Audi Workshop Service and Repair Manuals

Notes:

• ◆ Engine must be removed without transmission from front of vehicle.
• ◆ All cable ties unfastened or cut open on removing engine are to be re-attached in same position on installation.
• ◆ Coolant drained off must be collected in a clean container for disposal/re-use.

Vehicles with automatic gearbox:

• ‒ Move selector lever to position "N".

All models:

• ‒ Heed (if necessary obtain) code for vehicles with encoded radio/radio navigation system (RNS).
• ‒ → Remove rubber seal from front of plenum chamber cover -arrows-.
• ‒ Remove plenum chamber cover -1- from the front.

• ‒ → Disconnect earth strap -arrow- at battery with ignition switched off.

• ‒ Unscrew cap of coolant expansion tank.

• ‒ → Pull dipstick -1- out of guide tube.
• ‒ Unclipcaps.
• ‒ Remove nuts -arrows- and detach engine cover.
• ‒ Remove insulation lying below.
• ‒ Re-insert dipstick into guide tube.

• ‒ Unclipcaps.
• ‒ → Remove bolts -arrows- and detach air cleaner cover.

• ‒ → Screw out bolts -arrows-.
• ‒ Remove air duct -1- and -2-.

• ‒ Remove front bumper:

=> General Body Repairs, Exterior; Repair Group 63; Front Bumper; Removing and installing front bumper

• ‒ → Release quick-release fasteners -1 ... 3- and detach noise insulation (2 pieces).

• ‒ → Unbolt noise insulation holder -arrow-.

• ‒ → Remove air duct in front of charge air cooler -arrows-.

• ‒ Place drip tray V.A.G 1306 below engine.
• ‒ → Turn drain plug -arrow- at radiator anti-clockwise; attach auxiliary hose to connection if necessary.

• ‒ → Disconnect bottom coolant hose from radiator -arrow-.
• ‒ Detach connector -1- from radiator fan thermoswitch -F18/-F54 at bottom left of radiator and expose wire.

• ‒ → Detach air hose -arrow- to charge air cooler at bottom left of lock carrier.
• ‒ Detach turbocharger air hose at bottom right of lock carrier.

Vehicles with automatic gearbox:

Note:

Observe rules for cleanliness when working on automatic gearbox:

• ‒ Place drip tray in position.
• ‒ → Disconnect ATF lines -arrows-.
• ‒ Remove bolt from holder for ATF lines at left-hand side on sump.

Vehicles with air conditioner:

• ‒ → Where fitted, unclip green electrical connector
  -arrow- for AC compressor magnetic clutch from lock carrier at bottom right and disconnect, then expose wire.

All models:

• ‒ → Disconnect electric headlight connector -arrow- on both sides.

• ‒ → Disconnect electric turn signal connectors -2- on both sides.
• ‒ Disconnect electrical connectors -1- from both horns.
• ‒ Expose wire on right-hand side of vehicle.

• ‒ Detach bonnet lock cable from lock carrier:

=> General body repairs, exterior; Repair Group 55; Bonnet; Removing and installing bonnet lock cable

• ‒ Detach cover from power steering fluid reservoir.
• ‒ → Disconnect connectors -1-, -2-, -3- and -5- in front of ABS unit and expose wires.

• ‒ → Disconnect top coolant hose from radiator -arrow-.

Vehicles with air conditioner:

Note:

To prevent damage to condenser and refrigerant lines/hoses ensure that lines and hoses are not stretched, kinked or bent.

• ‒ → Unbolt air ducts on left and right sides of radiator -4-.
• ‒ Remove condenser bolts -1- and -2-.
• ‒ Detach connector -3- from air conditioner low-pressure switch -F73.
• ‒ Pull condenser up out of bracket, rotate towards the side and secure in place on front right wheel with wire.

Note:

Protect wing panel from damage.

All models:

• ‒ Unbolt lock carrier and place in a secure position.
• ‒ → Detach coolant hoses -1- and -3-.
• ‒ Unbolt coolant expansion tank -2- -arrows-.
• ‒ Disconnect wiring for coolant shortage indicator switch -F66 at bottom of coolant expansion tank .

• ‒ → Disconnect fuel supply pipe -2- from filter housing and fuel return pipe -1- from fuel cooling circuit cooler element and place aside.

• ‒ → Detach air hose from charge air cooler-arrow-.

• ‒ → Disconnect vent line -1- to air cleaner and vacuum line -2- to mechanical EGR valve.
• ‒ Disconnect air hose -3- from intake manifold.

• ‒ → Unplug connectors -2- and -4-.
• ‒ Pull off vacuum hose -5-.
• ‒ Screw out bolt -1-.
• ‒ Detach air pipe -3-.

• ‒ → Disconnect hose connections -arrows-.
• ‒ Detach vacuum line -1-.

• ‒ → Disconnect vent hose -2- from air cleaner housing.
• ‒ Unplug electrical connector -4- from air-mass meter.
• ‒ Detach EGR valve -N18 -3- from air cleaner housing and disconnect electrical connector.
• ‒ Detach wiring harness from air cleaner housing -arrow-.
• ‒ Detach air hose -5-.
• ‒ Screw out bolt -1-.
• ‒ Detach air cleaner housing.
• ‒ Place drip tray V.A.G 1306 underneath.

• ‒ → To drain off the remaining coolant, disconnect coolant hose -arrow- from oil cooler.

• ‒ → Detach coolant hose to heater heat exchanger from engine -arrow-.

Notes:

• ◆ In illustration shown on a vehicle with automatic gearbox.
• ◆ On vehicles with manual gearbox both hoses to the heater heat exchanger must be detached.

• ‒ → Detach coolant hoses -arrows-.

Vehicles with automatic gearbox:

• ‒ → Detach coolant hose from EGR cooler -arrow-.

All models:

• ‒ → Detach coolant hoses for fuel cooling circuit -arrows-.

• ‒ → Disconnect electrical connector -4- from fuel cooling pump -V166.
• ‒ Disconnect electrical connector -3- from charge pressure control solenoid valve -N75.
• ‒ Disconnect vacuum hoses -1- and -2-.
• ‒ Move wires clear.

• ‒ → Remove electronics box cover in plenum chamber -arrows-.

• ‒ → Carefully lever off retainer bar with screwdriver -arrow-.

• ‒ → Release the connector lock -arrows- and disconnect connectors -1- and -2- from the control unit.

• ‒ → Release catch -arrow- and pull auxiliary relay carrier in electronics box upwards to remove.

• ‒ Pull off fuse 2.
• ‒ → Release fuse box from auxiliary relay carrier and pull upwards to remove.
• ‒ Release connector contact in connector field 2 with VAS 1978/8.
• ‒ Disconnect connector from rear of connector rail.

• ‒ → Unscrew earth connection -3-.
• ‒ Remove connectors -1- and -2- from holder.
• ‒ Disengage wiring harness -arrow- and move clear.
• ‒ Unplug connector from speedometer sender -G22 on left of gearbox, and expose wire.

Vehicles with manual gearbox:

• ‒ Unplug connector for reversing light switch on gearbox, and move wire clear.

All models:

Note:

Before removing, mark direction of ribbed belt with chalk or felt-tipped pen. Running a used belt in the opposite direction could destroy it.

• ‒ → Swivel tensioner in direction of arrow to slacken off ribbed belt.
• ‒ Detach ribbed belt from alternator pulley.

• ‒ Unbolt pulley of power steering vane pump. Use a mandrel as a brace.
• ‒ → Unbolt power steering vane pump -arrow- and tie off. Leave pipes connected.

• ‒ Unbolt cable clamp for positive wire to starter on engine at right underneath exhaust manifold.
• ‒ → Unscrew turbocharger/catalytic converter nuts -arrows-.
• ‒ Detach front exhaust system clamp.
• ‒ Push clamp back to separate exhaust system.
• ‒ Disconnect catalytic converter with exhaust pipe from turbocharger.

Note:

To avoid damage, decoupling element of exhaust system is never to be kinked by more than 10 °.

Vehicles with air conditioner:

Note:

Before removing, mark direction of ribbed belt with chalk or felt-tipped pen. Running a used belt in the opposite direction could destroy it.

• ‒ → Slacken off bolts of tensioning roller for air-conditioner compressor ribbed belt -arrows-, slacken off ribbed belt and detach.
• ‒ Detach air conditioner compressor from bracket and secure to body with wire.

All models:

• ‒ → Slacken bolt -1- of soundproofing cover over right side drive shaft at front.
• ‒ Unhook catch -2- and detach soundproofing cover.

• ‒ → Unscrew earth wire from right side engine support -1-.
• ‒ Remove bracket -2- for turbocharger -arrows-.

• ‒ → Detach wires -1- and -2- from starter, remove insulator from positive connection on starter.
• ‒ Unbolt cable clamp -3-.
• ‒ Unbolt start from gearbox and detach it.

Vehicles with automatic gearbox:

• ‒ → Remove 3 torque converter bolts through opening of removed starter using Matra V175 15 mm A/F socket attachment (rotate crankshaft by 1/3 turn each time).

Note:

When loosening torque converter bolts, counterhold crankshaft by applying spanner to central bolt on vibration damper.

All models:

• ‒ → Mark positions of bolted joints -1- and locating sleeves -2- underneath right and left engine mounts.

Note:

Different mounting holes are provided for different engine versions.

• ‒ Unbolt wiring harness bracket from left side engine mount.
• ‒ Slacken bottom nuts -1- on right and left side engine mounts a few turns.
• ‒ Screw out engine/gearbox connecting bolts accessible from underneath.

Note:

If the bolts will not unscrew:

• ‒ → Raise engine and gearbox with workshop crane V.A.G 1202 A on torque reaction support bracket.
• ‒ Make sure no wires are damaged at the top on the bulkhead.

• ‒ Lower the engine back down.
• ‒ → Screw out the top nuts from both engine mounts.
• ‒ Screw out engine/gearbox bolts at top. Leave one bolt screwed in hand-tight.

• ‒ → Position support bar 10-222 A on wing mounting flange with spindle at front.

Notes:

• ◆ To maintain sufficient clearance for the lifting tackle 3033 on the engine, the support bar 10-222 A must be placed diagonally over the front bulkhead:
  The distance between the left side foot of the support bar 10-222 A and the left side bonnet hinge must be 290 mm. The distance between the right side foot of the support bar 10-222 A and the right side bonnet hinge must be 140 mm.
• ◆ In the illustration shown with the engine removed.

• ‒ Attach gearbox support 3147 in bolt hole of bell housing.
• ‒ Connect gearbox support 3147 to support bar 10-222 A using auxiliary hook 10-222 A/2.

• ‒ → Unbolt coolant pipe brackets -1- and -2-.

Note:

The coolant hoses can remain connected to the lines.

• ‒ Remove top toothed belt guard -arrows-.

• ‒ → Screw out bolts -3- and detach cover -2-.
• ‒ Place aside charge pressure control solenoid valve -N75 -item 1- together with connected wires.

• ‒ → Screw bracket T10014 into front of engine.

• ‒ → Expose rear left lifting eye on engine and mount shackle 10-222 A 12.
• ‒ Attach lifting tackle 2024 A with 2024 A/1 on engine and to workshop crane V.A.G 1202 A.

Note:

For alignment with centre of gravity of assembly, holes of support hook rails must be positioned as shown.

• ‒ Screw out last bolt.

Note:

Check that all hoses and other connections between engine and body have been detached.

• ‒ Lift engine over studs out of engine mounts.
• ‒ Turn spindle of support bar 10-222 A.

Note:

Make sure no wires are damaged at the top on the bulkhead.

Vehicles with automatic gearbox:

• ‒ → Separate gearbox from engine and at the same time detach torque converter from drive plate.

All models:

• ‒ Pull engine away from gearbox and lift engine out of engine compartment from the front.

Vehicles with automatic gearbox:

• ‒ If necessary, secure torque converter in gearbox with wire to prevent it falling out.