Audi Workshop Service and Repair Manuals

Removing engine   Note t  The engine is removed from underneath together with the gearbox. t  Renew all cable ties which are released or cut open when removing the engine. Refit in the same position when installing the engine. t  Collect drained coolant in a clean container for re-use or disposal.   WARNING t  The fuel system operates under high pressure. t  Do not open high-pressure section when removing engine. When removing the engine for repair procedures during which the high-pressure section must be opened (e.g. when removing the cylinder head), the fuel pressure in the high-pressure section of the injection system must be reduced to a residual pressure → Chapter. A clean cloth must then be wrapped around the connection and the residual pressure dissipated by carefully loosening the connection.

–  Unclip air intake hose from air duct -arrows-.

–  Unplug electrical connector at intake air temperature sender 2 -G299--item 2-. –  Detach vacuum hose -1- from actuator for intake air preheater.

–  Pull dipstick -1- out of guide tube. –  Remove the engine cover together with air cleaner housing -arrows-. –  Re-insert dipstick in guide tube.

–  Remove cover -1- over battery. To do so, press release tab -arrow-.

Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27. –  With ignition switched off, disconnect battery earth cable -arrow-.   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.

–  Remove both front wheels. –  Remove centre noise insulation -fasteners 1 ... 3-.

–  Remove noise insulation (left and right) -fasteners 1 ... 3-.

–  Unplug electrical connector -1- at radiator outlet coolant temperature sender -G83-. –  Place drip tray for workshop hoist -VAS 6208- under engine. Vehicles with drain plug: –  Turn drain plug -arrow- on radiator anti-clockwise, if necessary fit drain hose to connection. Vehicles without drain plug: –  Remove bottom coolant hose -2- from radiator by pulling off retaining clip. All models: –  Drain off coolant.

–  Detach coolant hose -arrow- at coolant expansion tank and guide downwards to drain off remaining coolant.

–  Detach coolant hose -1- at expansion tank. –  Disconnect vacuum hose -2- from activated charcoal filter and move hose clear.

–  Disconnect fuel supply pipe -3- by pulling release ring. Vehicles with engine code letters BAG: –  Disconnect fuel return pipe -2- by pulling release ring. All models:   Note Disregard -item 1-.

–  Detach rubber bellows -1- from air duct -2-. –  Release both retainers -arrows- and detach air duct.

–  Unbolt hot air collector plate -arrows-.

–  Unbolt front exhaust pipe from exhaust manifold -arrows-.

–  Remove battery → Rep. Gr.27. –  Remove battery tray -arrows-.

–  Detach top coolant hose from radiator -arrow-.

–  Detach coolant hoses -1- and -2- going to heat exchanger at bulkhead. –  Unclip coolant hose at bracket -arrow-.

–  Detach vacuum hose -2- at brake servo. –  Unplug electrical connector -1- at brake servo pressure sensor -G294-.

Vehicles with manual gearbox: –  Unclip securing clips -1- and -2- from both selector cables. –  Pull off selector cable end-pieces from gearbox selector lever and relay lever.

–  Remove cable support bracket from gearbox -arrows- and place to one side.

–  Detach slave cylinder -arrows- and place to one side. Do not open pipes.   Caution Do not press clutch pedal after removing slave cylinder.

Vehicles with automatic gearbox: –  Pry off selector lever cable -3- from lever for selector shaft using a 10 mm open-end spanner -Item 1-, or similar. –  Press together the retaining tabs on support bracket for selector lever cable -arrows- and pull selector lever cable out of support bracket on gearbox. –  Unplug electrical connector -4- and move electrical wire clear at bracket -2-.

All models: –  Lever off caps on windscreen wiper arms with a screwdriver. –  Loosen hexagon nuts -arrows- several turns. –  Loosen wiper arms from wiper shafts by tilting slightly, remove nuts and take off wiper arms.

–  Unclip washer jets -arrow-. –  Push washer jets through assembly opening back into plenum chamber, leaving hoses connected.

–  Pull off rubber seal -1- on plenum chamber cover. –  Detach plenum chamber cover -2-.

–  Detach engine wiring harness at rear of plenum chamber intermediate plate. –  Remove plenum chamber intermediate plate -arrows-.

–  Detach cover for engine control unit → Rep. Gr.24. –  Unplug engine wiring harness connector -1-.   Note The electrical connector -2- remains connected.

–  Release wiring protector for engine wiring harness -arrow- and lift off.

–  Open wiring duct brackets -arrows-.

–  Move electrical connector -1- clear and disconnect. –  Open wiring duct bracket located below -2--arrow-. –  Remove engine control unit wiring harness from wiring duct.

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

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

Vehicles with manual gearbox: –  Disconnect earth cable -1-.   Note On some versions the earth wire may be attached to the engine mounting. –  Detach wires -2- and -3- at starter and move wires clear.

–  Unplug electrical connector -2- for Lambda probe -G39-. –  Unplug electrical connector -1- for exhaust gas temperature sender 1 -G235- (if fitted). –  Unplug electrical connector -4- for reversing light switch -F4-. –  Move engine wiring harness at bracket -3- clear. –  Unscrew nut -arrow- and remove bracket with wiring from stud.

Vehicles with automatic gearbox: –  Disconnect earth cable -3-. –  Detach wires -1- and -2- at starter and move clear.

–  Unplug electrical connector -2- for Lambda probe -G39-. –  Unplug electrical connector -1- for exhaust gas temperature sender 1 -G235- (if fitted).

–  Detach electrical connector -1-. –  Detach vacuum hose -2-. –  Unscrew bolts -arrows- and remove vacuum pump for brake servo.

–  Unplug electrical connectors -1- and -3- at automatic gearbox. –  Unplug electrical connector -2- and move electrical wire clear.

All models:   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. –  Lock the belt tensioner with a 4 mm angled Allen key -Item 1-. –  Remove poly V-belt.   WARNING The air conditioner refrigerant circuit must not be opened.

–  Unplug electrical connector -1- for magnetic clutch of air conditioner compressor. –  Remove bolts -arrows- for air conditioner compressor.   Note To prevent damage to the air conditioner compressor and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent. –  Tie air conditioner compressor up to lock carrier.

–  Detach electrical connector -2-. –  Unscrew wire -1- at alternator. –  Unbolt wire clamp -3- at alternator and move wiring harness clear.

–  Unscrew bolts -arrows- and remove alternator.   Note t  If alternator sticks in its bracket, screw bolt back in again down to the last 2 turns. t  Tap carefully on bolt heads with flat side of hammer to release bushes of alternator mountings.

–  Unplug electrical connector -1- at oil level and oil temperature sender -G266-. –  Unclip bracket -2- for wire to oil level and oil temperature sender -G266- at subframe.

–  Unscrew bolts -1 ... 3- and remove pendulum support.

–  Remove nuts -2- and -3- at exhaust pipe flange. –  Separate exhaust system at flange. –  Remove bolts -1- and -5-. –  Pull off bracket -4- for exhaust system from pins on front exhaust pipe.   Note

To avoid damage, the flexible joints in the front exhaust pipe must not be bent more than 30°. Vehicles with engine code letters BAG: –  Unscrew bolts -arrows-. –  Swing front exhaust pipe forwards and remove.   Note Disregard -item 1-.

Vehicles with engine code letters BLF, BLP: –  Unscrew bolts -arrows- and remove bracket for front exhaust pipe. –  Swing front exhaust pipe forwards and remove.   Note Disregard -item 1-.

All models: –  Unscrew nuts -arrow- on both sides of vehicle and detach coupling rods from anti-roll bar.

–  Unscrew nuts -arrows- at swivel joint (left-side). –  If fitted, loosen nut at bracket for front left vehicle level sender -G78-. –  Detach swivel joint from transverse link. Vehicles with manual gearbox: –  Unbolt drive shafts (left and right) from gearbox flanges.

Vehicles with automatic gearbox: –  Swing suspension strut outwards and at the same time press drive shaft out of wheel bearing unit using wedge -T10161- (tapping lightly if necessary).

All models: –  Pivot drive shaft forwards; to do so, push the engine/gearbox assembly forwards. –  Secure the drive shaft to longitudinal member -arrow-. –  Repeat procedure on opposite side of vehicle.

–  Fit engine support -T40075- onto engine and gearbox jack -V.A.G 1383 A-. –  Secure engine support -T40075- to rear of cylinder block and tighten to approx. 20 Nm -arrows-. –  Lift engine/gearbox assembly slightly.   Note

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

–  Loosen bolts -arrows- of assembly mounting on gearbox.   Note t  Check that all hoses, pipes and wiring connections between engine, gearbox and body have been detached. t  Carefully guide engine/gearbox assembly when lowering to avoid damage. –  Pull engine/gearbox assembly as far forward as possible, and lower gradually.