Part 1
Engine, removing and installing
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 (R), switch-off the emergency (back-up) 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 Owner's Manual.
^ After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar (R), switch-on the emergency (back-up) battery for the Telematic/Telephone Control Module.
Engine, removing and installing
Special tools and equipment
^ 10-222A Engine support bridge
^ 2024A Engine Sling
^ 3147 Engine support adapter
^ 3299 Ribbed belt installation tool with 3299/1 claw for tensioner
^ VAG 1306 Drip tray for VAG1202A
^ VAG1383A Engine/transmission hoist
^ VAG1202A Workshop crane
or
^ VAS 6100 Workshop crane
^ T10062 Support
^ Oil receptacle
Removing
Note:
^ Engine is removed toward the front without transmission and with the lock carrier removed.
^ All cable ties opened or cut during engine removal must be reinstalled at the same locations.
^ Heat boots, which are removed during engine removal must be reinstalled at the same locations when re-installing engine.
^ Drained coolant must be stored in a clean container for disposal or reuse.
Vehicles with automatic transmission
- Shift selector lever into position "N".
All
WARNING! Observe safety precautions when disconnecting the battery.
- Pull off rubber seal of plenum chamber cover in direction of arrow.
- Remove cover -1- toward front.
See Caution before beginning repairs on the electrical system.
- Disconnect battery Ground (GND) strap (arrow) with ignition switched off.
WARNING! Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.
- Open cap of coolant expansion tank.
- Remove both front wheels.
- For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of auxiliary heater on sound insulation.
- Remove bolts or quick-release screws -1- and -2- and remove front sound insulation.
- Remove quick-release screws -3- and remove rear sound insulation, if present.
- Remove bracket for sound insulation (arrows).
- Remove front bumper.
- Place VAG1306 drip tray beneath engine.
Vehicles with drain plug
- Turn radiator drain plug -2- counterclockwise, if needed attach accessory hose to connection flange and drain coolant.
Vehicles without drain plug
- Remove retaining clamp for Engine Coolant Temperature (ECT) sensor (on radiator) -G83-.
- Remove Engine Coolant Temperature (ECT) sensor from outlet and drain coolant.
All
- Pull off retaining clip -1- for lower coolant hose and disconnect coolant hose from radiator.
- Disconnect left coolant hose from radiator (arrow).
- In addition, disconnect coolant hose at oil cooler (arrow) and drain remaining coolant.
- Place oil pan underneath.
- Disconnect hydraulic lines to cooling coil at rear of bumper (arrows).
Vehicles with automatic transmission
Note: Observe the rules of cleanliness for working on automatic transmissions.
- Place oil pan underneath.
- Remove union nuts -3- and disconnect ATF lines.
- Remove bracket for ATF lines, to do so remove nuts -1- and -2-.
All
- Remove cover -1- in engine compartment (right side).
- Remove bolts (arrows).
- Detach Evaporative Emission (EVAP) canister purge regulator valve -N80- -1- at air guide.
- Remove air guide -2-.
- Remove cover -1- in engine compartment (left side).
- Disconnect top coolant hose -1- from radiator.
- Remove electrical harness connector -2- for left and right airbag sensors on bumper..
- ..and move cables clear.
- Remove electrical harness connectors -1- and -2- from bracket and disconnect them.
- Disconnect electrical harness connector (arrow) for headlights at both sides of vehicle.
- Remove air guides from left and right of radiator (arrows).
- Unclip temperature sensor -2- for outside temperature display from bracket.
- Unscrew bolts -3- and -4- and remove power steering cooling coil.
- Disconnect harness connector -1- at High pressure sensor -G65-.
WARNING! Do not open refrigerant circuit for A/C system.
- Remove condenser mounting bolts (arrows).
Note: Do not bend or stretch lines or hoses as condenser and/or refrigerant lines/hoses may be damaged.
- Carefully swing condenser downward and move aside.
- Remove bolts (arrows) on left and right sides of bumper.
- Unhook hood cable from lock and move cable free.
- Unscrew bolts at impact absorbers (arrows) at left and right.
Note: A second technician is required to remove the lock carrier.
- Remove lock carrier and set aside so it cannot topple.
- Remove rear engine cover (arrows).
- Remove bolts for holding plate -3- for solenoid valves (arrows).
- Disconnect intake air hose -1- at Mass Air Flow (MAF) sensor.
- Remove hose -4- of crankshaft housing ventilation from air duct -2-.
- Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module.
- Disconnect hose -1- from air guide if installed.
Note: Illustration depicts air guide with the removed engine from rear.
- Remove coolant hoses -1- and -2-.
Note: Coolant hose -3- remains connected.
- Remove coolant reservoir (arrow)
- Disconnect electrical wiring to Engine Coolant Level (ECL) warning switch -F66- at bottom of expansion tank.
- Disconnect ground (GND) -2-.
- Disconnect vacuum hoses -1- and -3-.
- Disconnect vacuum line (arrow) to leak detection pump at throttle valve control module.
Vehicles with automatic transmission
- Disconnect electrical harness connector (arrow).
All
- Place oil pan underneath.
- Disconnect hose -1- from power steering fluid reservoir.
- Disconnect vacuum hose -2- to vacuum reservoir.
- Disconnect electrical harness connector (lower arrow) at Secondary Air Injection (AIR) pump motor -V101- and move cable free.
- Disconnect hose at tube to combination valve for Secondary Air Injection (AIR) (upper arrow).
Vehicles up to 06.03:
WARNING! Fuel system is under pressure! Before opening system, place rags around the connection. Then release pressure by carefully loosening connection.
- Disconnect fuel supply line -1- and fuel return line -2- and set aside.
Vehicles as of 07.03:
WARNING! Fuel system is under pressure! Before opening system, place rags around the connection. Then release pressure by carefully loosening connection.
- Unscrew fuel hose from connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head -1- and -3- and unscrew union nut -2-.
All:
- Remove the following lines/harness connectors:
1 - At Evaporative Emission (EVAP) canister purge regulator valve -N80-
2 - Vacuum hose at Evaporative Emission (EVAP) canister purge regulator valve -N80-
3 - at Mass Air Flow (MAF) sensor -G70-
- Disconnect hose connections, move wires free and remove air filter housing (arrows).
Note: Place a rag under the hydraulic pressure lines, to catch escaping hydraulic fluid.
- Unbolt hydraulic pressure line for power steering at rear coolant pipe -1- and disconnect line at height of right cylinder head -2-.
- Pry off both covers -3- using a screwdriver.
- Loosen hex-nuts -4- by several turns.
- Loosen wiper arm -2- by lightly tilting from wiper axle.
- Remove hex nuts completely and remove wiper arms.
- Disconnect securing clips -1- and remove cowl grill -5-.
Vehicles with automatic transmission
- Disconnect electrical harness connector (arrow) at Brake booster pressure sensor -G294-.
All
- Remove heater core E-box cover (arrows).
- Using a screwdriver, pry off retaining bracket (arrow).
- Disengage connector catches (arrows) and disconnect harness connectors -1- and -2-from Engine Control Module (ECM).
Vehicles with automatic transmission 01V
- Unclip Transmission Control Module (TCM) retaining bracket.
- Disengage harness connector (arrow) and disconnect it from Transmission Control Module (TCM).
All
- Disconnect rear connectors -2- on connector strip and set wiring harness aside.
- Unbolt electrical wire connection -1-.
- Disengage locking mechanisms (arrows) and remove secondary relay carrier in E-box toward top.
- Unhook engine wiring harness at E-box and at bulkhead and move it free.
- Remove heat shield for harness connectors at left of bulkhead, if installed.
- Remove harness connectors -1 to 4- from bracket at left of bulkhead.
- Disconnect electrical harness connectors -1- and -4-.
- Expose oxygen sensor wires.
- Remove bracket for harness connectors.
- Remove harness connectors -1 to 4- from bracket at right of bulkhead.
- Disconnect electrical harness connectors -1-, -3- and -4-.
- Expose oxygen sensor wires.
- Remove bracket for harness connectors.
- Remove nut -2- for left exhaust pipe/exhaust manifold which is accessible from top.
Note: Illustration is shown with engine removed.
- Remove nut -2- for right exhaust pipe/exhaust manifold which is accessible from top.
Note: Illustration is shown with engine removed.
- Disconnect coolant hoses to heater core at rear coolant pipe and at right coolant pipe. To do so, remove wiring harness screw clip on right side of vehicle.
- Remove upper mounting bolts for engine/transmission. One bolt remains tightened by hand.
- Remove front engine cover (arrows).
Note: Before removing ribbed belt, mark direction of rotation with chalk or felt-tip marker. Reversing the direction of rotation of a run-in belt can destroy the belt.
- Swing ribbed belt tensioner in direction of arrow to release tension on ribbed belt using 3299 ribbed belt installation tool and 3299/1 claw for tensioner.
- Remove ribbed belt from pulley of power steering pump.
- Place engine oil drip tray beneath engine.
- Drain engine oil.
- Remove oil filter -2-.
- Place VAG1306 drip tray beneath engine.
- Remove coolant hose -3- from oil cooler.
- Remove oil cooler -1-.
- Unbolt bracket for refrigerant line at oil pan (arrow).