Audi Workshop Service and Repair Manuals

Removing engine - vehicles with automatic gearbox

Special tools and workshop equipment required

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

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

t	Spark plug connector pliers -V.A.G 1922-

t	Stepladder -VAS 5085-

t	Scissor-type assembly platform -VAS 6131 A- with support set for Audi -VAS 6131/10-

t	Drip tray for workshop hoist -VAS 6208-

Note If the engine is going to be separated from the gearbox (after the entire assembly is removed), you will additionally need supplementary set -VAS 6131/11- and -VAS 6131/12-.

t  Eye-head bolt -3368-

t  Tensioning strap -T10038-

Procedure   Note 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. –  Pull off rubber seal on plenum chamber cover. –  Remove plenum chamber cover -1- to front -arrows-.   Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27.

–  With ignition switched off, disconnect earth strap -arrow- at battery. –  Discharge the refrigerant system → Air conditioner system - with refrigerant R134a. –  Extract hydraulic fluid for power steering from reservoir using used oil collection and extraction unit -V.A.G 1782-.   WARNING Hot steam/hot coolant may escape when opening expansion tank; cover filler cap with cloth and open carefully. –  Open filler cap on coolant expansion tank. –  Remove both front wheels.

–  Release quick-fasteners -1-, unscrew bolts -2- and take off noise insulation.

–  Unbolt bracket for noise insulation -arrows-. –  Remove front wheel housing liners (right and left) → Rep. Gr.66. –  Remove bumper cover (front) → Rep. Gr.63.

–  Remove air duct (left-side) -arrow- in front of auxiliary radiator.

–  Remove air duct (right-side) -arrow- in front of auxiliary radiator.

–  Place drip tray for workshop hoist -VAS 6208- under engine. –  Unscrew drain plug -arrow- at thermostat housing and drain off coolant at engine.

–  Disconnect coolant hose (bottom) at radiator -arrow- and drain off remaining coolant.

–  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Detach hydraulic lines going to cooling pipes (rear left) at lock carrier -arrows-.   Note

Observe rules for cleanliness when working on automatic gearbox → Rep. Gr.00. –  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Unscrew union nuts -arrows- and disconnect ATF lines.

–  Remove cover -1- on left side of engine compartment.

–  Remove cover -1- at right of engine compartment.

–  Disengage solenoid valve 1 for activated charcoal filter system -N80--item 1- at air duct. –  Remove bolts -arrows-. –  Remove air duct -2-.

–  Disconnect coolant hose (top) -arrow- from radiator.

–  Detach electrical connectors -1- and -2- from bracket and unplug. –  Move wiring going to lock carrier clear.

–  Unplug electrical connector -arrow- for headlights on both sides. –  Move wiring clear.

–  Unplug electrical connector -arrow- for airbag sensors (left and right) at lock carrier. –  Move wiring clear. –  Detach cable for bonnet at lock carrier → Rep. Gr.55.

–  Unplug electrical connector -arrow- for fan (right-side).   Note

To prevent damage to the condenser and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent. –  Detach refrigerant line -arrow- leading to AC compressor.

–  Detach refrigerant line -arrow- leading to evaporator for air conditioning system.

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

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

–  Pull off rear engine cover panel -arrows-.

–  Detach the front engine cover panel -arrows 1 and 2-.

–  Detach coolant hoses -1- and -2-. –  Unbolt coolant expansion tank -arrow-. –  Unplug electrical connector for coolant shortage indicator switch -F66- at expansion tank (below).

–  Detach vacuum line -arrow- going to brake servo at bulkhead.

–  Unclip coolant hose -arrow- from bracket at bulkhead.

–  If fitted, detach vacuum line -arrow- going to vacuum reservoir.

–  Detach vacuum hose -arrow- at intake manifold.

–  Disconnect coolant hose -arrow- going to heat exchanger at coolant pipe (rear) on engine.

–  If fitted, separate vacuum line at the point marked with an -arrow-.

–  If fitted, detach electrical connector -arrow- for continued circulation coolant pump -V51- (behind auxiliary radiator, left-side) and move wiring clear.   Note

Lay a cloth under the separating point to catch escaping hydraulic fluid. –  Detach hose -1- at power steering reservoir.   Note Disregard -item 2-.

–  Detach coolant hoses at the connections indicated -arrows-.

–  Detach coolant hoses at the connections indicated -arrows-.

–  Disconnect coolant hose going to oil cooler -arrow-.

–  Detach coolant hoses at the connections indicated -arrows-.

–  Remove bolts -1- and -2-. –  Remove auxiliary radiator (right-side) together with coolant hoses.   Note The hose -arrow- can remain attached to auxiliary radiator.   Caution Rules for cleanliness when working on the injection system → Chapter.   WARNING The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then release pressure by carefully loosening the connection.

Rest-of-world vehicles: –  Disconnect fuel supply pipe -1- and, if fitted, the fuel return pipe -2-.

USA vehicles: –  Unscrew fuel hose from connection at fuel rail pipe. To do so, counterhold on hexagon flats -1- and -3- with open-end spanner and loosen union nut -2-.

All models: –  Unplug electrical connector -2- at activated charcoal filter system solenoid valve 1 -N80-. –  Unplug electrical connector -3- at air mass meter -G70-. –  Disconnect hose -1- leading to secondary air pump. –  Detach air intake hose -4- at air mass meter. –  Move wiring harness at air cleaner housing clear. –  Detach clip -arrow- and remove air cleaner housing together with air mass meter.

–  Detach air hose (right-side) -arrow- at engine.

–  Remove bracket for electrical connectors -1 ... 4- (right-side) from bulkhead.

–  Unscrew nut -1- and detach strip fuse at positive terminal. –  Disconnect positive cable -2- at positive battery terminal. –  Pull out positive cable forwards through bulkhead. –  Move wiring harness clear.   Note Item -3- can be disregarded.

–  Lever off both cover caps -3- with a screwdriver. –  Loosen hexagon nuts -4- several turns. –  Loosen wiper arms -2- from respective wiper shaft by tilting slightly. –  Completely unscrew hexagon nuts and remove wiper arms.   Caution To avoid cracking the cowl panel grille -5- during removal, apply a small amount of soap solution to the joint between the windscreen and the cowl panel grille and pull the grille vertically up out of the fastening strip, starting from the edge of the windscreen. –  Pull off retaining clips -1- and detach cowl panel grille -5-.

–  Remove cover for electronics box in plenum chamber -arrows-.

–  Use a screwdriver to carefully lever out the retaining strap -arrow- and remove the engine control unit from the electronics box.   Note The engine control unit remains connected to the wiring harness.

–  Release retaining hooks -arrows- outwards and remove retaining strap.

–  Disconnect all electrical connectors from the connector point -2- using spark plug connector pliers -V.A.G 1922-. –  Unscrew electrical wiring -1-.

–  Release retainers -arrows- and push auxiliary relay carrier in electronics box upwards to remove. –  Detach the engine wiring harness at electronics box and at bulkhead.

–  Unscrew earth connection -arrow-.

–  Remove bracket for electrical connectors -1 ... 4- (left-side) from bulkhead. –  Move electrical wiring harness clear. –  Place the wiring harness on top of engine and secure the engine control unit to prevent it falling.

–  Unplug electrical connector -1- at secondary air pump motor -V101-. –  Unbolt earth cable -2- at longitudinal member.

–  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Separate the hydraulic pressure line for power steering -arrow- (left-side next to sump).   Note

To prevent damage to the condenser and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent. –  Remove bolts -1- and -2-. –  Detach refrigerant line (right-side) from AC compressor.   Note The refrigerant line (left-side) will be removed in a later step. –  Seal the open connections at AC compressor using clean plugs.

–  Unbolt bracket (left-side) for refrigerant line -arrows-.

–  Unbolt refrigerant line at bracket -arrow-.

–  Remove bolt -arrow- and detach refrigerant line going to AC compressor.

–  Have a 2nd mechanic press the brake pedal.   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). –  Unscrew flange bolt -2- from drive shaft -1- (left and right).

–  Unscrew nuts and bolts -arrows- evenly on both sides of vehicle. –  Take out anti-roll bar.

–  Unplug electrical connector at vehicle level sender. –  Unclip operating rod for front left vehicle level sender -G78- at track control link (bottom).

–  Working from engine compartment, remove outer securing bolt for suspension strut on both sides of vehicle. –  Screw eye-head bolt -3368- from below into bore in suspension turret on both sides of vehicle.   Caution To avoid damaging the bonnet when it is shut, screw in eye-head bolt -3368- only until it is flush with the top surface of the suspension turret. –  Tie up wheel bearing housing on both sides using tensioning strap -T10038- as illustrated.   Caution Before slackening bottom securing bolts for suspension struts, support wheel bearing housings to prevent damage to joints on upper links.

–  Unbolt suspension strut from track control link -arrow-.

–  Remove fasteners -arrows-. –  Unscrew nut -1- and remove cover behind wheel housing.

–  Unbolt guide link -1- and track control link -2- at subframe.

–  Pivot guide link -1- and track control link -2- outwards.   Caution The guide link and track control link must not be allowed to hang down without support. Tie up both links to wheel bearing housing as illustrated -arrows-. –  Repeat procedure on other side of vehicle.

–  Unbolt heat shield -1- for drive shaft (left-side). –  Unbolt drive shaft from flange shaft on gearbox. –  Pivot wheel bearing housing (left-side) outwards and remove drive shaft. –  Repeat procedure on other side of vehicle.   Note

To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°. –  Loosen clamps on exhaust system -arrows- and disconnect exhaust pipes.

–  Unscrew heat shield -A- for propshaft -arrows-. –  Unscrew bolts at gearbox/propshaft flange. –  Push propshaft back towards rear final drive. The constant velocity joints can be moved axially. –  Tie up propshaft to body.   Note

Mark installation position of support bracket for selector lever cable with felt pen. –  Push ball socket -1- of selector lever cable off selector shaft lever. –  Unbolt support bracket from gearbox -arrows-. –  Move selector lever cable clear.   Note Shown in illustration with gearbox support removed.

Set up the scissor-type assembly platform as follows: –  Set up scissor-type assembly platform -VAS 6131 A- with support set for Audi -VAS 6131/10- as follows:

Platform coordinates	Parts of support set for Audi -VAS 6131/10-
B4	/10-1	/10-4	/10-5	/10-11
G3	/10-1	/10-4	/10-5	/10-11
B10	/10-1	/10-2	/10-5	/10-8
G10	/10-1	/10-2	/10-5	/10-8
C15	/10-1	/10-3	/10-5	/10-12
F15	/10-1	/10-3	/10-5	/10-12

–  Initially tighten the support elements on the assembly platform only hand-tight. –  Adjust the scissor-type assembly platform -VAS 6131 A- so that it is horizontal. l  Take note of spirit level (bubble gauge). –  Place scissor-type assembly platform -VAS 6131 A- under engine/gearbox assembly.

–  Position support elements from -VAS 6131/10- at front of engine, as shown in illustration.

–  Position support elements from -VAS 6131/10- at left and right of subframe, as shown in the illustration.

–  Position support elements from -VAS 6131/10- at rear of gearbox, as shown in illustration. –  Turn all spindles for the support elements upwards until all locating lugs make contact with the mounting points. –  Tighten base plates for support elements to 20 Nm on scissor-type assembly platform -VAS 6131 A-.

–  Screw both spindles (at subframe) 2 turns upwards.

–  Screw both spindles (at gearbox) 4 turns upwards.

–  Remove bolts -1-. –  Mark the installation position of the subframe and the two consoles for engine mountings on the longitudinal members with felt-tip pen. –  Unscrew bolts -2-, -3- and -4- in a diagonal sequence and in stages.   Note t  Check that all hoses and wiring connections between engine, gearbox, subframe and body have been detached. t  Carefully guide out engine/gearbox assembly with subframe from engine compartment when lowering to avoid damage. –  Lower engine/gearbox assembly gradually. –  Pull out scissor-type assembly platform -VAS 6131 A- with engine/gearbox assembly from beneath vehicle.