Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

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

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

t	Stepladder -VAS 5085-

t	Drip tray for workshop hoist -VAS 6208-

t	Chain-type pipe cutter -VAS 6254-

t	Locking pin -T10060 A-

t  Setting tool -T40035-

t  Engine support -T40076-   Note t  The engine is removed from underneath together with the gearbox. 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.

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

Collect drained coolant in a clean container for re-use or disposal. –  Place drip tray for workshop hoist -VAS 6208- under engine. –  Unplug electrical connector -1- at radiator outlet coolant temperature sender -G83-. –  Disconnect coolant hose (bottom) at radiator -arrow- and drain off coolant.

–  Disconnect coolant hose from oil cooler -arrow-, guide downwards and drain off remaining coolant.

–  Unscrew all nuts -arrows- at exhaust system/turbocharger.   Note

To avoid any damage, the flexible joint must not be bent more than 10°. –  Support flexible joint (decoupling element) with fixing tool -T40035-.

–  Unbolt heat shield for exhaust system -arrows-.

–  On vehicles with two-piece exhaust pipes, loosen nuts on clamp -4- and move clamp towards rear to separate exhaust system. –  On vehicles with one-piece exhaust pipes, cut through exhaust pipe at a right angle at cutting point -2- using chain-type pipe cutter -VAS 6254-.   Note Disregard -items 1 and 3-.

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

–  Unbolt heat shield for drive shaft (left-side) -arrows-. –  Detach drive shaft (left-side) from flange shaft of gearbox and tie up. –  Remove drive shaft (right-side) → Rep. Gr.40.

Vehicles with engine code letters AMF: –  Detach air intake hose -6- from turbocharger. –  Detach charge pressure control hose -5- at turbocharger and at vacuum unit for charge pressure control. –  Disconnect breather hose -4-. –  Unscrew bolts -3- and detach air pipe from turbocharger.   Note t  The air pipe remains in installation position and is detached upwards at a later stage. t  Disregard -items 1 and 2-.

Vehicles with engine code letters ATL, BHC: –  Detach vacuum hose -1- from vacuum unit for charge pressure control and move it clear. –  Unscrew bolts -2- and detach air pipe from turbocharger.   Note The air pipe remains in installation position and is detached upwards at a later stage. –  Detach air intake hose -3- from turbocharger.

All models: –  Unbolt bracket for air pipe from sump -arrows-.

–  Remove air intake hose -2- (right-side) from charge air cooler.   Note Disregard -item 1-.

–  Unplug electrical connector -arrow- at oil level and oil temperature sender -G266-. –  Move wiring clear.   Note Depending on version, oil level and oil temperature sender -G266- can be located at front of sump.

–  If fitted, unclip bracket -1-. –  Take off engine cover panel -arrows-. –  Remove noise insulation beneath cover.

–  Lever off caps -3 and 4- on two-piece windscreen wiper arm with a screwdriver. –  Slacken nuts on two-piece windscreen wiper arm a few turns. –  Release arms -1 and 2- one after the other by tilting them slightly on the wiper shafts. –  Remove nuts completely and take off two-piece windscreen wiper arm.   Note Use puller (commercially available) to remove wiper arm if necessary.

–  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-.

–  Unscrew nuts and bolts -arrows-. –  Pull fresh air duct forwards and remove by turning it to right side of vehicle.

Vehicles with engine code letters AMF: –  Detach air hose -2- at mechanical exhaust recirculation valve. –  Disconnect vacuum hose -3- at mechanical exhaust gas recirculation valve. –  Disconnect vacuum hose -4- from vacuum unit for intake manifold flap.   Note Disregard -item 1-.

–  Remove air intake hose -2- from charge air cooler.   Note Disregard -item 1-.

Vehicles with engine code letters ATL: –  Remove air hose -3- from intake manifold flap motor -V157- by lifting retaining clip -2- slightly. –  Disconnect vacuum hose -1- at mechanical exhaust gas recirculation valve.

–  Remove air intake hose -2- from charge air cooler. –  Unplug electrical connector at charge pressure sender -G31--item 1-.

All models:   WARNING Risk of scalding - the temperature of the fuel and the fuel lines can be as high as 100 °C. t  Allow the fuel to cool down before disconnecting the lines. t  Wear protective gloves. t  Wear safety goggles. –  Mark fuel supply pipe -2- and fuel return pipe -1-. –  Move fuel lines clear.

–  Detach air intake hose -1- at air mass meter -G70-. –  Unplug electrical connector -3- at air mass meter -G70-. –  Remove nut -2-. –  Disconnect crankcase breather hose -4- at cylinder head cover. –  Pull air pipe out slightly together with air mass meter -G70-.

–  Detach electrical connector -arrow- at heater element for crankcase breather -N79- (if fitted). –  Remove air pipe.

Vehicles with engine code letters ATL: –  Detach electrical connector -arrow- at intake manifold flap motor -V157-. –  Move wiring clear.

All models: –  Pull oil dipstick out of guide tube. –  Remove guide tube for oil dipstick -1-. –  Pull oil filler pipe -2- off oil filler reservoir.

–  Disconnect drain hose -2-. –  Remove water collector -1-.

–  Remove top left coolant hose -items 1 and 2-.

–  Detach coolant hose from hose connection at front of engine -arrow-.

–  Disengage coolant hose from retainer -1- and detach.   Note Disregard -item 2-.

–  Mark coolant supply hose -1- and coolant return hose -2- going to heat exchanger and disconnect coolant hoses at bulkhead.

Vehicles with engine code letters ATL, BHC: –  Unplug vacuum hose -1-. All models: –  Detach vacuum hose -2- (going to brake servo) from tandem pump. –  Move vacuum hoses clear.

–  Detach coolant hoses from coolant expansion tank -arrows- and move top coolant hose clear.

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

–  Unplug electrical connector -4- at reversing light switch -F4-. –  Move wiring clear. –  Unplug electrical connector (terminal 50) -item 3- at starter solenoid switch. –  Unscrew nut -2- and detach B+ wiring. –  Unscrew nut -1- and detach earth wire.

–  Unplug electrical connector -1- for magnetic clutch of air conditioner compressor.   Note Disregard -arrows-.

–  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-. –  Unplug electrical connector -7- at fuel temperature sender -G81-.

–  Unplug electrical connector -arrow- at coolant temperature sender -G62-.

–  Unbolt bracket for wiring harness from coolant connection -arrow-. –  Move clear wiring harness leading to engine.

–  Remove nut -1- and bolt -2- and remove transverse support -A-.

–  Unbolt cable support bracket from gearbox -arrows-.

Caution Do not remove cable end-pieces from selector shaft lever or relay lever. The cable end-pieces must be renewed if they are removed. –  Press locking sleeve in direction of -arrow 2- as far as stop and lock by turning anti-clockwise in direction of -arrow 3- to release cable end-piece for gate selector cable and gear selector cable. –  Disengage cables -1- from cable end-piece.

–  Remove bolts -arrows-. –  Disengage retainer and place slave cylinder to one side (do not open system).   Caution Do not operate clutch pedal with slave cylinder removed.   Note To unscrew bolts for assembly mounting use stepladder -VAS 5085-.

Vehicles with cover for engine mounting –  Remove cover for engine mounting by unscrewing bolts -1 and 2-.

–  Loosen bolts -1 and 3- approx. 2 turns.   Note Disregard -item 2-.

Vehicles without cover for engine mounting   Note Do not loosen nut -3- unless renewing engine mounting. –  Loosen bolts -1 and 2- approx. 2 turns.

All models: –  Loosen bolts -arrows- of gearbox mounting approx. 2 turns.   Note

Mark rotation direction of poly V-belt with chalk or a 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- using a spanner to slacken the poly V-belt. –  Lock tensioner in position by inserting locking pin -T10060 A- in locating holes. –  Remove poly V-belt.

Caution The air conditioner refrigerant circuit must not be opened.   Note To prevent damage to the air conditioner compressor and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent. –  Remove bolts -arrows- for air conditioner compressor. –  Tie air conditioner compressor up to lock carrier.   Note Disregard -item 1-.

–  Unscrew bolts -arrows- and remove pendulum support.

–  Remove bolt -2-.   Note Disregard -item 1-.

–  Remove bolt -2-.   Note Disregard -item 1-.

–  Attach engine support -T40076- to cylinder block with bolt -1- (tightening torque: approx. 20 Nm). –  Insert pin of engine support -T40076- in cylinder block and tighten nut to approx. 20 Nm to secure pin -T40076/2-. –  Insert engine and gearbox jack -V.A.G 1383 A- in engine support -T40076-. –  Raise engine/gearbox assembly slightly.   Note To unscrew bolts for assembly mounting use stepladder -VAS 5085-.

Vehicles with cover for engine mounting –  Remove bolts -1 and 3- and detach support arm with engine mounting -2-.

Vehicles without cover for engine mounting   Note Do not loosen nut -3- unless renewing engine mounting. –  Remove bolts -1 and 2- and detach support arm with engine mounting.

All models: –  Remove bolts -arrows- on gearbox mounting.   Note t  Check that all hoses, pipes and wiring connections between engine, gearbox and body have been detached. t  Carefully guide engine/gearbox assembly when lowering to avoid damage. t  Make sure there is sufficient clearance from air conditioner compressor and between drive shaft and turbocharger. –  Lower engine and gearbox slowly using engine and gearbox jack -V.A.G 1383 A-.