Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

t	Removal lever -80 - 200-

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

t	Stepladder -VAS 5085-

t	Engine bung set -VAS 6122-

t	Drip tray for workshop hoist -VAS 6208-

t	Hose clip pliers -VAS 6362-

t  Hook -2024 A /1- of lifting tackle -2024 A-

t  Locking pin -T10060 A- t  Engine support -T10416- with adapters -T10416/1-, -T10416/2-, -T10416/3- Procedure   Note t  The engine is removed from underneath together with the gearbox. t  Fit cable ties in the original positions when installing.   WARNING The fuel system operates at extremely high pressure. This can cause injury. t  Do not open the high-pressure section of the injection system when removing the engine. t  However, if the engine has to be removed for repair procedures which necessitate opening the high-pressure section, the fuel pressure in the high-pressure section must be reduced in a controlled manner to a residual pressure prior to opening. –  Reduce fuel pressure in high-pressure section of injection system → Rep. gr.24.

WARNING Hot steam/hot coolant can escape - risk of scalding. t  The cooling system is under pressure when the engine is hot. t  To allow pressure to dissipate, cover filler cap on coolant expansion tank with cloth and open carefully. –  Open filler cap on coolant expansion tank.

–  Remove both front wheels. –  Remove noise insulation → Rep. gr.50.

–  Remove front left and front right wheel housing liners (front section) → Rep. gr.66.

–  Unplug electrical connector -1- at radiator outlet coolant temperature sender -G83-.   Note Collect drained coolant in a clean container for re-use or disposal. –  Place drip tray for workshop hoist -VAS 6208- beneath engine. –  Lift retaining clip -3-, disconnect coolant hose (bottom left) from radiator and drain off coolant.   Note Disregard -item 2-.

–  Lift retaining clips -1- and -2- and disconnect coolant hoses (bottom right) from radiator. Drain remaining coolant. –  Move coolant hose clear -arrow-.

–  Pull cover -1- off air duct (release clips on sides -arrows-).

–  Unclip air duct at the bottom by releasing clips -arrows-.

–  Release hose clip -1- and detach air hose from turbocharger. –  Disconnect vacuum hose -2-. –  Unscrew bolt -3- and remove air cleaner housing.

–  Remove battery → Electrical system; Rep. gr.27.

–  Remove bolts -arrows- and take out battery tray -1-.

–  Release hose clip -arrow- and disconnect coolant hose (bottom) from coolant expansion tank.

–  Release hose clip -1- and detach coolant hose (top) from coolant expansion tank. –  Disconnect vacuum hose -2- from activated charcoal filter and move hose clear.

–  Disconnect fuel supply pipe -2- (pull release ring). –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.   Note Disregard -item 1-.

–  Press release tab at bottom of bracket and unhook bracket -arrow- from timing chain cover (top) with coolant hoses still attached.

–  Lift retaining clips -1- and -2- and disconnect coolant hoses from heat exchanger for heater.

–  Unplug electrical connector -1-. –  Detach vacuum line -2- from brake servo.

–  Lift retaining clip -arrow- and disconnect coolant hose (top left) from radiator.

–  Remove bolts -top arrows- for radiator cowl. –  Move coolant hose -2- clear.   Note t  The bolts -bottom arrows- are removed at a later stage. t  Disregard -item 1-.

Vehicles with manual gearbox: –  Unclip securing clip -1- for gear selector cable. –  Detach cable end-piece from gearbox selector lever.   Note Disregard -item 2-.

l  To prevent damage to gate selector cable, cable end-piece must be detached from gate selector cable before removing –  Pull locking device forwards as far as stop -arrow 1- and lock by turning anti-clockwise -arrow 2-. –  Then press selector relay lever towards front -arrow 3-.

–  Remove bolts -arrows-, detach cable support bracket from gearbox and place to one side.

–  Remove bolts -arrows- and place clutch slave cylinder to one side. Do not open pipes.   Caution Avoid damage to clutch slave cylinder. Do not operate clutch pedal with slave cylinder removed.

Vehicles with dual clutch gearbox: –  Use removal lever -80 - 200- to prise selector lever cable -2- off gearbox selector lever. –  Detach circlip -1- for selector lever cable.   Caution Avoid damage to the selector lever cable. Do not press the selector lever cable rearwards out of the cable support bracket. The selector lever cable is guided out of the cable support bracket at a later stage when lowering the engine/gearbox assembly.

All vehicles (continued): –  Remove wiper arms → Electrical system; Rep. gr.92.

–  Unclip washer jets -arrow-. –  Push washer jets through assembly opening back into plenum chamber, leaving hoses connected.

–  Remove seal -1-.   Caution Risk of damage to plenum chamber cover. To avoid cracking the plenum chamber cover -2- during removal, apply a small amount of soap solution to the joint between the windscreen and the plenum chamber cover and pull the plenum chamber cover vertically up out of the windscreen surround, starting from the edge of the windscreen. –  Pull off plenum chamber cover -2-   Note

Use removal lever -80 - 200- to lever out the wiring clips when performing the next work steps.

–  Move clear engine wiring harness at rear of plenum chamber partition panel. –  Remove bolts -arrows- and detach plenum chamber partition panel.

–  Remove engine control unit → Rep. gr.24. –  Unplug electrical connector -1- for engine wiring harness.   Note Disregard -item 2-.

–  Release wiring protector for engine wiring harness -arrow- and lift off.

–  Open retainers for wiring duct -arrows-.   Note Disregard -item 1-.

–  Move clear and unplug electrical connector -1-. –  Open retainer -2- of wiring duct -arrow-. –  Remove wiring harness for engine control unit from wiring duct and place on engine.

–  Unplug electrical connector -arrow- at longitudinal member (bottom left).   Note For illustration purposes, the installation position is shown from below.

–  Slide the two clips in the direction of the -arrows- and remove cover from electronics box in engine compartment.

–  Remove nut -arrow-, detach „B+“ wire from electronics box in engine compartment and move wire clear.

–  Unscrew bolts -arrows- at engine mounting approx. 2 turns.

Vehicles with manual gearbox: –  Loosen bolts -arrows 1- at gearbox mounting approx. 2 turns.   Note Disregard -arrows 2-.

Vehicles with dual clutch gearbox: –  Loosen bolts -arrows- at gearbox mounting -1- approx. 2 turns.

Vehicles with manual gearbox: –  Remove nut -1- and detach earth wire.   Note On some versions the earth wire may be attached to the engine mounting. –  Remove nut -3-, detach electrical wiring and move clear. –  Unplug electrical connector -2- and move clear.

–  Unplug electrical connector -2- for Lambda probe -G39-. –  Unplug electrical connector -4- for reversing light switch -F4-. –  Move engine wiring harness clear at bracket -3-. –  Unscrew nut -arrow- and detach bracket with electrical wiring from stud. 1 -  Electrical connector for Lambda probe after catalytic converter -G130-

–  If fitted, unplug electrical connector -2- for gearbox neutral position sender -G701-.   Note Disregard -item 1-.

Vehicles with dual clutch gearbox: –  Unplug electrical connector -2- and move wiring clear. –  Push back protective cover -1- and unscrew „B+“ cable at starter solenoid switch. –  Remove nut -3- for earth wire.

–  Remove electrical connector -3- for Lambda probe after catalytic converter -G130- from bracket and unplug connector. –  Unplug electrical connector -2- for Lambda probe -G39- and -1- for dual clutch gearbox and move connectors clear. –  Move clear electrical wiring harness at gearbox.

All vehicles (continued):   Caution If a used belt runs in the opposite direction when it is refitted, this can cause breakage. Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen for re-installation. –  To slacken poly V-belt, turn tensioner in anti-clockwise direction -arrow-. –  Use locking pin -T10060 A- to lock poly V-belt tensioner and detach poly V-belt.

–  Unplug electrical connector -1- for air conditioner compressor regulating valve -N280-.   WARNING Risk of injury caused by refrigerant. The air conditioner refrigerant circuit must not be opened. –  Remove bolts -arrows- for air conditioner compressor.   Caution Danger of damage to refrigerant lines and hoses. Do NOT stretch, kink or bend refrigerant lines and hoses. –  Tie up air conditioner compressor together with refrigerant hoses to longitudinal member (refrigerant hoses remain connected).

–  Unplug electrical connector -1- at oil level and oil temperature sender -G266-. –  Unclip bracket -2- for wire to oil level and oil temperature sender -G266- from subframe.

Caution Avoid damage to flexible joint. Do NOT bend flexible joint in front exhaust pipe more than 10°. –  Remove nuts -2-.   Note Disregard -items 1, 3-.

–  Remove nuts -2- and -3- and disconnect exhaust system. –  Remove bolts -1- and -5-. –  Pull bracket -4- for exhaust system off studs on front exhaust pipe. –  Detach front exhaust pipe. –  Unbolt drive shaft (left and right) from gearbox flange shaft.

–  Remove bolts -1, 2, 3- and remove pendulum support.

–  Unplug electrical connector -1-. –  Remove bolts -bottom arrows- and take out air cowl downwards.

–  Unscrew nuts -arrows- for swivel joint (left-side). –  If fitted, loosen nut on bracket for front left vehicle level sender -G78-. –  Detach swivel joint from wishbone.

–  Swing suspension strut (left-side) outwards and support with support bracket -2024 A /1- as shown in illustration.   WARNING Accident risk from loose components of support bracket. Secure retaining pin and swivel joint with locking pin -arrow- and nut -1-.

Use engine support -T10416- with adapters -T10416/1-, -T10416/2- and -T10416/3- to lower engine/gearbox assembly.

–  Screw adapter -T10416/1- into hole on cylinder block as far as stop, as shown in illustration. –  Bring engine bracket -T10416- with adapters -T10416/2- and -T10416/3- into position on cylinder block.

–  Screw in bolt -1- by hand until it makes contact. –  Tighten all bolts on engine support to 20 Nm. –  Attach engine and gearbox jack -V.A.G 1383 A- to engine support -T10416-.   Note t  The adjusting nut -2- is used to set the correct angle between the pin on the engine support -T10416- and the engine and gearbox jack -V.A.G 1383 A-. t  To unscrew bolts for assembly mounting use stepladder -VAS 5085-.

–  Remove bolts -arrows- securing engine mounting.

Vehicles with manual gearbox: –  Remove bolts -arrows 1- securing gearbox mounting.   Note Disregard -arrows 2-.

Vehicles with dual clutch gearbox: –  Remove bolts -arrows- securing gearbox mounting -1-.   Caution Avoid damage to the selector lever cable. t  Guide the selector lever cable out of the cable support bracket when lowering the engine/gearbox assembly. t  Take care not to bend or kink selector lever cable. All vehicles (continued):   Caution Danger of damage to hydraulic lines, vacuum lines or electrical wiring and to engine compartment. t  Check that all hydraulic lines, vacuum lines and electrical wiring between engine, gearbox, subframe and body have been detached. t  Carefully guide out engine/gearbox assembly with subframe from engine compartment when lowering. –  Pull engine/gearbox assembly as far forward as possible, and lower gradually.