Audi Workshop Service and Repair Manuals

Removing engine   Note t  The engine is removed towards front with the lock carrier removed. 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. Procedure –  Move selector lever to position “N” on vehicles with automatic gearbox.   Caution Observe notes on procedure for disconnecting the battery → Electrical system; Rep. Gr.27.

–  With ignition switched off, disconnect battery earth cable -arrow-.   WARNING Hot steam/hot coolant can escape - risk of scalding. t  The cooling system is under pressure when the engine is hot. t  To allow pressure to dissipate, cover filler cap on coolant expansion tank with cloth and open carefully. –  Open filler cap on coolant expansion tank. –  Remove both front wheels.

–  Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release quick-release fasteners -1- and -2- and take off front noise insulation. –  If fitted, open quick-release fasteners -3- and remove rear noise insulation.

–  Unbolt bracket for noise insulation -arrows-.

–  Remove front bumper cover → General body repairs, exterior; Rep. Gr.63. –  Remove air ducts in front of charge air coolers (left and right) -arrows-.

–  Place drip tray for workshop hoist -VAS 6208- or drip tray -V.A.G 1306- under engine. –  Unscrew the drain plug -arrow- at coolant hose (bottom left) and drain off coolant.

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

–  Detach air intake hose -1- going to charge air cooler (bottom left).   WARNING The air conditioner refrigerant circuit must not be opened. –  Disengage refrigerant line at bracket -2-.

–  Detach air intake hose -1- going to turbocharger (bottom right). –  Detach air intake hose -2- going to charge air cooler at lock carrier.

–  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- underneath. –  Disconnect coolant hoses -arrows-.

Vehicles with automatic gearbox:   Note Observe rules for cleanliness when working on automatic gearbox → Rep. Gr.37. –  Place used oil collection and extraction unit -V.A.G 1782- underneath. –  Detach ATF lines -2 and 3- at connections. –  Unbolt bracket -1- for ATF lines at engine. All vehicles:

–  Pull off engine cover panel -arrows-.

–  Remove bolts -arrows-. –  Remove air ducts -1- and -2-.

–  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.

–  Detach electrical connectors -1- and -2- from bracket and unplug. –  Move wiring clear.

–  Unplug 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- and remove power steering cooling pipe. –  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 condenser and refrigerant pipes/hoses, 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.   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 belt tensioner/damper in direction of -arrow-. –  Lock tensioner in position with locking pin -T40098-. –  Remove poly V-belt.

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

–  Unbolt refrigerant pipe bracket from sump -arrow-.

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

–  Unscrew earth cable -1-. –  Disconnect vacuum hose going to brake servo at bulkhead -2-. –  Disconnect ACF hose -3-.

–  Disconnect coolant hoses -1 and 2- and detach coolant expansion tank -arrow-. –  Unplug electrical connector for coolant shortage indicator switch -F66- at bottom of coolant expansion tank.

–  Unplug electrical connector from charge pressure sender -G31--1-. –  Remove charge air hose (left-side) -2-.

–  Remove charge air hose (right-side) -1-.

–  Detach electrical connector -1- for Lambda probe after catalytic converter -G130- and Lambda probe 1 heater after catalytic converter -Z29- (brown connector) from retainer. –  Detach electrical connector -2- for Lambda probe -G39- and Lambda probe heater -Z19- (black connector) from retainer.   Caution The fuel pressure must be reduced prior to opening any components in the high-pressure section of the fuel system. It is very important to observe the procedure specified in → Rep. Gr.24.

–  Disconnect fuel line -arrow- (catch escaping fuel and seal off open pipes immediately). –  Disconnect coolant hoses going to heat exchanger at rear of engine. –  Remove wiper arms. –  Remove cowl panel.

–  Unfasten bolts -arrows-, then remove cover for electronics box in plenum chamber.

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

–  Unscrew electrical wiring -1-. –  Unplug electrical connectors -2 ... 4- in electronics box.

–  Unclip fuse holder -arrows-. –  Move wiring harness clear and place it on engine with engine control unit -J623- attached.

–  Unscrew bolt connections -1- on power steering pump (access via holes in pulley).

–  Unscrew mounting -arrow- on reverse side of power steering pump.

–  Detach electrical connectors -1 and 2- and move wire clear. –  Detach intake hose -3- (air cleaner/turbocharger).

–  Unplug electrical connector -1- at air mass meter -G70-. –  Move clear wiring harness at air cleaner housing and remove air cleaner housing -arrow-.

–  Unbolt earth cable -arrow- at longitudinal member (right-side).

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

Do not bend the flexible joint (de-coupling element) in the exhaust system more than 10°, otherwise it could be damaged. –  Loosen clamp -arrow- and push to rear.

–  Detach front exhaust pipe/catalytic converter -arrows-. –  Remove bolt -1- on bracket for front exhaust pipe and then detach front exhaust pipe.

–  Unplug electrical connector -arrow- from reversing light switch -F4- and move wire leading to wiring harness clear.

–  Remove engine/gearbox bolts -1 ... 3- and -7 ... 11- accessible from below.

–  Detach starter and swivel to one side. –  Unplug electrical connector -3-. –  Unscrew nut -1- for clamp. –  Unscrew nut -2- and detach electrical wiring. –  Detach starter.

–  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).

–  Slacken off top nut on left-side engine mounting several turns.

–  Attach lifting tackle -2024 A- to engine and workshop hoist -VAS 6100- 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 hook attachments and locating pins on the lifting tackle must be secured with locking pins. –  Unscrew remaining engine/gearbox bolt.   Note Check that all hoses and other connections between engine and body have been detached. –  Raise engine until the studs of the engine mountings are clear. –  Raise trolley jack until gearbox makes contact. –  Detach engine from gearbox and lift engine forwards out of engine compartment.