Audi Workshop Service and Repair Manuals

Removing engine   Caution When installing a new base engine, it is essential that the clamping pieces for the injectors are tightened to the specified torque → Rep. gr.23 after installing the high-pressure pipes. The clamping pieces are only secured hand-tight at the factory so the injectors can be aligned during installation. If these instructions are not observed, the engine could be damaged.

Special tools and workshop equipment required

t	Removal lever -80 - 200-

t	Engine and gearbox jack -V.A.G 1383 A-

t	Stepladder -VAS 5085-

t	Engine bung set -VAS 6122-

t	Drip tray for workshop hoist -VAS 6208-

t	Hose clip pliers -VAS 6362-

t  Engine bracket -T10012- t  Safety goggles t  Protective gloves Procedure   Note t  The engine is removed from underneath together with the gearbox. t  Fit cable ties in the original positions when installing.

WARNING Hot steam/hot coolant can escape - risk of scalding. t  The cooling system is under pressure when the engine is hot. t  To allow pressure to dissipate, cover filler cap on coolant expansion tank with cloth and open carefully. –  Open filler cap -1- on coolant expansion tank. –  Release hose clip -2- and detach coolant hose.

–  Remove engine cover panel -arrows-.

–  Disconnect earth wire -2- from battery terminal → Electrical system; Rep. gr.27.

–  Release fasteners -arrows- and detach air pipe -1-.

–  Unplug electrical connector -2-. –  Remove bolt -1-. –  Move clear vacuum hoses -arrows- and lay turbocharger air recirculation valve -N249- on top of engine.

–  Unplug electrical connector -3- from air mass meter -G70-. –  Release hose clip -2- and detach air hose. –  Version for countries with cold climates: Release hose clip -1- and detach air hose. –  Unscrew bolt -4- and detach air cleaner housing.

–  Remove noise insulation -1- → Rep. gr.66. –  Remove front left and front right wheel housing liner → Rep. gr.66.

–  Release hose clips -1- and -2- and remove air hose (bottom left). –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Release hose clips -1- and -2- and remove air hose (bottom right). –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Remove bolts -arrows-. –  Loosen hose clip -2-. –  Unplug electrical connector -1- on charge pressure sender -G31-/intake air temperature sender -G42- and move clear electrical wiring. –  Detach air pipe (right-side).   Note

Collect drained coolant in a clean container for re-use or disposal. –  Place drip tray for workshop hoist -VAS 6208- beneath engine. –  Release hose clip -arrow-, disconnect coolant hose from bottom of radiator and drain off coolant.

–  Release hose clip -arrow-, disconnect coolant hose from coolant pipes (right-side) and drain off coolant.

–  Release hose clip -arrow-, disconnect coolant hose at oil filter housing and drain off remaining coolant.

–  Unplug electrical connector -1- for radiator fan. –  Press locking tabs (left and right) for radiator cowl -arrow- simultaneously. –  Lift radiator cowl off radiator and detach it downwards.

–  Version for countries with cold climates: Unplug electrical connector -2-. –  Disconnect vacuum hose -arrow-. –  Press release tabs and disconnect crankcase breather hose -1- from cylinder head cover. –  Remove bolt -3-, swivel air pipe with connection to rear and detach from turbocharger.   Note Disregard -item 4-.

–  Place drip tray for workshop hoist -VAS 6208- under connection. –  Lift retaining clips -1 and 2- and disconnect coolant hoses from heat exchanger for heater. –  Guide coolant hoses downwards and drain off coolant.

–  Detach vacuum hose from brake servo -arrow-.

–  Slacken bolt -2- and remove clamp. –  Remove bolt -1-.

–  Take electrical connector -1- for exhaust gas temperature sender 1 -G235- out of bracket and unplug. –  Move clear electrical wiring at engine: 2 -  For exhaust gas temperature sender 3 -G495- 3 -  For exhaust gas temperature sender 4 -G648- 4 -  For Lambda probe -G39-

WARNING The fuel can become extremely hot. This can cause injuries. t  In extreme cases the temperature of the fuel lines and the fuel can be up to 100 °C after the engine is switched off. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles. –  Press release tabs at connector -1-, release hose clip -2- and detach fuel hoses. –  Release hose clip -3- and detach coolant hose. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Remove nut -1- and move earth wire clear. –  Loosen bolts -arrows- for support arm of engine mounting approx. 2 turns.

–  Release hose clips -1 and 2- and detach coolant hoses (top left) from radiator.

–  Unplug electrical connector -2- at throttle valve module -J338--arrow-.   Note Disregard -items 1, 3, 4-.

Vehicles with manual gearbox: –  Unplug electrical connector -1- at starter. –  Open covers -3-. –  Remove nuts -2 and 4- and move electrical wiring clear -arrow-.

–  Detach securing clip -2-. –  Detach gear selector cable -1- from gearbox selector lever -3-.

l  To prevent damage to gate selector cable, cable end-piece must be detached from gate selector cable before removing. –  Pull locking device forwards onto stop -arrow 1- and lock by turning anti-clockwise -arrow 2-. –  Press relay lever towards front -arrow 3-.

–  Remove bolts -arrows-, detach cable support bracket -1- and place to one side with selector cables attached.

–  Remove bolts -arrows-, detach clutch slave cylinder -1- and place to one side; do not open pipes.   Caution Risk of serious damage to clutch slave cylinder. Do not operate clutch pedal with slave cylinder removed.

–  Unplug electrical connector -1-.   Note Disregard -arrows-.

–  Vehicles with start/stop system: unplug electrical connector -3- for gearbox neutral position sender -G701-. –  Unplug electrical connector -2- at reversing light switch -F4-. –  Unscrew nut -1- and detach bracket for electrical wiring.

Vehicles with 7-speed dual clutch gearbox 0AM: –  Use removal lever -80 - 200- to prise selector lever cable -2- off gearbox selector lever. –  Pull off securing clip -1-, detach selector lever cable and move clear to one side.   Note Take care not to bend or kink selector lever cable.

–  Unplug electrical connector -1- at starter. –  Open covers -3-. –  Unscrew nut -2- and move clear electrical wiring going to starter. –  Move clear electrical wiring -arrow-.   Note Disregard -item 4-.

–  Detach electrical connectors -1 and 3- from bracket and unplug.   Caution Risk of serious damage to gearbox components. Do NOT touch the connector contacts in the gearbox connector with your hands as static discharge might damage the control unit and the mechatronic unit irreparably. –  Touch vehicle earth with bare hands to eliminate any static charge. –  Unplug electrical connector -2- for mechatronic unit for dual clutch gearbox -J743-.

All vehicles (continued): –  Unscrew nuts -1- and bolt -3-, and push electronics box -2- to the side.

–  Remove engine control unit → Rep. gr.23.

–  Unplug electrical connector -arrow-.

–  Move engine wiring harness clear -arrows- and lay on top of engine.

Vehicles with air conditioner compressor and tensioner:   Caution If a used belt runs in the opposite direction when it is refitted, this can cause breakage. Before removing, mark direction of rotation of poly V-belt with chalk or felt-tip pen for re-installation. –  To slacken poly V-belt turn tensioner in clockwise direction -arrow-. –  Lock tensioner with locking pin -T10060 A-. –  Take off poly V-belt.

Vehicles with air conditioner compressor and tensioning roller:   Caution If a used belt runs in the opposite direction when it is refitted, this can cause breakage. Before removing, mark direction of rotation of poly V-belt with chalk or felt-tip pen for re-installation. –  Remove bolt -arrow- and detach tensioner to slacken poly V-belt. –  Take off poly V-belt.

All vehicles with air conditioner compressor (continued): –  Unplug electrical connector -2- on air conditioner compressor regulating valve -N280-.   Caution Make sure that air conditioner compressor and refrigerant pipes and hoses are not damaged. Do NOT stretch, kink or bend refrigerant lines and hoses. –  Remove bolts -arrows-, detach air conditioner compressor -1- with pipe/hose assemblies connected and tie up to front.

–  Remove alternator → Electrical system; Rep. gr.27.

All vehicles (continued): –  Remove bolts -arrows- and detach heat shield for drive shaft (right-side). –  Unbolt drive shaft (left and right) from gearbox flange shaft. –  Tie up drive shaft (left-side).   Note Take care not to damage the surface coating of the drive shaft.

WARNING Risk of accident. Do NOT loosen bolted connection -1-. –  Remove bolts -arrows- and detach pendulum support.

–  Unscrew nuts -arrows- for swivel joint (right-side). –  Detach swivel joint (right-side) from wishbone.

–  Pivot drive shaft (right-side) forwards; to do so, push engine/gearbox assembly slightly forwards. –  Tie up drive shaft to longitudinal member -arrow-.   Note Take care not to damage the surface coating of the drive shaft.

–  Remove bolts -1- and nuts -2- and detach bracket for particulate filter. –  Tie up particulate filter.

–  Unscrew bolt -1- and press pump for exhaust gas recirculation cooler -V400- to the side.   Note Disregard items marked -2, 3- and -arrows-.

–  Unplug electrical connector -arrow- at oil level and oil temperature sender -G266-.

–  Release fasteners -arrows- and remove noise insulation -1- for sump.

–  Secure engine bracket -T10012- to cylinder block with bolt -1- and nut -2- (tightening torque: approx. 20 Nm). –  Insert engine and gearbox jack -V.A.G 1383 A- in engine support -T10012- and raise engine/gearbox assembly slightly.   Note To unscrew bolts for assembly mounting use stepladder -VAS 5085-.

–  Remove bolts -arrows- for support arm of engine mounting.

–  Remove bolts -arrows- securing gearbox mounting -1-.   Caution Danger of damage to hydraulic lines, vacuum lines or electrical wiring and to engine compartment. t  Check that all hydraulic lines, vacuum lines and electrical wiring between engine, gearbox, subframe and body have been detached. t  Carefully guide engine/gearbox assembly out of engine compartment when lowering. –  First lower engine/gearbox assembly only slightly. –  Then swing gearbox end of engine/gearbox assembly forwards and only then lower further.