Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required t  Support bracket -10 - 222 A- t  Lifting tackle -2024 A- t  Gearbox support -3147- t  Hose clip pliers -V.A.G 1921- t  Used oil collection and extraction unit -V.A.G 1782- (for vehicles with automatic gearbox) t  Workshop hoist -VAS 6100-

t  Drip tray for workshop hoist -VAS 6208-

t  15 mm socket insert -Matra V/175- for vehicles with automatic gearbox

t  Support bridge -30 - 211 A- for vehicles with automatic gearbox Procedure   Note t  The engine is removed from the front without the gearbox after removing the lock carrier. t  Fit all cable ties in the original positions when installing. t  Collect drained coolant in a clean container for re-use or disposal. –  Move selector lever to position “N” on vehicles with automatic gearbox.

–  Remove seal -arrows-. –  Pull off plenum chamber cover -1- towards front of vehicle.

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.

–  Release quick-release fasteners and remove engine cover panel -arrows-.

–  Detach air cleaner cover -arrow-.

–  Remove bolts -arrows-. –  Remove air duct -1 and 2-. –  Remove front bumper → Rep. Gr.63.

–  Release fasteners -arrows- and remove noise insulation.

–  Unbolt bracket for noise insulation -arrow-.

–  Remove air duct in front of charge air cooler -arrows-.

–  Unclip ambient temperature sensor -G17- from bracket. –  Detach cooling pipe for power steering hydraulic fluid -arrows- and move clear; do not open hydraulic fluid circuit.

–  Place drip tray for workshop hoist -VAS 6208- beneath engine. –  Turn drain plug -arrow- on radiator anti-clockwise, if necessary fit drain hose to connection.

–  Detach coolant hose at bottom of radiator -arrow-.

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

–  Detach air hose going to charge air cooler at lock carrier (bottom left) -arrow-. –  Detach air hose going to turbocharger from lock carrier (bottom right).

Vehicles with automatic gearbox:   Note Observe rules for cleanliness when working on automatic gearbox → Rep. Gr.37. –  Position used oil collection and extraction unit -V.A.G 1782- below connection point. –  Disconnect ATF pipes -arrows-. –  Detach bracket for ATF pipes (left-side) from engine.

All models: –  Unclip and disconnect green electrical connector -arrow- for magnetic clutch of air conditioner compressor at lock carrier (bottom right) and move wiring clear.

–  Unplug electrical connector (left and right) -arrow- for headlights.

–  Unplug electrical connector (left and right) -2- for turn signal indicator. –  Unplug electrical connector -1- at both horns and move wiring clear. –  Detach cable for bonnet at lock carrier → Rep. Gr.55.

–  Detach cover from power steering reservoir. –  Unplug electrical connectors -1 ... 5-. –  Move electrical wiring clear.

–  Detach coolant hose at top of radiator -arrow-.   WARNING The air conditioner refrigerant circuit must not be opened.   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 -4- (left and right) for air cowls from radiator. –  Remove bolts -1 and 2- for condenser. –  Unplug electrical connector -3- at air conditioner pressure switch -F129-. –  Pull condenser up out of its bracket, pivot to side and secure to right-side front wheel with wire.   Note Protect side panel (front) from damage. –  Unbolt and remove lock carrier. Place clear of vehicle and ensure that it cannot tip over.

–  Unplug electrical connectors: 1 -  On activated charcoal filter solenoid valve 1 -N80- 2 -  On air mass meter -G70- 3 -  On charge pressure control solenoid valve -N75- –  Detach solenoid valve 1 for activated charcoal filter -N80- from air cleaner housing. –  Detach hose connections, move electrical wiring clear and remove air filter housing -arrows-.

–  Unplug electrical connector -arrow- at secondary air pump motor -V101- at front right of engine compartment below air cleaner housing.

–  Detach secondary air hose from secondary air pipe -arrow-.

–  Detach coolant hoses -1- and -3-. –  Unbolt coolant expansion tank -2--arrows-. –  Detach electrical wiring at coolant shortage indicator switch -F66- on coolant expansion tank (bottom). –  Detach coolant hose (left-side) going to heat exchanger from coolant pipe (bottom) on engine. –  Disconnect coolant hose (right-side) going to heat exchanger at cylinder head connection.

–  Remove air hose -1-. –  Unplug electrical connector -2- at charge pressure sender -G31-.

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. –  Disconnect fuel supply line -1- and fuel return line -2- and move clear. –  Disconnect vacuum hoses: 3 -  To brake servo 4 -  To active charcoal filter system solenoid valve 1 -N80- 5 -  To vacuum reservoir

–  If fitted, detach hose -arrow-.

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

–  Carefully lever out retaining strap using a screwdriver -arrow-.

–  Release retainer catches -arrows- and unplug electrical connectors -1 and 2- from engine control unit.

–  Release retainer -arrow- and pull auxiliary relay carrier in electronics box upwards to remove. –  Unplug electrical connectors at rear of connector console.

–  Unscrew earth wire -6-. –  Detach electrical connectors -1 ... 5- from bracket. –  Unplug electrical connectors: 1 -  For Lambda probe after catalytic converter -G130- (brown) 2 -  For Lambda probe -G39- (before catalytic converter; black) –  Unhook wiring harness -arrow- and move it clear. –  Unplug electrical connector from speedometer sender -G22- on left of gearbox, and move wire clear. Vehicles with manual gearbox: –  Unplug electrical connector for reversing light switch -F4- from gearbox and move electrical wire clear. All models:   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.

–  Loosen securing bolts on tensioning roller for poly V-belt for A/C compressor -arrows-, slacken belt and remove.   WARNING The air conditioner refrigerant circuit must not be opened. –  Detach air conditioner compressor from bracket and secure to body with wire.

–  To slacken poly V-belt turn tensioner in direction of -arrow-. –  Remove poly V-belt from pulley on alternator.

–  Lock pulley for viscous fan with roll-pin drift -1- and unscrew using hexagon key -2-. –  Detach viscous fan from bearing. –  Remove poly V-belt pulley for power steering pump. –  Unbolt power steering pump and tie up to one side; the hydraulic fluid hoses/pipes remain connected.

–  Remove nuts -arrows- securing catalytic converter to turbocharger.

–  Unbolt bracket for exhaust system -arrow-.   Note To avoid any damage, the flexible joint in the front exhaust pipe must not be bent more than 10°. –  Disconnect exhaust pipe from turbocharger.

–  Detach electrical wires -1 and 2- at starter; remove insulator from positive connection on starter. –  Remove retaining clip -4-. –  Remove bracket for starter from cylinder block -3- and from starter. –  Remove starter from gearbox. –  Remove earth cable from engine support (right-side).

Vehicles with automatic gearbox: –  Unscrew 3 torque converter bolts through starter opening using  15 mm socket insert -Matra V/175- (turn crankshaft 1/3 turn each time).   Note When loosening torque converter bolts, counterhold at the toothed belt sprocket. All models:

–  Loosen top nuts -arrow- on engine mountings (right and left) several turns.

–  Mark position of nuts -1- and locating sleeves -2- on bottom of engine mountings (right and left).   Note Different mounting holes are provided for the different engine versions. –  Remove nut for engine mounting -1- on both sides.

–  Raise engine and gearbox using workshop hoist.   WARNING To avoid injury, ensure adequate support.   Note Make sure no wires/pipes are damaged at the top on the bulkhead. –  Remove bolts (accessible from below) securing engine to gearbox. –  Lower engine again.

–  Position support bracket -10 - 222 A- behind gas-filled strut on bolted flanges of wing panels. The spindle must be at the front. –  Insert gearbox support -3147- into bolt hole in gearbox bell housing. –  Connect gearbox support -3147- to support bracket -10 - 222 A- using hooks -10 - 222 A /2-.   Note Shown in illustration with engine removed. –  Unscrew top engine/gearbox securing bolts; leave one bolt in place (hand-tight).

–  Engage lifting tackle -2024 A- on engine and workshop hoist.   Note To adjust to the centre of gravity of the assembly, the perforated rails of the support hooks must be positioned as shown.   WARNING The support hooks and retaining pins on the lifting tackle must be secured with locking pins -arrows-. –  Remove remaining bolt securing engine to gearbox.   Note Check that all hoses and other connections between engine and body have been detached. –  Raise engine with workshop hoist until the studs of the engine mountings are clear. –  Tighten spindle of support bracket -10 - 222 A- further.

Vehicles with automatic gearbox: –  Separate gearbox from engine and at the same time detach torque converter from drive plate. All models: –  Separate engine from gearbox and guide engine forwards out of engine compartment.

Vehicles with automatic gearbox: –  Secure the torque converter in the gearbox using support bridge -30 - 211 A- to prevent it falling out.