Audi Workshop Service and Repair Manuals

Notes:

• ◆ The following procedures are described for vehicles with electronic throttle, secondary air system and exhaust gas recirculation system. The procedures for older vehicles without these features are the same, except that some of the steps will not be required.
• ◆ The engine is removed from underneath together with the gearbox.
• ◆ All cable ties which are opened or cut open when removing the engine must be replaced in the same position when installing the engine.
• ◆ Catch drained-off coolant in a clean container for re-use or disposal.

• ‒ Obtain code on vehicles with coded radio/integrated radio and navigation system.
• ‒ With ignition switched off disconnect battery earth strap.

• ‒ Open cap on coolant expansion tank.
• ‒ → Remove engine cover panel -arrows-.

• ‒ → On vehicles with automatic headlight range control, unbolt bracket for headlight range control at top of left wheelhousing -arrows-.

• ‒ → Remove noise insulation in the centre and on left and right sides -arrows-.

• ‒ Place drip tray V.A.G 1306 below engine.
• ‒ → Turn drain screw -1- on radiator anti-clockwise, if necessary fit drain hose to connection and drain coolant at radiator.
• ‒ Pull off bottom coolant hose retaining clip -2- and remove coolant hose from radiator.

• ‒ → In addition, detach coolant hose from bottom of oil cooler -arrow- and drain off remaining coolant.

• ‒ → Disconnect secondary air pump intake hose -1- from air cleaner housing.
• ‒ Unscrew bolt -7-.
• ‒ Disconnect air hose -2- from air mass meter.
• ‒ Unplug electrical connector -3- from air mass meter.
• ‒ Unscrew bolts -5- and -6-.
• ‒ Remove air cleaner housing and pull off vent hose -4- from behind.

• ‒ → Unplug electrical connector -3-.
• ‒ Disconnect hoses -1- and -4-.
• ‒ Remove air duct by releasing hose clip -2-.

• ‒ Open lid of main fuse box towards front of vehicle.
• ‒ → Remove protective cover -2- for wires.
• ‒ Unscrew black wire -1- from fuse bar.
• ‒ Remove battery.

• ‒ → Remove battery platform -arrows-.

• ‒ → Detach secondary air inlet valve -N112 from bracket on bulkhead -arrow-.

• ‒ → Disconnect hoses -1 ... 4-.

• ‒ → Disconnect coolant hoses (going to heat exchanger) at bulkhead -arrows- by releasing clips.

• ‒ → Disconnect and remove the coolant hoses at the shown points -1 ... 4-.

Note:

In the picture shown on vehicle with automatic gearbox.

Vehicles with automatic gearbox

• ‒ → Unplug electrical connections:

•     1 -    for solenoid valves (10-pin connector)
•     2 -    for road speed sender -G68
•     3 -    at multi-function switch -F125
•     4 -    at gearbox speed sender -G38

• ‒ Disengage wiring harness from retainers and move to one side.

All models

• ‒ → Unbolt earth wire -1- on engine/gearbox flange.
• ‒ Disconnect wires -3- and -4- from starter.
• ‒ Unplug connector -2- and pull out of retainer.
• ‒ Disengage wires from retainer on starter and move wires to one side.

Vehicles with manual gearbox:

• ‒ Unplug connector for reversing light switch on gearbox.

All models

• ‒ → Lever off cover caps -arrows- from wiper arms with a screwdriver. Loosen the hex nuts several turns.
• ‒ Loosen wiper arms -1- by moving them around gently on the wiper shafts.
• ‒ Remove hexagon nuts completely and take off wiper arms.
• ‒ Pull rubber seal -2- off plenum chamber cover.
• ‒ Detach cover from plenum chamber -3- and move clear towards windscreen.

• ‒ → Release left retainer catch -arrow- and unplug control unit connector.

• ‒ → Open cable duct on left side of engine compartment -arrows-.
• ‒ Unplug connector in cable duct

• ‒ → Take electric connector out of retaining clip and disconnect -arrow-.
• ‒ Release control unit wiring harness as far as engine.

Vehicles with manual gearbox (until approx. 07/98):

• ‒ → Pull the clip upwards -arrow- and press down the selector cable -2-.
• ‒ Detach gear selector cable -1-.

Vehicles with manual gearbox (from approx. 08/98):

Disconnect both selector cables at gearbox as follows:

• ‒ → Mark position of both selector cables on threaded rods -1-. Use waterproof felt-tip pen.
• ‒ Pull threaded collar in direction of arrow -2- (towards ball joint) to compress spring, then turn collar clockwise (arrow -3-) to lock in position.
• ‒ Disengage both selector cables.

All vehicles with manual gearbox:

• ‒ → Unclip clutch slave cylinder hose from selector cable support bracket.
• ‒ Remove selector cable support bracket from gearbox and place to one side -arrow-.

• ‒ → Remove the gearbox brace -arrow A- from the gearbox.

• ‒ → Remove clutch slave cylinder -arrows- and secure with wire; do not disconnect pipe.

Note:

Do not depress clutch pedal after removing slave cylinder.

Vehicles with automatic gearbox

• ‒ → Using a screwdriver, press selector cable -1- off selector lever on gearbox -4-, and pull retainer clip -3- off support bracket.
• ‒ Detach selector cable and move to one side.
• ‒ Unbolt bracket for power steering pressure pipe from gearbox support.

• ‒ → Detach power steering pipe from gearbox -arrows-.

All models

• ‒ → Disconnect coolant hoses -1- and -2-.

Note:

Before removing the ribbed belt, mark the direction of rotation with chalk or a felt pen. If a used belt rotates in the wrong direction when refitted, it can break.

• ‒ → To slacken ribbed belt, turn belt tensioner in direction of arrow.
• ‒ Remove ribbed belt.

Note:

→ The tensioning element must be secured with a suitable pin or mandrel of4.5 mm dia. and about 55 mm long. On vehicles without headlight washer system conrod support 3090 may also be used.

• ‒ → Press release catches and disconnect fuel supply line -1- and fuel return line -2.

• ‒ → Loosen the bolts -arrows- on the engine mounting ...

• ‒ → ... and the bolts on the gearbox (about 2 turns only).
• ‒ Unscrew fan cowl securing bolts accessible from above.

• ‒ Detach pulley from power steering pump using a mandrel as a brace.
• ‒ → Unplug connector -1- at power steering pressure switch -F88.
• ‒ Unbolt power steering pump -arrows-. Do not disconnect pipes/hoses.

Vehicles with manual gearbox

• ‒ → Detach power steering pipe from gearbox -arrows-.

All models

• ‒ → Disconnect hoses and connector from secondary air pump. Remove secondary air pump -arrows-.

• ‒ → Unplug both radiator fan connectors on fan cowl (bottom left).
• ‒ Reach in from beneath and unscrew bolts on fan cowl.
• ‒ Detach cowl together with the two fans and remove by pulling out from below.
• ‒ Tie up power steering pump with pipe on lock carrier panel

• ‒ → Pull retainer lugs -arrows- to disengage grille panel, then remove grille.

Vehicles with air conditioner:

• ‒ → Disconnect magnetic clutch connector -1- from A/C compressor.

• ‒ Unscrew bolts -arrow- for A/C compressor.

• ‒ → Unscrew air conditioner compressor mountings, lower out compressor with refrigerant hoses connected, and secure compressor to towline anchorage -arrow- with wire.

Note:

Use adhesive tape to prevent scratching bumper.

• ‒ → Unbolt connector cover -1- (-arrows-).
• ‒ Unplug electrical connectors and move clear wiring for lambda probes.

• ‒ → Remove heat shield for right drive shaft -arrows-.

Note:

The flexible pipe connection (de-coupling element) on the front exhaust pipe must not be bent more than 10 °- otherwise it can be damaged.

• ‒ → Unscrew retaining nuts -arrows- for front exhaust pipe/exhaust manifold.

• ‒ → Slacken clamp -arrows- on exhaust system and disconnect exhaust pipe.
• ‒ Pivot front exhaust pipe 180° and detach.

• ‒ → First remove bolts -A- , then remove bolts -B- on the pendulum support.
• ‒ Remove pendulum support.

• ‒ → Unbolt connecting link at right wishbone -arrow-.
• ‒ Unbolt left and right-hand drive shafts from gearbox flange.

Note:

Use adhesive tape to prevent scratching bumper.

• ‒ Turn the front wheels to the right.
• ‒ Press the engine forwards, at the same time swing the right drive shaft forwards.
• ‒ Tie up right drive shaft on towline anchorage with a loop of wire.

• ‒ Move left-hand drive shaft towards rear of vehicle.

• ‒ → Remove support bracket for secondary air pump -arrows-.

• ‒ → Bolt engine bracket T10012 to cylinder block with securing nut and bolt. Tighten to about 20 Nm.
• ‒ Fit engine/gearbox jack V.A.G 1383 A to engine bracket T10012 and raise engine/gearbox slightly.

Note:

Use step ladder VAS 5085 for access to engine compartment from above.

• ‒ → Remove engine/gearbox assembly mounting bolts on engine side -arrows- ....

• ‒ → ...and likewise on gearbox side.

Notes:

• ◆ Make sure that all hoses, pipes and wiring between engine, gearbox and body have been disconnected.
• ◆ The engine/gearbox assembly must be carefully guided while it is being lowered to avoid any damage.

• ‒ Pull engine/gearbox assembly as far forward as possible, and lower gradually.