Audi Workshop Service and Repair Manuals

Notes:

• ◆ The engine is removed from underneath together with the gearbox.
• ◆ Collect drained coolant in a clean container for re use or disposal.

• ‒ Refer to coding on vehicles with encoded radio/radio navigation system (RNS); if necessary, interrogate.
• ‒ With the ignition switched off disconnect the battery earth strap.

• ‒ → Remove oil dipstick -1- from guide tube.
• ‒ Remove engine cover -arrows-.
• ‒ Reinsert dipstick in guide tube.

• ‒ Open the cover of the coolant expansion tank

• ‒ → If installed, remove the headlight range control bracket in top right of wheel housing -arrows-.

• ‒ → Remove air duct pipe from right longitudinal member -arrows-.

• ‒ → Remove noise insulation from centre, left and right sides -arrows-

• ‒ → Detach electrical connector from oil level sender -arrow-.
• ‒ Move wiring to the top.

• ‒ Place drip tray V.A.G 1306 below engine.

Vehicles with drain plug:

• ‒ → Turn drain plug -1- on radiator anti-clockwise, fit auxiliary hose to connection if necessary.

All models:

• ‒ Pull off retaining clip -2- for bottom coolant hose and detach coolant hose from radiator.

• ‒ → Also disconnect coolant hose on oil cooler -arrow-, and drain off remaining coolant.

Note:

Illustration shows an engine with code ASZ.

• ‒ → Remove air duct hose -1- from air duct pipe.
• ‒ Detach connector of air mass meter -3-.
• ‒ Unscrew bolts -4- and -5-.
• ‒ Remove vent hose -2- off air cleaner housing.
• ‒ Remove air cleaner housing.

• ‒ Remove the battery.
• ‒ → Remove battery carrier -arrows-.

Vehicles with manual gearbox:

Detach both gear selector cables from gearbox as follows:

• ‒ → Mark installation position of threaded rods -1- of both gear selector cables with a waterproof felt-tip pen.
• ‒ Pull the spring with the knurled piece in direction of arrow -2- towards spherical joint and then turn knurled piece clockwise to secure in engaged position -arrow 3-.
• ‒ Detach both gear selector cables.

• ‒ → Remove cable counterhold from gearbox and place to one side
  -arrows-

Vehicles with engine code ATD, AXR:

• ‒ Unclip the clutch slave cylinder hose at the cable support bracket.

• ‒ → Remove gearbox strut -arrows A- from gearbox.

• ‒ → Remove clutch slave cylinder -arrows- and secure with wire, do not open cable system.

Vehicles with engine code ASZ:

• ‒ → Clamp off pressure line to clutch slave cylinder using a hose clamp 3094.
• ‒ Pull retainer upwards -arrow- and disconnect pressure line from hose connector -1-.

Vehicles with engine code ASZ, ATD:

• ‒ → Detach coolant hose -1- from engine.

All models:

• ‒ Detach connectors from glow plugs (coolant) -Q7 -Item 2-.
• ‒ Disconnect vacuum line -3- from tandem pump.
• ‒ Unplug connector -4- at coolant temperature sender -G62.
• ‒ Disconnect coolant hose to radiator heat exchanger from coolant pipe (rear of engine).

• ‒ Detach the heat protection sleeve at the speedometer sender -G22.
• ‒ → Detach connector -arrow- from speedometer sender -G22 from gearbox, lay wiring aside.

• ‒ → Unscrew earth wire -1- from flange engine/gearbox.
• ‒ Disconnect leads -3- and -4- to the starter.
• ‒ Take connector -2- out of bracket.
• ‒ Detach wiring from starter bracket.
• ‒ Unplug connector for reversing light switch on gearbox.

Vehicles with engine code ASZ:

• ‒ → Detach power steering line from gearbox -arrows-.

All models:

• ‒ → Detach coolant hose between engine and radiator -arrows-.

• ‒ → Detach coolant hoses -arrows- from front of engine.

• ‒ → Remove coolant hose -2- and set aside.
• ‒ Separate fuel feed pipe -3- and fuel return pipe -1- and set aside.
• ‒ Lay aside wiring at air duct hose.
• ‒ Where necessary, detach the housing cover at rear of right headlamp.
• ‒ Remove air duct pipe -arrows-.

Note:

Mark the running direction with chalk or a felt-tipped pen before removing the ribbed belt. If the belt runs in the opposite direction when it is refitted, this can cause breakage.

• ‒ → To slacken ribbed belt, turn tensioner in direction of arrow.

• ‒ → Lock ribbed belt tensioner using mandrel T10060.
• ‒ Remove ribbed belt.

• ‒ → Detach connector -2-.
• ‒ Unscrew wire -1- from alternator.
• ‒ Unbolt wiring clamp.

• ‒ → Unscrew the bolts -arrows- and remove alternator.

Vehicles with air conditioner:

• ‒ → Detach electrical connector -1- for solenoid clutch on air conditioner compressor.

• ‒ Screw out bolts -arrow- for air conditioner compressor.
• ‒ Suspend air conditioner compressor together with connected coolant hoses from engine bonnet lock.

All models:

• ‒ Unplug connector console from glow plugs.
• ‒ → Detach the following connectors:

•     1 -    Oil pressure switch -F1
•     2 -    Hall sender -G40
•     3 -    Engine speed sender -G28
•     4 -    Fuel temperature sender -G81

• ‒ → Open the knurled nut -arrow- and unplug central connector.
• ‒ Lay wiring aside.

Vehicles with engine code AXR:

• ‒ → Detach connector -arrow- at intake manifold flap motor.

All models:

• ‒ → Disconnect vacuum hoses -1 ... 3- at rear of intake manifold.

Note:

Illustration shows an engine with code ASZ, ATD.

• ‒ → If installed, detach connector for heating resistor (crankcase venting) -N79 -Item 1-.
• ‒ Detach vacuum hose -2- to solenoid valves.

Note:

Illustration shows an engine with code ASZ, ATD.

• ‒ → Loosen bolts -arrows- of assembly mounting on engine by 2 turns.

• ‒ → Loosen bolts -arrows- of assembly mounting on gearbox by 2 turns.

Vehicles with engine code ATD, AXR:

• ‒ → Detach power steering line from gearbox -arrows-.

All models:

• ‒ Detach pulley from power steering vane pump.
• ‒ → Detach vane pump for power steering -arrows-. Do not open hydraulic connections.
• ‒ Suspend vane pump for power steering from lock carrier.

• ‒ → Unbolt heat shield for right drive shaft -arrows-.

• ‒ → Unbolt bracket for exhaust system from assembly mounting
  -arrows-.

Note:

The isolating element in front exhaust pipe must not be deflected more than 10 °to avoid damage.

• ‒ → Unscrew securing bolts -arrows- of front exhaust pipe/turbocharger.

• ‒ → Detach the exhaust system at the clamping sleeve -arrows-.
• ‒ Remove the front exhaust pipe.

• ‒ → First remove bolts-A- and then bolts -B- from pendulum support.
• ‒ Detach pendulum support.

• ‒ → Unbolt right connecting rod at wishbone -arrows-.
• ‒ Unscrew drive shaft on left and right from gearbox flange.
• ‒ Push engine forward and at the same time swivel right drive shaft towards front.

• ‒ → Pull release tabs -arrows- and remove air intake grille.
• ‒ Suspend right drive shaft at towing eye -1- using a wire loop.

Note:

Protect bumper from scratches by using an adhesive tape.

• ‒ Move left drive shaft towards rear and attach to anti-roll bar using a wire loop.

• ‒ → Attach engine mounting T10012 with securing nut and bolt tightened to approx. 20 Nm to cylinder block.
• ‒ Insert engine/gearbox lifter V.A.G 1383 A in engine mounting T10012 and lift slightly.

Note:

To unscrew bolts for assembly mounting use stepladder VAS 5085.

• ‒ → Loosen bolts -arrows- of assembly mounting on engine...

• ‒ → ...and from gearbox.

Notes:

• ◆ Check that all hoses and wiring connections between engine, gearbox and body have been detached.
• ◆ Carefully guide engine/gearbox assembly when lowering to avoid damages.
• ◆ Make especially sure that there is free movement to vacuum unit of turbocharger.

• ‒ Pull engine/gearbox assembly as far forward as possible, and lower gradually.