With Tiptronic
Removing and Installing the Engine, Tiptronic VehiclesRemoving
Note: The engine-transmission assembly is removed completely downwards.
1. Support the vehicle at the support points.
Note: Align the rear right supports so that the transmission underbody cladding can be removed later on.
2. Disconnect the battery ground cable.
3. Disconnect the connectors (6 each) at the intake distributor and remove the cable clip on the air flow sensor. Pay attention to connector sealing.
4. Remove hot-air blower. The drawing shows the engine in dismantled condition
5. Undo the following plug-in connections and cables on the left of the engine compartment:
1. to the active-carbon container
2. to the brake booster
3. to the reference mark sensor
4. to the knock sensor
5. to temperature sensor II (cyl.3)
6. Fuel return line
7. Plug-in connection, cruise control
8. Plug-in connection, oxygen sensor
Note: In order to avoid discharge of fuel when the fuel tank is full, connect disconnected hose with special tool connecting hose 9507 Order No.000 721 950 70 and clamp off the connecting hose with a standard commercially available hose clamp.
6. Remove the cover on the engine electrics board. Disconnect both multiple connectors.
7. Disconnect both ignition cables 2 and the connector from the double ignition distributor.
8. Disconnect the connector from the belt monitoring device.
9. Undo bleeding hoses. These can also be disconnected after lowering the engine-transmission assembly.
10. On vehicles with air conditioning system, dismantle the compressor from the bracket and put down on a suitable surface at the left rear fender with connected hoses.
11. Remove air filter cover with filter insert.
12. Undo fuel supply line at fuel filter, countering at the same time. Collect residual fuel.
13. Empty supply reservoir of the power steering pump. Draw off fluid.
a. Undo hose clamp and pull off top hose, collect remaining oil.
b. Undo bottom line and remove with holder. Collect remaining oil.
14. Remove wheels at rear.
15. Disconnect the actuating pull of the throttle valve at the reversing lever of the foot controls, unlock ball head and unscrew.
16. Remove engine, transmission underbody cladding.
17. Drain engine oil at thermostat housing.
Note: In the case of engine overhauls, additionally drain engine oil at crankcase
18. Undo oil line in rear right wheel house with special tool 9501, countering under all circumstances. Remove line retaining clip at wheel house. Block off line.
19. Disconnect universal shaft from the differential at the flange and hang up.
20. Undo heating hoses at the heat exchanger.
21. Undo the ground strap between the body and starter at the bottom starter mounting point.
22. Disconnect cable, terminal 30, at starter
23. Pull throttle valve actuating pull out of guide tube of the underfloor assembly and disconnect.
24. Disconnect selector lever cord pull.
25. Undo holder for selector lever cord pull and disconnect completely.
26. Unlock cable holder, remove plug-in connection and disconnect.
27. Undo and remove stabilizer.
28. Undo oil lines and block off.
29. Undo oil hose of oil line in rear right wheel house and block off oil lines.
30. Undo securing holder for engine under- body cladding, remove and secure hexagon nut or hexagon screw again. (Bearing surface for engine support plate)
31. Place a jack with engine support plate underneath with a small amount of preloading. Pay attention to adapter position. (Engine-transmission horizontal).
32. Undo transmission transverse member (6 screws).
33. Remove cover on assembly bore of the engine suspension in the rear engine end plate and undo hexagon nuts of the engine mountings from below.
34. Lower engine-transmission assembly by approx. 10 cm:
a. Disconnect multiple connector at air flow sensor.
b. Disconnect connector from transmission socket. To do this, turn bayonet lock to left and disconnect connector.
35. Carefully lower engine-transmission assembly.
Note: Pay attention to universal shaft, selector lever cord pull and throttle valve actuating pull.
Installation
The following points must be observed for installation.
1. Before final positioning of the engine-transmission assembly in the installation position, the following connections must be made:
a. Plug multiple connector onto air flow sensor.
b. Connect wiring harness with transmission socket. To do this, carefully insert the connector in the socket (fits only in one position) and lock by turning the bayonet lock to the right.
2. Make sure that the inner rubber seals of the plug-in connections are fitted properly.
3. Make sure that the profile seals between the engine paneling and body are properly fitted.
4. When tightening the oil line in the rear right wheel house, make sure that the oil line does not turn as well and repeat tightening if necessary.
Tightening Torques:
Engine mount to engine bearing M 12 85 Nm (62 ft lbs)
Transmission mount to body M 12 46 Nm (34 ft lbs)
Central tube to transmission M 12 85 Nm (52 ft lbs)
Twin clamping sleeve to the central shaft 75 Nm (65 ft lbs)
Shift rod (body-fit screw) 23 Nm (17 ft lbs)
Drive shaft to transmission flange 42 Nm (31 ft lbs)
Stabilizer to stabilizer mount M 10 46 Nm (34 ft lbs)
Oil drain plug in thermostat housing 60 Nm (44 ft lbs)
Oil drain plug in crankcase 70 Nm (51 ft lbs)
Oil line to oil filter housing 80 Nm (59 ft lbs)