Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Lifting tackle -2024 A-

t	Hose clamps for hoses up to 25 mm Ø -3094-

t	Gearbox support -3147-

t	Workshop hoist -V.A.G 1202 A- or -VAS 6100-

t	Drip tray for workshop hoist -VAS 6208- or -V.A.G 1306-

t	Locking pin -3204-

t	2-hole pin wrench -3212-

t	Open-end spanner -3312-

t  Used oil collection and extraction unit -V.A.G 1782- Procedure   Note t  The engine is removed from the front without the gearbox. t  Collect drained coolant in a clean container for re-use or disposal. t  All cable ties which are released or cut open when removing must be fitted in the same position when installing. Vehicles with automatic gearbox: –  Move selector lever into position “N”.

All models:   Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27. –  Move windscreen wipers to the vertical position. –  Detach rubber seal from plenum chamber cover in direction of -arrow-. –  Detach plenum chamber cover -1- towards the front.

–  With ignition switched off, disconnect battery earth cable -arrow-.

–  Remove engine cover panel -arrows-.   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 noise insulation -arrows-.

–  Unbolt bracket for noise insulation -arrows-.

–  Remove front bumper → Rep. Gr.63. –  Unscrew coolant pipe for power steering hydraulic fluid -arrows- and move clear to side; do not open hydraulic fluid circuit.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Turn drain plug -arrow- on radiator anti-clockwise, if necessary fit drain hose to connection.

–  Also open coolant drain plug on engine -arrow-.

–  Pull out retaining clip -arrow- and disconnect coolant hose (bottom right) from radiator.

Vehicles with automatic gearbox:   Note Observe rules for cleanliness when working on automatic gearbox → Rep. Gr.37. –  Place a drip tray underneath. –  Unscrew union nuts -3- and disconnect ATF pipes. –  Remove retainer for ATF pipes (unscrew nuts -1- and -2-).

All models: –  Remove cover -arrow- at front of ABS unit.

–  Unplug electrical connectors -arrows-. –  Move wiring harness clear.

–  Detach cover -2- from air cleaner. –  Unbolt air duct -1- for air cleaner at lock carrier and lift out. –  Disconnect coolant hose (top left) at radiator.

–  Unplug electrical connectors for headlights and headlight range control on both sides of vehicle -arrows-. –  Turn bulb holders for turn signals anti-clockwise and remove from turn signal housing -left arrow-.

–  Unplug electrical connectors -1- and -2- on both horns. –  Disengage wiring at retainer -arrow-.

Vehicles with air conditioning: –  Remove air ducts -4- (left and right) from radiator. –  Unplug electrical connector -3- at low pressure switch for air conditioner -F73-.   WARNING The air conditioner refrigerant circuit must not be opened.   Note To prevent damage to the condenser and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent. –  Unscrew securing bolts -1- and -2- for condenser. –  Pull condenser up out of its bracket, pivot to side and secure to right-side front wheel with wire.

All models: –  Pull bonnet seals away from lock carrier and wing panels.   Note Protect wing panels from damage. –  Remove bolts (left and right) -arrows-. –  Disconnect bonnet lock cable at bonnet lock.

–  Unscrew bolts -arrows- from impact dampers (left and right).   Note A second mechanic is required for removing the lock carrier. –  Remove lock carrier and place down in a secure position.

–  Detach coolant hoses -1- and -3-. –  Unbolt coolant expansion tank -2--arrows-. –  Detach electrical connector at coolant shortage indicator switch -F66- on coolant expansion tank (bottom).

–  On vehicles with secondary air system, turn connecting pipe through 45° to the right -arrow- and detach from air cleaner housing.

–  Remove air intake hose between air mass meter -G70- and air intake elbow. –  Unplug electrical connector at solenoid valve 1 for activated charcoal filter system -N80- and detach solenoid valve from bracket. –  Detach electrical connector at air mass meter -G70-. –  Unscrew and remove air cleaner housing.   WARNING The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then dissipate pressure by carefully unfastening the connection. –  Unscrew fuel supply pipe and fuel return pipe

–  Remove cover for electronics box in plenum chamber -arrows-.

–  Carefully lever off retaining strap with a screwdriver -arrow-.

–  Release retainer catches -arrows- and unplug connectors -1- and -2- from engine control unit.

–  Release retainer -arrow- and pull auxiliary relay carrier in electronics box upwards to remove. –  Unplug electrical connectors at connector point and at altitude sensor -F96-.

–  Detach earth connection -2- and retainer -1- for electrical connectors from plenum chamber. –  Disengage engine wiring harness at electronics box and bulkhead -arrows- and move clear. –  Detach two coolant hoses for heat exchanger at engine (release retaining clamps on connecting flanges).

–  Detach electrical connectors at intake manifold change-over valve -N156- (blue), secondary air inlet valve -N112- (green) and intake air temperature sender -G42- (black) on air inlet connection. –  Cut open cable ties and move wiring clear. –  Detach vacuum lines -arrows A ... C-. –  Unscrew bolts -arrows 1 ... 3- and remove retaining plate. –  Disconnect lines between suction-jet pump and air intake connection piece.

Vehicles with throttle cable and cruise control system: –  Detach vacuum hose -2- at vacuum unit for cruise control. –  Unscrew bolts -1- and move vacuum unit downwards. All models: –  Detach electrical connectors at camshaft control valves and injectors. –  Detach wiring between activated charcoal filter system solenoid valve 1 -N80- and throttle valve unit at throttle valve unit. –  Move the disconnected lines and wiring clear to one side. –  Remove air intake elbow.

Vehicles with throttle cable: –  Detach throttle cable from throttle valve module and from support bracket (do not remove retainer). Move throttle cable clear to the side. –  Unplug electrical connector at kick switch -arrow- on vehicles with automatic gearbox.

All models: –  Detach connectors -1 to 4- from retainer at right of bulkhead. –  Unplug electrical connectors -1-, -3- and -4-. –  Cut open cable tie on bracket for connectors. –  Move Lambda probe wires clear.

–  Use hose clamps -3094- to pinch off both hoses at hydraulic fluid supply pipe. –  Disconnect supply pipe -arrow- below cylinder head (left-side). –  Place a cloth under the screw connection to catch escaping fluid.

–  Detach hydraulic pressure pipe at rear coolant pipe -left arrow-. –  Disconnect hydraulic pressure pipe at cylinder head (right-side) -right arrow-.

–  Use 2-hole pin wrench -3212- to support viscous fan pulley and unscrew viscous fan with open-ended wrench -3312--arrow- (left-hand thread).

Tensioning roller with hexagon flats:   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- using a 17 mm ring spanner to slacken the poly V-belt. –  Lock tensioner in position by inserting locking pin -3204- in locating holes -arrows-. –  Remove poly V-belt.

Tensioning roller with hexagon socket:   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- using a 10 mm hexagon key to slacken the poly V-belt. –  Lock tensioner in position by inserting locking pin -3204- in locating holes -arrow 1- and -arrow 2-. –  Remove poly V-belt. All models: –  Unscrew the securing bolts for engine/gearbox assembly that are accessible from above. Leave one bolt in place (finger-tight). –  Unscrew nuts (accessible from above) securing exhaust manifold to front exhaust pipe (left and right).

Vehicles with automatic gearbox: –  Unbolt air duct for alternator from fan cowl (bottom left) and pull air duct off alternator. –  Disconnect earth connection (engine / cross member) from engine -upper arrow-. –  Open cable duct for starter and alternator at longitudinal member -lower arrows-. –  Unscrew alternator. –  Pivot alternator to side and unscrew electrical wires.

–  Move alternator forwards between sump and body brace -arrow-.

–  Detach wires -1- and -2- at starter and detach insulator at positive connection of starter. –  Remove starter bolts -arrows- from gearbox side. –  Unscrew clamp on right of top section of sump and move electrical wiring clear. –  Take out starter downwards through gap between sump and body brace; leave alternator in vehicle.

–  Unscrew 3 bolts -arrow- for torque converter, working through opening of removed starter (turn crankshaft 1/3 turn each time).   Note When loosening torque converter bolts, counterhold crankshaft by applying spanner to central bolt on vibration damper. –  Secure alternator back on its bracket with one bolt in order to remove engine.

–  Remove bracket for ATF pipes -arrows-.

–  Turn locking lever -1- and detach electrical connector for gearbox. –  Unplug electrical connector -2- at multi-function switch -F125-.

–  Unscrew heat shields for drive shafts (left and right) -arrows-.

–  Unscrew engine speed sender -G28--item 1- at front left of gearbox. –  Unplug electrical connector -2- at sender for speedometer -G22-. –  Unscrew bolt -3- and detach ATF pipes from gearbox.   Note Observe rules for cleanliness when working on automatic gearbox → Rep. Gr.37. –  Move ATF pipes clear.

Vehicles with manual gearbox: –  Unclip and unplug electrical connector -3-. –  Unclip cover for wiring connections. –  Unscrew earth cable -1-. –  Unscrew wiring connection -2-. –  Unscrew clamp -4- and move wiring clear.

–  Detach electrical connector from speedometer sender -G22--arrow A-. –  Unplug electrical connector at reversing light switch -F4--arrow B-.   Note Shown in illustration with gearbox removed.

Vehicles with air conditioning:   WARNING The air conditioner refrigerant circuit must not be opened. –  Unbolt bracket at front of engine securing refrigerant pipes and coolant pipes to sump -arrows-.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Disconnect coolant hose at bottom of oil cooler -arrow- and drain off remaining coolant. –  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Remove oil filter and oil cooler.

–  Unplug connector for magnetic clutch of air conditioner compressor.   WARNING The air conditioner refrigerant circuit must not be opened. –  Unscrew air conditioner compressor from bracket -arrows-. –  Tie up air conditioner compressor to longitudinal member, with lines attached.

All models: –  Unbolt left and right front exhaust pipes from exhaust manifolds -arrows-. –  Unscrew spring-loaded securing bolts on mounting brackets for catalytic converters. –  Pull exhaust system rearwards off studs on exhaust manifolds.

–  Mark positions of bolt connections -1- and locating sleeves -2- on bottom of engine mountings (left and right).   Note Different mounting holes are provided for the different engine versions. –  Remove bottom nuts -1- at engine mounting (left and right).

–  Remove bottom engine/gearbox securing bolts -arrows-.

–  Set up support bracket -10-222 A- behind gas-filled strut on wing panel flanges. The spindle must be at the front. –  Insert gearbox support -3147- into bolt hole in gearbox bell housing. –  Connect the gearbox support -3147- and support bracket -10-222 A-.   Note Illustration shows engine removed.

–  Attach lifting tackle -2024 A- to engine and workshop hoist -VAS 6100- or -V.A.G 1202 A- as shown in illustration.   Note To adjust to the centre of gravity of the assembly, the perforated rails of the support hooks must be positioned as shown.   WARNING The support hooks and retaining pins on the lifting tackle must be secured with locking pins -arrows-. –  Unscrew remaining engine/gearbox securing bolt.   Note Check that all hoses and other connections between engine and body have been detached. –  Raise engine with workshop hoist -VAS 6100- or -V.A.G 1202 A- until the engine mounting studs are clear. –  Tighten spindle of support bracket -10-222 A- further.   Note Make sure no wires/pipes are damaged on the bulkhead.

Vehicles with automatic gearbox: –  Separate automatic gearbox from engine and simultaneously detach torque converter from drive plate All models: –  Detach engine from gearbox and lift engine forwards out of engine compartment. Vehicles with automatic gearbox: –  Secure the torque converter in the gearbox (using wire or similar) to prevent it falling out.