Removal and Installation of Engine
A description of engine removal for all engine types would go far beyond the scope of this manual. Only some essential points on this subject are given here.
The engine is removed upward without the transmission. For this you will need a hoist (chain hoist), which you can securely suspend at sufficient height. It is even better if you have an assistant who is already experienced.
Before beginning the actual engine removal, remove all parts of the vehicle that are in the way: the hood, the engine undershield, the air cleaner housing, the battery and, if necessary, the radiator.
Since a very large number of electrical wires and vacuum lines are installed on the Audi 80, you must first label all of them so that they can be reconnected to the correct locations during installation.
Before disconnecting the battery, make sure you have the numeric security code for the anti-theft coding of the radio.
Disconnect the battery only with the ignition switched off, otherwise the control modules may be damaged.
Before finally separating the engine from the transmission, support the transmission from below or slightly raise it together with the still-installed engine. In workshops, a special tool is used for this, which bears against the edge of the body mount.
The engine itself is equipped with lifting eyes, into which lifting tools can be fitted. Make sure the chains or cables are secured properly.
Tightening Torques
| Tightening torque, N·m | 4-cylinder | 5-cylinder | 6-cylinder |
| Transmission/engine guard | 10 | - | - |
| Exhaust pipe to exhaust manifold | 35 | 35 | 35 |
| Exhaust pipe to transmission bracket | 25 | 25 | 25 |
| Engine to transmission M8, M10, M12 | 20, 55, — | 20, 45, 65 | 25, 45, 65 |
| Engine bearing to engine mount bracket | 35 | 45 | 35 |
| Torque converter to flywheel | 35 | 35 | 35 |
| Engine torque support | 25 | 45 | - |
The illustrations show two important steps in engine removal (a 6-cylinder engine is shown). In the workshop, the engine is removed using such an engine lifting fixture. Only for this purpose does the engine have lifting eyes, into which chains or ropes can of course also be fitted. The illustration on the right shows the so-called support device (1), which here is integrated with the transmission holder (2). Its purpose is to support the transmission, which would otherwise sink down when the engine is removed. The same effect can be achieved by supporting the transmission from below.
Test yourself
A quick Audi 80 quiz: every answer comes with an explanation and a link to the manual page.