Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

t	Shackle -10-222 A/12-

t	Removal lever -80-200-

t	Lifting tackle -2024 A-

t	Ball joint puller -3287 A-

t	Pliers -3340-

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

t	Workshop hoist -VAS 6100-

t	Drip tray for workshop hoist -VAS 6208-

t	Transportation shackle -T40016- with -T40016/1-

t	Setting tool -T40035-

Note t  The engine is removed together with the gearbox from the front. t  Collect drained coolant in a clean container for re-use or disposal. t  All cable ties which are released or cut open when removing must be fitted in the same position when installing.   Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27.   Note

The battery is located in the luggage compartment panel. –  Switch off ignition and remove ignition key. –  Disconnect earth cable -arrow- at battery. –  Remove bonnet → Chapter.   WARNING Hot steam or hot coolant can escape when expansion tank is opened; cover filler cap with cloth and open carefully.

–  Open filler cap -arrow- on coolant expansion tank.   Note

Press in pins -1- of fasteners -2- not more than approx. 4 mm to release and remove fastener. Do not press through pin. –  Release fastener on bumper cover. –  Remove bolts -3- and -4-.

–  Remove front wheels. –  Remove noise insulation -arrows-.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Disconnect coolant hose (bottom) at radiator -arrow- and drain off coolant.

–  Remove air intake hose from charge air cooler -arrow-.   Note

Press in pins -1- of fasteners -2- not more than approx. 4 mm to release and remove fastener. Do not press through pin. –  Release fastener on wheel housing liner. –  Remove bolt -3-. –  Detach front sections of wheel housing liners (left and right) .

–  Unscrew bolts -arrows- at bumper cover.   Note Mark position of bolts for re-installation.

–  First press bottom of bumper cover -arrow- out of groove -1-. Then unclip upper section from inside -2-. –  Remove bumper cover. –  If fitted, unplug electrical connectors at fog lights.   Note Lay bumper cover aside on a soft surface.

–  Unplug electrical connector -arrow- at radiator fan thermoswitch -F18-.

–  Unplug electrical connector -arrow- at radiator fan -V7-.

–  Unplug electrical connector -2-. –  Detach water hose -1- from windscreen washer fluid pump and plug connection with suitable plug.

–  Move wiring harness clear from bottom of lock carrier -arrows-.

–  Use removal lever -80-200- to lever out the wiring harness clips.   Note To ease removal, use silicon-free lubricant if necessary.

–  Unplug electrical connector at horn. –  Remove two bolts each on left and right -3- and detach rail. –  Lever off circlips -2-. –  Remove bolts on left and right -1- and detach bumper carrier.

–  Remove securing bolts -arrows- for lock carrier on left and right sides.

–  Detach electrical connector -arrow- at ambient temperature sensor -G17-. –  Unplug electrical connector at washer fluid warning contact -F77-. –  Detach wiring harness from air duct (left-side) (use removal lever -80-200- to unclip wiring clips).

–  Take off engine cover panel -arrows-. –  Remove noise insulation underneath (detach crankcase breather hose).

–  Detach vacuum hose -1-. –  Detach air intake pipe -2- at air mass meter -G70-.

–  Unplug electrical connector -1- at intake manifold pressure sender -G71- and move wiring clear. –  Remove air intake hose -2- between charge air cooler and intake manifold.

–  Unplug electrical connector -arrow- for headlights on both sides. –  Open cable tie at wiring to headlight (right-side) from lock carrier (use removal lever -80-200- to unclip).

–  Unscrew bolts -arrows- and detach bonnet lock cable.

–  Detach electrical connector -3- at bonnet contact switch -F266-. Detach wiring harness from lock carrier (use removal lever -80-200- to unclip). –  Pull oil dipstick out of guide tube. –  Detach guide tube -4- for oil dipstick from lock carrier. –  Pull oil filler pipe -5- off oil filler reservoir.   Note Disregard items marked -1- and -2-.

–  Pull drain hose -2- off water collector -1-.

–  Detach coolant hose (top left) from coolant hose/pipe connection at the location indicated -1-.   Note Disregard -item 2-.

–  Remove bolt -arrow- on left and right sides.   Note A second mechanic is required for removing the lock carrier. –  Remove lock carrier and place down in a secure position.

–  Use screwdriver to lever off cover caps -3- and -4- from wiper arms. –  Slacken nuts on both wiper arms a few turns. –  Loosen wiper arms -1- and -2- from wiper shafts by tilting slightly. –  Completely remove nuts and take off wiper arms.

–  Disconnect washer fluid hose -3-. –  If fitted, unplug electrical connectors -4- and -5- for heated washer jets. –  Open hose clip -6- using hose clip pliers -V.A.G 1921- and detach water drain hose from cowl panel grille. –  Pull off rubber seal -1- on cowl panel grille. –  Disconnect cowl panel grille -2-. –  Move washer fluid hose clear.

–  Unscrew nuts and bolts -arrows-. –  Pull air duct forwards, move it to right side of vehicle and remove.

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

–  Cut through cable tie -2- and lift off cover -3- protecting solenoid switch -1-.

–  Detach cover -3-. –  Unplug electrical connector terminal 50 -item 2- at solenoid switch. –  Unscrew nut -4- and detach B+ wiring.   Note Pay attention to locating element -1-.

–  Unscrew nut and remove earth wire -1-. –  Unplug electrical connector -2- at reversing light switch -F4- and move wiring clear.

–  Unplug electrical connector terminal D+ -item 1- at alternator. –  Unplug electrical connectors -2- on glow plugs. –  Pull retaining tab and loosen knurled nut -3- at main connector for unit injectors. –  Unplug electrical connector for Hall sender -G40--item 4- and for engine speed sender -G28--item 5-. –  Unplug electrical connector -6- at oil pressure switch -F1- and move wiring harness clear.

–  Unclip coolant hoses from coolant expansion tank -arrows-.

–  Detach vacuum hose -1- going to brake servo from tandem pump. –  Unplug electrical connector -2- at fuel temperature sender -G81- and move wiring clear. –  Unplug electrical connector -3- at coolant temperature display sender -G2-/coolant temperature sender -G62-.

–  Disconnect vacuum hose -1- from mechanical exhaust gas recirculation valve. –  Disconnect vacuum hose -2- from throttle butterfly valve -N211-.

–  Unplug electrical connector -1- at air mass meter -G70-. –  Unscrew nut -2-.

–  Detach vacuum hose -arrow- from vacuum unit for charge pressure control.   WARNING t  In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with unit injector engine. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles.

–  Mark fuel supply pipe -2- and fuel return pipe -1-.

–  Mark fuel supply pipe -1- and fuel return pipe -2- going to heat exchanger and remove hoses from bulkhead.

–  Unbolt bracket for wiring harness from gearbox -arrow-.

–  Unscrew nuts -arrows- at turbocharger/starter catalytic converter.

–  Remove bolt -1- on gear actuator heat shield.   Note The two remaining bolts at the bottom of the heat shield are unscrewed at a later stage. –  Unplug electrical connector -2- at sender for speedometer -G22-.

–  Unplug electrical connector -arrow- at gearbox speed sender -G38-.

–  Slacken lock nut -B- and adjusting nut at clutch cable. –  Disengage clutch cable at operating lever.   Note Do not open hydraulic pipe at clutch slave cylinder. –  Disengage retainer at the location indicated -arrow- and detach clutch slave cylinder from support bracket -A-. –  Move clutch slave cylinder clear to one side (do not open hose/pipe circuit).

–  Remove bolts -1- and -3- and detach pendulum support.   Note Disregard -item 2-.

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

–  Remove bolt -1- for coupling rod at suspension link -2-.

–  Unscrew nut at swivel joint (counterhold with Allen key 5 mm if necessary). 1 -  Allen key 5 mm (shortened by approx. 10 mm). 2 -  Ring insert 3 -  Torque wrench -V.A.G 1331-

–  Apply ball joint puller -3287 A--item 1- as shown in illustration and press off swivel joint.   Note Take care not to damage the boot of the drive shaft when applying ball joint puller.

–  Mark installation position of drive shaft relative to flange shaft at gearbox for re-installation. –  Cut through cable tie at gearbox side of drive shaft boot using pliers -3340-.   Caution t  Make sure triple rollers do not drop to the ground when pulling drive shaft apart from flange shaft. t  Hold triple rollers in place and secure with adhesive tape. –  Swivel suspension strut outwards and pull drive shaft apart from flange shaft. –  Repeat procedure on other side of vehicle. –  Tie both drive shafts to front onto longitudinal member.   Note Take care not to damage the surface coating of the drive shafts.

–  Remove bottom bolts on heat shield for gear actuator.   Note Do not open hydraulic pipes at gear actuator. –  Slacken bolt -1- a few turns. –  Detach selector finger -A- from gearbox selector rod. –  Remove bolts -2- and -3-. –  Tie up gear actuator to body as far as possible.   Note

Do not bend the flexible joint (de-coupling element) between starter catalytic converter and main catalytic converter more than 10°, otherwise it could be damaged. –  Support flexible joint with fixing -T40035-.

–  Remove bolts -2- on bracket for starter catalytic converter.   Note Disregard -item 1-. –  Disconnect starter catalytic converter from turbocharger. –  Tie up starter catalytic converter to body.

–  Screw transportation shackle -T40016- onto front right of cylinder head.

–  Screw transportation shackle -T40016/1- onto rear left of cylinder head.

–  Screw both shackles -10-222 A/12- onto transportation shackle -T40016- on rear left of cylinder head. –  Attach the lifting tackle -2024 A- to engine and workshop hoist -VAS 6100- as shown in the 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. –  Slightly lift engine using workshop hoist -VAS 6100-.   Note

Do not loosen nut -3- unless renewing engine mounting. –  Remove bolts -1- and -2- and detach support arm with engine mounting.

–  Remove bolts -2- and move motor/pump unit -3- to side.   Note Disregard -item 1-.

–  Remove bolts -arrows- for gearbox mountings. –  Pull out engine/gearbox assembly from the front. –  Separate gearbox from engine if necessary.