Table of contents: Removal ↓ Installation ↓
Removal
50. Place the vehicle on a firm, level surface with sufficient space around it.
51. Remove the battery as described in chapter 5A.
52. Place chocks under the rear wheels, securely tighten the handbrake. Loosen the front wheel mounting bolts. Raise the front of the car. Install safety supports.
53. If installed, unscrew the mounting screws and remove the powertrain protective cover from under the vehicle.
54. If equipped, remove the top engine cover.
55. Remove the front bumper as described in chapter 11.
56. As described in chapter 1B, do the following:
- a) Drain the coolant. The drain plug is located at the front left of the radiator. The remaining coolant can be drained by removing the thermostat cover and removing the sealing ring and thermostat
- b) If you disassemble the engine, drain the engine oil.
57. Remove the clamp and disconnect the lower hose from the radiator.
58. On models with an electric cooling fan, disconnect the wiring from the thermostatic sensor located at the bottom left of the radiator. Move the wiring to the side.
59. On models with automatic transmission, place a suitable container under the radiator. Disconnect the automatic transmission hydraulic pipes from the radiator and plug them.
60. Loosen the clamps and disconnect the intake air duct from the intercooler at the bottom left of the hood lock bracket (front body panel).
61. Loosen the clamp and disconnect the turbocharger air hose from the lower right side of the hood latch bracket (front body panel).
62. Loosen the bolts and remove the air duct leading to the air filter from the front panel of the body.
63. Remove the air filter as described in chapter 4B.
64. Disconnect the wiring from the headlights and headlight corrector unit.
65. Disconnect the front turn signal bulb sockets.
66. Loosen the clamp and disconnect the upper hose from the radiator.
67. On models produced from 07.97. Remove the air pipe and hose from the left side of the engine. To do this, unscrew the mounting bolt and loosen the clamps.
68. Disconnect the hood lock control cable from the hood lock bracket.
69. Remove the cover from the power steering reservoir.
70. Disconnect the wiring from the ABS units installed on the left under the hood.
71. At the top left of the front body panel, disconnect the wiring connector from the anti-theft system.
72. Disconnect the wiring from the two packs and release it from the bracket.
73. On models equipped with air conditioning, unbolt and remove the air deflectors from both sides of the radiator. Then unbolt the condenser. Disconnect the wiring from the low pressure sensor and disconnect the wiring from the electromagnetic clutch of the air conditioner at the bottom of the hood lock bracket. Remove the condenser from the bracket, unfold and tie it to the front wheel to secure it when removing the engine and cover the condenser with cardboard or rags.
Attention! Be careful - do not open the refrigerant circuit of the air conditioner under any circumstances.
74. Loosen the hood lock bracket mounting bolts (front body panel) then, together with an assistant, remove the front panel and move it as far away from the body as possible.
75. Loosen the clamps and remove the air intake duct at the rear of the engine. Disconnect the wiring from the sensors where necessary. On models from 07/97 onwards, unscrew the mounting nut.
76. Disconnect the hoses and wiring from the wastegate valve. If necessary, remove the bolts and valve from the front of the engine.
77. Loosen the clamps and disconnect the hose from the expansion tank of the cooling system, remove the tank and disconnect the wiring from the coolant level drop sensor.
78. Disconnect the fuel lines from the fuel filter cover on the left side of the engine.
79. On the engine shield, remove the protective cover of the engine control unit, move it aside and pry up the latch. Release the fasteners and disconnect the wiring connector from the unit. If there is one, disconnect the vacuum hose from the unit.
80. Use a screwdriver to release the retainer and lift the additional belt block upwards. Release the two fuse blocks and the plug connector. If available, I use the Audi VAS1975 tool. If not, a screwdriver will do.
81. Disconnect the ground wire from the accumulation chamber and release the wiring from the plastic clamps.
82. Loosen the clamps and disconnect the heater hose at the rear of the engine.
83. Disconnect the brake booster vacuum hose from the pump.
84. To the left of the gearbox, disconnect the speedometer sensor wiring.
85. On models with manual transmission, disconnect the wiring from the reverse light switch.
86. Remove the auxiliary belts as described in chapter 2B. Remove the fan viscous coupling as described in chapter 3.
87. As described in chapter 3, remove the air conditioning compressor from the engine, move the compressor to the side and tie it up there so that it doesn't get in the way.
Attention! Be careful - do not open the refrigerant circuit of the air conditioner under any circumstances.
88. Remove the pulley from the power steering pump and remove the pump from the bracket and tie it away from the engine. Do not disconnect the hydraulic tubes/hoses.
89. Loosen the nut and disconnect the positive power wire from the starter, which is installed under the exhaust manifold to the right of the engine.
90. Remove the nuts securing the turbine to the catalytic converter. Loosen the front clamp on the downpipe and slide it back to disconnect the downpipe. Disconnect the downpipe and catalytic converter from the turbine. Do not over-bend the flexible section of the downpipe.
91. Disconnect the ground wire from the right engine support.
92. If installed, remove the turbine support bracket from the right engine mount.
93. Remove the starter as described in chapter 5A.
94. On models with automatic transmission, unscrew the three torque converter mounting nuts, which are now accessible through the starter hole. In order to unscrew all the bolts, the engine will have to be turned. To prevent the faceplate from turning while loosening the nuts, insert a screwdriver between the teeth of the ring gear or hold the crankshaft by the central bolt securing the sprocket.
95. On models with automatic transmission, remove the hydraulic pipe bracket on the left side of the engine.
96. Loosen the upper engine mount nuts a few turns. Mark the engine mount positions on the subframe to install them correctly later. Loosen the mount nuts a few turns.
96. Disconnect the hoist from the engine and lift the power unit slightly. Make sure that the engine is securely fastened to the hoist.
97. Loosen the bolts securing the gearbox to the rear of the engine, lower the engine into place. Leave one bolt in this position.
98. Place a trolley jack under the gearbox, placing a piece of board between them. You can transfer the weight of the gearbox to a beam placed in the grooves of the wings.
100. Remove the last bolt. Make sure all wires and hoses are disconnected and remove the engine from the engine compartment. On models with automatic transmission, make sure the torque converter remains inside the bell housing and does not fall. Secure it in the bell housing by screwing an iron strip across the bell housing with two bolts.
101. If the guide bushings are loose, remove them from the rear of the block. If necessary, remove the intermediate plate from the rear of the engine.
102. On models with manual transmission, remove the clutch as described in chapter 6.
Installation
103. Installation - reverse procedure. Before installation on models with manual transmission, lubricate the gearbox shaft splines with a small amount of high-temperature grease. Lightly lubricate the contact surface of the release bearing, but DO NOT lubricate the release bearing guide sleeve. On models with automatic transmission, check that the torque converter is correctly installed on the automatic transmission shaft by measuring the distance between the mating surface of the bellhousing and the surface of the torque converter. It should be approximately 23.0 mm. If only 13 mm, the torque converter is not fully inserted into the bellhousing. Make sure that the engine and gearbox mounts are not overloaded, tighten the threaded connections to the specified torques. Install all attachments in accordance with the description of the relevant chapters. Fill the engine with clean engine oil and fill the system with coolant as described in chapter 1A.
(The article is a reprint of material from: «Audimanual.ru»)