Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

t	Drip tray for workshop hoist -VAS 6208-

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

t	Locking pin -T10060 A-

t	Engine bracket -T10012-

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

t	Stepladder -VAS 5085-

Note t  The engine is removed from underneath together with the gearbox. t  Renew all cable ties which are released or cut open when removing the engine. Refit in the same position when installing the engine. t  Collect drained coolant in a clean container for re-use or disposal.

–  Lift off engine cover panel -arrows-.   WARNING Hot steam/hot coolant may escape when opening expansion tank. Cover cap with cloth and open carefully. –  Open filler cap on coolant expansion tank

–  Remove cover -1- over battery. To do so, press release tab -arrow-.   WARNING Observe notes on procedure for disconnecting the battery. → Electrical system; Rep. gr.27.

–  With ignition switched off, disconnect battery earth cable -arrow-. –  Remove both front wheels.

–  Remove centre noise insulation - fasteners -1 ... 3-.

–  Remove noise insulation (left and right) - fasteners -1 ... 3-.

–  Unplug electrical connector -1- from coolant temperature sender -G2- - radiator outlet. –  Place drip tray for workshop hoist -VAS 6208- beneath engine. –  Turn drain plug -arrow- on radiator anti-clockwise, if necessary fit drain hose to connection. –  Pull off retaining clip for bottom coolant hose and detach coolant hose -2- from radiator.

–  Unplug electrical connector -1- from oil pressure sender. –  Also disconnect bottom coolant hose at coolant pipe -2-, and drain off remaining coolant.

–  Disconnect air intake hose -arrow- at bottom of resonator (loosen hose clip using hose clip pliers -V.A.G 1921-).

–  Detach hose -1- from air cleaner housing. –  Unplug electrical connector -2- from air cleaner housing. –  Remove bolt -3-. –  Disconnect air intake hose -4- from throttle valve unit (loosen hose clip using hose clip pliers -V.A.G 1921-). –  Take out air cleaner housing. –  Disconnect air intake hose between resonator and lock carrier and take out. –  Remove battery. → Electrical system; Rep. gr.27.

–  Remove battery tray -arrows-. –  Detach battery tray from front of air duct. –  Use screwdriver to pry off cover caps on wiper arms and unscrew hexagon nuts. –  Pull wiper arms off wiper shafts and remove.

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

–  Pull off rubber seal -1- on plenum chamber cover. –  Detach plenum chamber cover -2-. –  Detach engine wiring harness at rear plenum chamber panel.

–  Remove plenum chamber intermediate plate -arrows-. –  Remove engine control unit → Rep. gr.24.

–  Unplug engine wiring harness connector -1 and 2-.

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

–  Remove electrical connector -1- for Lambda probe 2 -G108- (before catalytic converter) from bracket and unplug. –  Remove electrical connector -2- for Lambda probe -G39- (before catalytic converter) from bracket and unplug.

–  Open wiring duct brackets -arrows-.

–  Move electrical connector -1- clear and unplug connector. –  Open wiring duct bracket located below -2-. –  Open wiring duct bracket -3-. –  Remove engine control unit wiring harness from wiring duct.

–  Unplug electrical connector -4- for reversing light switch. –  Disconnect earth cable -3-. –  Detach wires -1 and 2- at starter. –  Move wiring clear.

–  Remove the cover above the fuse box (press release tabs -arrows-).

–  Unscrew the electrical wire -arrow- and move clear up to alternator.

–  Detach coolant hose -1-. –  Detach coolant hoses going to heat exchanger at bulkhead -2 and 3-.

–  Detach vacuum hose -3- going to brake servo at intake manifold. –  Disconnect coolant hose -1-. –  Disconnect coolant hose - 2- going to throttle valve unit.

–  Detach top coolant hose from radiator -arrow-.

–  Disconnect coolant hose -arrow- and remove.

–  Unclip securing clips -1- and -2- on both selector cables. –  Pull off selector cable end-pieces from gearbox selector lever and relay lever. –  Detach cable support bracket from gearbox -arrows- and place to one side.

–  Remove the support -1-. –  Detach slave cylinder -arrows- and place to one side. Do not open pipes.   WARNING Do not press clutch pedal after removing slave cylinder.

–  Disconnect coolant hoses -1 and 2- at expansion tank.   WARNING The fuel system is pressurised. Wrap a cloth around the connection before opening the system. Then release pressure by carefully loosening the connection. –  Mark fuel supply and return lines.

–  Detach hose going to activated charcoal filter -1-. –  Disconnect fuel supply line -2- by pulling release tab. –  Disconnect fuel return line -3- by pulling release tab.

–  Disconnect vacuum line -1- going to activated charcoal filter by pressing release tab. –  Disconnect fuel supply line -2- by pulling release tab. –  Disconnect fuel return line -3- by pulling release tab.

–  Lift out activated charcoal filter from retainer with pipes connected -arrow-.   Note Before removing, mark direction of rotation of poly V-belt with chalk or felt-tip pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage.

–  To slacken poly V-belt, turn tensioner in direction of -arrow-.

–  Lock tensioner in position with locking pin -T10060A-. –  Take off poly V-belt.

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

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

–  Unplug electrical connector -1-. –  Release cable retainers -2 and 3- and move electrical wiring clear. –  Remove bumper (front) → General body repairs, exterior; Rep. gr. 63; Front bumper.

–  Detach the refrigerant line bracket at the right longitudinal member -arrow-.

–  Tape off the ends of the wing panels (left and right) using adhesive tape -1-. –  Mark the position of the front end on both wing flanges -2- e.g. using a felt-tip pen -3-. –  Remove bolts -4-.

–  Mark the position of the front end -2- on the longitudinal members e.g. using a suitable pen -1-. –  Remove the upper securing bolts -3- of the front end on the left and right and insert long bolts -4- (e.g. M10×120). –  Remove the securing bolts -5- of the front end.

–  Carefully pull the front end forward. –  Secure the front end on the left and right with a bolt -2- (e.g. M10×120) and bush 10-222 A17.   WARNING The air conditioner refrigerant circuit must not be opened.

–  Unplug electrical connector -1- for magnetic clutch on air conditioner compressor. –  Remove bolts -arrows- for air conditioner compressor.   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. –  Tie up air conditioner compressor together with the connected refrigerant hoses to longitudinal member.

–  Unplug electrical connector -1-. –  Remove electric fan with radiator cowl (unscrew bolts on left and right -arrows-).

–  Remove coolant hose -2- (pull out retaining clip -1-).

–  Unplug electrical connector at oil level sender -arrow-.

–  Remove underbody cover (right-side) -arrows-. Engine code AXW, BLX:

–  Unplug electrical connector -1- from NOx sensor control unit -J583-. –  Detach NOx sensor control unit -J583--arrows- and move wiring with control unit clear. –  Unplug electrical connector -2- for exhaust gas temperature sender 1 -G235- and move wiring clear. –  Unplug electrical connector (black) -3- for Lambda probe after catalytic converter -G130- and move wiring clear. –  Unplug electrical connector (brown) -4- for Lambda probe 2 after catalytic converter -G131- and move wiring clear. Engine code BHD, BMB, BLR, BLY:

–  Unplug electrical connectors for Lambda probes. All vehicles (continued):

–  Remove front cross-piece for underbody -arrows-.   Note To avoid damage, the flexible joints in the front exhaust pipe must not be bent more than 10°.

–  Separate exhaust system at clamp -arrows-.

–  Unbolt bracket for exhaust system -arrows-.

–  Unbolt heat shield for drive shaft (right-side) -arrows-.

–  Remove securing nuts -arrows- on front exhaust pipe/exhaust manifold. –  Remove front exhaust pipe. –  Unbolt drive shafts (left and right) from gearbox flanges. –  Tie up the left drive shaft.

–  Detach coupling rod from anti-roll bar -arrow-.   WARNING The wheel bearing must not be under load when loosening the drive shaft flange bolt (vehicle must not be standing on its wheels). –  Have a second mechanic press the brake pedal.

–  Unscrew flange bolt -2- from drive shaft (right-side). –  Remove drive shaft (right-side).

–  Unscrew bolts -1 and 3- and remove pendulum support.

–  Detach electrical connector -1- from bracket. –  Remove bolts -1 and 3-.

–  Remove bolt -arrow-.

–  Bolt engine bracket -T10012- with securing bolt -1- and nut -2- to cylinder block (tightening torque: approx. 20 Nm). –  Insert engine and gearbox jack -V.A.G 1383 A- in engine bracket -T10012- and raise engine slightly.   Note To unscrew bolts for assembly mounting use stepladder -VAS 5085-.

–  Remove bolts -arrows- of assembly mounting on engine.

–  Remove bolts -arrows- of assembly mounting for gearbox.   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. –  Pull engine/gearbox assembly as far forward as possible, and lower gradually.