Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

t	Drip tray for workshop hoist -VAS 6208-

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

t	Spring type clip pliers -VAS 5024A-

t	Stepladder -VAS 5085-

t	Engine bracket -T10012-

t	Hexagon key extension, 8 mm -3247-

Engine bung set -VAS 6122-   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. –  Detach engine cover panel with air cleaner → Rep. gr.24.

–  Remove electrical connector -arrow- for Lambda probe (before catalytic converter) from bracket, unplug and move clear.   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 cover -1- over battery. To do so, press release tab -arrow-.   Caution To prevent irreparable damage to the electronic components when disconnecting the battery: Observe notes on procedure for disconnecting the battery.

–  With ignition switched off, disconnect battery earth cable -arrow-. –  Remove battery. → Electrical system; Rep. gr.27.

–  Remove battery tray -arrows-. –  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-.

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

–  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 -1- for reversing light switch. –  Disconnect earth cable -2-. –  Slide cover -3- to rear.

–  Detach wires -1 and 2- at starter and move clear.

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

–  Unscrew the electrical wire -arrow- and move clear up to alternator. –  Remove both front wheels. –  Remove noise insulation → Rep. gr.50.

–  Remove noise insulation (left and right) - fasteners -1 ... 3-. –  Place drip tray for workshop hoist -VAS 6208- beneath engine.

–  To drain off coolant, detach bottom coolant hose -arrow-.

–  Detach top coolant hose from radiator -2-.

–  Detach coolant hoses going to heat exchanger -arrows-.   Note Shown in illustration from rear with engine removed.

–  Unscrew securing bolts -arrows- for front exhaust pipe/turbocharger accessible from above.

–  Disconnect vacuum hose -arrow- leading to brake servo.

–  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.   WARNING Do not press clutch pedal after disconnecting hose leading to slave cylinder.

–  Pull out clip -2- as far a stop in -direction of arrow- and detach hose -1-.   WARNING Fuel supply line is pressurised. Wear safety goggles and protective clothing to avoid possible injury and skin contact. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

–  Mark fuel line -2- and line going to ACF -1-. –  Disconnect fuel line -2- and move clear. –  Disconnect ACF line -1- and move clear. –  Disconnect vacuum line -3- going to activated charcoal filter (press release tabs). –  Lift out ACF.

–  Detach coolant hoses -1 and 2-. –  Discharge air conditioner → Rep. gr.87.

–  Disconnect air conditioner pipe -arrow- from compressor.

–  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.

–  Unscrew bolts -1- from above.

–  Remove air pipe -1 and 2- for charge air cooler.

–  Unplug electrical connector -2-. –  Unscrew the bolts -3- and remove radiator cowl from below.

–  Detach electrical connector -1- from longitudinal member (left-side) and move wire clear.

–  Detach air pipe -arrow- from charge air cooler.

–  Detach air conditioner pipe from condenser -arrow-. –  Unplug connector from charge pressure sender -G31- → Rep. gr.24.

–  Unplug electrical connector at oil level sender -1-. –  Unclip bracket -2-. –  Unplug electrical connector at continued coolant circulation pump -3- and move wiring clear. –  Remove propshaft (front) → Rep. gr.39.

–  Remove heat shield above drive shaft using hexagon key extension, 8 mm -3247-. –  Remove drive shafts (left and right) → Rep. gr.40.

–  Remove underbody cover (right-side) -arrows-.

–  Unplug electrical connector -arrow- for Lambda probe after catalytic converter and move wiring clear.

–  Unscrew remaining securing nuts -arrows- for front exhaust pipe/turbocharger from below. –  Remove support for front exhaust pipe with catalytic converter (unscrew bolts -1 and 2-).   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-.

–  Remove front cross-piece for underbody -arrows-.

–  Unbolt bracket for exhaust system -arrows-. –  Detach catalytic converter with front exhaust pipe.

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

–  Remove additional coolant pump -arrows-.

–  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.