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  Heat insulation sleeves removed when taking out the engine are to be reinstalled in the original position. t  Collect drained coolant in a clean container for re-use or disposal.   Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27.

–  Remove the moulded insert for tools from beneath the luggage compartment floor cover. –  Unscrew the lid -arrow- of the battery compartment. –  Remove moulded insert from top of battery.

–  With ignition switched off, disconnect earth wire -arrow- at battery.   WARNING Hot steam/hot coolant can escape - risk of scalding. t  The cooling system is under pressure when the engine is hot. t  Cover filler cap on coolant expansion tank with a cloth and open carefully to dissipate pressure. –  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. All vehicles (continued): –  Remove bottom coolant hose -2- from radiator by pulling off retaining clip. –  Drain cooling system.

–  In addition, remove lower coolant hose to continued circulation coolant pump -V51--arrow- and drain off remaining coolant.   Note Illustration shows vehicle with direct shift gearbox.

–  Detach vacuum hose -2- from air intake hose (if fitted). –  Detach air hose -1- at the throttle valve module -J338-. –  Unplug electrical connector for air mass meter -G70- -item 3-. –  Unscrew air cleaner housing (upper section) -arrow-. –  Take out filter element.

–  Pull cover -1- off air duct (release clips on sides). –  Unclip air duct -2-.

–  Unscrew air cleaner housing (lower section) -arrows-.

–  Unscrew bracket for air cleaner housing -arrows-.

–  Unplug electrical connector -1- for Lambda probe 2 -G108- and connector -2- for Lambda probe -G39-. –  Move electrical wiring to Lambda probes clear.

–  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 jet 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 plenum chamber panel. –  Remove plenum chamber intermediate plate -arrows-.

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

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

Vehicles with electronics box (previous version): –  Press retaining clips in direction of the -arrows- and remove cover from electronics box in engine compartment.

Vehicles with electronics box (current version): –  Press the two clips in direction of the -arrows- and remove cover from electronics box in engine compartment.

–  Unscrew terminal 30 wire -arrow- from electronics box in engine compartment and move it clear.

–  Open wiring duct brackets -arrows-.

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

Use removal lever -80-200- to lever out the wiring clips.

–  Disconnect secondary air hose at the position marked with an -arrow-. –  Move air hose to secondary air pump clear.

Vehicles with manual gearbox: –  Remove cable tie -arrow- for protective cover -3-. –  Unplug electrical connector -2-. –  Push back protective cover and unscrew B+ cable at solenoid switch. –  Disconnect earth cable -1-. –  Unscrew top starter securing bolt.

–  Unbolt cable support bracket from gearbox -arrows-.

–  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. –  Tie selector cables with cable support bracket to one side.

–  Clamp off pressure hose to clutch slave cylinder using a hose clamp -3094-. –  Pull out retainer towards the top -arrow- and disconnect pressure hose -1- from hose connector.   Caution The clutch pedal must not be depressed after disconnecting the pressure hose going to the clutch slave cylinder.

Vehicles with direct shift gearbox: –  Unplug electrical connectors -1-, -3- and -5-. –  Detach protective cover and unscrew wire -2- at starter solenoid switch. –  Disconnect earth cable -4-.

–  Unscrew bolts -1- for support bracket -D-. –  Pull off the retaining clip -A- upwards -arrow- and detach selector lever cable from gearbox.   Note Ignore items marked -B- and -C-.

All vehicles (continued): –  Detach coolant hoses going to to heat exchanger at bulkhead -arrows-.

–  Detach coolant hoses at the connections indicated -arrows-.

–  Unplug electrical connector -1- at throttle valve module -J338-. –  Detach coolant hoses at the connections indicated -arrows-.

–  Unbolt the throttle valve module -J338- from the intake manifold -arrows-.   WARNING The fuel system is pressurised. Wrap a cloth around the connection before opening the system. Then release pressure by carefully loosening the connection.

USA vehicles: –  Disconnect following hose connections: 1 -  Coolant hose to expansion tank 2 -  Vacuum hose to activated charcoal filter 3 -  Vacuum hose to tank leak diagnostic pump 4 -  Fuel supply pipe 5 -  Coolant hose to expansion tank

Rest-of-world vehicles: –  Disconnect vacuum line -1- from activated charcoal filter and move line clear. –  Pull off fuel supply hose -3-. –  Detach coolant hoses -2- and -4-.

All vehicles (continued):   Note Some versions have plug-in vacuum connections on the intake manifold as illustrated. To disconnect, push back rubber cap -1- and slide back retaining tab -2-.

–  Disconnect hoses and electrical connectors at indicated locations: 1 -  Electrical connector at activated charcoal filter system solenoid valve 1 -N80- 2 -  Vacuum hose to brake servo 3 -  Vacuum hose to exhaust flap; fitted in addition to the tank leak diagnostic pump on USA vehicles 5 -  Vacuum hose to activated charcoal filter solenoid valve 1 -N80-   Note Disregard -item 4-. –  Unbolt hose bracket -arrows-. –  Remove hose bracket with coolant hoses and vacuum hoses.

–  Unscrew Lambda probe 2 -G108--item 1- and Lambda probe -G39--item 2-.

–  Unscrew bolts -1- and -3- and remove support -2- for front exhaust pipe.

–  Unscrew nuts of front exhaust pipe at exhaust manifolds -arrows-.

–  Unscrew upper securing bolts -upper arrows- for radiator cowl.   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 tensioner in direction of -arrow- to slacken poly V-belt and lock in position with locking pin -T10060 A-. –  Remove poly V-belt.

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

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

–  Remove underbody cover (right-side) -arrows-.

–  Unplug electrical connector -1- for Lambda probe after catalytic converter -G130- and connector -2- for Lambda probe 2 after catalytic converter -G131-. –  Remove plug connector from bracket and move wiring to Lambda probes clear.

–  Remove front cross member for underbody; to do so, unscrew nuts -1- and -2-.   Note To avoid damage, the flexible joints in the front exhaust pipe must not be bent more than 30°. –  Disconnect exhaust system at clamp -3-.

–  Unscrew bracket for exhaust system -arrows- and remove exhaust system.

Vehicles with manual gearbox: –  Unplug electrical connector -2- at reversing light switch -F4-. –  Unscrew nut -1- and remove bracket with wiring from bottom starter securing bolt.

–  Unplug electrical connector -arrow- at longitudinal member (bottom left).

All vehicles (continued): –  Move coolant hose at bottom of radiator cowl clear. –  Detach electrical connector -3- at secondary air pump motor -V101- and move wire clear. –  Unscrew bracket -2- for coolant pipe going to gearbox oil cooler on vehicles with direct shift gearbox. –  Remove bolts -1-. –  Loosen bolt -4- and remove secondary air pump with bracket.

–  Detach electrical connectors -1- for radiator fans at bottom of radiator cowl. –  Unscrew lower securing bolts -lower arrows- for radiator cowl. –  Remove the radiator cowl with both fans from below.

–  Unplug electrical connector -1- for magnetic clutch at AC compressor and move electrical wiring clear.   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 at front of longitudinal member (refrigerant hoses remain connected).

–  Unscrew wire -1- at alternator. –  Unplug electrical connector -2-.   Note Disregard -item 3-.

–  Remove the upper idler roller -1-. –  Unscrew securing bolts -2- and -3- for alternator.   Note The alternator can only be removed from bracket with upper securing bolt still inserted. –  Detach alternator from bracket for ancillaries. –  Take out alternator to the bottom left.

–  Unplug electrical connector -arrow- at secondary air inlet valve -N112-.   Caution When slackening the flange bolt securing the drive shaft, the wheel bearing must not be under load (vehicle must not be standing on its wheels).

–  Have a 2nd mechanic press the brake pedal. –  Unscrew flange bolt -2- from drive shaft (right-side) -1-.

–  Unscrew heat shield for drive shaft (right-side) from bevel box -arrows-. –  Remove drive shaft (right-side) → Rep. Gr.40. –  Detach drive shaft (left-side) from flange shaft of gearbox.

–  Mark position of flexible coupling and flange for bevel box in relation to each other. –  Unbolt flexible coupling for propshaft at bevel box -arrows-.   Note When loosening bolts, counterhold at propshaft flange/final drive with a suitable lever.

–  Push propshaft horizontally as far back as possible.   Caution t  The oil seal -arrow- in the flange of propshaft must not be damaged when removing and installing the engine/gearbox assembly. The propshaft must be renewed if oil seal is damaged. t  When unscrewing the bolts for the pendulum support/subframe, the engine/gearbox assembly swings slightly forward.

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

–  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.

–  Unplug electrical connector -arrow- at continued coolant circulation pump -V51-. –  Pull the continued circulation coolant pump -V51- downwards out of the rubber retainers on bracket (with coolant hoses attached). If necessary, spray rubber retainers with silicone-free lubricant.   Note The coolant pump with attached coolant hoses can be left in place on the engine. –  Remove bolts -1 ... 5- and detach bracket for ancillaries.

–  Secure engine support -T40074- to cylinder block and tighten to approx. 20 Nm -arrows-. –  Insert engine and gearbox jack -V.A.G 1383 A- in engine support -T40074- and raise engine/gearbox assembly slightly.   Note

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

–  Unscrew bolts of assembly mounting at gearbox -arrows-.   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.