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	Poly V-belt lever -3299- with bracket -3299/1-

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

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

t	Support bridge -30-211 A- for vehicles with automatic gearbox 01V

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

t	Workshop hoist -VAS 6100-

t	Support -T10062-

t  Mud wing compensation plate -T40045- for vehicles with multitronic gearbox 01J or automatic gearbox 01V Procedure   Note t  The engine is removed from the front without the gearbox after removing the lock carrier. t  Heat insulation sleeves removed when taking out the engine are to be reinstalled in the original position. 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 01J or automatic gearbox 01V.   Caution Observe notes on procedure for disconnecting the battery → Rep. Gr.27.

–  Detach rubber seal from plenum chamber cover in direction of -arrow-. –  Detach plenum chamber cover -1- towards the front.

–  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. –  Remove bumper cover (front) → Rep. Gr.63.

–  Vehicles with auxiliary heater: remove bolts -arrows- securing exhaust pipe for auxiliary/additional heater to noise insulation.

–  Release bolts or quick-release fasteners -1- and -2- and take off front noise insulation. –  If fitted, open quick-release fasteners -3- and remove rear noise insulation.

–  Unbolt bracket for noise insulation -arrows-.

–  Place drip tray for workshop hoist -VAS 6208- under engine. Vehicles with drain plug: –  Turn drain plug -2- on radiator anti-clockwise and drain coolant (attach hose to connection if necessary). Vehicles without drain plug: –  Pull out retaining clip and remove radiator outlet coolant temperature sender -G83--item 3-. –  Pull radiator outlet coolant temperature sender -G83- out of hose connection and drain off coolant. All vehicles: –  Detach retaining clip -1- for bottom coolant hose and disconnect coolant hose from radiator.

–  Disconnect coolant hose (left-side) from radiator -arrow-.

–  Also disconnect coolant hose at oil cooler -arrow-, and drain off remaining coolant.

–  Place used oil collection and extraction unit -V.A.G 1782- underneath. –  Detach hydraulic pipes going to cooling pipes at rear of lock carrier -arrows-.

Vehicles with multitronic gearbox 01J or automatic gearbox 01V:   Note Observe rules for cleanliness when working on automatic gearbox → Rep. Gr.00 or → Rep. Gr.37. –  Place used oil collection and extraction unit -V.A.G 1782- under connection. –  Unscrew union nuts -3- and disconnect ATF pipes. –  Remove retainer for ATF pipes (unscrew nuts -1- and -2-).

All vehicles: –  Remove cover -1- at right of engine compartment.

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

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

–  Remove upper coolant hose -1- at radiator. –  Unplug electrical connector -2- for airbag sensors (left and right) at lock carrier. –  Move wiring clear.

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

–  Unplug electrical connector -arrow- for headlights (left and right). –  Detach cable for bonnet at lock carrier → Rep. Gr.55.

–  Unbolt left and right air guides from 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 (left and right) -arrows-. –  Pull bonnet seal away from 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.

–  Pull off engine cover panel (rear) -arrows-.

–  Unbolt retaining plate -3- for solenoid valves -arrows-. –  Detach air intake hose -1- at air mass meter -G70-. –  Disconnect crankcase breather hose -4- at air duct -2-.

–  Unscrew bolt -arrow- and pull air duct -2- off throttle valve module -J338-. –  If fitted, disconnect hose -1- from air duct.   Note Shown from rear with engine removed for illustration purposes.

–  Detach coolant hoses -1- and -2-.   Note Leave coolant hose -3- connected. –  Unbolt coolant expansion tank -arrow-. –  Unplug electrical connector for coolant shortage indicator switch -F66- below coolant expansion tank.

–  Unscrew earth connection -2-. –  Disconnect vacuum hoses -1- and -3-.

USA models: –  Disconnect vacuum hose -arrow- leading to fuel system diagnostic pump -V144- from throttle valve module -J338-.

Vehicles with multitronic gearbox 01J or automatic gearbox 01V: –  Unplug electrical connector -arrow- at vacuum pump for brakes -V192-.

All models: –  Extract hydraulic fluid for power steering from reservoir using used oil collection and extraction unit -V.A.G 1782-. –  Detach hose -1- at power steering reservoir. –  Disconnect vacuum hose -2- going to vacuum reservoir.

–  Unplug electrical connector -bottom arrow- at secondary air pump motor -V101- and move wiring clear. –  Disconnect hose -top arrow- at pipe leading to combination valve for secondary air system.

Vehicles with return line:   WARNING The fuel system is pressurised. Wrap a cloth around the connection before opening the system. Then release pressure by carefully loosening the connection. –  Disconnect fuel supply pipe -1- and fuel return pipe -2-. –  Move fuel lines clear.

Vehicles without return line:   WARNING The fuel system is pressurised. Wrap a cloth around the connection before opening the system. Then release pressure by carefully loosening the connection. –  Unscrew fuel hose from connection at fuel rail pipe. To do so, counterhold on hexagon flats -1- and -3- with open-end spanners and loosen union nut -2-.

All vehicles: –  Disconnect following wiring and electrical connectors: 1 -  On activated charcoal filter solenoid valve 1 -N80- 2 -  Vacuum hose at activated charcoal filter solenoid valve 1 -N80- 3 -  On air mass meter -G70- –  Disconnect hoses, move wiring clear and remove air cleaner housing -arrows-.   Note

Lay a cloth under the hydraulic pressure pipes to catch any escaping hydraulic fluid. –  Unbolt hydraulic pressure line for power steering at rear coolant pipe -1- and disconnect line near cylinder head (right-side) -2-.

–  Lever off caps -3- on windscreen wiper arms with a screwdriver. –  Slacken nuts -4- on both wiper arms a few turns. –  Loosen each of the wiper arms -2- from wiper shafts by tilting slightly. –  Completely remove nuts and take off wiper arms. –  Pull off retaining clips -1- and detach cowl panel grille -5-.

Vehicles with multitronic gearbox 01J or automatic gearbox 01V: –  Unplug electrical connector -arrow- at brake servo pressure sensor -G294-.

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

–  Pry off retainer with a screwdriver -arrows-.

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

Vehicles with automatic gearbox 01V: –  Unclip retaining strap for gearbox control unit. –  Release connector -arrow- and unplug from gearbox control unit.

All vehicles: –  Unplug connectors -2- from rear of connector console and move wiring clear. –  Unscrew electrical wiring -1-.

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

–  If fitted, remove heat shield for connections from bulkhead (left-side). –  Remove electrical connectors -1 ... 4- from bracket (at left on bulkhead). –  Unplug electrical connectors -1- and -4-.

–  Remove electrical connectors -1 ... 4- from bracket (on right side of bulkhead). –  Unplug electrical connectors -1-, -3- and -4-. –  Move Lambda probe wires (left and right) clear. –  Remove brackets for connectors (left and right).

Rest-of-world vehicles: –  Unscrew nut -2- (accessible from above) securing front exhaust pipe to exhaust manifold (left-side).   Note Shown in illustration with engine removed.

–  Unscrew nut -2- (accessible from above) securing front exhaust pipe to exhaust manifold (right-side).   Note Shown in illustration with engine removed.

USA models: –  Unscrew nut -2- (accessible from above) securing front exhaust pipe to exhaust manifold (left-side).   Note Shown in illustration with engine removed.

–  Unscrew nut -2- (accessible from above) securing front exhaust pipe to exhaust manifold (right-side).   Note Shown in illustration with engine removed. All models: –  Disconnect coolant hoses (going to heat exchanger) at rear coolant pipe and at coolant pipe (right-side). To do this, detach wiring harness retaining clamp on right side of vehicle. –  Unscrew engine/gearbox securing bolts that are accessible from above. Leave one bolt in place (hand-tight).

–  Pull off engine cover panel (front) -arrows-.   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. –  Turn the tensioner in the direction of the -arrow- using ribbed belt lever -3299- and mounting bracket -3299/1- to slacken the poly V-belt. –  Remove poly V-belt from power steering pump pulley.

–  Place used oil collection and extraction unit -V.A.G 1782- under engine. –  Drain off engine oil. –  Remove oil filter -2-. –  Remove coolant hose -3- at oil cooler. –  Remove oil cooler -1-.

–  Unbolt refrigerant pipe bracket from sump -arrow-.   Note Illustration shows vehicle with manual gearbox.

–  Unplug electrical connector -1- for magnetic clutch of air conditioner compressor.   WARNING The air conditioner refrigerant circuit must not be opened. –  Unscrew air conditioner compressor from bracket -arrows-. –  Tie up air conditioner compressor and condenser to right side of vehicle, with hoses/pipes connected. –  Detach wiring at alternator.

–  Unscrew bolts -arrows- and remove alternator.   Note t  If alternator sticks in its bracket, screw bolt back in again down to the last 2 turns. t  Tap carefully on bolt heads with flat side of hammer to release threaded bushes of alternator mount.

–  Unbolt heat shield -1- for drive shafts (left and right).

–  Detach electrical wiring -1- and -2- at starter. –  Disconnect earth cable -3-.

–  Pull heat shield -1- off solenoid switch. –  Remove bolts -2- and -3- and detach starter.

Vehicles with automatic gearbox 01V: –  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.

Rest-of-world vehicles:   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.

–  Remove nuts -1- and -3- (accessible from below) securing front exhaust pipe to exhaust manifold (left-side).   Note Shown in illustration with engine removed. –  Move Lambda probe wires clear. –  Detach front exhaust pipe from exhaust manifold (left-side).

–  Remove nuts -1- and -3- (accessible from below) securing front exhaust pipe to exhaust manifold (right-side).   Note Shown in illustration with engine removed. –  Move Lambda probe wires clear. –  Detach front exhaust pipe from exhaust manifold (right-side).

USA models: –  Unscrew bolts -1 … 4- and remove front cross-piece.   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.

–  Remove nuts -1- and -3- (accessible from below) securing front exhaust pipe to exhaust manifold (left-side).   Note Shown in illustration with engine removed. –  Detach front exhaust pipe from exhaust manifold (left-side).   Note The front exhaust pipe remains in vehicle.

–  Remove nuts -1- and -3- (accessible from below) securing front exhaust pipe to exhaust manifold (right-side).   Note Shown in illustration with engine removed. –  Detach front exhaust pipe from exhaust manifold (right-side).

All models: –  If fitted, remove heat shield for engine speed sender -G28- on left side of gearbox and unscrew bolt -arrow-. –  Detach engine speed sender -G28- and move to one side.

Vehicles with manual gearbox: –  Unplug electrical connector -arrow- at reversing light switch -F4- on right side of gearbox. –  Move wiring clear.   Note Illustration shows vehicle with manual gearbox 01E, four-wheel drive.

–  If fitted, unplug electrical connector -arrow- at speedometer sender -G22- on left side of gearbox.   Note Illustration shows vehicle with manual gearbox 01E, four-wheel drive.

Vehicles with multitronic gearbox 01J: –  Release electrical connector -A- in direction of -arrow- and disconnect at gearbox. –  Move wiring harness clear.

Vehicles with automatic gearbox 01V: –  Turn locking lever and unplug connector for gearbox wiring harness -1-. –  Unplug electrical connectors at speedometer sender -G22--item 2- and multi-function switch -F125--item 3-.

All vehicles: –  Mark positions of bolt connections -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.

–  Remove torque reaction support -arrows-.

–  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.   Note On vehicles with four-wheel drive, ensure that the front propshaft joint is not damaged when lifting the engine.

–  Remove bottom engine/gearbox securing bolts -arrows-. –  Lower the engine back down.

Vehicles with manual gearbox or multitronic gearbox 01J:

–  Place compensation plates -T40045- between the wing mounting flange and the body panel underneath, so that the support bracket -10-222 A- does not damage the wing mounting flanges. –  Set up support bracket -10-222 A- behind gas-filled strut on wing panel flanges. l  The spindle is located at the front. –  Insert gearbox support -3147- into centre bolt hole in gearbox bell housing. –  Connect gearbox support -3147- to support bracket -10-222 A-.   Note t  Shown in illustration with engine removed. t  If the routing of the lines was modified and it is not possible to insert gearbox support -3147- into bolt hole in gearbox bell housing sufficiently, use a long M10 bolt and hook -10-222 A/2- instead.

Vehicles with automatic gearbox 01V:

–  Place compensation plates -T40045- between the wing mounting flange and the body panel underneath, so that the support bracket -10-222 A- does not damage the wing mounting flanges. –  Set up support bracket -10-222 A- behind gas-filled strut on wing panel flanges. l  The spindle is located at the front. –  Insert gearbox support -3147- into left bolt hole in gearbox bell housing. –  Connect gearbox support -3147- to support bracket -10-222 A- and hook -10-222 A/2-.   Note Shown in illustration with engine removed.

All vehicles: –  Attach lifting tackle -2024 A- to workshop hoist -VAS 6100- as shown in the 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 support hooks and retaining pins on the lifting tackle must be secured with locking pins -arrows-. –  Unscrew remaining engine/gearbox securing bolt.   Note Check that all hoses and other connections between engine and body have been detached. –  Raise engine with workshop hoist -VAS 6100- until engine mountings are clear. –  Turn spindle of support bracket -10-222 A- to take up slack.   Note Make sure no wires/pipes are damaged on the bulkhead.

Vehicles with automatic gearbox 01V: –  Separate gearbox from engine and at the same time 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 support bridge -30-211 A- to prevent it falling out.