engine AUDI A4 1997 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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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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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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10-5

- 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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10-8

- Unbolt hydraulic pump from mounting bracket.

CAUTION!

Hydraulic lines should remain connected.

- Unscrew bolts and secure A/C compressor to
one side with wire.

CAUTION!

Disconnect at mounting points only.
DO NOT open the air conditioning refrigerant
circuit.
Set the A/C compressor aside carefully.
Refrigerant lines kink easily.
The A/C refrigerant circuit must only be
opened by specially trained technicians
using the proper tools and equipment.

- Remove bolts securing exhaust manifold and
front exhaust pipe at top.

- Disconnect battery positive (B+) cable from
starter at right of engine below exhaust manifold.
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- Remove starter, take off insulator at starter
positive (B+) connection, unbolt fixture at engine
block, disconnect ground wire from engine
support.

- Unscrew four engine mounting bolts.
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10-9

- Support weight of transmission using engine
support bridge 10-222A.

- Attach engine support adapter 3147 to bolt hole of transmission bell
housing.
(Adapter installation shown with engine removed)

CAUTION!
The mounting hooks and pins on the lifting device must be secured
with locking pins. - Attach engine sling 2024A to engine and workshop crane 1202A.
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10-10

Mounting engine cylinder block on assembly
stand

CAUTION!
DO NOT have the cylinder block mounted to the assembly stand
while measuring the cylinder bores (Repair Group 13). The cylinder
block is deformed by its own weight under these conditions and
such stress will result in false measurements that are not accurate
after the tension has been relieved. - Mount engine to stand using holding fixture VW 540 along with VW
540/2.
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10-11

Installing

The engine is installed in the reverse order of
removal, with the addition of the following special
conditions and steps:

WARNING!

Do not re-use any fasteners that are worn or
deformed in normal use. Many fasteners are
designed to be used only once and become
unreliable and may fail when used a second
time. This includes, but is not limited to, nuts,
bolts, washers, self-locking nuts or bolts,
circlips and cotter pins. Always follow
recommendations given in this publication.
Always replace these fasteners with new
parts.

- Check that alignment sleeves for centering
engine and transmission are properly installed in
cylinder block. Install sleeves if necessary.

- Always install new seals and gaskets.

- Check centering of clutch disc, if necessary.

- Check clutch release bearing for wear and
replace if necessary.

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