LEMON Manuals: Even more car manuals for everyone
Home >> Audi >> 1980 >> 5000 Base, Automatic Trans >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Mechanical >> 4000 & 5000 5 Cylinder >> Engine & Cylinder Head >> Engine >> Removal (4000)

Removal (4000)

  1. Disconnect battery ground cable. Open heater control valve fully. Open cap on coolant expansion tank and drain coolant. Remove engine-to-transmission bolt holding coolant pipe. Remove upper coolant hose from pipe on left side of engine.
  2. Remove upper radiator cover and upper radiator hose from engine. Remove vacuum hose at brake booster and at cruise control unit. Remove power steering pump and place in cowl.
  3. Detach coolant hose at thermostat housing. Disconnect wires from oil pressure switch and control pressure regulator. Remove throttle push rod and control pressure regulator, leaving fuel lines connected.
  4. Remove remaining coolant hose. Remove alternator adjusting bolt and mounting bolt and place alternator into lower radiator cover. Remove alternator bracket from engine block and remove front stop.
  5. Loosen clamps and remove air duct. Disconnect plugs from frequency valve and ground point. Remove distributor vacuum unit hoses. Disconnect plugs at cold start valve, auxiliary air regulator and throttle switch. Remove coil high tension wire at ignition coil.
  6. Pull out fuel injectors and remove cold start valve. Leave all fuel lines connected, protecting injectors and valve with caps. Remove fuel distributor with air flow sensor plate. Disconnect fuel feed and return lines. Pull PCV valve hose from valve
  7. Loosen upper air filter housing clips and housing bolt. Disconnect oxygen sensor, thermo switch, thermo-time switch, temperature sending unit, and ignition distributor connectors.
  8. On air conditioned vehicles, remove coolant hoses at oil cooler. Remove heater hoses. Remove hose flange from engine block and remove cover for right engine mount. Loosen left and right engine mounts. Detach ground strap from mounting bracket. Remove upper engine-to-transmission bolts, leaving one easy-to-reach bolt installed.
  9. Loosen "V" belt adjusting bolts for air conditioner compressor. Disconnect wire from oil temperature switch. Remove compressor clamping bolt, bracket from engine block, and wire from compressor clutch. Remove upper compressor mounting bolt and wire compressor out of way, leaving hoses connected.
  10. Disconnect starter cables. Remove both front subframe bolts. Remove exhaust pipe attaching nuts from manifold. Remove bolt from exhaust pipe support. Remove starter.
  11. Working through starter mounting hole, remove 3 torque converter mounting bolts from drive plate. Remove lower engine-to-transmission bolts. Unhook shift rod clip. Install transmission support tool (VW 785/1).
  12. Attach engine sling (US 9010 and US 1105) to engine. Adjust support bar to contact transmission. Remove upper engine-to-transmission bolt, left in earlier. Lift engine slightly and pry engine away from transmission. Continue to lift engine, while turning it toward the left.
  13. Use care when guiding engine out of engine compartment. Be sure all wires, hoses, and vacuum lines have been removed. Secure torque converter so it does not fall out. Mount engine on stand (VW 540).
scientia non olet · About LEMON Manuals