Disassembling Engine Down To Crankcase

→ Absolute cleanliness is essential when working on the engine.

→ Lay removed engine parts on a clean base and make sure to cover them.

→ Use the cover for dust protection when fitting the engine NR.165  on the engine assembly support.

→ Avoid contact with caustic fluid.

→ Wear personal protective gear.

→ Ensure that there is good ventilation.

→ If you do come into contact, wash off immediately with plenty of warm water and contact a doctor if necessary.

→ Wear protective gloves and goggles.

→ If the fluid gets into your eyes or on your skin, rinse or wash immediately with water.

→ Collect emerging Pentosin. Clean hoses which come into contact with Pentosin thoroughly.

→ Use caps to protect the wiring against soiling and damage.

→ Let the fluid cool down.

→ Wear personal protective gear.

Information 

• The central screws of the camshaft control elements must be undone before removing the cylinder head cover  .
• This ensures that the camshafts are not under tension in the cylinder head and the valves are not touching against the pistons  .

Information 

• The bearing housing remains screwed to the retaining device when the bearing housing and intermediate shaft are disassembled  .

1. Engine support 9589  must be secured to the crankcase using special tool mounting elements 9590  . Refit engine with support on the engine assembly support.
   Fig 1: Locating Engine Support

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2. Drain engine oil. Unscrew oil drain plug (hexagon socket a/f 8) → Draining engine oil .
   Fig 2: Removing Oil Drain Plug

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3. Remove pulley -2-  of power-steering pump. To do this, counter the pulley -2-  as shown using a screwdriver, then remove three Torx screws (M8 x 12) -1-  .
   Fig 3: Removing Pulley Of Power-Steering Pump

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4. Disconnect cable plug -2-  of the solenoid valves -3-  .
5. Disconnect cable plug -4-  for engine compartment temperature sensor -5-  .
6. Disconnect cable plugs -1-  for all fuel injectors.
   Fig 4: Identifying Engine Compartment Temperature Sensor

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7. Disconnect cable plug -arrow-  for carbon canister solenoid valve.
   Fig 5: Locating Carbon Canister Valve

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8. Loosen support for power-steering lines -2-  by unclipping the oxygen sensor line from the support -3-  and unscrewing two Torx screws (M6 x 12) -1-  .
   Fig 6: Identifying Power-Steering Line Supports

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9. Unscrew six fastening screws (M6 x 35) for each intake-air distributor.
10. Completely remove the intake bridge. Replace seals during installation.
11. Remove drive belt cover by unscrewing three Torx screws (M6 x 12) -arrows-  .
    Fig 7: Locating Pulley Cover

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12. Disconnect cable plug -1-  on generator.
13. Unscrew collar nut (M8) -2-  and remove ground B+ line -3-  .
    Fig 8: Identifying Generator Connections

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14. Remove generator -3-  by unscrewing the Torx screws (M10 x 35) -1-  and (M10 x 145) -2-  . The deflection roller is removed together with the generator (-3-  ) → Removing generator .
    Fig 9: Identifying Generator, Pulleys And Screws

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15. Remove oil filler neck -2-  by unscrewing two Torx screws (M6 x 11) -1-  . Replace O-ring and screws during installation.
    Fig 10: Identifying Oil Filler Neck

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16. Unscrew union nut on the power-steering pressure line (a/f 16) -1-  .
17. Remove power-steering pump with the lines by unscrewing three Torx screws (M8 x 30) -3-  and the Torx screw (M8 x 12) -2-  .
    Fig 11: Identifying Fastening Screws For Power-Steering Pump

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18. Remove power-steering pump support -2-  by unscrewing four Torx screws (M8 x 35) -1-  . The power-steering pump support -2-  is additionally fixed with roll pins; if necessary use a rubber hammer for the removal.
    Fig 12: Identifying Power-Steering Pump Support

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19. Remove the positive crankcase ventilation line -1-  by releasing and disconnecting the rapid-action couplings -arrows-  . Replace O-rings during installation.
    Fig 13: Locating Positive Crankcase Ventilation Line

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20. Unscrew collar nut (M8) -1-  and remove terminal 30 line -2-  .
21. Unscrew collar nut (M6) -3-  and remove terminal 50 line -4-  .
    Fig 14: Identifying Electric Leads On Starter

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22. Remove engine wire harness. To do this, remove all remaining cable plugs, unscrew Torx screws (M6 x 12) -1-  of the ground straps -2-  and unscrew two Torx screws (M6 x 12) and (M8 x 20) for each of the plastic cable wiring harness guides.
    Fig 15: Identifying Ground Strap

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    Fig 16: Identifying Ground Strap

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23. Remove oil-water heat exchanger -1-  by unscrewing four Torx screws (M6 x 16) -2-  . Replace all O-rings during installation.
    Fig 17: Identifying Heat Exchanger

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24. Remove oil mist separator -3-  by unscrewing two Torx screws (M6 x 20) -1-  and loosening the spring band clamp -2-  . Pull oil mist separator -3-  from the cylinder head and pull off the hose. Replace O-ring during installation.
    Fig 18: Identifying Oil Mist Separator

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25. Unscrew three Torx screws (M6 x 20) -1-  on the bracket for the secondary air pump.
    Fig 19: Identifying Secondary Air Pump With Bracket

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26. Unscrew two Torx screws (M6 x 20) -1-  on the flange of the secondary air line -2-  . Remove secondary-air pump. Replace both metal seals during installation.
    Fig 20: Identifying Secondary Air Line

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27. Remove starter -2-  by unscrewing two Torx screws (M10 x 35) -1-  . → Removing starter .
    Fig 21: Identifying Starter And Screws

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28. Remove knock sensors -2-  by unscrewing one Torx screw (M8 x 35) on each -1-  . Mark the position of the electric connection for re-installation.
29. Unscrew oil level sensor using a ring wrench (a/f 19) -3-  . Replace copper sealing ring during installation.
30. Remove spacer sleeve -4-  .
    Fig 22: Identifying Knock Sensors

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31. Unscrew oil pressure sender using a ring wrench (a/f 24) -1-  . Replace aluminum sealing ring during installation.
    Fig 23: Identifying Oil Pressure Sender

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32. Remove connection piece for positive crankcase ventilation -2-  by unscrewing two Torx screws (M6 x 11) -1-  . Replace O-ring during installation.
    Fig 24: Identifying Connection Piece For Positive Crankcase Ventilation

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33. Remove both hall senders -2-  by unscrewing one Torx screw (M6 x 11) on each -1-  . Replace O-rings during installation.
    Fig 25: Identifying Hall Sender

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34. Remove deflection roller by unscrewing the Torx screw (M8 x 60). Check deflection roller for damage, wear and smooth operation.
35. Remove engine ground strap on cylinder 1-3 by unscrewing the Torx screw (M8 x 30).
36. Remove crankshaft belt pulley by countering the belt pulley with special tool retaining device 9593  and screwing out central screw (M16 x 60).
    Fig 26: Removing Crankshaft Belt Pulley

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37. Remove engine mounting by unscrewing the three hexagon-head bolts (M10 x 120) and the hexagon-head bolt (M10 x 80). Only loosen the left upper hexagon-head bolt (M10 x 120); the hexagon-head bolt can be unscrewed after the engine mounting has been removed.
38. Tiptronic only: Remove clip for belt routing by unscrewing two Torx screws (M6 x 12).
39. Remove coolant guide housing by unscrewing five external Torx screws (M6 x 35) and three internal Torx screws (M6 x 20). Replace O-rings during installation.
40. Remove ignition coils -1-  by unscrewing two Torx screws (M6 x 25) -2-  .
    Fig 27: Ignition Coil And Torx Screws

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41. Remove crankshaft pulse sender -1-  by unscrewing the Torx screw (M6 x 15) -2-  .
    Fig 28: Identifying Crankshaft Pulse Sender

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42. Remove coolant lines -1-  and -2-  by unscrewing two Torx screws (M6 x 16) -3-  .
    Fig 29: Identifying Coolant Lines

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43. Remove coolant pump by unscrewing six hexagon-head bolts (M6 x 25, M6 x 30) -arrows-  . Replace metal seal during installation.
    Fig 30: Locating Coolant Pump Bolts

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44. Remove thermostat housing. Unscrew four Torx screws (M6 x 20) and remove housing complete with thermostat. Replace seal during installation.
45. Remove tandem pump by unscrewing four Torx screws (micro-self-locking, M6 x 30) -arrows-  . During installation, note the position of the pump drive with respect to the groove on the camshaft sprocket. Both parts must be in line in installation position. Otherwise the pump drive must be rotated. Replace O-ring and screws during installation.
    Fig 31: Locating Tandem Pump Bolts

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    Fig 32: Locating Pump Drive

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46. Remove solenoid hydraulic valve for camshaft control → Removing hydraulic valve for camshaft timing .
47. Remove coolant adapter by unscrewing six Torx screws (M6 x 20) -arrows-  . Replace metal seal during installation.
    Fig 33: Locating Coolant Adapter Torx Screws

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48. Remove brackets for oxygen sensor cables by unscrewing five Torx screws (M6 x 12) -arrows-  .
    Fig 34: Locating Brackets Screws For Oxygen Sensors 1 And 3

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    Fig 35: Locating Brackets Screws For Oxygen Sensors 3 And 6

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49. Remove all remaining plastic accessories (clips, supports etc.).
50. Remove transport eyebolt -1-  by unscrewing two Torx screws (M6 x 16) -2-  .
51. Remove supports -3-  by unscrewing one Torx screw (M6 x 12) -4-  .
    Fig 36: Identifying Assembly Eye

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52. Remove spark plugs → Removing Spark Plugs .
53. Remove cylinder head cover 1 - 3 → Removing cylinder head cover .
54. Remove camshaft 1-3 → Removing camshafts .
    NOTE: Interchanged or dirty bucket tappets

    • Scoring on cylinder head

    → Since the bucket tappets have been run-in in the fitting bores, do not interchange them.

    → Absolute cleanliness is essential.

55. Remove bucket tappets 1-3 → Preliminary work for cylinder head 1-3 .
    Fig 37: Example Of Laying Aside Flat-Base Tappets

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56. Remove cylinder head 1-3. Loosen and unscrew 12 Torx screws M10 x 230 from outside to inside on each cylinder head. Lift cylinder head and seal from crankcase → Removing cylinder head .
57. Remove cylinder head cover 4-6 → Removing cylinder head cover .
58. Remove camshaft 4-6 → Removing camshafts .
    NOTE: Interchanged or dirty bucket tappets

    • Scoring on cylinder head

    → Since the bucket tappets have been run in in the fitting bores, do not interchange them.

    → Absolute cleanliness is essential.

59. Remove bucket tappets 4-6 → Preliminary work for cylinder head 4-6 .
60. Remove cylinder head 4-6. Loosen and unscrew 12 Torx screws (M10 x 230) from outside to inside on each cylinder head. Lift cylinder head and seal from crankcase → Removing cylinder head .
61. Remove oil pump with housing -1-  by unscrewing two hexagon-head bolts (M6 x 80) -2-  , two Torx screws (M6 x 20) -3-  and (M10 x 100) -4-  . Remove housing and ensure that the flange projection of the oil pump drive is not tilted. Replace both O-rings and both seals during installation.
    Fig 38: Identifying Oil Pump With Housing

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62. Remove all carbon deposits and other residues on all six pistons with a brass brush, which will make the engraved markings -arrow-  visible. In addition, number and mark the pistons in installation position before removal.
    Fig 39: Locating Installation Position Of Pistons

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63. Unscrew aluminum screw plug (M27) for the assembly bore (piston pin).
64. Remove lower M6 guide and tensioning rail screws (hexagon socket a/f 5), remove the guide and tensioning rails from the chain spaces.
65. Remove oil filter with special tool release key 9204  .
66. Unscrew 13 Torx screws (M6 x 20) on the oil pan cover. Tap cover gently on the sides using a plastic hammer, then carefully lift it at the leverage bar → Lifting the oil pan cover using a plastic-coated mounting lever and remove the oil pan.
    Fig 40: Lifting Oil Pan Cover

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67. Remove air/oil separator (swirl pots) and oil suction tube. To remove each separator, unscrew two Torx screws (M6 x 20) and pull out the separator. Unscrew two Torx screws (M6 x 20) on the oil suction tube and remove the oil suction tube. Replace O-rings during installation.
    Fig 41: Identifying Oil Pan Components

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68. Remove bearing cover for intermediate shaft → Removing bearing cover for intermediate shaft .