Engine, Removing
Engine, removing
CAUTION:
Before beginning repairs on the electrical system:
- Obtain the anti-theft radio security code.
- Switch the ignition off.
- Disconnect the battery Ground (GND) strap.
- On vehicles equipped with Audi Telematics by OnStar ©, switch-off the emergency (backup) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery.
- After reconnecting vehicle battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Repair Manual and/or Owner's Manual.
- After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar ©, switch-on the emergency (backup) battery for the Telematic/Telephone Control Module.
Special tools and equipment
- Special tool 3204
- Special tool 3212
- V.A.G 1306
- Special tool 3094
- Special tool VW 540
- Special tool VW 540/1 B
- Special tool 1 0-222A and 10222A/1 and 0-222A/3
- Special tool 2024 A
- V.A.G 1202 A
- V.A.G 1331
Engine, removing
Notes:
- All cable ties opened or cut during engine removal must be reinstalled at the same locations.
- Remove engine without transmission toward the front.
- Drained coolant must be stored in a clean container for disposal or reuse.
- Always replace seals and gaskets.
- Do not open coolant circulation system.
- See Caution! before beginning repairs on the electrical system
- Remove plenum cover.
- Switch ignition off and disconnect battery Ground (GND) strap.
- Remove bolts (arrows) and remove engine covers -A- and -C-.
- Remove cover above air filter.
- Remove sound-proofing material (arrows).
- Remove bracket for sound-proofing at unit support.
- Drain engine coolant Cooling System, Draining and Filling
- Remove bumper
- Remove lock carrier
- Remove viscous fan counter-hold using 3212 spanner wrench.
Note: The viscous fan has a left-handed thread.
- Mark direction of rotation of ribbed belt
- To loosen ribbed belt, turn clockwise using 17 mm box wrench until two holes are aligned (arrow). Counter-hold in position using 3204 drift.
Note: Mark direction of rotation of ribbed belt. Reversing the direction in which it runs can ruin it.
- Remove ribbed belt.
- Cut coolant hoses -1- and -2
- Remove coolant reservoir (arrows).
- Disconnect connector for coolant level display.
- Remove valve cover (cylinder bank 4-6).
- Remove hose -1- to vacuum reservoir.
- Remove air distributor (arrows).
WARNING: Fuel system is under pressure! Before opening the system place a rag around the connection. Then release pressure by carefully loosening the connection.
- Disconnect fuel supply and return lines -1 and -2- and move aside.
- Remove hose from Evaporative Emission (EVAP) canister purge regulator valve -3-.
- Disconnect connector -1- at Mass Air Flow (MAF) sensor.
- Disconnect connectors -2- from power output stage and move cables aside.
- Remove air filter.
- Disconnect connector -1- for oxygen sensor at bulk head.
- Disconnect connector -2- for knock sensor.
- Disconnect harness connector -3-.
- Move cables clear.
- Remove pressure hoses (arrows) from charge air cooler to left and right pressure lines.
- Disconnect cable at B+ on battery.
- Disconnect B+ battery cable.
- Move cables to starter aside together with cable channels (arrows).
- Remove pressure pipes-1-.
Note: Watch position of retaining strips -2-.
- Disconnect hose from power steering reservoir to power steering pump with special tool 3094.
- Disconnect power steering hose (arrow)
- Disconnect hydraulic line (arrow).
- Disconnect harness connector from vehicle speed sensor.
- Disconnect harness connector from reverse gear switch.
- Unscrew heat sensor -1- from right hand turbocharger using 3035.
- Detach heat shield -2- from left and right turbochargers.
- Unscrew upper bolts -3- from front exhaust pipes at left and right turbochargers.
- Remove wiper arms (arrows).
- Disconnect retaining clip -1- at water deflector.
- Pull off left and right retaining clips -3 on water deflector.
- Remove water deflector.
- Remove cover -2- from E-box (electronics box).
- Open E-box in plenum.
- Unclip ECM retaining bracket.
- Remove ECM, disconnect harness connectors -2- and -3- and remove.
- Disconnect harness connectors -1-.
- Remove hose -1- to power brake booster at bulk head.
- Disconnect ground (GND) -3-.
- Disconnect connectors -2- and -5- at bulk head and remove lower part of connectors from bracket.
- Pull connector -4- out of bracket and move wiring clear.
- Remove bracket for cable plug.
- Remove both coolant hoses to heat exchanger at engine by un-clipping retaining clips on flange.
- Remove both coolant hoses to heat exchanger at engine by un-clipping retaining clips on flange.
- Release hose clamp -arrow-.
- Remove intake pipe -1-.
- Remove water pipe -2-.
- Remove pressure hoses-arrows- between turbocharger and charge air cooler (left and right sides).
- Move aside cable -1- to starter by cutting cable tie and un-clipping bracket (arrow).
- Remove hose -2- for cooling generator.
- Disconnect ground (GND) (arrow) from engine support.
- Remove torque support -1-.
- Remove hose clamps (arrows).
- Remove coolant line -2-.
- Place VAG1306 Drip Tray beneath engine.
- Remove oil filter.
- Remove hose clamps (arrow).
- Remove oil cooler -1-.
- Remove heat shield (arrows) above left and right drive axle to transmission.
- Remove hose clamp -1- from left and right heat shield for turbocharger.
- Unbolt left and right exhaust pipes -2 from turbocharger.
- Detach air conditioner pipe from sump -arrow-.
CAUTION: Do not open file refrigerant circuit of the AC system.
- Remove A/C compressor-1...2-.
- Attach A/C compressor (with refrigerant hoses attached) to vehicle using wire.
Notes:
- When installing pay attention to guide bushings.
- When installing first insert bolt -1- in A/C compressor.
- Do not bend or stretch lines or hoses as condenser and/or refrigerant lines/hoses may be damaged.
Vehicles with automatic transmission:
- Remove right charge air cooler by disconnecting upper hose connection; charge air cooler supported in 3x rubber bearings.
- Disconnect air guide at generator support -3
- Unbolt cable at terminal 30/B+ -1-. Tightening torque: 16 Nm
- Unbolt cable at terminal D+ -2-. Tightening torque: 4 Nm
- Remove hex socket bolt -1- , retaining nut -2. Tightening torque: 45 Nm
- Remove bolt -3-. Tightening torque: 22 Nm
- Remove generator -4- downward and out.
1. Remove air intake -1-.
2. Securing points for oil and A/C lines
3. Securing point to engine block
4. Remove hose clamp
- Unbolt cable for terminal 30/B+ -1-.
Tightening torque: 16 Nm
- Disconnect connector for terminal 50 -2-.
- Remove upper bolt -1- through right wheel housing. Tightening torque: 65 Nm
- Remove lower bolt from engine side. Tightening torque: 65 Nm
- Remove starter forward and out.
- Using special tool V175 disconnect torque converter from drive plate.
All models
- 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 10-222 A on bolted flanges of wing panels using 10-222A1 and extension 10-222A3.
- Lift engine upward with support bar 10222A.
- 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 center of gravity of the engine) secure the hook attachments in the positions shown in the illustration.
WARNING: The hook attachments and locating pins on the lifting tackle must be secured with locking pins.
- Remove front left wheel.
- Support transmission using floor jack.
- Push engine crane VAG1202A into position and attach to engine sling.
Note: Verify that all hoses and lines between engine and transmission have been disconnected.
- Carefully pull engine out toward front until free.
- Guide engine forward out of engine compartment.
- Remove spacer between engine and transmission.