Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Shackle -10 - 222 A /12-

t	Removal lever -80 - 200-

t	Lifting tackle -2024 A-

t	Pin wrench -3212-

t	Workshop hoist -VAS 6100-

t  Drip tray for workshop hoist -VAS 6208-

t  Hose clip pliers -VAS 6362-

t  Locking tool -T40098- Procedure   Note t  The engine is removed upwards without gearbox. t  Fit cable ties in the original positions when installing.

Caution To prevent irreparable damage to the electronic components when disconnecting the battery: Observe notes on procedure for disconnecting the battery. –  Disconnect earth wire -2- from battery terminal → Electrical system; Rep. gr.27.

–  Remove engine cover panel -arrows-.

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 coolant expansion tank with cloth and open carefully. –  Open filler cap on coolant expansion tank. –  Remove front left and front right wheel housing liner → Rep. gr.66.

–  Remove noise insulation panels -1- and -2- → Rep. gr.66.   Note

Collect drained coolant in a clean container for re-use or disposal. –  Place drip tray for workshop hoist -VAS 6208- beneath engine. –  Open radiator drain tap -1- at connection and drain off coolant; then detach connection -2- from radiator (lift retaining clip). –  Move coolant hose clear at longitudinal member.

–  Release hose clip -arrow-, disconnect air hose and press to one side.

–  Remove nuts -arrows- for front exhaust pipe.

Caution Risk of damage to flexible joints in front exhaust pipe Do not bend flexible joints in front exhaust pipe more than 10°. –  Loosen bolts -arrows-, push back clamp and detach front exhaust pipe.

–  Remove bolt -2- on mounting for particulate filter.   Note Disregard -item 1-.

–  If fitted, unplug electrical connector -arrow- on steering box.

–  Move lock carrier into service position → Rep. gr.50. –  Remove bolts -1- and detach torque reaction support. –  Remove bolts -2- on both sides and detach cross member -3-.

–  Detach bottom cover -1- from gearbox -arrow-.

–  Detach cap from vibration damper. –  Counterhold crankshaft on central bolt for vibration damper using angled ring spanner -1- when loosening bolts for drive plate.   Note When performing the next step, turn the crankshaft only in the normal direction of rotation -arrow-.

–  Remove 3 bolts -arrow- for drive plate, turning crankshaft 120° in normal direction of rotation each time.

–  Remove bolts -1, 7, 8, 9, 10- securing engine to gearbox.   Note Disregard -item A-.

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-tip pen for re-installation. –  Swivel tensioner in clockwise direction -arrow-, detach poly V-belt from pulley for air conditioner compressor and lock tensioner using locking tool -T40098-. –  Take off poly V-belt.

–  Unplug electrical connectors -1- and -2- and move electrical wiring clear.   WARNING Risk of injury caused by refrigerant. The air conditioner refrigerant circuit must not be opened. –  Remove bolts -arrows- for air conditioner compressor.   Caution Danger of damage to refrigerant lines and hoses. Do NOT stretch, kink or bend refrigerant lines and hoses. –  Tie up air conditioner compressor together with lines to one side (lines remain connected).   Note Disregard -item 3-.

–  Take electrical connector -1- for radiator fan out of bracket and unplug connector (push retainer to the rear -arrow- and press down release catch). –  Move clear electrical wiring harness going to radiator fan control unit.

–  Unscrew nut -arrow- on longitudinal member (right-side) and move earth cables clear.

–  Lift retaining clips -1- and -3- and disconnect coolant hoses.   Note Ignore items marked -2- and -arrows-.

–  Release hose clips -arrows- and remove air hose. –  Unplug electrical connector for charge pressure sender -G31-/intake air temperature sender -G42--item 1- and move wiring clear.

–  Unplug electrical connector -3- from air mass meter -G70-. –  Release hose clip -4- and detach air hose from air mass meter -G70-. –  Disconnect vacuum hose -arrow-. –  Detach air cleaner housing -2- and, if fitted, unplug electrical connector -1- at air filter bypass flap valve -N275- on reverse side of air cleaner.

–  Mark position of poly V-belt pulley for power steering pump relative to hub -arrow- for re-installation.

–  Remove bolts -arrows- (counterhold with pin wrench -3212-) and detach poly V-belt pulley for power steering pump.

–  Remove bolts -arrows- and tie power steering pump up to one side (hydraulic lines remain connected).

–  Lift retaining clip -2- and disconnect coolant hose.   Note Disregard -item 1-.

Caution Protect fuel system against contamination. Rules for cleanliness when working on the injection system → Chapter. –  Release hose clips and disconnect fuel hoses. 1 -  Fuel hose (yellow) 2 -  Fuel hose (blue) 3 -  Fuel hose (white)

–  Lift off foam plastic block -1- on both sides of vehicle.

–  Remove plenum chamber cover -1- → Rep. gr.50.

–  Release retainer -arrow A- and open cover -arrow B-.

–  Remove nuts -1 ... 3- for electrical wiring. –  Detach electrical connector -4- from bracket and unplug. –  Remove bolt -5- and detach terminal 30 wiring junction 2 -TV22- from plenum chamber partition panel -arrow-.

–  Unplug electrical connector at brake servo pressure sensor -G294--arrow-.

–  Working from wheel housing, release catches using a 5.5 mm ring spanner -item 1- and remove wiring protector -2- from above. –  Release wiring harness -3- leading to alternator and starter using removal lever -80 - 200- and move clear.

–  Release catch -arrow- to open wiring duct -1- and move electrical wiring harness clear.

–  Disconnect vacuum hose -2- on rear of plenum chamber partition panel -arrow- and detach vacuum connection -1- from plenum chamber partition panel.

–  Remove nut -1- and swivel filler neck for washer fluid reservoir slightly upwards -arrow A-. –  Pull filler neck -2- with filler pipe out of washer fluid reservoir and through opening in body -arrow B-.

–  On vehicles with auxiliary heater: remove bolts -2- and move pump unit -1- clear to one side.

–  Remove bolts -arrows- and detach cover for electronics box in engine compartment. –  Remove nut -1- and move electrical wiring clear.

–  Release catches -arrows A- and take out engine control unit -arrow B-.

–  If fitted, unplug electrical connector -2-. –  Unplug electrical connectors -4- and unscrew nut -3- for wiring. –  Release catches -arrow- and detach relay carrier with fuse holder -1-. –  Disengage engine wiring harness at electronics box in engine compartment and move clear.

–  Release catches -arrows A- and lift off wiring protector -2--arrow B-. –  Move wiring harness clear, place on engine and secure engine control unit to prevent it from dropping.   Note Disregard -item 1-.

Vehicles without auxiliary heater: –  Remove nut -5-. –  Lift retaining clips -1, 2- and disconnect coolant hoses. –  Guide coolant hoses through plenum chamber partition panel and move clear.   Note Disregard -items 3, 4-.

Vehicles with auxiliary heater: –  Remove nut -3-. –  Release hose clips -1, 2- and disconnect coolant hoses. –  Guide coolant hoses through plenum chamber partition panel and move clear. All vehicles (continued): –  Remove plenum chamber partition panel.

–  Unplug electrical connector -3- for pressure differential sender -G505-. –  Remove bolt -2- and move hoses -1- clear at bracket. –  Move pressure differential sender -G505- to rear.

–  Move clear electrical wiring harness -arrow-. –  Remove nuts -1- and detach bracket -2-. –  Remove Lambda probe → Rep. gr.23.

–  Detach electrical connector from bracket and unplug: 4 -  For exhaust gas temperature sender 3 -G495-   Note Disregard -items 1, 2-.

–  Remove nuts -arrows- and move particulate filter to rear.

–  Unplug electrical connector -2- at reversing light switch -F4- and move electrical wire clear.   Note Disregard -items 1, 3-.

–  Unclip electrical wiring -A- from gearbox and unplug electrical connector -C-.   Note Disregard -item B-.

–  Unplug electrical connector -arrow- for gearbox neutral position sender -G701- and move electrical wire clear.

–  Remove bolts -2 ... 6- securing gearbox to engine. –  Separate starter from gearbox and leave in position.   Note Disregard -item A-.   Note

Bolt -2- secures the starter to the gearbox and is provided with an additional spacer sleeve -arrow-.

–  Set up support bracket -10 - 222 A- on suspension turrets (left and right) as illustrated. –  Secure shackle -10 - 222 A /12- to gearbox and hook spindle -10 - 222 A /11- onto shackle.   Note For illustration purposes, the installation position is shown with the engine removed. –  Take up weight of gearbox with spindle -10 - 222 A /11-.

–  Remove lifting eye of lifting tackle -2024 A- (pull out split pin and press out pin). –  Reinsert lifting eye in 4th hole from front on lifting tackle. –  Secure pin with split pin again. –  Attach lifting tackle -2024 A- to engine and workshop hoist -VAS 6100- as shown in illustration.   WARNING Accident risk from loose components of lifting tackle. The support hooks and retaining pins on the lifting tackle must be secured with locking pins.

–  Remove bolts -1- for engine mounting on both sides. –  Remove nut -2- and move bracket with electrical wiring clear. –  Take electrical connectors (left and right) -arrow- out of bracket and unplug connectors. –  Raise engine until engine mountings are clear. –  Tighten spindle -10 - 222 A /11- further.   Caution Danger of damage to hoses, pipes and wiring connections and to engine compartment. t  Check that all hoses and wiring connections between engine, gearbox, subframe and body have been detached. t  Carefully guide engine out of engine compartment when lifting out.   Note

A second mechanic is required to carefully open bonnet as much as possible when lifting engine out. –  Use small screwdriver to slightly lift retaining clip -arrow- at both ends and detach gas strut -1- from ball stud -2- at top. –  Separate engine from gearbox and lift engine out of engine compartment. –  Press gas struts back onto ball studs.