Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Removal lever -80-200-

t	Lifting tackle -2024 A-

t	Gearbox support -3147-

t	Drip tray -V.A.G 1306-

t	Engine and gearbox jack -V.A.G 1383 A-

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

t  Support -T10062- t  Drip tray Procedure   Note t  The engine is removed from the front without the gearbox after removing the lock carrier. t  Renew all cable ties which are released or cut open when removing the engine. Refit in the same position when installing the engine. t  Collect drained coolant in a clean container for re-use or disposal. Vehicles with automatic gearbox 01J: –  Move selector lever into position “N”. All models:   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- towards the front.

–  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.

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

–  Release bolts or 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 → General body repairs, exterior; Rep. Gr.63. –  Place drip tray -V.A.G 1306- under engine.

Vehicles with drain plug: –  Turn drain plug -2- on radiator anti-clockwise and drain coolant (attach hose to connection if necessary). Vehicles without drain plug: –  Pull off retaining clip from radiator outlet coolant temperature sender -G83--item 3-. –  Pull coolant temperature sender out of hose connection and drain off coolant. All models: –  Detach retaining clip -1- for bottom coolant hose and disconnect coolant hose from radiator.

–  Also open coolant drain plug on engine -arrow-.   Note Renew O-ring.

–  Also disconnect coolant hose at oil cooler -arrow-, and drain off remaining coolant.

–  Place a drip tray underneath. –  Detach hydraulic pipes going to cooling pipes at rear of lock carrier -arrows-.

Vehicles with automatic gearbox 01J:   Note Note the rules for cleanliness when working on the automatic gearbox → multitronic 01J, front-wheel drive; 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 engine cover panel -arrows-.

–  Remove cover -1- at right of engine compartment.

–  Remove bolts -arrows-. –  Disengage activated charcoal filter solenoid valve 1 -N80--item 1- at air duct. –  Remove air duct -2-.

–  Remove cover -1- on left side of engine compartment.

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

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

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

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

–  Unclip ambient temperature sensor -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. –  Carefully swivel down condenser and move clear. –  Disconnect bonnet lock cable at bonnet lock and move cable clear.

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

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

–  Unscrew securing bolts -arrows- of retaining plate -3- for solenoid valves. –  Detach electrical connector -2- from intake air temperature sender -G42-. –  Detach air intake hose -1- at air mass meter -G70-.

–  Unscrew bolt -arrow- and pull air duct -2- off throttle valve module -J338-. –  If fitted, pull hose -1- off at air duct.   Note Illustration shows air duct from rear with engine removed.

–  Disconnect coolant hoses -1 ... 3-. –  Unbolt coolant expansion tank -arrow-. –  Disconnect electrical wiring for coolant shortage indicator switch -F66- at coolant expansion tank (bottom).

–  Unscrew earth connection -2-. –  Disconnect vacuum hoses -1- and -3-.

Vehicles with automatic gearbox 01J: –  Unplug electrical connector -arrow-.

All models: –  Place a drip tray underneath. –  Detach hose -1- at power steering reservoir. –  Disconnect vacuum hose -2- leading to vacuum reservoir.

–  Disconnect hose -arrow- from secondary air connecting pipe.

–  Unplug electrical connector -2- at secondary air pump motor -V101--item 1-. –  Move wire clear.

–  Disconnect wires/unplug connectors: 1 -  On activated charcoal filter solenoid valve 1 -N80- 2 -  Vacuum hose at activated charcoal filter solenoid valve 1 -N80- 3 -  On air mass meter -G70-   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 -4- and fuel return pipe -5- and move pipes clear. –  Pry off wiring harness -2- from air cleaner housing (use removal lever -80-200-). –  Detach hose connections and remove air cleaner housing -arrows-.   Note Lay a cloth under the hydraulic pressure pipes to catch any escaping hydraulic fluid.

–  Unscrew hydraulic power steering pipe from coolant pipe (rear) -left arrow- and disconnect pipe in vicinity of right-hand cylinder head -right arrow-.

–  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-.

Vehicles with automatic gearbox 01J: –  Unplug electrical connector -arrow- at brake servo pressure sensor -G294-.

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

–  Pry off retainer with a screwdriver -arrows-.

–  Release retaining tabs -arrows- and unplug connectors -1- and -2- from engine control unit.   Note

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

–  Unplug connectors -2- from rear of connector console and move wiring harness clear. –  Unscrew electrical wiring -1-.

–  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. –  If fitted, remove heat shield for connections from bulkhead (left-side).

–  Detach connectors -1 ... 5- from retainer at left of bulkhead. –  Unplug electrical connectors -1-, -2- and -5-. –  Move Lambda probe wires clear. –  Remove retainer for connectors.

–  Detach connectors -1 ... 4- from retainer at right of bulkhead. –  Unplug electrical connectors -1-, -3- and -4-. –  Move Lambda probe wires clear. –  Remove retainer for connectors.

–  Unscrew nut -2- (accessible from above) securing front exhaust pipe to exhaust manifold (left-side).   Note Illustration shows engine removed.

–  Unscrew nut -2- (accessible from above) securing front exhaust pipe to exhaust manifold (right-side).   Note Illustration shows engine removed. –  Disconnect coolant hoses (going to heat exchanger) from rear coolant pipe and from coolant pipe (right-side). To do so, remove retaining clips for wiring harness.   Note Retaining clips must also be slackened so that the gearbox support -3147- can be inserted later → Anchor. –  Unscrew top engine/gearbox securing bolts. Leave one bolt in place (hand-tight).   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.

–  Swivel tensioner in -direction of arrow- with ring spanner (17 mm) to slacken off poly V-belt. –  Lock tensioner by inserting locking pin -3204- into locating holes -arrows-. –  Remove poly V-belt from power steering pump pulley.

–  Remove torque reaction support -arrows-.

–  Place a drip tray underneath. –  Drain off engine oil. –  Remove oil filter -5-. –  Place drip tray -V.A.G 1306- beneath engine. –  Detach coolant hoses -1-, -6- and -7-. –  Remove oil cooler. –  Remove bolts -2- and -3- and detach coolant pipe from sump (top section).

–  Unbolt refrigerant pipe bracket from sump -arrow-.   Note Illustration shows vehicle with manual gearbox.

–  Unplug electrical connector -1- for magnetic clutch on air conditioner compressor.   WARNING The air conditioner refrigerant circuit must not be opened. –  Unbolt air-conditioner compressor from bracket -arrows-. –  Tie up air conditioner compressor and condenser with hoses/pipes connected to left side of vehicle.

–  Detach wiring at alternator. –  Unscrew bolts -arrows- and remove alternator.

–  Remove heat shields for drive shafts -1- (left and right).

–  Detach wires -1- and -2- from starter. –  Disconnect earth cable -3-.

–  Pull heat shield -1- off solenoid switch. –  Remove bolts -2- and -3- and detach starter.

–  Remove front cross-piece for underbody -1 … 4-.   Note

To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°. –  Loosen clamps on exhaust system -arrows- and disconnect exhaust pipes.

–  Unbolt bracket for front exhaust pipe (left-side) -arrow-.   Note Illustration shows vehicle with manual gearbox.

–  Unbolt bracket for front exhaust pipe (right-side) -arrow-.   Note Illustration shows vehicle with manual gearbox.

–  Remove nuts -1- and -3- (accessible from below) securing front exhaust pipe to exhaust manifold (left-side).   Note Illustration shows engine removed. –  Move Lambda probe wires clear. –  Remove front exhaust pipe (left-side).

–  Remove nuts -1- and -3- (accessible from below) securing front exhaust pipe to exhaust manifold (right-side).   Note Illustration shows engine removed. –  Move Lambda probe wires clear. –  Remove front exhaust pipe (right-side).

Vehicles with automatic gearbox 01J: –  Remove heat shield for gearbox -arrows-.

All models: –  If fitted, unbolt heat shield for engine speed sender. –  Remove engine speed sender -G28- on left of gearbox -arrow- and move clear.

Vehicles with manual gearbox: –  Detach electrical connector from speedometer sender -arrow A-. –  Detach electrical connector at reversing light switch -arrow B-.

Vehicles with automatic gearbox 01J: –  Release connector -A- in direction of arrow and disconnect at gearbox. –  Move wiring harness clear.

All models: –  Mark position of nuts -1- and locating sleeves -2- on bottom of engine mountings (right and left).   Note Different mounting holes are provided for the different engine versions. –  Remove bottom nut -1- at engine mountings (left and right).

–  Loosen top nuts -arrow- on engine mountings (right and left) several turns.

–  Attach support -T10062- at tapped holes for torque reaction support and tighten to 20 Nm. –  Using engine and gearbox jack -V.A.G 1383 A-, lift engine just far enough to remove bottom engine/gearbox securing bolts.

–  Remove bottom engine/gearbox securing bolts -arrows-. –  Lower the engine back down.

Vehicles with manual gearbox or automatic gearbox 01J: –  Position support bracket -10-222 A- behind gas-filled strut on bolted flanges of wing panels. The spindle must be at the front. –  Engage gearbox support -VAS 3147- into the bolt hole (left-side) in gearbox bell housing. –  Connect the gearbox support -VAS 3147- and support bracket -10-222 A- using hooks -10-222 A/2-.   Note Illustration shows engine removed.

All models: –  Attach lifting tackle -2024 A- to engine and workshop hoist -VAS 6100- or workshop hoist -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-. –  Remove the remaining 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 workshop hoist -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. –  Detach engine from gearbox and lift engine forwards out of engine compartment.