Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

t	Removal lever -80-200-

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

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

t	Stepladder -VAS 5085-

t	Scissor-type assembly platform -VAS 6131 A- with support set for Audi -VAS 6131/10- and adapter -VAS 6131/10-12-

t	Drip tray for workshop hoist -VAS 6208-

t	Eye-head bolt -3368-

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

t	Tensioning strap -T10038-

Note If the engine is going to be separated from the gearbox (after the entire assembly is removed), you will additionally need supplementary set -VAS 6131/11- and -VAS 6131/12-. Procedure –  Move selector lever to position “N”. –  Discharge the refrigerant system → Air conditioner system - with refrigerant R134a.

Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27. –  With ignition switched off, disconnect battery earth cable -arrow-.

–  Pull off engine cover panel (rear) -arrows-.

–  Pull off engine cover panel (front) -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 both front wheels. –  Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Open quick-release fasteners -1 … 3- and take off front and rear noise insulation.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Disconnect coolant hose -arrow- at oil cooler and drain off coolant.

–  Disconnect coolant hose (bottom right) at radiator -arrow- and drain off remaining coolant.

–  Remove bolts -arrows- on stop for torque reaction support.

–  Remove bolts -arrows- for torque reaction support.   Note The torque reaction support and the stop for the torque reaction support are detached at a later stage in the procedure.   Note

Observe rules for cleanliness when working on automatic gearbox → Rep. Gr.00. –  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Unscrew union nuts -3- and disconnect ATF lines.   Note Disregard items marked -1- and -2-.

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

–  Detach brake servo vacuum hose from grommet -arrow- at bulkhead.

–  Disconnect earth cable -arrow- at bulkhead.

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

–  Detach coolant hose -arrow- from coolant pipe (front).

–  Remove coolant hose (front left) in engine compartment -arrows-.

–  Detach coolant hose -arrow- from coolant pipe (front).

USA models: –  Disconnect vacuum hose -arrow- leading to leak diagnostic pump.

All vehicles:   Note Lay a cloth under the hydraulic lines to catch any escaping hydraulic fluid. –  Unbolt hydraulic pressure line -2- at power steering pump and lay onto longitudinal member above. –  Clamp off hydraulic hose -1- for power steering pump using a hose clamp -3094-. –  Disconnect hydraulic hose from power steering pump.   Note

To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent. –  Remove bolts -arrows-.   Note The refrigerant lines are disconnected from the air conditioner compressor at a later stage.

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

–  Detach vacuum hose -1- from exhauster pump. –  Unscrew bolts -arrows- and remove exhauster pump.   Caution Rules for cleanliness when working on the injection system → Chapter.   WARNING The fuel system is pressurised. Before opening the low-pressure part of the injection system a clean cloth must be wrapped around the connection and the residual pressure dissipated by carefully loosening the connection.

–  Disconnect fuel line -arrow- and move it clear.

–  Pull non-return valve -1- off connection at air intake hose. –  Remove air intake hose. To do so, release hose clip -2- and clamps -arrows-.

–  Pull pin out of fastener -arrow-. –  Detach air cleaner housing.

–  Disconnect vacuum hose -arrow- leading to activated charcoal filter at solenoid valve 1 for activated charcoal filter system -N80-.

–  Disconnect coolant hose -arrow- leading to heat exchanger for heater at rear of engine.

–  Unscrew nuts and detach bracket (left-side) for connectors -1- and -2- from bulkhead.

–  Unscrew nuts and detach bracket (right-side) for connectors -1- and -2- from bulkhead.

–  Pull off rubber seal -2- on plenum chamber cover. –  Detach plenum chamber cover -1-.

–  Unscrew nut -1- and detach strip fuse at positive terminal. –  Disconnect positive cable -2- at positive battery terminal. –  Pull out positive cable forwards through bulkhead. –  Move wiring harness clear and place on top of engine.   Note Disregard -item 3-.

–  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.   Caution To avoid cracking the cowl panel grille -5- during removal, apply a small amount of soap solution to the joint between the windscreen and the cowl panel grille and pull the grille vertically up out of the fastening strip, starting from the edge of the windscreen. –  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 -arrow- 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.

–  Unplug all electrical connectors at connector point -2-. –  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 the wiring harness on top of engine and secure the engine control unit to prevent it falling.

–  Have a 2nd mechanic press the brake pedal.   Caution When slackening the flange bolt securing the drive shaft, the wheel bearing must not be under load (vehicle must not be standing on its wheels). –  Unscrew flange bolt -2- from drive shaft -1- (left and right).

–  Unbolt heat shield -1- for drive shafts (left and right). –  Unbolt drive shafts (left and right) from gearbox flange shafts.   Note The drive shafts are removed at a later stage.   Note

To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent. –  Unbolt retainer for refrigerant pipe (right-side) from sump -arrow-. –  Detach refrigerant lines from AC compressor. –  Tie up refrigerant line leading to reservoir (right side of vehicle) to body. –  Seal the open connections at AC compressor using clean plugs.

–  Unscrew nuts and bolts -arrows- evenly on both sides of vehicle. –  Take out anti-roll bar.

–  If fitted, unplug electrical connector at front left vehicle level sender -G78-. –  Unclip operating rod for front left vehicle level sender -G78- at track control link (bottom) -arrow-.

–  Working from engine compartment, remove outer securing bolt for suspension strut on both sides of vehicle. –  Screw eye-head bolt -3368- from below into bore in suspension turret on both sides of vehicle.   Caution To avoid damaging the bonnet when it is shut, screw in eye-head bolt -3368- only until it is flush with the top surface of the suspension turret. –  Tie up wheel bearing housing on each side using tensioning strap -T10038- as illustrated.

Caution To prevent damage to the joints on the upper links, the weight of the wheel bearing housings must be supported before slackening the bottom securing bolts for the suspension struts. –  Unbolt suspension strut from track control link -arrow-.

–  Unscrew nuts -1- and -2- on bolt connections securing track control link and guide link.   Note The bolts are removed from the subframe at a later stage. –  Repeat procedure on other side of vehicle.

–  Slacken clamps -arrows-.

–  Unscrew heat shield -A- for propshaft -arrows-. –  Unscrew bolts at gearbox/propshaft flange. –  Push propshaft back towards rear final drive. The constant velocity joints can be moved axially. –  Place the propshaft onto exhaust system.

Set up the scissor-type assembly platform as follows: –  Set up scissor-type assembly platform -VAS 6131 A- with support set for Audi -VAS 6131/10- as follows:

Platform coordinates	Parts of support set for Audi -VAS 6131/10-
B4	/10-1	/10-4	/10-5	/10-11
G4	/10-1	/10-4	/10-5	/10-12
B11	/10-1	/10-2	/10-5	/10-8
G11	/10-1	/10-2	/10-5	/10-8
D15	/10-1	/10-3	/10-5	/10-12
F15	/10-1	/10-3	/10-5	/10-12

–  Initially tighten the support elements on the assembly platform only hand-tight. –  Adjust the scissor-type assembly platform -VAS 6131 A- so that it is horizontal. l  Take note of spirit level (bubble gauge). –  Place scissor-type assembly platform -VAS 6131 A- under engine/gearbox assembly.

–  Position support elements from -VAS 6131/10- at front of engine, as shown in illustration. –  Make sure that threaded spindles are screwed in completely.

–  Position support elements from -VAS 6131/10- at left and right of subframe, as shown in the illustration.

–  Position support elements from -VAS 6131/10- at rear of gearbox, as shown in illustration. –  Turn all spindles for the support elements upwards until all locating lugs make contact with the mounting points. –  Tighten base plates for support elements to 20 Nm on scissor-type assembly platform -VAS 6131 A-.

–  Remove bottom nuts -A- at engine mountings (left and right).

–  Cut open the cable ties -arrows-, open bracket for starter wire and take out the electrical wire.

–  Remove bolts -1-. –  Mark the installation position of the subframe and the two consoles for engine mountings on the longitudinal members with felt-tip pen. –  Unscrew bolts -2-, -3- and -4- in a diagonal sequence and in stages. –  Take out consoles for engine mounting (left and right).   Note t  Check that all hoses and wiring connections between engine, gearbox, subframe and body have been detached. t  Carefully guide out engine/gearbox assembly with subframe from engine compartment when lowering to avoid damage.

–  Lower the engine/gearbox assembly using scissor-type assembly platform -VAS 6131 A- initially only as far as distance -a-. l  Distance -a- = 80 mm.

–  Remove bolts for guide link -1- and track control link -2- from subframe.

–  Pivot guide link -1- and track control link -2- outwards.   Caution The guide link and track control link must not be allowed to hang down without support. Tie up both links to wheel bearing housing as illustrated -arrows-. –  Pivot wheel bearing housing outwards and remove drive shaft. –  Repeat procedure on other side of vehicle.   Note

Mark installation position of support bracket for selector lever cable with felt pen. –  Push ball socket -1- of selector lever cable off selector shaft lever. –  Unbolt support bracket from gearbox -arrows-. –  Move selector lever cable clear.   Note t  Take care not to bend or kink selector lever cable. t  Shown in illustration with gearbox support removed. –  Push scissor-type assembly platform -VAS 6131 A- back about 20 mm and remove torque reaction support with stop for torque reaction support. –  Push scissor-type assembly platform -VAS 6131 A- back into its original position and lower scissor-type assembly platform -VAS 6131 A- completely. –  Pull out scissor-type assembly platform -VAS 6131 A- with engine/gearbox assembly from beneath vehicle.