Disassembly

Tools

Preliminary work for disassembling engine

1. Remove engine.
2. Remove transmission.
3. Remove exhaust manifold.

Tiptronic transmission:
4. Remove drive plate for converter.

Manual transmission:
5. Remove clutch.
6. Remove flywheel.

Component overview - engine

Note: The overview graphics are shown schematically and may be different to how the components actually look.

Intake system, belt drive

Engine lubrication, engine cooling

Cylinder head, crankcase

Crank drive, pistons

Disassembling engine down to crankcase

ATTENTION
Risk of damage due to particles of dirt.
^ Oil bores/oil ducts can become blocked up.
^ When working on the engine, absolute cleanliness is essential.
^ Lay removed engine parts on a clean base and cover them without fail.
^ Use the cover for dust protection when fitting the engine NR.165 on the engine assembly support.

WARNING
Coolant is corrosive and hazardous to health.
^ Skin and eye irritation
^ Wear protective gloves and goggles.
^ If you come into contact with coolant, wash off immediately with plenty of warm water.

WARNING
Pentosin is hazardous to health
^ Danger of material damage and injury
^ Wear protective gloves and goggles.
^ If the eyes or skin come into contact with the fluid, 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.

WARNING
Danger due to oil draining out and spraying when the engine is hot!
^ Danger of scalding and injury
^ Allow the engine to cool
^ Wear specified protective gear.

Note:
^ The central screws of the camshaft adjustment elements must be undone before removing the cylinder head cover.

Note:
^ 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.

2. Drain engine oil. Unscrew the oil drain plug (hexagon socket a/f 8).

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-.
4. Disconnect cable plug -2- of solenoid valves -3-.
5. Disconnect cable plug -4- of engine-temperature sensor -5-.

6. Disconnect cable plug -1- of all fuel injector valves.

7. Disconnect cable plug -Arrow- for carbon canister solenoid valve.

8. Loosen support for servo lines -2- by unclipping the oxygen sensor line from the support -3- and unscrewing two Torx screws (M6 x 12) -1-.
9. Unscrew six fastening screws (M6 x 35) for each intake-air distributor.
10. Completely remove the intake bridge. Replace gaskets during installation.

11. Remove drive belt cover by unscrewing three Torx screws (M6 x 12) -Arrows-.
12. Disconnect cable plug -1- on generator.

13. Unscrew collar nut (M8) -2- and remove ground B+ line -3-.

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.

15. Remove oil filler neck -2- by unscrewing two Torx screws (M6 x 11) -1-. Replace O-ring and screws during installation.
16. Unscrew union nut of servo 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-.

18. Remove power-steering pump support -2- by unscrewing four Torx screws (M8 x 35) -1-. The power-steering pump support -2- is also fixed with roll pins; if necessary use a rubber hammer for the removal.

19. Remove the positive crankcase ventilation line -1- by releasing and disconnecting the rapid-action couplings -Arrows-. Replace O-rings during installation.
20. Unscrew collar nut (M8) -1- and remove terminal 30 line -2-.

21. Unscrew collar nut (M6) -3- and remove terminal 50 line -4-.

22. Remove engine wire harness; to do this, remove all remaining cable plugs, unscrew Torx screws (M6 x12) -1- of the ground straps -2- and unscrew two Torx screws (M6 x 12) and (M8 x 20) for each of the plastic cable wire harness guides.

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

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.

25. Unscrew three Torx screws (M6 x 20) -1- on the bracket for the secondary air pump.

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

27. Remove starter -2- by unscrewing two Torx screws (M10 x 35).
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 with a ring wrench (a/f 19) -3-. Replace copper sealing ring during installation.

30. Remove spacer sleeve -4-.

31. Unscrew oil pressure sender with a ring wrench (a/f 24) -1-. Replace aluminum sealing ring during installation.

32. Remove connection piece for positive crankcase ventilation -2- by unscrewing two Torx screws (M6 x 11) -1-. Replace O-ring during installation.

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

41. Remove crankshaft pulse sender -1- by unscrewing the Torx screw (M6 x 15) -2-.

42. Remove coolant lines -1- and -2- by unscrewing two Torx screws (M6 x 16) -3-.

43. Remove coolant pump by unscrewing six hexagon-head bolts (M6 x 25, M6 x 30) -Arrows-. Replace metal seal during installation.
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.
46. Remove solenoid hydraulic valve for camshaft adjustment.

47. Remove coolant adapter by unscrewing six Torx screws (M6 x 20) -Arrows-. Replace metal seal during installation.

48. Remove brackets for oxygen sensor cables by unscrewing five Torx screws (M6 x 12) -Arrows-.
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-.
52. Remove spark plugs.
53. Remove cylinder head cover.
54. Remove camshaft.

ATTENTION
Interchanged or dirty flat-base tappets.
^ Damage to engine components
^ The components have been run in in the fitting bores in the housing, therefore do not interchange them.
^ Pay attention to cleanliness.

55. Remove flat-base tappet.
56. Remove cylinder head.
57. Remove cylinder head cover.
58. Remove camshaft.

ATTENTION
Interchanged or dirty flat-base tappets.
^ Damage to engine components
^ The components have been run in in the fitting bores in the housing, therefore do not interchange them.
^ Pay attention to cleanliness.

59. Remove flat-base tappet.
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.

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 the two O-rings during installation.

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.
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.

67. Remove air/oil separator (swirl pots) and oil suction pipe. To remove each separator, unscrew two M6 x 20 Torx screws and pull out the separator. Unscrew two M6 x 20 Torx screws on the oil suction pipe and remove the oil suction pipe. Replace O-rings during installation.
68. Remove bearing cover for intermediate shaft.