Audi Workshop Service and Repair Manuals

Removing engine   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  Fit all heat insulation sleeves in the original position when installing. t  Collect drained coolant in a clean container for re-use or disposal.   Caution Observe notes on procedure for disconnecting the battery → Electrical system; Rep. Gr.27.

–  Detach rubber seal from plenum chamber cover in direction of -arrow-. –  Detach plenum chamber cover -1-, if fitted.

–  With ignition switched off, disconnect battery earth cable -arrow-.   WARNING Hot steam/hot coolant may escape when opening expansion tank; 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 quick-fasteners -1- and -2- and take off front noise insulation. –  If fitted, release quick fasteners -3- and remove rear noise insulation.

–  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 drip tray -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-.

–  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. –  Unscrew bolts -arrows-. –  Remove air duct -2-.

–  Remove cover -arrow- at power steering fluid reservoir.

–  Remove upper coolant hose -1- at radiator. –  Unplug electrical connector -2- for airbag sensors (left and right) at lock carrier and move wiring clear.

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

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

–  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 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. –  Pull bonnet seal away from lock carrier and wing panels.

–  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.

–  Lift off engine cover -arrows-.

–  Detach vacuum hose -3- leading to brake servo at bulkhead. –  Detach vacuum hose leading to solenoid valve 1 for activated charcoal filter system -N80--item 1-. –  Unscrew earth connection -2- from bulkhead.

–  Detach coolant hoses -1- and -2- 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 drip tray -V.A.G 1306- under engine. –  Disconnect coolant hose leading to oil cooler -arrow-, and drain off remaining coolant.

–  Detach coolant hose -1- from top coolant pipe.   Note Disregard -item 2-.   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. –  Remove poly V-belt.

–  Unscrew front bolts -arrows- for power steering pump.

–  Unscrew rear bolt -arrow- for power steering pump. –  Move power steering pump aside and place onto longitudinal member. Leave pipes connected.

–  Unplug electrical connector -bottom arrow- at secondary air pump motor -V101- and move wiring clear. –  Pull back heat insulation sleeves and disconnect hose -top arrow- at pipe leading to combination valve for secondary air.

–  Unplug electrical connector -4- at air mass meter -G70-. –  Move electrical wiring at air cleaner housing clear. –  Disconnect air hose -1- leading to secondary air pump. –  Detach air intake hose -3- at air mass meter -G70-. –  Remove fastener -2- and detach air cleaner housing.

–  Detach vent hose -2- leading to exhaust gas recirculation valve -N18-. –  Disconnect hose -4- for crankcase breather system at air pipe. –  Detach air pipe -3- at throttle valve module -J338-.   Note Disregard -item 1-.   WARNING The fuel system is pressurised. Before opening the system place a cloth around the connection. Then dissipate pressure by carefully unfastening the connection.

–  Detach fuel supply pipe -2- and fuel return pipe -1- and move clear.

–  Disconnect coolant hose (right-side) -1- leading to heat exchanger at cylinder head connection. –  Disconnect coolant hose (left-side) -2- leading to heat exchanger at coolant pipe.

–  Lever off both cover caps -3- with a screwdriver. –  Loosen hexagon nuts -4- several turns. –  Detach wiper arms -2- from wiper shaft 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-.

–  Pry off retainer with a screwdriver -arrows-.

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

t  On vehicles with engine control unit -1- with protective housing -4- the electrical connectors remain plugged in. t  Place engine control unit on engine and secure it to prevent it falling.

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

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

–  Release retainers -arrows- and push auxiliary relay carrier in electronics box upwards to remove. –  Disengage engine wiring harness at electronics box and bulkhead and move clear.

–  Remove bracket for electrical connectors -1 ... 4- from bulkhead.

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

–  Unscrew nut -2- at bracket for front exhaust pipe.   Note Disregard -item 1-.

–  Loosen bolt connections of front clamp -arrows-. –  Push the clamp back in order to separate the exhaust system.   Note To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°.

–  Remove bolts -arrows- securing front exhaust pipe/catalytic converter. –  Detach front exhaust pipe from catalytic converter.

–  If fitted, unplug electrical connector at speedometer sender -G22- at left of gearbox -bottom arrow-. –  On vehicles with manual gearbox unplug electrical connector at reversing light switch -F4- on gearbox -top arrow-. –  Move wiring clear.

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

–  Unbolt refrigerant pipe bracket from sump -arrow-.

–  Unplug electrical connector -1- for magnetic clutch on air conditioner compressor.   WARNING 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 to vehicle, with lines attached.

–  Unscrew earth wire -1- at engine support (right-side). –  Detach electrical wires -2- and -3- at starter. –  Detach insulator at positive connection of starter. –  Unscrew clamp -4-. –  Unbolt bracket -5- for starter. –  Unbolt starter from gearbox and remove.

–  Mark position of nuts -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 -arrows- accessible from below.

If the bottom bolts on engine/gearbox assembly flange cannot be unscrewed: –  Raise engine/gearbox assembly at torque reaction support using engine and gearbox jack -V.A.G 1383 A-. –  Make sure no wires/pipes are damaged at the top on the bulkhead.   WARNING To avoid injury, ensure adequate support. –  Lower the engine back down.

–  Unscrew nut -arrow- at top of engine mounting (left-side). –  Unscrew top bolts on engine/gearbox assembly flange; leave one bolt in place (finger-tight).

–  Set up support bracket -10-222 A- behind gas-filled strut on wing panel flanges. The spindle is located at front. –  Engage gearbox support -3147- in bolt holes at top of bell housing as shown in illustration. –  Connect gearbox support -3147- with spindle of support bracket -10-222 A-.   Note Shown in illustration with engine removed. –  Take up weight of engine using spindle of support bracket -10-222 A-.

–  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 bolt on engine/gearbox assembly flange.   Note Check that all hoses and other connections between engine and body have been detached. –  Lift engine until studs are clear of engine mountings. –  Turn spindle of support bracket -10-222 A- to take up slack.   Note Make sure no wires/pipes are damaged at the top on the bulkhead. –  Remove engine mounting (left-side). –  Detach engine from gearbox and lift engine forwards out of engine compartment.