audi Workshop Repair Guides

Audi Workshop Service and Repair Manuals

Separating engine and gearbox > < Removing and installing engine
Removing engine
   
Removing engine
t  Hose clamps for hoses up to 25 mm Ø -3094-
t  Drip tray for workshop hoist -VAS 6208- or -V.A.G 1306-
t  Engine and gearbox jack -V.A.G 1383 A-
t  Hose clip pliers -V.A.G 1921-
t  Stepladder -VAS 5085-
t  Engine bracket -T10012-

   
t  Locking pin -T10060 A-
  W00-10235
t  Used oil collection and extraction unit -V.A.G 1782-
Procedure
  Note
t  The engine is removed from underneath together with the gearbox.
t  The following description corresponds to the removal and installation on vehicles with secondary air system. Certain work steps may not apply to vehicles without secondary air system.
t  All heat insulation sleeves which are removed must be fitted in the same position when installing.
t  All cable ties which are released or cut open when removing must be fitted in the same position when installing.
t  Collect drained coolant in a clean container for re-use or disposal.
  W00-10211
–  Remove engine cover -arrows- and cover in front of intake manifold.
  A10-0515
–  Unscrew bolt -arrow- and remove cover over expansion tank.
  A10-1164
–  Remove front left cover -arrows-.
  A10-1254
–  Note (if necessary obtain) code on vehicles with coded radio / radio and navigation system (RNS).
–  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
  A10-1255
–  Remove both front wheels.
–  Unbolt bracket for headlight range control sender in wheel housing (left-side, top) -arrows-.
  A10-0458
–  Remove centre noise insulation -arrows-.
  A10-1256
–  Remove left noise insulation -arrows-.
  A10-1144
–  Remove right noise insulation -arrows-.
  A10-1145
–  If fitted, detach power steering line from connecting pipe for charge air coolers -arrows-.
  A10-1152
–  Unbolt connecting pipe for charge air coolers on left side -arrows-.
  A10-0461
–  Unbolt connecting pipe for charge air coolers on right side and detach air intake hoses from charge air coolers -arrows-.
–  Remove connecting pipe for charge air coolers.
  A10-0460
–  Place drip tray for workshop hoist -VAS 6208- under engine.
–  Turn drain plug -1- on radiator anti-clockwise and drain coolant (attach hose to connection if necessary).
–  Disconnect coolant hose from radiator by pulling off retaining clip -2- at bottom.
  A19-0276
–  Disconnect bottom coolant hose from oil cooler -arrow-, and drain off remaining coolant.
  A10-0162
–  Remove cross piece -1- for suspension strut -arrows-, if fitted.
  A10-1135
–  Disconnect vacuum line and coolant pipe at locations marked with arrows.
  A10-1249
–  If fitted, detach air intake hose -1- leading to secondary air pump at air cleaner housing.
–  Release hose clip -2- and detach air intake hose from air mass meter -G70-.
–  Unplug electrical connector at air mass meter -G70- -item 3-.
–  Unscrew bolts -4- and -5- and remove air cleaner housing.
  A10-0443
Detach air duct between air cleaner and turbocharger as follows:
–  Remove pressure control valve of crankcase breather -1- and mechanical air recirculation valve -2- from air duct.
–  Detach hose going to activated charcoal filter at non-return valve -3-.
–  Disconnect electrical connector -4- at charge pressure control solenoid valve -N75-.
–  Detach hoses -5- and -6- from charge pressure control solenoid valve -N75-.
–  Detach air duct -7- from connection on turbocharger and pull out hose -5-, guiding as required.
  A10-1253
–  Detach coolant hoses going to to heat exchanger at bulkhead -arrows- by releasing retaining clips.
  A10-0911
–  Open cover -1- of main fuse box.
–  Unclip protective cover -3- for electrical cables.
–  Unscrew black wire -2- at fuse block.
–  Remove bracket for main fuse box -arrows-.
–  Remove battery.
  A10-1258
–  Remove battery tray -arrows-.
  A10-1259
–  Unscrew earth wire -1- at engine/gearbox connection.
–  Detach electrical wiring -3- and -4- at starter.
–  Detach electrical connector -2- from bracket and unplug.
–  Disengage wiring from bracket on starter and move it clear to the side.
  A37-0195
–  Use screwdriver to pry off caps on wiper arms -arrows- and slacken off nuts several turns.
–  Loosen wiper arms -1- from wiper shafts by tilting slightly.
–  Remove nuts completely and take off wiper arms.
–  Pull off rubber seal -2- and plenum chamber cover -3-.
–  Detach the washer hose and electrical connectors at windscreen washer jets.
–  Lay aside plenum chamber cover (towards windscreen).
Vehicles with protective housing for engine control unit:
–  Remove protective housing for engine control unit → Rep. Gr.24.
  A92-0015
All vehicles:
–  Release retaining tab (left-side) -arrow- and unplug connector from control unit.
  A10-0454
–  Open cable duct (left-side) in engine compartment -arrows-.
–  Unplug electrical connector in cable duct.
  A10-0453
–  Take electrical connector out of bracket (near left-side headlight) and unplug connector -arrow-.
–  Move clear wiring harness between engine control unit and engine.
  A10-0915
–  Unbolt cable support bracket from gearbox -arrows-.
  N34-1039
Vehicles up to 06.2001:
–  Press locking sleeve in direction of -arrow 1- as far as stop and lock by turning anti-clockwise in direction of -arrow 2- to release cable end-piece for gate selector cable and gear selector cable.
–  Disengage cables from cable end-piece.
  N34-1087
Vehicles from 07.2001:
–  Unclip retaining clip -1- from gear selector cable and retaining clip -2- from gate selector cable.
–  Pull selector cable end-pieces with selector cables off selector shaft lever and relay lever.
  A34-0620
All vehicles:
–  Clamp off hydraulic line to clutch slave cylinder using a hose clamp -3094-.
–  Pull out retainer towards the top -arrow- and disconnect hydraulic line -1- from hose connector.
  Caution
Do not press clutch pedal after disconnecting hydraulic line.
  A10-0937
–  Unplug electrical connector at charge pressure sender -G31- and unclip wiring from air intake hose.
–  Detach air intake hose from throttle valve module -J338-.
  A10-0457
–  Remove coolant hose -1- between engine and radiator.
  A10-0927
Vehicles with secondary air system:
–  Unplug electrical connector -arrow- at secondary air inlet valve -N112-.
  A10-1251
Vehicles with exhaust temperature control:
–  Unplug electrical connector -arrow- at exhaust gas temperature sender 1 -G235-.
  A26-0490
All vehicles:
–  Unplug electrical connector -right arrow- at continued coolant circulation pump -V51-.
–  Unbolt continued coolant circulation pump -V51- from radiator cowl -left arrows- (coolant hoses remain connected).
–  Unscrew bolts for radiator cowl which are accessible from above.
  A10-0465
–  Remove air pipe -arrows-.
  A10-0442
–  Detach vacuum line -2- from intake manifold.
–  Detach coolant hose -1- from coolant pipe/coolant expansion tank.
  Note
  A10-1250
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.
  A13-0083
–  Lock tensioner in position with locking pin -T10060 A-.
  N13-10135
  WARNING
The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection.
–  Disconnect fuel supply pipe -1- and fuel return pipe -2- by pressing release tabs.
  A10-0140
–  Loosen bolts -arrows- of assembly mounting for engine approx. 2 turns.
  A10-0125
–  Loosen bolts -arrows- of assembly mounting for gearbox approx. 2 turns.
  A10-0126
–  Unbolt pulley -1- for power steering pump (counterhold with hexagon key).
  A48-0118
–  Use hose clamps -3094- to clamp off both hydraulic hoses to power steering pump.
  Note
Disregard -item 1-.
  A10-1252
–  Unplug electrical connector -1- at power assisted steering pressure switch -F88-.
–  Place used oil collection and extraction unit -V.A.G 1782- under power steering pump.
–  Disconnect hydraulic hoses from power steering pump.
–  Unscrew power steering pump from bracket -arrows-.
  A10-0920
–  Detach power steering cooling pipe from gearbox -arrows-.
  A10-0459
–  Unplug electrical connector -arrow- for reversing light switch -F4- on gearbox.
  A10-1158
Vehicles with secondary air system:
–  Unplug electrical connector at secondary air pump motor -V101-, detach hoses and remove nuts -arrows-.
–  Detach secondary air pump.
–  Release wiring harness leading to body from retainers, etc.
  A10-0464
All vehicles:
–  Detach electrical connectors -arrows- for radiator fan on bottom left of radiator cowl.
–  Unscrew bolts on radiator cowl (accessible from below) and remove radiator cowl with both fans from below.
  A10-0415
Vehicles with air conditioning:
–  Unplug electrical connector -1- for magnetic clutch of air conditioner compressor.
  WARNING
The air conditioner refrigerant circuit must not be opened.
–  Unscrew bolts -arrow- for air conditioner compressor.
–  Tie up air conditioner compressor together with refrigerant hoses to radiator (refrigerant hoses remain connected).
  A10-0941
–  Unscrew heat shield for drive shaft (right-side) from bevel box -arrows-.
–  Unbolt drive shafts (left and right) from gearbox flange shafts.
  A10-10260
–  Remove cross piece -arrows-.
  A10-1140
Vehicles with 2 Lambda probes:
–  Unbolt protective cover -2--arrows-.
–  Unplug electrical connector for Lambda probe after catalytic converter -G130--item 1- and move wiring clear.
  A24-0457
All vehicles:
–  Unbolt catalytic converter from front exhaust pipe -arrows-.
  A39-0273
–  Separate exhaust system at clamp -arrows-.
–  Push the clamp back and remove the catalytic converter.
  V26-0733
–  Remove rubber mounting -arrow- for front exhaust pipe.
  A26-0515
–  Unbolt front exhaust pipe from turbocharger connection and move to rear.
  Note
t  The top bolts securing the front exhaust pipe are accessible through the brake pipe opening in the right wheel housing (remove plug).
t  To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°.
  A26-0260
–  Mark position of flexible coupling on bevel box.
–  Unbolt propshaft with flexible coupling from bevel box -arrows-.
  Note
When loosening the bolts, counterhold using a suitable lever at the triangular flange.
  V34-2101
  Caution
Avoid damaging the seal -arrow- in the propshaft flange when removing. If a seal is damaged the propshaft must be renewed.
–  Push propshaft horizontally as far back as possible.
  V39-1817
  Caution
After unscrewing the bolts -A-, the engine/gearbox assembly swings slightly forward.
–  First remove bolts -A-, then bolts -B- and remove pendulum support.
  N34-0712
–  Unbolt coupling rod from anti-roll bar -arrow- on left and right side of vehicle.
–  Push engine forward. At the same time swivel right drive shaft towards front and tie up with wire.
–  Tie up left-side drive shaft with wire.
  Note
Take care not to damage the surface coating of the drive shafts.
  A10-1141
Vehicles with secondary air system:
–  Remove bracket for secondary air pump -arrows-.
  A10-1159
All vehicles:
–  Attach engine bracket -T10012- with nut and bolt to cylinder block: approx. 20 Nm.
–  Insert engine and gearbox jack -V.A.G 1383 A- in engine bracket -T10012- and raise engine slightly.
  N10-0056
–  Remove bolts -arrows- of assembly mounting on engine.
  Note
To unscrew bolts for assembly mounting use stepladder -VAS 5085-.
  A10-0125
–  Remove bolts -arrows- of assembly mounting for gearbox.
  Note
Check that all hoses, pipes and wiring connections between engine, gearbox and body have been detached.
–  Pull engine/gearbox assembly as far forward as possible, and lower gradually using engine and gearbox jack -V.A.G 1383 A-.
  Note
Carefully guide engine/gearbox assembly when lowering to avoid damage.
  A10-0126

Separating engine and gearbox > < Removing and installing engine