Audi Workshop Service and Repair Manuals

Removing engine

t	Drip tray for workshop hoist -VAS 6208- or -V.A.G 1306-

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

t	Stepladder -VAS 5085-

t	Engine bracket -T10012-

t  Locking pin -T10060 A- Procedure   Note t  The engine is removed from underneath together with the gearbox. t  The following description corresponds to the removal and installation on vehicles with electronic throttle and secondary air system. Some operations may not be required for earlier vehicles. t  All cable ties which are released or cut open when removing must be fitted in the same position when installing. t  Collect drained coolant in a clean container for re-use or disposal. –  Note (if necessary obtain) code on vehicles with coded radio / radio and navigation system (RNS). –  Disconnect earth wire at battery with ignition switched off. –  Turn front wheels to the right.   WARNING Hot steam or hot coolant can escape when expansion tank is opened; cover filler cap with cloth and open carefully. –  Open filler cap on coolant expansion tank

–  Take off engine cover panel -arrows-.

–  Remove cover in front of intake manifold -arrows-.

–  Disconnect air pipe at bottom of right-hand longitudinal member -arrows- (air pipe leads to charge air cooler).

–  Remove noise insulation panels (centre, left and right) -arrows-.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Turn drain plug -1- on radiator anti-clockwise and drain coolant (attach hose to connection if necessary). –  Pull out retaining clip -2- and remove coolant hose from radiator.

–  Disconnect bottom coolant hose from oil cooler -arrow-, and drain off remaining coolant.

–  Detach air intake hose -1- leading to secondary air pump at air cleaner housing. –  Release hose clip -2- and detach air duct from air mass meter -G70-. –  Unplug electrical connector at air mass meter -G70- -item 3-. –  Unscrew bolts -4- and -5- and remove air cleaner housing.

Vehicles with hoses routed according to version 1: –  Disconnect electrical connector -6- and hose -4- at charge pressure control solenoid valve -N75-. –  Detach charge pressure control solenoid valve -N75--item 5-, mechanical air recirculation valve -3- and pressure control valve of crankcase breather system -8- from air duct. –  Pull locking clip out at turbocharger connection and detach air duct -7-.   Note Seal off opening in turbocharger intake system with a clean cloth. –  Disconnect hose -2- between coolant expansion tank and engine at bulkhead. –  Disconnect hose -1- between charge pressure control solenoid valve -N75- and turbocharger at bulkhead.

Vehicles with hoses routed according to version 2: –  Disconnect electrical connector -5- and hose -3- at charge pressure control solenoid valve -N75-. –  Detach charge pressure control solenoid valve -N75--item 4-, mechanical air recirculation valve -1- and pressure control valve of crankcase breather system -2- from air duct. –  Pull locking clip out at turbocharger connection and remove air duct -6-.   Note Seal off opening in turbocharger intake system with a clean cloth.

All models: –  Detach coolant hoses going to to heat exchanger at bulkhead -arrows- by releasing retaining clips.

–  Open cover of main fuse box. –  Unclip protective cover -2- for electrical cables. –  Unscrew black wire -1- at fuse block. –  Remove battery.

Vehicles with battery tray (version 1): –  Remove battery tray -arrows-.

Vehicles with battery tray (version 2): –  Lift off side wall -1- together with main fuse box. –  Remove battery tray -arrows-.

All models: –  Unscrew earth wire -1- at engine/gearbox connection. –  Detach electrical wiring -3- and -4- at starter. –  Detach electrical connector -2- from bracket and unplug. –  Disengage wiring from bracket on starter and move it clear to the side.

Vehicles with manual gearbox: –  Unplug electrical connector -arrow- at reversing light switch -F4- on gearbox.

All models: –  Use screwdriver to pry off caps on wiper arms -arrows- and slacken off nuts several turns. –  Loosen wiper arms -1- from wiper shafts by tilting slightly. –  Remove nuts completely and take off wiper arms. –  Detach the washer hose and electrical connectors at windscreen washer jets. –  Lay aside plenum chamber cover (towards windscreen). Vehicles with protective housing for engine control unit: –  Remove protective housing for engine control unit → Rep. Gr.24.

All models: –  Release retaining tab (left-side) -arrow- and unplug connector from control unit.

–  Open cable duct (left-side) in engine compartment -arrows-. –  Unplug electrical connector in cable duct.

–  Take electrical connector out of bracket and unplug it -arrow-. –  Set aside wiring harness leading to engine control unit. –  Place engine control unit with wiring harness on top of engine. –  Secure the engine control unit to prevent it falling.

Vehicles with manual gearbox to 07.1998: –  Mark installation position of gear selector cable -B- on selector shaft lever. –  Remove damper weight -A- and gear selector cable -B- for selector shaft lever. –  Lift lug in direction of -arrow- and detach gate selector cable from relay lever -C-.

Vehicles with manual gearbox 08.1998 to 06.2001: –  Press locking sleeve in direction of -arrow 1- as far as stop and lock by turning anti-clockwise in direction of -arrow 2- to release cable end-piece for gate selector cable and gear selector cable. –  Disengage cables from cable end-piece.

Vehicles from 07.2001: –  Unclip retaining clip -1- from gear selector cable and retaining clip -2- from gate selector cable. –  Pull selector cable end-pieces with selector cables off selector shaft lever and relay lever.

All vehicles with manual gearbox: –  Unbolt cable support bracket from gearbox and unclip hose going to clutch slave cylinder -arrows-.

Vehicles with front-wheel drive: –  Detach gearbox strut -arrows A- from gearbox.

All models: –  Remove clutch slave cylinder -arrows- and use a piece of wire to secure in position (do not open pipes).   Caution Do not operate clutch pedal with slave cylinder removed.

Vehicles with automatic gearbox 01M: –  Pry selector lever cable -1- off selector shaft lever -4- using a screwdriver and detach retaining clip -3- from support bracket. –  Detach selector lever cable and move to one side.

–  Unplug electrical connectors: 1 -  To solenoid valves 2 -  To vehicle speed sender -G68- 3 -  At multi-function switch -F125- 4 -  At gearbox speed sender -G38- –  Disengage wiring harness from brackets and move clear.

–  Detach power steering line from gearbox -arrows-.

Vehicles with automatic gearbox 09A: –  Remove bracket -arrow-, if fitted. –  Move selector lever to position “P” and pry selector lever cable -1- off selector shaft lever -4- using a screwdriver.   Note Do not loosen bolt -2-. –  Unclip retaining clip -3- at support bracket. –  Detach selector lever cable and move to one side.

–  Unplug electrical connectors: 1 -  At multi-function switch -F125- 2 -  At gearbox wiring harness (turn locking lever)   Note Disregard -item 3-.

–  Unscrew earth cable -1- from bracket. –  Unbolt power steering line -arrows-. –  Unscrew bracket -3-. –  Detach rear power steering line from gearbox and tie up to side.

Vehicles with hoses routed according to version 1: –  Detach vacuum line -arrow- going to brake servo at intake manifold.

Vehicles with hoses routed according to version 2: –  Detach vacuum line -arrow- going to brake servo.

All models: –  Remove coolant hose -1- between engine and radiator.

–  Detach pipe for secondary air system from brackets on engine -arrows-.

–  Remove bolts -2- and -3- and detach bracket for dipstick guide tube -4-. –  Unplug connectors -1- for turbocharger air recirculation valve -N249- and secondary air inlet valve -N112- on underside of retainer for electrical change-over valves. –  Detach vacuum hose going to electrical change-over valves from intake manifold.

–  Unplug electrical connector -2- and move wiring clear. –  Detach coolant hose -1- going to engine.

Vehicles with electronic throttle up to model year 2000: –  Release catch -1- at turn signal housing with cross-head screwdriver -2- by turning 1/4 turn to left. –  Press down catch and slide turn signal housing to front -arrow- out of guide.

–  Reach through opening for turn signal and unplug connector at charge pressure sender -G31-. Vehicles from model year 2001 onwards: –  Remove washer fluid reservoir → Rep. Gr.94. –  Unplug electrical connector at charge pressure sender -G31-.

Vehicles with throttle cable: –  Disengage nipple -1- on end of throttle cable from cable cam. –  Pull grooved section of throttle cable sheath -4- out of rubber grommet -2- at support bracket -5-.   Note Disregard -item 3-.

All models: –  Detach vacuum line -1- leading to activated charcoal filter from throttle valve module -J338-. –  Detach air intake hose -2- from throttle valve module -J338-. –  Unbutton heat insulation sleeve and remove.

–  Detach hose -arrow- at non-return valve.

WARNING The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then dissipate pressure by carefully unfastening the connection. –  Disconnect fuel supply pipe -1- and fuel return pipe -2- by pressing release tabs. –  Move fuel supply pipe and fuel return pipe clear.

–  Detach coolant hoses (right-side) -arrows- at engine.   Note

Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage. –  Turn the tensioner in the direction of the -arrow- to slacken the poly V-belt. –  Remove poly V-belt.

–  Lock tensioner in position with locking pin -T10060 A-.

–  Loosen bolts -arrows- of assembly mounting for engine approx. 2 turns.

–  Loosen bolts -arrows- of assembly mounting for gearbox approx. 2 turns. –  Unscrew bolts for radiator cowl which are accessible from above.

–  Unbolt pulley for power steering pump. –  Unplug electrical connector -1- at power assisted steering pressure switch -F88-. –  Unbolt power steering pump -arrows-; hydraulic lines remain attached.

–  Detach power steering cooling pipe from gearbox -arrows-.

Vehicles with secondary air system: –  Unplug electrical connector at secondary air pump motor -V101-, detach hoses and remove nuts -arrows-. –  Remove secondary air pump. –  Move aside wiring harness leading to body.

All models: –  Detach electrical connectors -arrows- for radiator fan on bottom left of radiator cowl. –  Unscrew bolts on radiator cowl (accessible from below) and remove radiator cowl with both fans from below. –  Tie up power steering pump together with hydraulic line onto lock carrier on left side.

Vehicles with air conditioning: –  Unplug electrical connector -1- for magnetic clutch of air conditioner compressor.   WARNING The air conditioner refrigerant circuit must not be opened. –  Unscrew bolts -arrow- for air conditioner compressor. –  Tie up air conditioner compressor together with refrigerant hoses to bonnet lock (refrigerant hoses remain connected).

All models: –  Unbolt protective cover -2--arrows-. –  Unplug the electrical connectors and move wiring to lambda probes -1- and -3- clear.   Note

To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°. –  Unscrew nuts -arrows- securing front exhaust pipe to turbocharger.

–  Separate exhaust system at clamp -arrows-. –  Push clamp back and remove front exhaust pipe with catalytic converter.

Vehicles with front-wheel drive: –  Unbolt heat shield for drive shaft (right-side) from cylinder block -arrows-.

Vehicles with four-wheel drive: –  Mark position of propshaft at flexible coupling on bevel box. –  Unscrew propshaft with flexible coupling from bevel box -arrows- (counter-hold using a suitable lever at the triangular flange).

Caution Avoid damaging the seal -arrow- in the propshaft flange when removing. If a seal is damaged the propshaft must be renewed. –  Push propshaft horizontally as far back as possible.

All models:   Caution After unscrewing the bolts -A-, the engine/gearbox assembly swings slightly forward. –  First remove bolts -A-, then bolts -B- and remove pendulum support.

–  Unbolt right coupling rod from wishbone -arrow-. –  Unbolt drive shafts (left and right) from gearbox flange shafts.   Note Use adhesive tape to prevent bumper from being scratched. –  Push engine forward. At the same time swivel right drive shaft towards front and tie up with wire. –  Suspend right drive shaft at towing eye using wire. –  Move left drive shaft towards rear and attach to anti-roll bar using wire.   Note Take care not to damage the surface coating of the drive shafts.

Vehicles with secondary air system: –  Remove bracket for secondary air pump -arrows-.

All models: –  Attach engine bracket -T10012- with nut and bolt to cylinder block: approx. 20 Nm. –  Insert engine and gearbox jack -V.A.G 1383 A- in engine bracket -T10012- and raise engine/gearbox assembly slightly.

–  Remove bolts -arrows- of assembly mounting on engine.   Note To unscrew bolts for assembly mounting use stepladder -VAS 5085-.

–  Remove bolts -arrows- of assembly mounting on gearbox.   Note Check that all hoses, pipes and wiring connections between engine, gearbox and body have been detached. –  Pull engine/gearbox assembly as far forward as possible, and lower gradually using engine and gearbox jack -V.A.G 1383 A-.   Note t  Carefully guide engine/gearbox assembly when lowering to avoid damage. t  Make sure there is sufficient clearance for vacuum unit of charge pressure control system on turbocharger.