Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

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  Extension -2024 A /1-

t  Assembly tool -T10118- Procedure   Note t  The engine is removed from underneath together with the gearbox. t  Collect drained coolant in a clean container for re-use or disposal.

–  Lift off engine cover panel (outside -1- and inside -2-) by pulling up evenly.

–  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-.

–  Remove air intake hose (left-side) by lifting retaining clips -arrows- slightly.

Vehicles with manual gearbox: –  Unplug electrical connector -2- for reversing light switch -F4-. All vehicles (continued): –  Unscrew nut -1- and remove bracket with wiring from stud. –  Unclip bracket from wiring.

–  Unplug electrical connector -arrow- for magnetic clutch of air conditioner compressor.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Lift retaining clip -arrow- and disconnect coolant hose from radiator.

–  Remove bolt -arrow- for air intake pipe (left-side).

–  Pull cover off air duct (release clips on sides) -arrows-.

–  Release clips on left and right -arrow A- and unclip air duct at bottom -2-. –  Swivel air duct (bottom) slightly to the rear and detach air duct (bottom) from retainers -3-. –  Detach air pipe -1- from air duct (bottom) -arrow B-.

–  Unplug electrical connector -1- at air mass meter -G70-. –  Detach vent hose -3- and air hose -2-. –  Unscrew bolt -4- and remove air cleaner housing.

–  Unscrew air duct at lock carrier -arrows-.

–  Disconnect coolant hose at bottom of engine oil cooler -arrow- and drain off remaining coolant.

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

–  Lift retaining clip -arrow- and disconnect coolant hose (top left) from radiator.

–  Detach crankcase breather hose -2-. –  Move vent hose -4- and vacuum hoses -1- clear at air intake hose. –  Remove bolt -3-. –  Swing air hose to rear and detach from turbocharger.

WARNING t  In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with unit injector engine. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles. –  Disconnect fuel supply hose -2- and fuel return hose -1- from fuel lines. –  Detach coolant hose -3-. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Remove bolt -1-. –  Remove air pipe (right-side) by lifting retaining clips -arrows- slightly.

Vehicles with air conditioning:   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. –  To slacken poly V-belt turn tensioner in clockwise direction -arrow-. –  Remove poly V-belt. –  Slacken tensioner.

All vehicles (continued): –  Unplug electrical connector -2-. –  Unscrew wire -1- at alternator. –  Unscrew wire clamp on alternator.

–  Disconnect coolant hoses -arrows-. –  Move coolant hoses clear.

–  Unscrew top bolts -upper arrows- for radiator cowl.   Note The bolts -bottom arrows- are removed at a later stage.

Vehicles with dual clutch gearbox: –  Unscrew bolts -1- for cable support bracket -D-. –  Pull off the retaining clip -A- upwards -arrow- and detach selector lever cable from gearbox.   Note Disregard items -B- and -C-.

Vehicles with manual gearbox: –  Detach securing clip -3- for gear selector cable from gearbox selector lever -1- and pull cable off pin -arrow-. Metal gate relay lever: –  Detach securing clip -4- for gate selector cable from gate relay lever -2- and pull cable off pin -arrow-.

Plastic gate relay lever: 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 gate relay lever towards front -arrow 3-.

Vehicles with manual gearbox (continued): –  Remove cable support bracket -arrows- from manual gearbox and place to one side (selector cables remain fitted).

–  Vehicles with plastic pipe between clutch master cylinder and slave cylinder: clamp off supply hose at brake fluid reservoir using hose clamp -3094-.

–  Vehicles with pipe/hose assembly between clutch master cylinder and slave cylinder: clamp off hose -A- at pipe/hose assembly using hose clamp -3094-.   Note Disregard -arrow-.   Note

Make sure brake fluid does not come into contact with starter or gearbox when performing the following operations. If it does, clean affected area thoroughly. –  Pull out clip -arrow- as far as stop. –  Pull plastic pipe or pipe/hose assembly -A- out of bleeder connection for clutch slave cylinder.   Note Disregard -item B-. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.   Caution Do not operate clutch pedal with slave cylinder removed.

All vehicles (continued): –  Unclip wiring clip -1-. –  Remove bolts -2- and -3-. –  Detach air pipe (left-side) from turbocharger by lifting retaining clip -4- slightly. –  Remove air pipe from engine compartment downwards.

–  Disconnect vacuum hose -arrow- at brake servo.

–  Unplug electrical connectors: 1 -  Charge pressure control solenoid valve -N75- 2 -  Exhaust gas temperature sender 1 -G235- (black) 4 -  Lambda probe -G39-   Note Disregard -item 3-. –  Unscrew bolts and place charge pressure control solenoid valve -N75- on engine (hoses remain connected).

–  Detach coolant hoses going to heat exchanger at plenum chamber partition panel -arrows-.

–  Unplug electrical connector -arrow- at radiator outlet coolant temperature sender -G83-.

–  Remove electrical connector -arrow- for Hall sender -G40- from bracket and unplug.

–  Unplug electrical connector -arrow- at oil pressure switch -F1-. –  Unscrew oil pressure switch.

–  Unplug electrical connector -arrow- at engine speed sender -G28- using assembly tool -T10118-. –  Move wiring harness clear.

–  Unplug electrical connector -arrow- at coolant temperature sender -G62-.

–  Detach connector rail from glow plugs -arrows-.

–  Unplug electrical connector -arrow- at fuel temperature sender -G81- and move wiring clear.

–  Pull the release pin -arrow 1- and unscrew knurled nut -arrow 2-. –  Disconnect main connector for unit injectors and move wiring harness clear.

Vehicles with manual gearbox: –  Disconnect earth cable -1-. –  Detach electrical wires -2- and -3- at starter.

Vehicles with dual clutch gearbox: –  Remove cable tie for protective cover. –  Unplug electrical connector -3-. –  Push back protective cover and unscrew B+ cable -2- at solenoid switch. –  Unplug electrical connector -5-. –  Disconnect earth cable -4-.   Note Disregard -item 1-. All vehicles (continued): –  Set aside wiring harness leading to body.

–  Detach electrical connector -1- at intake manifold flap motor -V157-. –  Remove bolts -arrows- and detach intake manifold flap motor -V157-.

–  Unplug electrical connector -1- at exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212-. –  Remove bolts -arrows-. –  Detach exhaust gas recirculation valve -N18- at intake manifold.   Note Shown from rear with engine removed for illustration purposes.

–  Slacken retaining clamp -1- for particulate filter. –  Detach retaining clamp.   Note Disregard items marked -2 ... 5-.

–  Unplug electrical connector -arrow- at exhaust gas pressure sensor 1 -G450-. –  Remove exhaust gas pressure sensor 1 -G450- with bracket and move clear.

–  Unplug electrical connector at exhaust gas recirculation cooler change-over valve -N345--arrow-. –  Set aside wiring harness leading to body.

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

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

–  Unplug electrical connector -1-. –  Unscrew bottom bolts for radiator cowl -bottom arrows- and remove radiator cowl downwards.

–  Remove bolts -arrows- at rear and lift out radiator.   WARNING The air conditioner refrigerant circuit must not be opened.   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.

–  Unscrew bolts -1- and -2- for air conditioner compressor. –  Tie air conditioner compressor up to lock carrier.   Note Disregard -item 3-.

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

Vehicles with auxiliary heater: –  Remove exhaust pipe -3- for auxiliary heater → Rep. gr.82. –  Detach coolant hoses -1- and -2- for auxiliary heater and move hoses clear.

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

–  Remove nuts -arrow- for coupling rod on anti-roll bar on both sides.

Vehicles with four-wheel drive: –  Remove bolts -arrows- and detach heat shield for drive shaft (right-side). –  Detach drive shaft (left-side) from flange shaft of gearbox and tie up. –  Detach drive shaft (right-side) from flange shaft of bevel box.   Note Take care not to damage the surface coating of the drive shafts.

All vehicles (continued): –  Remove bolts -1, 2, 3- and remove pendulum support.

–  Mark position of nuts -arrows- securing swivel joint. –  Remove nuts for swivel joint (right-side). –  If fitted, remove nut on bracket for front right vehicle level sender -G289-. –  Detach swivel joint from wishbone.

–  Swing suspension strut (right-side) outwards and support with extension -2024 A /1- as shown in illustration.   WARNING Accident risk from loose components of support bracket. Secure retaining pin and swivel joint with locking pin -arrow- and nut -1-.   Note The illustration shows the installation position on front suspension (left-side).

Vehicles with front-wheel drive: –  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.

Vehicles with four-wheel drive: –  Mark position of flexible coupling and flange for bevel box in relation to each other. –  Unbolt flexible coupling for propshaft at bevel box -arrows- (counterhold using a suitable lever at the triangular flange).

–  Push engine/gearbox assembly forward slightly (towards front end) and pull propshaft off bevel box.   Caution Make sure not to damage the seal -arrow- in the propshaft flange. Push the propshaft horizontally to the rear and towards the right side of vehicle as far as possible.   Note The propshaft must be renewed if oil seal is damaged.

All vehicles (continued): –  Remove nuts -1, 3- and bolt -2- and detach bracket for particulate filter. –  Tie up particulate filter to rear.   Note

t  On vehicles with auxiliary heater the coolant pipes leading to the auxiliary heater must be disconnected from the cylinder block in order to attach engine bracket -T10012-. t  Remove coolant hose bracket to gain access to drilling at front of cylinder block. –  Attach engine bracket -T10012- with securing nut and bolt to cylinder block: approx. 20 Nm. –  Apply engine and gearbox jack -V.A.G 1383 A- to engine bracket -T10012- and raise engine/gearbox assembly slightly.   Note

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

–  Loosen and remove 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. t  Make sure there is sufficient clearance from air conditioner compressor. –  First lower engine/gearbox assembly only slightly. –  Then swing gearbox end of engine/gearbox assembly forwards and only then lower further.