Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

t	Lifting tackle -2024 A-

t	Hose clamps for hoses up to 40 mm -3093-

t	Pin wrench -3212-

t	Open-end spanner -3312-

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

t	Locking pin -T10060 A-

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

t	Workshop hoist -VAS 6100-

t	Drip tray for workshop hoist -VAS 6208-

t	Special tool -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. t  Collect drained coolant in a clean container for re-use or disposal. t  Fit all cable ties in the original positions when installing. –  Move selector lever to position “N” on vehicles with automatic gearbox.

–  If fitted, remove seal from plenum chamber cover -arrows-. –  Detach plenum chamber cover -1- towards the front.

Caution To prevent damage to the electronic components when disconnecting the battery: Observe notes on procedure for disconnecting the battery. –  Disconnect earth wire -arrow- from battery terminal → Rep. Gr.27.   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 expansion tank with cloth and open carefully. –  Open filler cap on expansion tank.

–  Detach caps on engine cover panel. –  Unbolt and remove engine cover panel -arrows-.

–  Remove air duct -1- leading to air cleaner. –  Detach cover -2- from air cleaner.

–  Remove front bumper → Rep. Gr.63. –  Remove air duct in front of charge air cooler -arrows-.

–  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.

–  Remove noise insulation (front and rear) -arrows A ... C-.

–  Unbolt bracket for noise insulation -arrow-.

–  Remove air hoses leading to charge air coolers on left and right side of vehicle -arrows-.

–  Clamp off power-steering hoses at bottom left of engine compartment using hose clamps -3094-. –  Disconnect hoses -arrows- from cooling pipe and catch any escaping hydraulic fluid.

–  Open drain plug -arrow- and drain off coolant.

–  Disconnect connector -1- in bottom right coolant hose. –  Pull out retaining clip -2- and disconnect coolant hose from radiator.

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-. –  Unbolt bracket for ATF pipes (left-side) at engine.

Vehicles up to approx. 11.1997: –  Unplug connectors for headlights and headlight adjustment -arrows-. –  Turn bulb holders for turn signals anti-clockwise and remove from turn signal housing -left arrow-.

–  Unplug connectors -1- and -2- on both horns, disengage electrical wiring at bracket -arrow- and move wiring clear.

Vehicles from approx. 11.1997 onwards: –  Unplug electrical connector -arrow- for headlights on both sides.

–  Unplug electrical connector -2- for indicator lights on both sides. –  Unplug electrical connector -1- at both horns and move wiring clear. All vehicles (continued): –  Lift retaining clip and disconnect coolant hose (top left) from radiator. –  Detach cable for bonnet at lock carrier → Rep. Gr.55.

–  Disconnect vacuum hose -arrow- at cut-off flap connection.

–  Release hose clips -arrows- and remove air hose leading to charge air cooler (left-side).

–  Remove cover -arrow- at power steering fluid reservoir.

–  Unplug connectors located in front of ABS unit -arrows- and move wiring clear. –  Unplug connector for anti-theft alarm on lock carrier (top left) and move wiring clear.

Caution The air conditioner refrigerant circuit must not be opened. Danger of damage to refrigerant lines and hoses. Do NOT stretch, kink or bend refrigerant lines and hoses. –  Detach air ducts (left and right) from radiator -4-. –  Remove bolts -1- and -2- for condenser. –  Unplug connector -3- at air conditioning system pressure switch -F129-. –  Pull condenser up out of its bracket, pivot to side and secure to right-side front wheel with wire. –  Unbolt and remove lock carrier. Place clear of vehicle and ensure that it cannot tip over.

–  Slacken hose clip -3-. –  Unplug connector -4-. –  Pull hose -2- off air cleaner housing. –  Unscrew bolt -1- and remove air cleaner housing.

–  Release hose clips -1- and -2- and remove air hose leading to charge air cooler (right-side). –  Disconnect coolant hose -3-.

–  Remove heat shield above turbocharger -arrows-.

–  Unbolt front exhaust pipe from connection for turbocharger -arrows-.

–  Remove coolant hoses -2-. –  Unbolt coolant expansion tank -arrows 1-. –  Disconnect wiring to coolant shortage indicator switch -F66- and remove coolant expansion tank.

–  Disconnect vacuum hose -arrow- from exhauster pump and move clear to one side.

–  Disconnect vacuum hoses -arrows- from turbocharger and mechanical exhaust gas recirculation valve.

–  Disconnect fuel hoses -arrows- from fuel filter.

–  Unplug connectors -1 ... 3-. –  Unplug connector -4- from injection pump. –  Unplug connector -5- from coolant temperature sender. –  Unplug connectors from glow plugs.

–  Unplug connector -arrow- on engine mounting (right-side).

–  Unplug connector -arrow- from intake manifold pressure sender -G71-. –  Remove cable clamp on cylinder head cover (left-side) and move wiring harness clear to the rear.

–  Unplug connector -arrow- and move wiring for needle lift sender clear.

–  Lift retaining clips -arrows- and detach coolant hoses leading to heat exchanger from coolant pipes. –  Move rear wiring harness at heat shield clear to one side.

–  Unscrew viscous fan (32 mm).

–  Remove poly V-belt cover -arrows-.   Note Watch position of spacer sleeves for poly V-belt cover.

–  Detach cover from tensioning roller of air conditioner compressor.   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-tipped pen for re-installation. –  Slacken off bolt -arrow- of tensioning roller for air conditioner compressor and detach poly V-belt. –  On vehicles with automatic gearbox, unbolt bracket -2- for ATF lines (right-side) from sump.

Caution The air conditioner refrigerant circuit must not be opened. Danger of damage to refrigerant lines and hoses. Do NOT stretch, kink or bend refrigerant lines and hoses. –  Detach both brackets for refrigerant pipes -1- and -3- from sump.

–  Unbolt air-conditioner compressor from bracket -arrows-.

–  Tie up air conditioner compressor onto subframe, leaving refrigerant lines connected -arrow-.

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-tipped pen for re-installation. –  To slacken poly V-belt, use an Allen key to turn tensioner in anti-clockwise direction -arrow- until the two bores align and locking pin -T10060- or -T10060 A- can be inserted. –  Take off poly V-belt.

–  Unbolt poly V-belt pulley at power steering pump -arrows-, using pin wrench -3212- as a counterhold. –  Unbolt power steering pump from bracket and place it on longitudinal member.   Note Pipes of power steering pump remain connected. –  Remove bolts for alternator. –  Detach alternator to front. –  Unbolt wiring from removed alternator.

–  Detach wires -2- and -3- at starter; remove insulator from positive connection on starter. –  Unbolt earth wire -1- from engine support (right-side). –  Unscrew bolts -arrows- securing starter working from gearbox side and remove starter.

Vehicles with automatic gearbox: –  Use special tool -V/175- to unscrew 3 bolts for torque converter through opening for starter (turn crankshaft 1/3 turn further each time).   Note When loosening torque converter bolts, counterhold crankshaft by applying spanner to central bolt on vibration damper.

All vehicles (continued): –  Unscrew engine/gearbox securing bolts (accessible from below).

–  Unbolt cross member -1-. –  Remove front exhaust pipe together with catalytic converter -arrows-.

–  Unplug connector on engine mounting (left-side) and unclip wiring -arrows-. –  Remove rear bolts -1- and -2- on engine supports (left and right).   Note Do not remove the two front bolts on the engine supports.

–  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 bottom nut -1- at engine mountings (left and right). –  Unscrew engine/gearbox securing bolts (top); leave one bolt in place (hand-tight).

–  Loosen bolt -A- (at rear of turbocharger) a few turns and turn brace -B- to side in direction of -arrow-. Then tighten bolt -A- again slightly.   Note In the illustration the engine is shown from the rear with the gearbox removed.

–  Engage lifting tackle -2024 A- on engine and workshop hoist -VAS 6100-.   Note To adjust to the centre of gravity of the assembly, the perforated rails of the support hooks must be positioned as shown.   WARNING Accident risk from loose components of support bracket. The support hooks and retaining pins on the support bracket must be secured with locking pins. –  Unscrew final bolt. –  Raise engine and gearbox using workshop hoist -VAS 6100-.   Note Make sure no wires/pipes are damaged at the top on the bulkhead. –  Remove front bolts on both engine supports and remove engine supports together with engine mountings. –  Lower engine again slightly.   Note Check that all hoses and other connections between engine and body have been detached. –  Guide engine forwards out of engine compartment.

–  On vehicles with automatic gearbox, separate gearbox from engine and at the same time detach torque converter from drive plate. –  Detach engine from gearbox and lift engine forwards out of engine compartment.

–  On vehicles with automatic gearbox, secure torque converter in gearbox using support bridge -30 - 211 A- to prevent it falling out.