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 25 mm Ø -3094-

t	Pin wrench -3212-

t	Engine and gearbox jack -V.A.G 1383 A-

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

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

t	Workshop hoist -VAS 6100- or workshop hoist -V.A.G 1202 A-

t	Drip tray for workshop hoist -VAS 6208- or drip tray -V.A.G 1306-

t	Locking pin -T10060- or -T10060 A-

t	Support -T10062-

Procedure   Note t  The engine is removed from the front without the gearbox after removing the lock carrier. 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/automatic gearbox 01V.   Caution Observe notes on procedure for disconnecting the battery → Electrical system; Rep. Gr.27.

–  Detach rubber seal from plenum chamber cover in direction of -arrow-. –  Detach plenum chamber cover -1-, if fitted.

–  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. –  On vehicles with auxiliary/additional 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-. –  Remove front bumper → General body repairs, exterior; Rep. Gr.63.

–  Remove air ducts in front of charge air coolers (left and right) -arrows-.

–  Place drip tray for workshop hoist -VAS 6208- or -V.A.G 1306- under engine. Vehicles with coolant drain plug: –  Unscrew coolant drain plug -1- in coolant hose connection -2- and drain coolant (fit hose to hose connection if necessary). –  Detach coolant hose from bottom of radiator.

Vehicles without coolant drain plug: –  Pull off retaining clip -1- on coolant temperature sender. –  Pull coolant temperature sender out of coolant hose connection and drain off coolant. –  Detach coolant hose from bottom of radiator.

All vehicles: –  Remove air intake hoses -1- and -2- going to charge air coolers (left and right).

–  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- under connection. –  Disconnect coolant hoses -arrows-.

–  Place used oil collection and extraction unit -V.A.G 1782- under connection.   Note Observe rules for cleanliness when working on automatic gearbox → Rep. Gr.00 or → Rep. Gr.37. –  Unscrew union nuts -3- and disconnect gear oil pipes/ATF pipes. –  Remove clamp -2- for gear oil pipes/ATF pipes.   Note If necessary, also detach gear oil/ATF oil pipes from gearbox → Rep. Gr.34 or → Rep. Gr.37.

–  Pull off engine cover panel -arrows-.

–  Detach air cleaner cover -2-, if fitted. –  Remove air duct -1- going to air cleaner housing.

–  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.

–  Remove electrical connectors -1- and -2- from bracket. –  Unplug electrical connectors and move wiring clear.

–  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 refrigerant lines, 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). –  Disconnect bonnet lock cable at bonnet lock. –  Pull bonnet seal off lock carrier and wing panels.

–  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 coolant hoses -1 ... 3-. –  Unbolt coolant expansion tank -arrow-. –  Disconnect electrical connector for coolant shortage indicator switch -F66- at bottom of coolant expansion tank and remove expansion tank.

–  Place drip tray for workshop hoist -VAS 6208- or drip tray -V.A.G 1306- under engine. –  Disconnect coolant hose -arrow- and press hose downwards to drain off remaining coolant.

–  Remove heat shield above turbocharger -arrows-.

–  Disengage retaining clips -arrows- and disconnect coolant hoses (going to heat exchanger) from coolant pipes. –  Move rear wiring harness at heat shield clear to one side.

–  Detach vacuum hose -1-. –  Detach vacuum hose -2- for exhauster pump on bulkhead. –  Slacken engine wiring harness clamp on cylinder head cover (left-side).

–  Disconnect hoses -arrows- at turbocharger and mechanical exhaust gas recirculation valve. –  Move hoses clear.

–  If fitted, disconnect vacuum pipe -arrow- at cut-off flap.

–  Detach air intake hose -1- going to charge air cooler (left-side) from intake manifold. –  Unplug electrical connector -2-.

–  Unscrew viscous fan (32 mm).

–  Release fasteners -arrows- and remove toothed belt cover (left and right).

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

–  Unscrew bolts -arrows- and remove torque reaction support together with stop for torque reaction support.   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. –  Slacken off bolt -arrow- of tensioning roller for air conditioner compressor and detach poly V-belt for air conditioner compressor.   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. –  To slacken poly V-belt, use an Allen key to turn tensioner in direction of -arrow- until the two bores align and locking pin -T10060- or -T10060 A- can be inserted. –  Detach poly V-belt for power steering pump, alternator and viscous fan.

–  Unbolt poly V-belt pulley at power steering pump -arrows-, using pin wrench -3212- as a counterhold. –  Unbolt power steering pump from bracket and tie up.   Note Pipes of power steering pump remain connected.

–  Slacken hose clips -arrows- and remove air intake hose going to charge air cooler (right-side).

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

–  Remove air intake hose -arrows-.

–  Unplug electrical connectors -1 ... 3-. –  Detach electrical connector -4- at injection pump. –  Unplug electrical connector -5- at coolant temperature sender -G62-. –  Detach electrical connectors at glow plugs. –  Move wiring harness clear.

–  Unplug connector -arrow- and move wire for needle lift sender -G80- clear to the side.

–  Disconnect fuel hoses -arrows- from fuel filter. –  Unscrew nuts and detach fuel filter together with bracket from bulkhead.

–  Remove noise insulation -1- in wheel housing (left-side).

–  Unbolt heat shield -arrows- for drive shaft (left-side) -1-.

–  Unbolt front exhaust pipe from starter catalytic converter -1-.

–  Unscrew bolt -arrow- at bracket for front exhaust pipe.   Note Illustration shows vehicle with manual gearbox.

–  Loosen clamps on exhaust system -arrows- and disconnect exhaust pipes. –  Detach front exhaust pipe with main catalytic converter.

–  Unbolt refrigerant pipe bracket -arrow- from sump.   WARNING The air conditioner refrigerant circuit must not be opened.

–  Unplug electrical connector -1- at air conditioner compressor regulating valve -N280-.   Note To prevent damage to the refrigerant lines, ensure that the pipes and hoses are not stretched, kinked or bent. –  Unscrew air conditioner compressor from bracket for power steering pump and oil cooler -arrows-.

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

–  Unplug electrical connector at oil level/temperature sender -G266--arrow-. –  Move wiring clear.

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

–  Remove bolts -arrows-. –  Pivot alternator to front and unscrew electrical wires.

–  Unscrew earth wire -1- at engine support (right-side). –  Detach electrical wires -2- and -3- at starter. –  Remove starter bolts -arrows- from gearbox side. –  Detach starter.

Vehicles with automatic gearbox: –  Unscrew 3 bolts -arrow- for torque converter, working through opening of removed starter (turn crankshaft 1/3 turn each time).   Note When loosening torque converter bolts, counterhold crankshaft by applying spanner to central bolt on vibration damper.

All vehicles: –  Mark position of nuts -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).

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

–  Attach support -T10062- at tapped holes for torque reaction support and tighten to 20 Nm. –  Using engine and gearbox jack -V.A.G 1383 A-, lift engine just far enough to remove bottom engine/gearbox securing bolts.

–  Unscrew engine/gearbox securing bolts that are accessible from below -arrows-.   Note On removal, note down bolt lengths and original installation position for re-installation. –  Lower the engine back down. –  Unscrew remaining engine/gearbox securing bolts that are accessible from below -arrows-.

–  Unscrew nuts -1- and remove starter catalytic converter. –  Unscrew engine/gearbox securing bolts that are accessible from above; leave one bolt in place (finger-tight).   Note On removal, note down bolt lengths and original installation position for re-installation.

–  Slacken off bolt -A- (at rear on turbocharger) a few turns and turn brace -B- aside in direction of -arrow-. –  Re-tighten bolt -A- finger-tight.   Note The engine is shown in the illustration from the rear, with gearbox removed.

–  Attach lifting tackle -2024 A- to engine and workshop hoist -VAS 6100- or -V.A.G 1202 A- as shown in illustration.   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 hook attachments and locating pins on the lifting tackle must be secured with locking pins. –  Unscrew remaining engine/gearbox securing bolt.   Note Check that all hoses and other connections between engine and body have been detached. –  Lift engine until studs are clear of engine mountings.   Caution t  Support gearbox from below using a trolley jack. t  Do not support automatic gearbox 01V by positioning trolley jack at gearbox oil pan.   Note Make sure no wires/pipes are damaged at the top on the bulkhead.

Vehicles with automatic gearbox 01V: –  Separate automatic gearbox from engine and simultaneously detach torque converter from drive plate All vehicles: –  Detach engine from gearbox and lift engine forwards out of engine compartment. Vehicles with automatic gearbox 01V: –  Secure the torque converter in the gearbox (using wire or similar) to prevent it falling out.