Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

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

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

t	Stepladder -VAS 5085-

t	Drip tray for workshop hoist -VAS 6208-

t	Engine bracket -T10012-

t  Tool set for wiper arms -T10369- Procedure   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.

–  Remove engine cover panel -arrows-.

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

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

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

–  Unplug electrical connector -1- at radiator outlet coolant temperature sender -G83-. –  Place drip tray for workshop hoist -VAS 6208- under engine. –  Turn drain plug -arrow- on radiator anti-clockwise, if necessary fit drain hose to connection. –  Disconnect coolant hose -2- (bottom) from radiator (pull out retaining clip).

–  Also disconnect coolant hose at bottom of oil cooler -arrow-, and drain off remaining coolant.

–  Disconnect air hose -arrow- at bottom of resonator.

–  Detach hoses -1-, -3- and -4-. –  Release spring-type hose clips -2- and -5- and remove air hose.

–  Disconnect hoses -1- and -2- from air cleaner housing. –  Remove bolt -3-. –  Take out air cleaner housing. –  Disconnect air intake hose between resonator and lock carrier and take out.

–  Remove battery → Rep. gr.27. –  Unclip front section of trim for battery. –  Remove battery tray -arrows-. –  Detach battery tray from front of air duct.

–  Lever off caps -arrows- on wiper arms -1- with a screwdriver. –  Slacken nuts -2- one turn.

–  Apply puller -T10369/1- to wiper arm -1-, as shown in illustration. –  Apply thrust piece -2- onto wiper shaft. –  Turn bolt -3- in clockwise direction until wiper arm is pulled off wiper shaft. –  Remove nuts and detach windscreen wiper arms.

–  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 -2-.   Note The electrical connector -1- remains connected.

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

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

–  Open wiring duct brackets -arrows-.

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

Vehicles with manual gearbox: –  Disconnect earth cable -1-. –  Disconnect wires -2- and -3- from starter. –  Move wiring clear.

–  Unplug electrical connector -3- for reversing light switch. –  Move engine wiring harness at bracket -2- clear. –  Unscrew nut -1- and remove bracket with wiring from stud.

Vehicles with automatic gearbox: –  Disconnect earth cable -3-. –  Disconnect wires -1- and -2- at starter and move wires clear.

–  Unplug electrical connector -1-. –  Detach vacuum hose -2-. –  Unscrew bolts -arrows- and remove vacuum pump for brake servo.

–  Unplug electrical connectors -1- and -3- at automatic gearbox. –  Unplug electrical connector -2- and move electrical wire clear.

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

Caution Risk of serious damage to gearbox components. Do NOT touch connector contacts in gearbox connector with your hands as static discharge might damage the control unit and the mechatronic unit irreparably. –  Touch vehicle earth with bare hands to discharge any static charge. –  Pull locking device upwards -arrow- and unplug electrical connector -1- for mechatronic unit for dual clutch gearbox -J743-. –  Remove nuts -2- and -3- and detach bracket for electrical wiring from gearbox.

All vehicles (continued): –  If fitted, unplug electrical connector -arrow- at secondary air pump motor -V101-. –  Move wire clear.

–  Detach coolant hoses going to heat exchanger at bulkhead -arrows-.

–  Detach vacuum hose -arrow- going to brake servo at intake manifold.

Vehicles with manual gearbox: –  Unclip securing clips -1- and -2- on both selector cables. –  Pull selector cable end-pieces with selector cables off selector shaft lever and relay lever.

–  Detach cable support bracket from gearbox -arrows- and place to one side.

–  Detach slave cylinder -arrows- and place to one side. Do not open pipes.   Caution Do not press clutch pedal after removing slave cylinder.

Vehicles with automatic gearbox: –  Pry off selector lever cable -3- from lever for selector shaft using a 10 mm open-end spanner -item 1-, or similar. –  Compress retaining tabs on support bracket for selector lever cable -arrows- and pull selector lever cable out of support bracket on gearbox. –  Unplug electrical connector -4- and release electrical wiring at bracket -2-.

Vehicles with dual clutch gearbox: –  Use removal lever -80 - 200- to lever off selector lever cable -2- from selector shaft lever. –  Detach circlip -1- for selector lever cable.   Caution Avoid damage to the selector lever cable. t  Carefully guide selector lever cable out of cable support bracket. t  Take care not to bend or kink selector lever cable.

All vehicles (continued): –  Lift retaining clip and disconnect coolant hose -arrow- (top) from radiator.

–  Detach coolant hoses -1- and -2-.

–  Detach coolant hose -arrow- at expansion tank.

–  Disconnect vacuum hose going to activated charcoal filter at the position marked with an -arrow-.   WARNING The fuel system is pressurised. Wrap a cloth around the connection before opening the system. Then release pressure by carefully loosening the connection.

–  Disconnect fuel supply pipe -2- by pulling release tab. –  Disconnect vacuum line -1- going to activated charcoal filter (press 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-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage. –  To slacken the poly V-belt, turn the tensioner in the direction of the -arrow-. –  Lock the belt tensioner with an angled Allen key. –  Remove poly V-belt.

–  Unplug electrical connector -2-. –  Unscrew wire -1- at alternator. –  Unbolt wiring clamp at alternator and move wiring clear.

–  Unscrew bolts -arrows- and remove alternator.

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

–  Loosen bolts -arrows- of assembly mounting for gearbox approx. 2 turns.   WARNING The air conditioner refrigerant circuit must not be opened.

–  Unplug electrical connector -1- for magnetic clutch of 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.

–  Release retaining hooks -arrows- using a screwdriver and remove air intake grille from bottom of bumper.

–  Protect bumper from scratches using adhesive tape -arrow-. –  Tie up air conditioner compressor together with refrigerant hoses on bumper (refrigerant hoses remain connected).

–  Unplug electrical connector at oil level and oil temperature sender -G266--arrow-.

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

–  Unplug electrical connector -1- for Lambda probe after catalytic converter -G130-. –  Remove the plug connector from the bracket -2- and move the Lambda probe wiring clear.

–  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°. –  Disconnect exhaust system at clamp -1-.

–  Unbolt bracket for exhaust system -arrows-.

–  Unbolt heat shield for drive shaft (right-side) -arrows-. Vehicles with engine codes BGU, BSE, BSF, CCSA

–  Remove securing nuts -arrows- on front exhaust pipe/exhaust manifold. Vehicles with engine code CMXA

–  Remove support -A-.

–  Remove securing nuts -arrows- on front exhaust pipe/exhaust manifold. All models: –  Detach front exhaust pipe with catalytic converter. –  Unbolt drive shafts (left and right) from gearbox flanges. –  Tie up the left drive shaft.   Caution When slackening the flange bolt securing the drive shaft, the wheel bearing must not be under load (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 ... 3- and remove pendulum support.

–  Unscrew sealing bolt -arrow- at front of cylinder block.

–  Attach engine bracket -T10012- with securing 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.   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.