Audi Workshop Service and Repair Manuals

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-

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.

–  Remove engine cover -arrows- and cover in front of intake manifold.

–  Unscrew bolt -arrow- and remove cover over expansion tank.

–  Remove front left cover -arrows-.

–  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

–  Remove both front wheels. –  Unbolt bracket for headlight range control sender in wheel housing (left-side, top) -arrows-.

–  Remove centre noise insulation -arrows-.

–  Remove left noise insulation -arrows-.

–  Remove right noise insulation -arrows-.

–  If fitted, detach power steering line from connecting pipe for charge air coolers -arrows-.

–  Unbolt connecting pipe for charge air coolers on left side -arrows-.

–  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.

–  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.

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

–  Remove cross piece -1- for suspension strut -arrows-, if fitted.

–  Disconnect vacuum line and coolant pipe at locations marked with arrows.

–  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.

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.

–  Detach coolant hoses going to to heat exchanger at bulkhead -arrows- by releasing retaining clips.

–  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.

–  Remove battery tray -arrows-.

–  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.

–  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.

All vehicles: –  Release retaining tab (left-side) -arrow- and unplug connector from control unit.

–  Open cable duct (left-side) in engine compartment -arrows-. –  Unplug electrical connector in cable duct.

–  Take electrical connector out of bracket (near left-side headlight) and unplug connector -arrow-. –  Move clear wiring harness between engine control unit and engine.

–  Unbolt cable support bracket from gearbox -arrows-.

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.

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.

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.

–  Unplug electrical connector at charge pressure sender -G31- and unclip wiring from air intake hose. –  Detach air intake hose from throttle valve module -J338-.

–  Remove coolant hose -1- between engine and radiator.

Vehicles with secondary air system: –  Unplug electrical connector -arrow- at secondary air inlet valve -N112-.

Vehicles with exhaust temperature control: –  Unplug electrical connector -arrow- at exhaust gas temperature sender 1 -G235-.

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.

–  Remove air pipe -arrows-.

–  Detach vacuum line -2- from intake manifold. –  Detach coolant hose -1- from coolant pipe/coolant expansion tank.   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. –  Turn the tensioner in the direction of the -arrow- to slacken the poly V-belt. –  Remove poly V-belt.

–  Lock tensioner in position with locking pin -T10060 A-.

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.

–  Loosen bolts -arrows- of assembly mounting for engine approx. 2 turns.

–  Loosen bolts -arrows- of assembly mounting for gearbox approx. 2 turns.

–  Unbolt pulley -1- for power steering pump (counterhold with hexagon key).

–  Use hose clamps -3094- to clamp off both hydraulic hoses to power steering pump.   Note Disregard -item 1-.

–  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-.

–  Detach power steering cooling pipe from gearbox -arrows-.

–  Unplug electrical connector -arrow- for reversing light switch -F4- on gearbox.

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.

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.

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).

–  Unscrew heat shield for drive shaft (right-side) from bevel box -arrows-. –  Unbolt drive shafts (left and right) from gearbox flange shafts.

–  Remove cross piece -arrows-.

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.

All vehicles: –  Unbolt catalytic converter from front exhaust pipe -arrows-.

–  Separate exhaust system at clamp -arrows-. –  Push the clamp back and remove the catalytic converter.

–  Remove rubber mounting -arrow- for front exhaust pipe.

–  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°.

–  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.

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.

Caution After unscrewing the bolts -A-, the engine/gearbox assembly swings slightly forward. –  First remove bolts -A-, then bolts -B- and remove pendulum support.

–  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.

Vehicles with secondary air system: –  Remove bracket for secondary air pump -arrows-.

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.

–  Remove bolts -arrows- of assembly mounting on engine.   Note To unscrew bolts for assembly mounting use stepladder -VAS 5085-.

–  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.