Audi Workshop Service and Repair Manuals

Note:

Check whether a coded radio is installed as during the forthcoming work sequences the battery earth strap must be disconnected. Obtain radio code first if necessary.

• ‒ The engine is removed upwards together with the gearbox.
• ‒ With ignition switched off disconnect battery earth strap.
• ‒ All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
• ‒ Remove air cleaner housing:

=> Repair group 24; Servicing injection system; Removing and installing air cleaner

• ‒ → Remove battery and battery retainer.

• ‒ → Now separate fuel supply pipe 1 (press release button).
• ‒ Pull hose off solenoid valve 1 (N80) at intake manifold.
• ‒ Seal the pipes so that the fuel system is not contaminated by dirt etc.
• ‒ Observe rules for cleanliness .

• ‒ Loosen or separate the following components:
• ‒ The vacuum hose from inlet manifold to brake servo
• ‒ The connector from engine speed sender and from intake manifold pressure sender or intake air temperature sender
• ‒ The connector from ignition transformer, from Hall sender and throttle valve control part
• ‒ The connector from coolant temperature sender and from oil pressure switch
• ‒ Injector connectors
• ‒ Lambda probe connector
• ‒ The 2-pin connector from knock sensor (rear of cylinder block)
• ‒ Disconnect all electric wires from gearbox, alternator and starter and move clear.
• ‒ Pull off/disconnect all other electrical connections as necessary from engine and lay to one side.

• ‒ Pull vacuum and breather hoses off engine.
• ‒ Remove noise insulation tray:

=> General body repairs, exterior; Repair group 50; Front body; Noise insulation - Assembly overview

Vehicles with drive unit protection plate

• ‒ Remove drive unit protection plate

=> General body repairs, exterior; Repair group 50; Front body; Noise insulation - Assembly overview

Continuation for all vehicles

• ‒ Disconnect selector mechanism from gearbox.

=> 5-Speed manual gearbox 02T; Repair group 34; Servicing selector mechanism

• ‒ Remove hydraulic clutch slave cylinder:

=> 5-Speed manual gearbox 02T; Repair group 30; Servicing clutch mechanism

Note:

Clutch pedal must not be depressed.

• ‒ Loosen belt pulley securing bolts from power steering vane pump.
• ‒ Remove ribbed belt => Page 13-9.
• ‒ Remove securing clamps for power steering pressure pipe.
• ‒ Unbolt power steering vane pump and secure to sub-frame with wire; hoses remain connected:

=> Running gear, axles, steering; Repair group 48; Assembly overview: vane pump, reservoir, hydraulic pipes; Removing and installing power steering vane pump.

• ‒ Open and close the expansion tank sealing cap to release pressure in cooling system.
• ‒ Drain coolant.
• ‒ Pull off coolant hose at engine with assembly tool for spring-type clamps VAS 5024.

Vehicles with air conditioner

• ‒ Removing air conditioner compressor:

=> Heating, Air conditioning; Repair group 87; removing and installing compressor bracket

• ‒ Observe additional notes and assembly work
  

Continuation for all vehicles

• ‒ → Disconnect pendulum support -arrows-.
• ‒ Separate front exhaust pipe from exhaust manifold => Page 26-2, exhaust manifold, front exhaust pipe and catalytic converter with attachments.
• ‒ Remove left and right-hand drive shaft on gearbox and tie up:

=> Running gear, axles, steering; Repair group 40; Removing and installing drive shaft

• ‒ → Attach lifting tackle 2024 A as follows and lift slightly with workshop crane:

    Pulley end:
    3rd hole in hook at position 1

    Flywheel end:
    3rd hole in hook at position 5

Notes:

• ◆ The positions marked 1...4 on the bar must be towards the pulley end.
• ◆ The holes in the hook rails are counted up from the hook.

• ‒ → Unbolt engine side of assembly mounting from engine bracket -arrows-.

• ‒ → Unbolt gearbox side of assembly mounting from gearbox bracket -arrows-.

Turn assembly slightly to left (engine forwards, gearbox rearwards) and lift out engine carefully.

Note:

When the assembly is lifted off, it must be carefully guided to prevent damage to the bodywork.