Removal and installation the engine (Audi A4 B7)

Note: The engine is removed forward without the transmission with the radiator frame removed. When installing the engine, do not forget to return all removed or cut electrical wiring fasteners to their original places.

1. On models with AT or CVT, place the selector lever in the "N" position

2. Follow the steps described in paragraphs 3-6 of Section 5.

3. Remove the front bumper cover (see Chapter 10), press the clamps (see illustration) and remove the air ducts of the left and right intercoolers.



4. Place a pan under the engine and remove the drain bolts (see illustration) on the water hose at the bottom left and drain the coolant.





5. Remove the lower engine cooling system hose from the radiator (see illustration 5.8).

6. Disconnect the air duct hose (1 in the illustration) to the intercooler on the bottom left and the coolant line from the bracket (2).

Caution: Do not open the refrigerant circuit.

7. Disconnect the air duct (1 in the illustration) to the turbocharger on the bottom right and the air duct (2) to the intercooler from the radiator frame.



8. Clamp the hoses to the power steering fluid radiator using clamps No.3094, place a tray under the power steering hose connections and disconnect the power steering hoses (see illustration).





9. On models with AT, place a pan under the ATF line connections and disconnect the ATF lines (2 and 3 in the illustration) and unscrew the fastener of the bracket (1) of the ATF lines on the engine.



10. Remove the top engine cover as shown in the illustration.





11. Remove the bolts (arrows in the illustration) and remove the air ducts and 2).



12. Remove the upper hose from the radiator (1 in illustration 5.14) engine cooling system, disconnect the connectors (2) of the left and right frontal impact sensors on the radiator frame.

13. Disconnect the electrical wiring connectors of both headlights (see illustration 5.15).

14. Remove the connectors (1 and 2 in the illustration) from the holder and disconnect them, put the wiring aside.



15. Disconnect the connectors on the left and right (3 in the illustration) horns (2).

Note: Please ignore point 1 in the illustration.

16. Remove the bolts and the ampere beam (see illustration).



17. Perform the actions described in paragraphs 17-20 Section 5.

18. Mark the alternator belt with chalk or a felt-tip pen to indicate the direction of rotation so that you can install the belt in the same way. Loosen the belt tension by turning the tensioner in the direction of the arrow (see illustration). Secure tensioner clamp No. T40098 and remove the alternator belt.



19. Follow the steps described in paragraphs 47-49 of Section 5.

20. Disconnect the ground wire from the engine compartment bulkhead (1 in the illustration), eVAP hose (3) and the vacuum tube (2) going to the brake booster.





21. Disconnect the water hoses (1 and 2 in the illustration) and unscrew the fastener of the expansion tank of the cooling system (arrow). Disconnect the connector of the K/L low coolant level sensor on the bottom of the expansion tank.



22. Disconnect the boost pressure sensor connector (1 in the illustration) and disconnect the left boost air hose (2).





23. Disconnect the right boost air hose (1 in the illustration).



24. Disconnect the connectors from the bracket (1 and 2 in the illustration) respectively post-catalytic (brown connector) and pre-catalytic (black connector) lambda probes and their heaters.



25. Disconnect the fuel line (arrow on the illustration) and collect the leaked fuel. Disconnect the water hoses of the heater radiator at the rear of the engine.





26. Remove the windshield wiper arms (see Chapter 12) and windshield fairing (see Chapter 11).

27. Remove the cover of the mounting block in the water drainage box (see illustration 5.33).

28. Using a screwdriver, lift the bracket (see illustration 5.34).

29. Give the nut (1 in the illustration) and disconnect the wire. Disconnect the connectors (2 and 4 in the illustration) in the mounting block.



30. Remove the fuse box retainer (arrows in the illustration). Release the wiring harness and place it with the ECM connected on the engine.



31. Unscrew the front and rear power steering pump mounting bolts (by analogy with illustrations 5.27a,b). Remove the power steering pump and place it on the side member without disconnecting the power steering fluid lines.

32. Disconnect the connectors (1 and 2 in the illustration) and release the electrical wiring. Disconnect the air cleaner/turbocharger inlet hose (3).



33. Disconnect the connector (1 in the illustration) air flow meter, release the wiring harness on the air cleaner and remove the air cleaner housing (arrow).



34. Unscrew the bolt (see illustration) and disconnect the ground wire from the right side member.



35. Remove the heat shield (1 in illustration 5.43) of the inner CV joint of the right drive shaft.

36. Loosen the clamping sleeve mounting nuts (see illustration 5.42) and slide the clamp back.

Caution: Do not bend the flexible section of the exhaust pipe more than 10°.

37. Remove the bolts (arrows in the illustration) and disconnect the exhaust pipe and the catalytic converter. Loosen the bolt (1) on the exhaust pipe bracket and remove it.



38. Disconnect the connector (see illustration) D/V reverse lights and release the electrical wiring.



39. Remove the transmission mount to the engine, accessible from below: (1-3 and 7-11 in Illustration 5.64b).

40. Disconnect the connector (3 in the illustration), remove the clamp nut (1), nut (2) and remove the electrical wiring. Remove the starter and move it to the side.



41. Mark the mounting position of the connections (1 in illustration 5.51) and fixing bushings (2) at the bottom on the right and left engine support cushions.

Note: Different engines have different mounting holes. Loosen the nuts (1) from the bottom of the left and right mounts.

42. Loosen the top nut (see illustration 5.53) on the left engine mount.

43. Hang the hanging device No.2024A from the engine and from the crane No. VAS-6100 as shown in the illustration.

Note: To align the center of gravity of the power unit, the hook bars must be inserted as shown in the illustration.

44. Remove the last engine/transmission connecting bolt. Check that all hoses and wires between the engine and the body are disconnected.

45. Raise the engine so that the engine mount studs are free. Raise the jack until the transmission is flush, separate the engine from the transmission and remove it from the engine compartment.

46. Installation is carried out in the reverse order of dismantling the components. Please note the following information.

47. Use new self-locking nuts and bolts/screws, as well as bolts/screws tightened to a certain angle. Use new O-rings, lip seals and gaskets. Use clamps of the appropriate series to secure all hose connections. All cable ties must be installed in their original places. Hoses and fittings of the air boost system must be cleaned of oil and grease before installation.

48. On models with CVT or AT, clean the splines of its primary shaft and flywheel damper from dirt and rust, apply a very thin layer of G 000 100 grease to them. Be sure to remove excess grease.

49. On models with manual transmission:

• when installing a new clutch disc in conjunction with an old self-adjusting pressure plate, the pressure plate adjusting ring should be turned to the stop, otherwise the pressure plate will operate with reduced contact pressure (the clutch is slipping);
• if the clutch disc is not being changed, do not turn the adjusting ring; the new self-adjusting pressure plates are already pre-set and do not require adjustment;
• check the clutch release bearing for wear, replace it if necessary (see Chapter 6);
• lightly lubricate the gearbox input shaft teeth with G 000 100 grease (do not lubricate the clutch release bearing guide bushing);
• if necessary, check the centering of the clutch driven disc;
• check the clutch release bearing for wear and replace it if necessary;
• if the plastic ring of the release bearing is not tightly fitted, glue the plastic ring to the bearing ring using AMV 195 KD1 01 glue - three rectangular protrusions (arrows in illustration 5.60) plastic rings will fall into the grooves of the bearing ring; if the grooves are deeper than 0.5 mm, replace the clutch release bearing;
• the engine must have a needle bearing installed on the crankshaft - install the bearing if necessary.

50. Check that the intermediate shield is suspended on the flange and the mounting bushings are fitted (see illustration 5.61).

51. Mate the engine to the transmission and tighten one bolt by hand.

52. Lower the engine and at the same time install the threaded bolt of the engine mount and engine mount console.

53. Tighten the bolts to the torques specified below in accordance with with illustration 5.64b.

Note: The tightening torques given are ±15% and are valid for lightly greased, phosphated or oxidized nuts and bolts. Always use new bolts/nuts to secure the AT or CVT. Additional lubricants, such as engine or transmission oils, are permitted, except for those containing graphite. Do not use degreased parts.

For models with manual transmission:

• 1. 6 Bolt M12x105, 65 Nm
• 2. 4 Bolt M 12x80, 65 Nm
• 3. Bolt M 12x90, 65 Nm
• 5. 7 Bolt M 12x95, 65 Nm*
• 8. Bolt M 10x50, 45 Nm
• 9-11. Bolt M 10x45, 45 Nm
• A. Centering bushings

For models with AT/CVT:

• 1. Bolt M 12x67, 65 Nm
• 2. Bolt M 10x70, 45 Nm
• 3-5, 7. Bolt M 12x75, 65 Nm 6 Bolt M12x105, 65 Nm *
• 8. Bolt M 10x60, 45 Nm
• 9-11. Bolt M10x45, 45 Nm
• A. Centering bushings

54. After installation, check the engine oil, transmission oil and power steering fluid levels (see Chapter 1).

55. Fill the coolant (see Chapter 3).

Note: Drained coolant may only be reused if it is clean and the cylinder head or cylinder block has not been replaced.

56. Tighten threaded connections with the following forces: (see note in paragraph 64):

• engine mount to console // engine support 40 // 23 Nm
• wiring to the starter
• and generator 16 Nm
• cV joint heat shield
• to transmission 23 Nm
• rocker support thrust 28 Nm
• hose pools
• width 9 // 13 mm 3 // 5.5 Nm
• other details (thread Mb // M8 // M10 // M12) 9 // 20 // 40 // 65 Nm

[This article was copied from the website: AudiManual]