Engine Overhaul — Disassembly Procedures (Audi A4 B5)

Table of contents: Petrol models ↓ Diesel models ↓ All engines ↓

It is much easier to repair an engine if it is mounted on a small stand. Such equipment is often available even in small auto repair shops. Before mounting the engine on the stand, the flywheel/faceplate must be removed to allow the stand bolts to be screwed into the rear of the engine block.

Note: Measuring cylinder diameters on such a stand may lead to errors.

If a stand is not available, you can disassemble the engine by placing it on a sturdy workbench, or, at worst, on the floor. Be extremely careful and attentive, do not tip over or hit the engine when working without a stand.

If you are going to purchase a remanufactured engine, remove external components and parts from the old engine to install on the newly purchased engine. These components are listed below.

Petrol models

a) Generator with brackets and starter (ch. 5A).
b) High-voltage wires and spark plugs (chap. 1A or 5B).
c) Components of the fuel injection system (ch. 4A).
d) All electrical sensors and actuators and engine wiring (chap. 4A and 5B).
d) Intake and exhaust manifolds (chapter. 4A and 4B).
e) Oil dipstick and dipstick tube.
g) Engine mounts (ch. 2A).
h) Flywheel or faceplate (ch. 2A).
i) Clutch components (chapter 6).

Diesel models

a) Generator with brackets and starter (ch. 5A).
b) Fuel injection pump, fuel injectors and glow plugs (ch. 5B).
c) All components of the fuel system, including injection pumps, sensors and actuators (ch. 4B).
d) Vacuum pump (chapter 9).
d) All electrical sensors and actuators, engine wiring (chap. 4B, 5B).
e) Intake and exhaust manifolds and turbocharger (chap. 4B and 4B).
g) Engine oil dipstick and dipstick tube.
c) Engine mounts (ch. 2B).
i) Flywheel or faceplate (ch. 2B).
k) Clutch (chapter 6).

All engines

Note: When removing engine attachments, pay attention to small parts that will be useful during assembly - gaskets, seals, spacers, washers, pins, bolts, etc.

If you purchase an engine in an incomplete configuration (block assembly with crankshaft and piston group), then you will need to remove the head, pan, oil pump, timing drive (with covers and tensioner), auxiliary drive belts (with tensioners). water pump, thermostat housing with outlet pipes, oil filter housing and, if provided, oil cooler.

If you are planning to perform a complete overhaul of your engine, you must disassemble it in the sequence indicated below, and then proceed in the following order: