Rotary Resurrection - Tech Section
 
87-91 TURBO ENGINE TEARDOWN (S4 Pictured S5 Very Similar)

 

1)
 
Pictured 87-8 turbo engine as removed from car, with a/c and p/s removed.
 
2)
Remove intercooler, 4 12mm bolts, 2 hoses on back, 2 hoseclamps.
 
3)
Remove oil filler neck, by the 2 10mm bolts in the middle.
 
4)
 
Disconnect the TPS plug, intake air temp sensor plug (2 wire small plug on intake) and single wire knock sensor on intercooler support bracket.
 
5)
 
ON the front of the throttlebody, disconnect the oil metering pump rod, by removing the cotter pin and washer. Disconnect the 3 vacuum hoses from the upper intake, I find a long flatblade screwdriver and needlenose pliers helpful.
 
6)
 
Unplug the BAC valve connector, the coolant hose on the front of it, as well as the vacuum hose underneath leading to the intercooler pipe.
 
7)
 
On the back/top of the intake manifold, unplug both air valves (each has a white 2 wire plug).
 
5)
Disconnect or cut the 90 degree coolant hose under the throttlebody on the backside of the engine. Disconnect the vacuum hoses on the back side of the intake manifold.
 
5)
 
Loosen or remove the 12mm nut on the drivers side intercooler support bracket.
 
5)
 
Remove the 4 12mm nuts and 1 12mm bolt from the UIM on the passenger side, and bend up the tab on the metal vacuum rack.
 
5)
 
Slowly lift the upper intake manifold with throttlebody off the engine.
 
5)
 
Remove the 3 12mm bolts on the drivers side that hold on the intercooler support bracket, and remove it.
 
5)
 
Unplug the acv and green water thermosensor plugs, and lay the harness back out of the way.
 
5)
 
remove the 4 12mm bolts holding down both fuel rails.
 
5)
 
Unplug the temp sending unit on the drivers side of the engine, under the oil filter.
 
5)
 
Remove the 2 12mm bolts on the drivers side vacuum rack. Remove the 10mm bolt holding on the secondary metal vacuum rail on the passengers side. Disconnect the 4 oil metering injector vacuum hoses.
 
5)
 
Disconnect the oil purge valve hose from the block.
 
5)
 
bend up the clip on the wiring harness, on the drivers side by the oil tube.
 
5)
 
disconnect the vacuum hose on the turbo oil supply line.
 
5)



 
disconnect the remaining vacuum hoses to the lower intake manifold. Slowly lift off the vacuum rack, fuel injectors, wiring harness, and fuel rails from the engine. Don’t forget the black plastic spacer below the primary fuel rail.
 
5)
 
disconnect the metal vacuum line for turbo/twinscroll.
 
5)
 
remove turbo shield.
 
5)
 
remove acv valve, and turbo/intercooler extension hose. disconnect oil and water connections to the turbo. The upper metal oil feed line requires 2 17mm wrenches, hold the left in place while loosening the right. The upper water feed line is held in place by 2 10mm nuts.
 
5)
 
The water return line is just a rubber hose connecting to the water pump housing with a clamp, disconnect this. The turbo oil drain line is held in place by 2 12mm bolts, remove these.
 
5)


 
remove the 4 14mm bolts holding the turbo in place. One is hidden on under the turbine housing, and is accessible with a wrench only. Remove the turbo assembly, and then the inner turbo shield.
 
5)
 
Remove manifold shield, and exhaust manifold.
 
5)
 
remove 4 10mm bolts, and the 3 crank pully plates.
 
5)
 
disconnect and push back oil metering pump lines at the OMP.
 
5)
 
Remove the 12mm bolt on the alternator bracket at the water pump.There are now 2 12mm bolts and 4 12mm nuts holding the pump on. Remove the 4 nuts and washers.
 
5)
 
Slowly remove the water pump/housing/alternator.air pump assembly as a whole.
 
5)
 

don’t forget about the 2 thin spacers behind the WPH on s4 engines ONLY…

 
5)
 
remove turbo oil supply line.
 
5)
 
remove crank angle sensor.
 
5)
 
remove OMP and extension tube.
 
5)
 
remove sparkplug wire clip, knock sensor, and dipstick.
 
5)
 
carefully remove oil metering injectors and lines.
 
5)
 
remove oil filter pedestal, drivers side heater hose, oil pressure sending unit, and temperature sending unit probe.
 
5)
 
remove 4 12mm bolts and 2 12mm nuts, and remove the lower intake manifold. Remove flywheel.
 
5)
 
remove motor mounts.
 
5)
 
remove oilpan and oil pickup tube
 
5)
 
the engine is now ready to ship.
 
Rotary Resurrection - Tech Section
 
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