AUDI A4 1999 B5 / 1.G AFC Engine Assembly Workshop Manual

10-1


Engine, removing and
installing

Rules of cleanliness


CAUTION!

Whenever carrying out work on the fuel
supply and fuel injection systems, carefully
observe the following five rules of
cleanliness.
1 - Thoroughly clean fuel system line and hose
connections and the surrounding area before
disconnecting.
2 - Place removed components on a clean
surface and cover. Use plastic sheeting or paper.
Do not use fluffy rags that could leave lint!
3 - Carefully cover over or seal any components
that have been opened if repairs are not carried
out immediately.
4 - Install only clean parts:

Do not remove replacement parts from the
packaging until immediately before they are to
be installed.

Do not use parts that have been stored without
packaging (e.g. in toolboxes, etc.).
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5 - When the fuel system is opened:

Avoid working with compressed air whenever
possible.

Avoid moving the vehicle if possible.
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10-2

Safety precautions


WARNING!

Be sure the ignition is switched OFF, when:

Disconnecting ignition wires
Disconnecting fuel injection system wiring
Connecting or disconnecting test equipment
leads
Disconnecting the battery
Washing the engine or engine
compartment.

CAUTION!

BEFORE disconnecting the battery:
Stop the engine.
Be sure the ignition is switched OFF (also
applies when connecting the battery). Failure
to do so may damage the Engine Control
Module (ECM).
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Be sure of the proper radio code (for vehicles
equipped with coded anti-theft radio).
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10-3

Removing

The engine is removed from the front, after being
separated from the transmission.

CAUTION!

Determine correct radio anti-theft coding
before disconnecting the battery.

Note:
All tie wraps that are loosened or removed in
order to remove the engine must be replaced or
reinstalled in the same place when the engine is
installed.

Ignition switched off

- Disconnect battery Ground (GND) strap.

- Unbolt bumper by unclipping vent grille at left
and right and removing from bumper
Repair Manual, Body Exterior, Repair Group
63
.

- Remove noise insulation panel.
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10-4

- Unbolt cooling coil for power steering fluid at
bottom left of radiator.

- Drain coolant at radiator.
- Remove locking element for connection flange of coolant hose at
bottom of radiator; pull off connection flange.
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10-5

- Remove intake air duct to air cleaner at air
scoop and lift out.

- Disconnect harness connectors for headlights and turn signal lights.
- Disconnect harness connector of engine coolant temperature sensor
near bottom coolant hose at left of radiator.

- Disconnect four harness connectors at ABS hydraulic unit.
- Disconnect harness connectors for anti-theft warning system at upper
left of front end.
- Disconnect coolant hose at top left of engine.
- Unclip and disconnect A/C clutch harness connectors at radiator air
guide on lower right.
- Disconnect harness connectors at both horns, let cables hang free.
- Remove air scoop.
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10-6

- Disconnect harness connectors at Mass Air
Flow (MAF) sensor and Idle Air Control (IAC)
valve, unbolt hose from plenum chamber and
unclip.

- Disconnect hose connection at IAC valve.

- Remove air guide between air cleaner and
throttle body.

- Remove air cleaner housing.

- Disconnect fuel supply and return lines.

- Remove coolant expansion tank.

- Remove cover for electronics box.
- Unclip engine control module and disconnect harness connectors.
- Disconnect harness connectors at connector station below engine
control module.
- Disconnect ground connection and bracket for harness connectors at
plenum chamber.
- Disconnect both coolant lines to heater core between plenum chamber
and engine.
- Disconnect accelerator pedal cable and let hang free.
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- Disconnect both harness connectors at top of transmission.
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10-7

- Loosen V-belt for hydraulic pump, viscous fan
and generator and secure with special tool 3204.

- Use screwdriver to counter-hold belt pulley for
viscous fan and unbolt with open-end wrench
3312.

Tightening torque with torque wrench 1331 and
open-end wrench 3312 is 37 Nm (27 ft lb);
without open-end wrench 3312 tightening torque
is 70 Nm (52 ft lb).

Note:
Refer to table for torque wrenches of a different
length; length of torque wrench from socket drive
to center of handle.

Length of torque
wrench Tightening
torques
220 mm 33 Nm (24 ft lb)
280 mm 37 Nm (27 ft lb)
300 mm 39 Nm (29 ft lb)
440 mm 45 Nm (33 ft lb)
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