Engine: Service and Repair

1. Disable airbag system, refer to MAINTENANCE PROCEDURES/AIRBAG ARMING & DISARMING.
2. Disconnect battery ground cable, then remove engine hood.
3. Remove radiator grille, then the outside temperature sensor from upper apron.
4. Remove bumper, then the brake cooling air ducts.
5. Drain coolant into a suitable container, then disconnect coolant hoses from auxiliary radiator.
6. Remove auxiliary radiator from side mounting, then loosen wiring on front cross member.
7. Remove pressure pipe from intercooler and pressure hose, then the front cross member with auxiliary radiator and pressure pipe.
8. Remove lower mountings between front panel and fenders, then both lower radiator mounting bolts.
9. Remove left lower bracket for horn and radiator, then the lower side cowling.
10. Remove lower radiator cowling, then unclip wiring harness from both sides of front panel.
11. Remove rear alternator guard, then disconnect wiring from alternator and starter.
12. Remove and plug oil cooler hoses from oil filter housing, then the starter motor.
13. Remove A/C compressor from mounting bracket, and secure to left side member. Leave refrigerant lines attached.
14. Disconnect wiring from oil pressure switch, then pull harness for starter and alternator from between turbocharger and intercooler hose.
15. Unscrew mountings between exhaust pipe and catalytic converters, then loosen lower engine mounting nuts on both sides.
16. Loosen lower engine/transmission mounting bolts, then disconnect intake hose from air mass sensor.
17. Cover open end of intake hose with tape, then remove air cleaner housing.
18. Remove mountings between front panel and side member, then the upper radiator cover.
19. Disconnect radiator side cowling from front panel, then the upper radiator support at front panel.
20. Disconnect hose to intercooler/intake pipe at intake pipe, then unhook hood release cable.
21. Disconnect wiring at headlight, then remove front panel with intercooler and headlight assemblies from fenders.
22. Remove coolant hose at side of turbocharger coolant pump, then disconnect power steering pump hoses.
23. Remove power steering pump, then disconnect wiring from oil pressure sender.
24. Remove connectors from oil pressure switch, temperature switch for radiator after run and coolant pump for turbocharger.
25. Disconnect electronic thermoswitch, then remove knock sensors.
26. Disconnect plug at coolant pump for turbocharger, then the vacuum line from cruise control vacuum unit.
27. Remove both ground cables from cruise control vacuum control unit bracket, then the intake air temperature sender from intake manifold.
28. Disconnect, then remove idle stabilizer valve, then the mounting for engine speed and reference mark sensors.
29. Cut tie wrap securing wiring to coolant hose, then remove clip from cruise control vacuum unit bracket.
30. Remove ground strap at engine support, then pull out wiring harness toward rear between engine and crankcase breather hose.
31. Disconnect Hall sending unit, then the coil wire and coolant temperature sensor at rear of cylinder head.
32. Remove carbon filter (blue) solenoid valve from crankcase breather hose located at rear of cylinder head.
33. Disconnect throttle potentiometer, then the injectors. Carefully pry off cover for injector lines toward intake manifold side.
34. Carefully pull out injector lines towards rear between intake manifold and cylinder head.
35. Disconnect green vacuum line for Motronic control unit, then pull off heater hoses from coolant pipe (left side) and crankcase (right side).
36. Cut tie wrap securing oxygen sensor wire, then disconnect oxygen sensor probe and oxygen sensor heater from mounting brackets.
37. Disconnect electrical connectors from oxygen sensor and oxygen sensor heater, then the exhaust pipe and corrugated tube from turbocharger.
38. Disconnect fuel supply line from collector line, then fuel return line from pressure regulator.
39. Disconnect accelerator cable at throttle housing, then pull cable from support.
40. Remove heat deflector plates from right front side member, then the left/right engine support nuts.
41. Remove upper engine/transmission mounting bolts, leaving last bolt at top in but loose.
42. Place fixture 3147 or equivalent into top right hole of transmission, then position support bar 10-222A or equivalent onto inner fender mounting area and attach draw hook.
43. Raise or lower transmission to desired height using wing nut, then attach and secure engine sling 2024A or equivalent at front left and on throttle support bracket.
44. Hook engine sling to crane VAG 1202 or equivalent, then relieve weight and tighten tool 3147.
45. Remove last engine/transmission bolt at top, then mark left and right engine mounts and remove.
46. Remove left engine support from crankcase, then pry engine/transmission apart.
47. Remove engine assembly from vehicle.
48. Reverse procedure to install, noting the following:
a. Ensure dowels for centering engine to the transmission are in the engine block.
b. Replace all self-locking nuts.
c. Tighten fasteners to specifications.