Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

t	Support bracket -10-222 A-

t	Shackle -10-222 A/12-

t	Lifting tackle -3033-

t	Hose clamps for hoses up to 25 mm Ø -3094-

t	Gearbox support -3147-

t	Used oil collection and extraction unit -V.A.G 1782-

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

t	Workshop hoist -VAS 6100-

t	Drip tray for workshop hoist -VAS 6208-

t	Locking pin -T10060 A-

t	Safety goggles

t	Protective gloves

Procedure   Note t  The engine is removed towards front with the lock carrier removed. 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. –  Move selector lever to position “N” on vehicles with multitronic gearbox.   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 bumper cover (front) → Rep. Gr.63.

–  Remove air duct (left-side) in front of charge air cooler -arrows-.

Vehicles with engine code letters BRD, BVA: –  Remove air duct (right-side) in front of charge air cooler -arrow-.

All vehicles: –  Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Open quick-release fasteners -1 … 3- and take off front and rear noise insulation.

–  Unbolt bracket for noise insulation -arrows-.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Unscrew the drain plug -arrow- at coolant hose (bottom left) and drain off coolant.

–  Detach coolant hose (bottom) from radiator -arrow-.

–  Detach air intake hose -1- going to charge air cooler at lock carrier (bottom left).   WARNING The air conditioner refrigerant circuit must not be opened. –  Disengage refrigerant line at bracket -2-.

–  Detach air intake hose -1- at lock carrier (bottom right).

–  Detach resonator from retainer -arrow-.   Note Air intake hose remains connected.

–  Clamp off hydraulic hoses going to cooling pipe for power steering using hose clamps -3094-. –  Place used oil collection and extraction unit -V.A.G 1782- underneath. –  Disconnect coolant hoses -arrows-.

Vehicles with multitronic gearbox:   Note Observe rules for cleanliness when working on multitronic gearbox → Rep. Gr.00. –  Place used oil collection and extraction unit -V.A.G 1782- underneath. –  Disconnect ATF pipes at connection point. –  Unbolt bracket for ATF pipes at engine.

All vehicles: –  Pull off engine cover panel -arrows-.

–  Remove bolts -arrows-. –  Remove air ducts -1- and -2-.

–  Disconnect top coolant hose -1- at radiator. –  Unplug electrical connector -2- for airbag sensors (left and right) at lock carrier.

–  Unplug electrical connector -arrow- for headlights on both sides. –  Detach cable for bonnet at lock carrier → Rep. Gr.55.

–  Detach electrical connectors -1- and -2- from bracket and unplug. –  Move wiring clear.

–  Unplug electrical connectors (left and right) -3- for horns -2-.   Note Disregard -item 1-.

–  Remove bumper -arrows-.

–  Unbolt air cowls (left and right) at radiator -arrows-.

–  Unclip ambient temperature sensor -G17--item 2- from bracket. –  Unscrew bolts -3- and -4- and remove power steering cooling pipe. –  Detach electrical connector -1- at high-pressure sender -G65-.   WARNING The air conditioner refrigerant circuit must not be opened. –  Unscrew securing bolts -arrows- for condenser.   Note To prevent damage to the condenser and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent. –  Pivot condenser downwards with pipes/hoses attached.

–  Remove bolts -arrows- at lock carrier (left and right). –  Remove engine compartment seal from lock carrier and wing panel flanges.

–  Unscrew bolts -arrows- from impact dampers (left and right).   Note A second mechanic is required for removing the lock carrier. –  Remove lock carrier and place down in a secure position.

–  Disconnect vacuum hose going to brake servo at bulkhead -arrow-.

–  Detach coolant hoses -1 ... 3- and unfasten coolant expansion tank -arrow-. –  Unplug electrical connector for coolant shortage indicator switch -F66- at bottom of coolant expansion tank.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Disconnect rear coolant hose from oil cooler -arrow-, and drain off remaining coolant.

–  Disconnect coolant hose -arrow- leading to heat exchanger for heater at rear of engine.

–  Remove air intake hose at intake manifold flap motor -V157- by lifting retaining clip -arrow- slightly.

–  Detach coolant hose at the connection indicated -1-.   Note Disregard -item 2-.

–  Disconnect coolant hose from hose connection for thermostat -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. –  Turn tensioner in -direction of arrow- and lock with locking pin -T10060 A- to slacken the poly V-belt. –  Remove poly V-belt.

–  Counterhold power steering pump pulley with drift to unbolt pulley -arrows-.

–  Unbolt power steering pump -arrows- and tie up to one side; the hoses/pipes remain connected.

–  Unplug electrical connector -1- at air mass meter -G70-. –  Loosen hose clip -2- to remove air intake hose. –  Move clear wiring harness at air cleaner housing and remove air cleaner housing -arrow-.

–  Detach coolant hose from exhaust gas recirculation cooler -arrow-.

–  Unscrew nuts on turbocharger -arrows-.

–  Unplug electrical connector at fuel temperature sender -G81--arrow- and move wiring clear.   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 return pipe -1- and fuel supply pipe -2- from tandem pump.

–  Move clear electrical wiring at bracket for fuel filter. –  Unscrew nuts -arrows- and move fuel filter to side.

–  Unscrew engine/gearbox bolts -4-, -5- and -6- (accessible from above); leave bolt -6- screwed in finger-tight.

–  Unplug electrical connector -arrow- at engine mounting (left-side).

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

–  Unbolt refrigerant pipe bracket from sump -arrow-.

–  Unplug electrical connector -1- for magnetic clutch on air conditioner compressor.   Caution The air conditioner refrigerant circuit must not be opened. –  Unscrew air conditioner compressor from bracket -arrows-.   Note To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent. –  Tie up air conditioner compressor with pipes attached to right-side of vehicle.

–  Disconnect air intake hose from turbocharger -arrow-.

–  Unscrew earth wire -arrow- at engine support (right-side).

–  Unbolt heat shield -1- for drive shaft (right-side).   Note

Do not bend the flexible joint (de-coupling element) in the exhaust system more than 10°, otherwise it could be damaged. –  Loosen clamp -arrow- and push to rear. –  Disconnect exhaust system at clamp. –  Disconnect front exhaust pipe / particulate filter from turbocharger and tie up on body.

–  Remove engine/gearbox bolts -1 ... 3- and -7 ... 11- accessible from below.

–  Detach starter and swivel to one side. –  Unplug electrical connector -3-. –  Unscrew nut -1- for clamp. –  Unscrew nut -2- and detach electrical wiring. –  Detach starter.

–  Mark positions of bolt connections -1- and locating sleeves -2- on bottom of engine mountings (left and right).   Note Different mounting holes are provided for the different engine versions. –  Unscrew nuts -1- (bottom) at engine mountings (left and right).

–  Unplug electrical connector -2- at exhaust gas recirculation cooler change-over valve -N345-. –  If fitted, unplug electrical connector -1- at intake manifold flap valve -N316-.

–  Unplug electrical connector at charge pressure control solenoid valve -N75--arrow- and move wiring harness clear.

–  Pull the release pin -arrow 1- and unscrew knurled nut -arrow 2-.   Note Shown from rear for illustration purposes.

–  Unplug electrical connector at coolant temperature sender -G62--arrow- and move wiring harness clear.   Note Shown from rear for illustration purposes.

–  Unplug electrical connector at engine speed sender -G28--arrow- using assembly tool -T10118-.   Note To release electrical connector without assembly tool -T10118-, press connector on engine speed sender in with a screwdriver and at the same time lift release tab with a thin wire hook. –  Move wiring clear.

–  Unplug electrical connector -arrow- at Hall sender -G40-.

–  Unplug electrical connectors at exhaust gas recirculation valve -N18- / exhaust gas recirculation potentiometer -G212--item 1- and at intake manifold flap motor -V157--item 2-. –  Move electrical wiring harness clear.

–  Unplug electrical connector -2-. –  Unbolt electrical wiring -1- at alternator and move wiring harness clear.

–  Slacken off top nut on left-side engine mounting several turns.

–  Set up support bracket -10-222 A- behind gas-filled strut on wing panel flanges. The spindle is located at the front. –  Engage gearbox support -3147- in bolt hole at top of bell housing as shown in illustration. –  Connect the gearbox support -3147- to support bracket -10-222 A- using shackle -10-222 A/12-.   Note Shown in illustration with engine removed.

–  Attach lifting tackle -3033- to engine and workshop hoist -VAS 6100- as shown in illustration. –  Unscrew remaining engine/gearbox bolt.   Note Check that all hoses and other connections between engine and body have been detached. –  Raise engine until the studs of the engine mountings are clear. –  Turn spindle of support bracket -10-222 A- to take up slack. –  Detach engine from gearbox and lift engine forwards out of engine compartment.