
55. Disconnect the exhaust mounting bracket on the gearbox housing.
56. Disconnect the front engine mount from the engine and from the cross member.
57. Fix the gearbox on the stand or use the lifting device AUDI 10-222A with the holding device for the gearbox 3147 (see illustration 4.66a).
58. Insert the hoist cable into the engine lugs and raise the power unit.
59. Place a support under the gearbox, taking into account that the power unit is raised.
60. Turn out the remained bolt of fastening of a transmission to the engine.
61. Press the gearbox away from the engine and remove the engine from the engine compartment.
For vehicles with automatic transmission, after removing the engine, secure the torque converter in the transmission so that it does not fall out.
Gasoline engines
The procedure for removing all types of gasoline engines is generally the same and is largely identical to the steps for removing diesel engines. The following are just the basic steps.
62. First remove all parts that will prevent the engine from being removed from the engine compartment. These include: hood, engine mudguard, air filter, battery, and, if necessary, a radiator.
63. Mark the connecting wires and hoses accordingly so that when installing the engine in place, do not confuse them.
64. Make sure you have the radio's security code written down before disconnecting the battery.
65. Turn off the ignition before disconnecting the battery. If this requirement is not observed, the electronic control units of the vehicle's systems may be damaged.
66. Disconnect the gearbox from the engine only before removing it directly from the engine compartment. To do this, place an appropriate support under the gearbox and disconnect the power unit, or raise it slightly and secure the gearbox so that it does not fall after disconnecting from the engine. In the workshops, for this, they use a special device that rests on the edges of the wings (see illustrations).
Installation
When reinstalling the engine, pay special attention to the following points:
67. Install fitting bushings to center the engine and gearbox, if there are none on the cylinder block.
68. Lubricate the clutch release bearing and gear rim of the input shaft of the gearbox with a thin layer of G 000100 grease. Do not lubricate the release bearing guide sleeve.
69. Install the engine in place without tension. To do this, before finally tightening the engine mount bolts, shake it from side to side.
70. Fix the exhaust pipe without stress.
Attention! Be sure to replace self-locking nuts with new ones.
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