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  Engine bracket -T10012-

t  Locking pin -T10060 A- for vehicles with air conditioner compressor and tensioner t  Safety goggles t  Protective gloves Procedure   Note t  The engine is removed from underneath together with the gearbox. t  Fit cable ties in the original positions when installing. t  Fit heat insulation sleeves in the original positions when installing.

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 engine cover panel -arrows-.

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

–  Release clips on left and right -arrow A- and unclip air duct at bottom -2-. –  Swivel air duct (bottom) slightly to the rear and detach air duct (bottom) from retainers -3-. –  Detach air pipe -1- from air duct (bottom) -arrow B-.

–  Unplug electrical connector -1- from air mass meter -G70-. –  Detach hose -3-. –  Release hose clip -2- and detach air hose. –  Unscrew bolt -4- and remove air cleaner housing.

–  Remove bolts -arrows- and detach air duct from lock carrier.

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

–  Remove both front wheels. –  Remove noise insulation -1- → Rep. gr.50.

–  A3 Cabriolet: Remove noise insulation frame -arrow- → Rep. gr.50.

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

–  Release hose clips -1- and -2- and remove air hose.

–  Release hose clips -1- and -2- and remove air hose. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Unplug electrical connector -1-. –  Remove bolts -bottom arrows- and take out air cowl downwards.   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 -arrow-, disconnect coolant hose (bottom right) from radiator and drain off coolant.

–  Open hose clip -arrow-, disconnect coolant hose (bottom) leading to pump for exhaust gas recirculation cooler -V400- and drain off coolant.

–  Release hose clip -arrow-, disconnect coolant hose at oil filter housing and drain off remaining coolant.

Vehicles with auxiliary heater: –  Release hose clips -arrows-, disconnect coolant hoses and drain off coolant.

–  Remove bolt -3-. –  Loosen nut -2- and detach exhaust pipe -1- for auxiliary heater.

All vehicles (continued): –  Remove bolts -bottom arrows- on rear side of radiator.   Note The bolts -top arrows- are removed at a later stage.

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

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

–  Press release tabs and disconnect crankcase breather hose -1- from cylinder head cover. –  Move clear vacuum hoses -arrows- at air pipe. –  Remove bolt -2-, swivel air hose with connection to rear and detach from turbocharger.

–  Detach vacuum hose -2- from vacuum unit of turbocharger. –  Disconnect vacuum hose -3-.   Note Disregard -item 1-.

–  Detach vacuum hose from brake servo -arrow-.   Note

Place a cloth underneath heat exchanger to catch escaping coolant. –  Lift retaining clips -arrows- and disconnect coolant hoses from heat exchanger for heater. –  Guide coolant hoses downwards and drain off coolant.

–  Detach electrical connector -3- from bracket, unplug and move clear. –  Move clear electrical wiring from turbocharger.   Note Disregard -items 1, 2-.

–  Slacken bolt -2- and remove clamp.   Note Disregard -items 1, 3-.

–  Remove bolt -1-. –  Push filler pipe with filler neck -2- for washer fluid reservoir to side.   Note t  Disregard -item 3-. t  For illustration purposes, the installation position is shown with the fuel filter removed.

–  Lift off bracket with hoses -arrow-. –  Move clear hoses at bracket -2-. –  Unplug electrical connector -3-. –  Remove bolts -1- and move pressure differential sender -G505- clear to one side.

–  Remove top bolt -arrow- at particulate filter.

–  Unplug electrical connector -1- on fuel temperature sender -G81-.   WARNING The fuel can become extremely hot. This can cause injuries. t  In extreme cases the temperature of the fuel lines and the fuel can be up to 100 °C after the engine is switched off. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles. –  Release hose clips -2- and -4-, then disconnect fuel return hose and fuel supply hose and move clear fuel supply hose -arrow-. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-. –  Release hose clip -3- and detach coolant hose.

–  Release hose clip -1-, detach coolant hose from coolant expansion tank and move coolant hose clear.   Note Disregard -items 2, 3-.

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

–  Unplug electrical connector -A- at high-pressure sender -G65--item B-.   Note Disregard -item C-.

–  Unplug electrical connector -2- at throttle valve module -J338--arrow-.   Note Disregard -items 1, 3, 4-.

–  Detach sealing lip at lock carrier (top). –  Remove bolts -top arrows- at rear and lift out radiator.

–  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. Apply a small quantity of soap solution to transition between windscreen and plenum chamber cover -2-. Then, starting at edge of windscreen, carefully pull plenum chamber cover upwards off retainer at windscreen. –  Pull off plenum chamber cover.   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 bolt and nut -arrows- and detach plenum chamber partition panel.

–  Remove engine control unit → Rep. gr.23.

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

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

–  Release catch -arrow-, detach electrical connector -1- and unplug.

–  Move clear and unplug electrical connector -1-. –  Open retainer for wiring duct -2-. –  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 terminal 30 wire from electronics box in engine compartment and move it clear.

–  Unplug electrical connector -1-.   Note Disregard -arrows-.

Vehicles with manual gearbox: –  Cut open cable tie -arrow- for protective cover -3-. –  Unplug electrical connector -2-. –  Push back protective cover and unscrew B+ cable at starter solenoid switch –  Remove nut -1- for earth wire.

–  Move clear line/pipe -2- at bracket -1-. –  Remove bolt -3- and detach bracket.

–  Lift clip and detach retaining clip -3- for gear selector cable from gearbox selector lever -1-. –  Detach gear selector cable -2- from pin -arrow-.

–  Pull locking device forwards onto stop -arrow 1- and lock by turning anti-clockwise -arrow 2-. –  Press gate relay lever towards front -arrow 3-, take gate selector cable out of end-piece.

–  Remove bolts -arrows-. –  Unclip securing clip -2-. –  Pull selector cable end-piece with selector cable off selector shaft lever. –  Tie selector cables with cable support bracket to one side.

–  Detach brace -1-. –  Remove bolts -arrows-, detach clutch slave cylinder and place to one side. Do not open pipes.   Caution Risk of serious damage to clutch slave cylinder. Do not operate clutch pedal with slave cylinder removed.

–  Loosen bolts -arrows- at gearbox mounting approx. 2 turns.

Vehicles with 7-speed dual clutch gearbox 0AM:   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 eliminate any static charge. –  Unplug electrical connector -1- for mechatronic unit for dual clutch gearbox -J743-. –  Push back terminal cover -4- and unscrew „B+“ cable at starter solenoid switch. –  Remove nut -3- for earth wire.

–  Use removal lever -80 - 200- to prise selector lever cable -2- off gearbox selector lever. –  Pull off securing clip -1-, detach selector lever cable and move clear to one side.   Note Take care not to bend or kink selector lever cable.

–  Loosen bolts -arrows- securing gearbox mounting to gearbox support -1- approx. 2 turns.

All vehicles (continued): –  Unscrew bolts -arrows- at engine mounting approx. 2 turns.

–  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.

–  If fitted, remove bolts -arrows- and detach heat shield for drive shaft (right-side). –  Unbolt drive shafts (left and right) from gearbox flange shaft. –  Tie up drive shaft (left-side).   Note Take care not to damage the surface coating of the drive shaft.

–  Remove nuts -arrow- for coupling rod on anti-roll bar on both sides.

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

–  Mark position of nuts -arrows- securing swivel joint. –  Remove nuts for swivel joint (right-side). –  If fitted, unscrew nut on bracket for front left vehicle level sender -G78-. –  Detach swivel joint from wishbone.

–  Pivot drive shaft (right-side) forwards; to do so, push engine/gearbox assembly slightly forwards. –  Tie up drive shaft to longitudinal member -arrow-.   Note Take care not to damage the surface coating of the drive shaft.

–  Remove nuts -1- and -2- and detach bracket for particulate filter. –  Tie up particulate filter to rear.

–  Remove bolts -arrows-. –  Move coolant hose -3- clear. –  Loosen hose clip -2-. –  Unplug electrical connector -1- at charge pressure sender -G31-/intake air temperature sender -G42- and detach air pipe (right-side).

Vehicles with air conditioner compressor and tensioner:   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-tip pen for re-installation. –  To slacken poly V-belt turn tensioner in clockwise direction -arrow-. –  Lock tensioner with locking pin -T10060 A-. –  Take off poly V-belt.

Vehicles with air conditioner compressor and tensioning roller:   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-tip pen for re-installation. –  Remove bolt -arrow- and detach tensioner to slacken poly V-belt. –  Take off poly V-belt.

All vehicles with air conditioner compressor (continued): –  Unplug electrical connector -2- on air conditioner compressor regulating valve -N280-.   Caution Make sure that air conditioner compressor and refrigerant pipes and hoses are not damaged. Do NOT stretch, kink or bend refrigerant lines and hoses. –  Remove bolts -arrow-, detach air conditioner compressor -1- with refrigerant lines connected and tie up to front.

All vehicles (continued): –  Remove bolt -arrow- and push pump for exhaust gas recirculation cooler -V400- to the side.   Note Disregard -items 1, 2, 3-.

Vehicles with manual gearbox: –  Unplug electrical connectors -2- at reversing light switch -F4- and -3-. –  Unscrew nut -1- and detach bracket for electrical wiring.

All vehicles (continued): –  Release fasteners -arrows- and remove noise insulation -1- for sump.

–  Secure engine bracket -T10012- to cylinder block with bolt -1- and nut -2- (tightening torque: approx. 20 Nm). –  Insert engine and gearbox jack -V.A.G 1383 A- in engine support -T10012- and raise engine/gearbox assembly slightly.   Note

To unscrew bolts for assembly mounting use stepladder -VAS 5085-. –  Remove bolts -arrows- securing engine mounting.

Vehicles with manual gearbox: –  Remove bolts -arrows- securing gearbox mounting.

Vehicles with 7-speed dual clutch gearbox 0AM: –  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 hoses, pipes and wiring connections and to engine compartment. t  Check that all hoses and wiring connections between engine, gearbox, subframe and body have been detached. t  Carefully guide engine/gearbox assembly out of engine compartment when lowering. t  Make sure there is sufficient clearance from air conditioner compressor. –  First lower engine/gearbox assembly only slightly. –  Then swing gearbox end of engine/gearbox assembly forwards and only then lower further.