Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

t	Lifting tackle -2024 A-

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

t	Used oil collection and extraction unit -V.A.G 1782-

t	Hose clip pliers -V.A.G 1921-

t	Spark plug connector pliers -V.A.G 1922-

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

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

t  Locking pin -T10060 A- or -T10060- t  Trolley jack (commercially available) Procedure   Note t  The engine is removed from the front without the gearbox after removing the lock carrier. t  All cable ties which are released or cut open when removing must be fitted in the same position when installing. t  Collect drained coolant in a clean container for re-use or disposal. –  Move selector lever to position “N” on vehicles with multitronic gearbox.   Caution Observe notes on procedure for disconnecting the battery → Electrical system; Rep. Gr.27.

Vehicles up to 10.2004: –  Detach rubber seal from plenum chamber cover in direction of -arrow-. –  Detach plenum chamber cover -1- towards the front.

All models: –  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. –  On vehicles with auxiliary/additional heater, remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release fasteners -1 … 3- and take off front noise insulation and rear noise insulation (if fitted).

–  Unbolt bracket for noise insulation -arrows-. –  Remove front bumper cover → General body repairs, exterior; Rep. Gr.63.

–  Place drip tray for workshop hoist -VAS 6208- or -V.A.G 1306- under engine. Vehicles with coolant drain plug: –  Open coolant drain plug on coolant hose (bottom) at radiator. –  Unplug electrical connector at radiator outlet coolant temperature sender -G83- and move wiring clear. Vehicles without coolant drain plug: –  Pull out retaining clip -1- for radiator outlet coolant temperature sender -G83--item 2-. –  Pull radiator outlet coolant temperature sender -G83- out of hose connection and drain off coolant. –  Move wiring clear.

All models: –  Detach coolant hose (bottom) from radiator -arrow-.

–  Clamp off hydraulic hoses going to cooling pipe for power steering using hose clamps -3094-. –  Place used oil collection and extraction unit -V.A.G 1782- under connection. –  Disconnect coolant hoses -arrows-.

Vehicles with multitronic gearbox: –  Place used oil collection and extraction unit -V.A.G 1782- under connection.   Note Observe the rules for cleanliness when working on the gearbox → multitronic 01J, front-wheel drive; Rep. Gr.00. –  Disconnect ATF pipes going to radiator -arrows-.

All models: –  If fitted, detach cover -1- on right of engine compartment.

–  Unplug electrical connector at solenoid valve 1 for activated charcoal filter system -N80--item 1-. –  Disengage solenoid valve 1 for activated charcoal filter system -N80- at air duct. –  Remove bolts -arrows-. –  Remove air duct -2-.

–  If fitted, remove cover -arrow- at power steering fluid reservoir.

–  Disconnect top coolant hose -1- at radiator. –  Unplug electrical connector -2- for airbag sensors (left and right) at lock carrier.

–  Unplug electrical connector -arrow- for headlights on both sides.

–  Remove electrical connectors -1- and -2- from bracket. –  Unplug electrical connectors and move wiring clear.

–  Unplug the electrical connectors (left and right) -3- for horns -2-.   Note Disregard -item 1-.

–  Remove bumper -arrows-.

–  Unbolt air cowls (left and right) at radiator -arrows-.

–  Unclip ambient temperature sensor -G17--item 2- from bracket. –  Unscrew bolts -3- and -4- for power steering cooling pipe; the hydraulic hoses remain attached. –  Detach electrical connector -1- at high-pressure sender -G65-.   WARNING The air conditioner refrigerant circuit must not be opened. –  Unscrew securing bolts -arrows- for condenser.   Note To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent. –  Pivot condenser downwards with pipes/hoses attached.

–  Remove bolts -arrows- at lock carrier (left and right). –  Disconnect bonnet lock cable at bonnet lock. –  Remove engine compartment seal from lock carrier and wing panel flanges.

–  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.

–  Pull off engine cover panel -arrows-.

–  Detach air intake pipe from throttle valve module -J338--arrow-.

–  Move electrical wiring clear of air pipe (rear). –  Detach air pipe from air cleaner housing -1- and from retaining stud -2-.   WARNING The fuel system is pressurised. Wrap a cloth around the connection before opening the system. Then release pressure by carefully loosening the connection.

–  Disconnect fuel supply pipe -1- and fuel return pipe -2-. –  Disconnect fuel return pipe -3- and vacuum hose -4- going to brake servo. –  Unscrew earth connection -5- from bulkhead.

–  Detach hose going to activated charcoal filter from throttle valve module -J338--arrow-.

–  Detach coolant hoses -1 ... 3- and unfasten coolant expansion tank -arrow-. –  Unplug electrical connector for coolant shortage indicator switch -F66- at bottom of coolant expansion tank.

–  Place drip tray for workshop hoist -VAS 6208- or -V.A.G 1306- under engine. –  Disconnect coolant hose -arrow- going to heat exchanger from coolant pipe (small), and drain off remaining coolant. –  Disconnect coolant hose going to heat exchanger from connection of coolant pipe (large).

–  Unplug electrical connectors for Lambda probes and move wiring clear. 1 -  To Lambda probe -G39- (black) 2 -  To Lambda probe after catalytic converter -G130- (brown)   Note

Lay a cloth under the hydraulic lines to catch any escaping hydraulic fluid. –  Clamp off hydraulic hose for power steering pump using a hose clamp -3094-. –  Disconnect hydraulic hose -1- from power steering pump. –  Unbolt hydraulic pressure line -2- at power steering pump and lay onto longitudinal member above.   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 tensioner for poly V-belt in position with locking pin -T10060 A- or -T10060-. –  Remove poly V-belt.

–  Unplug electrical connector -1- at air mass meter -G70-. –  Remove fastener -2- and detach air cleaner housing.

–  Disconnect connecting pipe for exhaust gas recirculation -arrow- at starter catalytic converter.

–  Unbolt starter catalytic converter from exhaust manifold -arrows-.

Vehicles from 11.2004 onwards: –  Pull off rubber seal -2- on plenum chamber cover -1-. –  Detach plenum chamber cover.

All models: –  Lever off both cover caps -3- with a screwdriver. –  Loosen hexagon nuts -4- several turns. –  Detach wiper arms -2- from wiper shafts by tilting slightly. –  Completely unscrew hexagon nuts and remove wiper arms. –  Pull off retaining clips -1- and detach cowl panel grille -5-.

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

–  Use a screwdriver to carefully lever out the retaining strap -arrows- and remove the engine control unit from the electronics box.   Note The engine control unit remains connected to the wiring harness.

–  Release retaining hooks -arrows- outwards and remove retaining strap.

–  Disconnect all electrical connectors from the connector point -2- using spark plug connector pliers -V.A.G 1922-. –  Unscrew electrical wiring -1-.

–  Release retainers -arrows- and push auxiliary relay carrier in electronics box upwards to remove. –  Detach the engine wiring harness at electronics box and at bulkhead. –  Place engine control unit with wiring harness attached on top of engine.   Note Secure the engine control unit to prevent it falling.

–  Unbolt heat shield -1- for drive shaft (right-side).

–  Remove bolts -arrows- securing starter catalytic converter to front exhaust pipe. –  Unbolt exhaust bracket -1-.   Note To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°. –  Lift out starter catalytic converter from engine compartment.

Vehicles with multitronic gearbox: –  Remove nut -2-. –  Unbolt bracket for ATF pipes at engine.   Note Disregard -item 1-.

–  Place used oil collection and extraction unit -V.A.G 1782- under connection. –  Remove ATF pipes -arrow-.

All models: –  Unscrew earth wire -1- at engine support (right-side). –  Detach electrical wires -2- and -3- at starter. –  Unscrew clamp -4-. –  Remove bracket -5-, if fitted. –  Unbolt starter from gearbox and remove.

–  Take electrical connector -arrow- for exhaust gas temperature sender 1 -G235- out of bracket. –  Unplug electrical connector and move wiring going to engine clear.

–  Release electrical connector -1- at gearbox. –  Move wiring harness going to engine clear -arrows-.

–  Unplug electrical connector at oil level/temperature sender -G266--arrow-.

–  Unbolt refrigerant pipe bracket from sump -arrow-.

–  Unplug electrical connector -1- for magnetic clutch of air conditioner compressor. –  Move wiring clear.   Caution The air conditioner refrigerant circuit must not be opened. –  Unscrew air conditioner compressor from bracket -arrows-.   Note To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent. –  Tie up air conditioner compressor and condenser (with pipes attached) to vehicle.

–  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. –  Unscrew nuts -1- (bottom) at engine mountings (left and right).

–  Unscrew engine/gearbox securing bolts that are accessible from below -arrows-.

–  Slacken off top nut -arrow- on left-side engine mounting several turns. –  Unscrew engine/gearbox securing bolts that are accessible from above; leave one bolt in place (finger-tight).

–  Hook lifting tackle -2024 A- onto engine and workshop hoist -VAS 6100- or -V.A.G 1202 A-.   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. –  Lift engine until studs are clear of engine mountings.   Caution Support gearbox from below using a trolley jack.   Note Make sure no wires/pipes are damaged at the top on the bulkhead. –  Detach engine from gearbox and lift engine forwards out of engine compartment.