Audi Workshop Service and Repair Manuals

Notes:

• ◆ All cable ties which are released or cut open when removing the engine must be replaced in the same position when installing the engine.
• ◆ The engine is removed from the front without the gearbox.
• ◆ Catch drained-off coolant in a clean container for re-use or disposal.
• ◆ Renew all gaskets and seals.
• ◆ Do not open the air conditioner refrigerant circuit.

• ‒ Obtain radio code on vehicles with coded radio.
• ‒ With ignition switched off, disconnect battery earth strap.
• ‒ → Unscrew bolts -arrows- and remove engine cover panels -A...C-.
• ‒ Remove cover above air cleaner.
• ‒ Remove plenum chamber cover.

• ‒ → Remove noise insulation -arrows-.
• ‒ Remove retaining bracket for noise insulation on subframe.
• ‒ Drain off coolant
• ‒ Remove front bumper:

=> General body repairs; Repair group 63; Front bumper; Removing and installing front bumper

• ‒ Remove lock carrier

=> General body repairs; Repair group 50; Removing and installing lock carrier

• ‒ → Remove viscous fan (counter-hold with pin wrench 3212).

Note:

Viscous fan has left-hand thread: turn in direction indicated.

• ‒ Mark direction of rotation of ribbed belt.
• ‒ → To slacken ribbed belt, turn to the right using a 17 mm ring spanner until the two holes are aligned with each other -arrow- and hold in position with mandrel 3204.

Note:

Mark direction of rotation of ribbed belt. The belt can break if it runs in the opposite direction when refitted.

• ‒ Take off ribbed belt.

• ‒ → Disconnect water hoses -1- and -2-.
• ‒ Remove coolant reservoir (arrows).
• ‒ Unplug connector for coolant level monitor.
• ‒ Remove cover panel from cylinder head cover (cylinder bank 4-6).

• ‒ → Pull off hose -1- going to vacuum reservoir.

• ‒ → Remove air duct -arrows-.

• ‒ → Disconnect fuel supply line and fuel return line -1- and -2-, and move fuel lines clear.
• ‒ Pull hose off ACF valve -3-.

• ‒ → Unplug connector -1- from air mass meter.
• ‒ Unplug connectors -2- from ignition output stages, and move wiring clear.
• ‒ Remove air cleaner.

• ‒ → Unplug connector -1- for lambda probe at bulkhead.
• ‒ Unplug connector -2- for knock sensor.
• ‒ Unplug connector -3-.
• ‒ Move wiring harness clear.

• ‒ → Remove pressure hoses -arrows- between charge air coolers and pressure pipes (right and left).

• ‒ Unscrew and disconnect cable from positive battery terminal.
• ‒ Disconnect positive terminal from battery.
• ‒ → Move wiring harness clear together with cable duct for starter -arrows-.

• ‒ → Fit clamp (special tool 3094) on hose from power steering reservoir to power steering pump.
• ‒ Disconnect power steering hose -arrow-.

• ‒ → Disconnect hydraulic pipe -arrow-.
• ‒ Unplug connector from speedometer sender.
• ‒ Unplug connector from reverse gear switch.

• ‒ → Take off wiper arms -arrows-.
• ‒ Pull clips -1- off water deflector.
• ‒ Pull clips -3- off water deflector (left and right).
• ‒ Take off water deflector.
• ‒ Unbolt cover -2- from electronics box.
• ‒ Open electronics box in plenum chamber.

• ‒ Unclip retainer for engine control unit.
• ‒ → Detach engine control unit, release catches on connectors -2- and -3- and unplug connectors.
• ‒ Unplug connectors -1-.

• ‒ → Pull off brake servo hose -1- at bulkhead.
• ‒ Unscrew and detach earth connection -3-.
• ‒ Unplug connectors -2- and -5- at bulkhead, and pull lower parts of connectors out of their brackets.
• ‒ Pull connectors -4- out of bracket and move wiring clear.
• ‒ Remove bracket for plug connectors.
• ‒ Pull both heater hoses off engine. To do this, disengage retainers on connector flange.

• ‒ → Remove pressure hoses -arrows- between turbocharger and charge air cooler (left and right sides).

• ‒ → Move starter cable -1- clear. To do this, cut open cable tie and unclip retainer -arrows-.
• ‒ Remove alternator cooling hose -2-.

• ‒ → Unbolt earth cable -arrow- from engine support.

• ‒ → Release hose clamp -arrow-.
• ‒ Remove intake pipe -1-.
• ‒ Remove water pipe -2-.

• ‒ → Remove torque reaction support -1-.
• ‒ Release hose clamps -arrows-.
• ‒ Remove water pipe -2-.

• ‒ Place drip tray V.A.G 1306 under engine.
• ‒ Remove oil filter.
• ‒ → Release hose clamps -arrows-.
• ‒ Remove oil cooler -1-.

• ‒ → Unscrew exhaust gas temperature sensor -1- from right-hand turbocharger using special tool 3035.
• ‒ Detach heat shield -2- from left and right turbochargers.
• ‒ Unscrew upper bolts -3- from front exhaust pipes at left and right turbochargers.

• ‒ → Detach guard plates -arrows- above left and right drive shafts from gearbox.

• ‒ → Release hose clamps -1- from left and right turbocharger guard plates.
• ‒ Unbolt left and right exhaust pipes -2- from turbochargers.

• ‒ → Detach air conditioner pipes from sump -arrows-.

• ‒ → Disconnect gearbox oil pipes -1-.
• ‒ Detach oil pipe at turbocharger -2-.

• ‒ → Remove air conditioner compressor -1...3-.
• ‒ Move compressor clear to the side and attach it to the body with wire, leaving the pipes connected.

Notes:

• ◆ Note position of guide bushes when installing.
• ◆ When installing, insert bolt -1- into compressor first.

• ◆ To prevent damage to the condenser and refrigerant pipes/hoses. ensure that the pipes and hoses are not stretched, kinked or bent.

• ‒ → Mark positions of securing points -1- and locating sleeves -2- under engine mountings on right and left sides.
• ‒ Unscrew nuts -1- at engine mountings on left and right sides.

Note:

When installing, ensure that locating sleeves -2- engage in position.

• ‒ Set up support bar 10-222A with 10-222A1 on bolted flanges of wing panels.
• ‒ → Using support bar 10-222A with 10-222A1 and extension 10-222A3, lift engine upwards.
• ‒ Unscrew engine/gearbox bolts from underneath.
• ‒ Remove support bar.
• ‒ Unscrew engine/gearbox bolts from above.

• ‒ → Attach lifting tackle 2024 A at rear right and front left, and secure attachment points.

Note:

To balance the centre of gravity of the engine, secure the hook attachments in the positions shown in the illustration.

• ‒ Remove front left wheel.
• ‒ Support gearbox with trolley jack.
• ‒ Bring workshop crane into position and hook up lifting tackle.

Note:

Check that all hoses, pipes and electrical wires between engine and gearbox have been disconnected.

• ‒ Carefully pull out engine towards the front until there is sufficient clearance.
• ‒ Guide engine forwards out of engine compartment.
• ‒ Remove spacer plate between engine and gearbox.