Audi Workshop Service and Repair Manuals

Removing engine - vehicles with front-wheel drive with engine codes BMN, BUY

Special tools and workshop equipment required

t	Removal lever -80 - 200-

t	Hose clamps, up to 25 mm -3094- (only for vehicles with manual gearbox)

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  All cable ties which are released or cut open when removing must be fitted in the same position when installing. t  Collect drained coolant in a clean container for re-use or disposal.

–  Lift off engine cover panel (outside -1- and inside -2-) by pulling up evenly.

–  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-.

–  Remove air intake hose (left-side) by lifting retaining clips -arrows- slightly.

–  Remove air intake hose (right-side) by lifting retaining clips -arrows- slightly.   Caution Seal opening of charge air cooler with a piece of clean foam or similar to prevent coolant from entering.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Pull out retaining clip at the bottom -arrow-, disconnect coolant hose from radiator and drain off coolant. –  Move coolant hose clear at air pipe.

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

–  Unclip air duct at the bottom by releasing clips -arrows-. –  Detach air duct (bottom) together with air hose.

–  Unplug electrical connector -1- at air mass meter -G70-. –  Detach vent hose -3- and air hose -2-. –  Unscrew bolt -4- and remove air cleaner housing.

–  Disconnect coolant hose at bottom of oil cooler -arrow- and drain off remaining coolant.

–  Remove battery → Rep. Gr.27. –  Remove battery tray -arrows-.

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

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

–  Clamp off pressure hose to clutch slave cylinder using a hose clamp -3094-. –  Detach pressure hose -1- from hose connector by pulling securing clip -arrow- upwards.   Caution Do not operate clutch pedal with slave cylinder removed.

All vehicles (continued): –  Detach coolant hoses at the connections indicated -arrows-.

–  Disconnect vacuum hose -arrow- from brake servo.

–  Remove crankcase breather hose -2-. –  Move vent hose -4- and vacuum hoses -3- clear at air intake hose. –  Slacken hose clip -1-. –  Swing air hose to rear and detach from turbocharger.

–  Disconnect electrical connector -1- at charge pressure control solenoid valve -N75-. –  Unscrew nuts and place charge pressure control solenoid valve -N75- on engine (hoses remain connected).   Note Disregard -items 2, 3, 4 and 5-.

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

–  Unclip change-over valve for exhaust gas recirculation cooler -N345--item 2- from bracket. –  Unplug electrical connector -1- and move wiring clear. –  Remove bolts -arrows-.   Note Disregard -items 3, 4, 5 and 6-.

–  Unplug electrical connector -3- for exhaust gas temperature sender 1 -G235- and electrical connector -4- for Lambda probe -G39-. –  Move wiring clear.   Note Disregard -items 1, 2 and 5-.

–  Unscrew Lambda probe -3- → Rep. Gr.23. –  Remove temperature sender before particulate filter -G506--item 5- and move wiring clear. –  Unbolt bracket -2- for pressure pipes. –  Detach pressure pipe -4- from particulate filter. –  Remove exhaust gas pressure sensor 1 -G450- together with pressure pipes. –  Slacken and remove retaining clamp -1- for particulate filter.

–  Detach coolant hose -arrow- at coolant expansion tank.

Caution Rules for cleanliness when working on the injection system → Chapter.   WARNING t  In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with unit injector engine. Allow the fuel to cool down before disconnecting the lines - danger of scalding. t  Wear protective gloves. t  Wear safety goggles. –  Disconnect fuel supply pipe -2- and fuel return pipe -1- by pulling release tabs.

–  Detach coolant hose -2- at front of engine.   Note Disregard -item 1-.

–  Detach fuel supply hose -2- and fuel return hose -1- from fuel pipes.

–  Slacken bolt -1- one turn. –  Remove bolt -2- and nut -3-. –  Remove fuel filter with hoses attached.   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. –  Turn the tensioner in the direction of the -arrow- to slacken the poly V-belt. –  Remove poly V-belt.

–  Unscrew bolts -arrows- and remove alternator.   Note t  If alternator sticks in its bracket, screw bolt back in again down to the last 2 turns. t  Tap carefully on bolt heads with flat side of hammer to release bushes of alternator mountings. –  Swivel alternator towards right side of vehicle with wiring connected.

–  Unplug electrical connector -2-. –  Unscrew wire -1- and wire clamp -3- at alternator. –  Lift out alternator.

–  Unscrew air duct at lock carrier -arrows-.

–  Unscrew top bolts -upper arrows- for radiator cowl.

–  Lever off caps on windscreen wiper arms with a screwdriver. –  Loosen nuts -arrows- several turns.

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

–  Unclip washer jets -arrow-. –  Push washer jet 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.23. –  Unplug electrical connector -2- for engine wiring harness and move connector clear.   Note The electrical connector -1- remains connected.

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

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

–  Unscrew terminal 30 wire -arrow- from electronics box in engine compartment and move it clear.

–  Open wiring duct brackets -arrows-.

–  Unclip electrical connector -1- from bracket and unplug it. –  Open wiring duct bracket located below. –  Unclip engine control unit wiring harness from wiring duct.   Note Disregard -item 2-.   Note

Use removal lever -80 - 200- to lever out the wiring clips.

Vehicles with manual gearbox: –  Disconnect earth cable -1-. –  Unplug electrical connector -2-. –  Push back protective cover and unscrew B+ wire -3- from starter solenoid switch.

–  Unplug electrical connector -2- for reversing light switch. –  Unscrew nut -1- and remove bracket with wiring from stud.

Vehicles with direct shift gearbox: –  Remove cable tie -arrow- for protective cover -1-. –  Unplug electrical connector -2-. –  Push back protective cover and unscrew B+ wire from starter solenoid switch. –  Disconnect earth cable -3-. –  Turn retainer catch anti-clockwise and unplug electrical connector -4- at gearbox.

–  Unplug electrical connector -1-.

All vehicles (continued): –  Unplug electrical connector -arrow- at longitudinal member (bottom left).

–  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-. –  Unscrew the bottom bolts -bottom arrows- and remove radiator cowl from below.

–  Unplug electrical connector -3- at air conditioner compressor.   Note Disregard items marked -1- and -2-.

–  Unplug electrical connector -2- at charge pressure sender -G31-/intake air temperature sender -G42-. –  Remove bolts -1- and -3-. –  Disconnect air pipe from air hose -4- and remove pipe downwards.   WARNING The air conditioner refrigerant circuit must not be opened.   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.

–  Unscrew bolts -1- and -2- and tie air conditioner compressor up to lock carrier.   Note Disregard -item 3-.

–  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.

–  Unbolt heat shield for drive shaft (right-side) -arrows-. –  Unbolt drive shafts (left and right) from gearbox flanges. –  Tie up drive shaft (left-side), push back drive shaft (right-side).

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

–  Unscrew temperature sender after particulate filter -G527--item 1- from exhaust pipe behind particulate filter and move wiring clear. –  Unscrew pressure pipe -2- going to exhaust gas pressure sensor 1 -G450-.

Vehicles with direct shift gearbox: –  Unscrew bolts -1- for support bracket -D-. –  Pull off the retaining clip -A- upwards -arrow- and detach selector lever cable from gearbox.   Note Disregard items -B- and -C-.

All vehicles (continued): –  Remove nuts -1- and -3- and bolt -2- and detach bracket for particulate filter.

–  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°. –  Loosen nuts on clamp -1-.

–  Unbolt bracket for exhaust system -arrows-. –  Take out particulate filter: turn it 180° clockwise and at the same time push engine/gearbox assembly slightly forwards. –  Tie up drive shaft (right-side) towards rear.   Note Take care not to damage the surface coating of the drive shaft.

–  Attach engine bracket -T10012- with securing nut and bolt to cylinder block: approx. 20 Nm. –  Apply engine and gearbox jack -V.A.G 1383 A- to engine bracket -T10012- and raise engine/gearbox assembly slightly.   Note

To unscrew bolts for assembly mounting use stepladder -VAS 5085-. –  Loosen and remove bolts -arrows- of assembly mounting on engine.

–  Loosen and remove bolts -arrows- of assembly mounting on 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. 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.