Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Pry Lever - Remove Outside Mirror (80 - 200)
• Hose Clamps Up to 25 mm Diameter (3094)
• Step Ladder (VAS 5085)
• Engine Bung Set (VAS 6122)
• Scissor Lift Platform (VAS 6131 A) with Support Set for Audi (VAS 6131/10)
• Drip Tray for Workshop Crane (VAS 6208)
• Used Oil Collecting and Extracting Device (V.A.G 1782)
• Hose Clamp Pliers (VAS 6362)
• Tension Strap (T10038)
• Puller (T10369)
Procedure
• With lock carrier installed, engine is removed downward with transmission and subframe.
• All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
• Drained coolant must be stored in a clean container for disposal or reuse.
CAUTION!
Before removing engine, secure vehicle against tipping over. For this the luggage compartment must be empty.
CAUTION!
Observe safety precautions when disconnecting the battery.
• So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted.
With the ignition switched off, disconnect the battery Ground (GND) cable - arrow -.
- Pull rear engine cover off - arrows -.
- Pull front engine cover off - arrows -.
CAUTION!
Cover cap of expansion tank with rag and open carefully, as hot steam for example hot coolant may escape when opening.
- Open cap of coolant expansion tank.
• Before removing the ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.
- Pivot tensioning device in direction of - arrow - to relieve tension on ribbed belt.
- Remove ribbed belt and release tensioning device.
- Remove both front wheels.
• Secure brake discs using a wheel bolts.
- Remove noise insulation.
- Place Drip Tray for Workshop Crane (VAS 6208) under engine.
- Open drain plug - 1 - and allow coolant to drain.
- Then disconnect coolant hose - 2 - from radiator.
- Disconnect coolant hose - arrow - from engine oil cooler and drain remaining coolant.
- Then remove coolant hose.
- Separate connector - 1 - for wiring to air conditioning compressor clutch solenoid.
CAUTION!
The air conditioning refrigerant circuit must not be opened.
- Remove air conditioning compressor from bracket - arrows -.
• To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
- Hang up the air conditioning compressor with attached lines on left side of vehicle.
• Place a rag under hydraulic lines to catch escaping hydraulic fluid.
- Clamp off hydraulic hose - 1 - for power steering pump with a Hose Clamps Up to 25 mm Diameter (3094).
- Remove hydraulic hose from power steering pump.
- Unbolt hydraulic pressure line - 2 - at power steering pump and set it aside on top of the longitudinal member.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Remove bolts - arrows - and remove torque support from engine.
• Observe the rules of cleanliness for working on automatic transmissions.
- Place the Used Oil Collection and Extraction Device (V.A.G 1782) under the disconnection point.
- Loosen union nuts - 2 - and - 3 - and disconnect ATF lines.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
• Ignore - 1 -.
- Remove Ground (GND) cable - arrow - from right longitudinal member.
- Remove the brake booster vacuum hose - arrow - on the plenum chamber bulkhead.
- Remove coolant hose - arrow - to heater core on rear of engine.
- Remove coolant hoses - 1 - and - 2 - at coolant expansion tank.
- Remove coolant expansion tank - arrow -.
- Disconnect electrical connector on Engine Coolant Level (ECL) Warning Switch (F66) at bottom of expansion tank.
- Remove coolant hose - arrow - from front coolant line.
- Remove the left front coolant hose in engine compartment - arrows -.
- Remove coolant hose - arrow - from front coolant line.
- Disconnect vacuum hose - arrow - to leak detection pump.
CAUTION!
Note rules of cleanliness for working on the fuel injection system. Refer to => [ Fuel Supply and Injection System, Clean Working Conditions ] Fuel Supply and Injection System, Clean Working Conditions.
CAUTION!
Fuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.
- Disconnect the fuel line - arrow - and free it up.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Remove bolts - arrows -.
- Remove air duct - 1 - and - 2 -.
- Disconnect check valve - 1 - from air duct hose.
- Remove the air duct hose, thereby loosening the hose clamp - 2 - and opening the clips - arrows -.
- Open the clips - arrows - and remove the air filter lower section.
- Disconnect the vacuum line - 1 -.
- Remove pin from spreader clips - 3 -.
- Remove the air filter lower section and disconnect the connector - 2 - on the rear side at the Intake Air Switch-Over Valve (N335).
- Disconnect vacuum hose - arrow - to EVAP canister.
- Remove nuts - 2 - and - 3 - and remove right bracket for harness connectors from plenum chamber bulkhead.
- Remove Ground (GND) wire - 1 - on right strut tower.
- Remove Ground (GND) wire - arrow - on left strut tower.
- Remove the left bracket for the connectors - 1 - and - 2 - from the plenum chamber bulkhead.
- Remove rubber seal - 1 - and remove plenum chamber cover - 2 -.
- Pry out cover caps on windshield wiper arms with a screwdriver and loosen nuts - arrows - a few turns.
- Position the Puller (T10369/1) on the windshield wiper arm - 1 - as illustrated.
- Mount the pressure piece - 2 - on the wiper axle.
- Turn the bolt - 3 - clockwise until the wiper arm is pulled off the wiper axle.
- Remove nuts completely and remove wiper arms.
- Remove the cowl panel - 1 - screws - arrows -.
CAUTION!
To prevent the cowl grille - 1 - from tearing when removing, coat transition between windshield and cowl grille with a soapy solution and pull grille up vertically out of fastening strip beginning at edge of window.
- Remove cowl grill from the windshield.
- Remove the bolts - 1 - and - 3 - and then remove the dome brace - 2 -, if equipped.
- Remove bolts - arrows - and remove cover form E-box at left in engine compartment.
- Release the retaining tabs and pull the fuse holder - 1 - and the 3-socket relay carrier - 4 - upward and off.
- Remove electrical wire connection - 3 -.
- Disconnect all electrical connections - 2 - at rear on the connector strip.
- Disengage and free up engine wiring harness at E-Box.
- Remove bolts - arrows - and remove cover for E-box at right in engine compartment.
- Open the cover - 1 - using a screwdriver - arrow - and remove, if equipped.
CAUTION!
The heater pump valve unit (on the left in front of the E-box) becomes very hot during operation and could cause burns.
- Carefully pry off the retaining clip - 3 - with a screwdriver - arrows 1 and 2 - and remove the ECM from the E-box.
• Engine Control Module (ECM) remains connected at wiring harness.
- Unclip suppression capacitor - 5 - from bracket in E-box.
- Disconnect the electrical connection - 4 - at rear on the connector strip.
- Remove electrical wiring connections - 1 - and - 2 -.
- Free electrical wiring up to generator using Pry Lever - Remove Outside Mirror (80 - 200).
- Set both wiring harnesses on engine and secure Engine Control Module (ECM) against falling down.
- Have a second technician press the brake pedal.
CAUTION!
To loosen collar bolt for drive axle, the wheel bearing must not be under load (vehicle must not be standing on its wheels).
- Remove collar bolt - 2 - at left and right drive axles - 1 -.
- Evenly remove left and right nuts - 1 -.
- Remove left and right bolts - 2 - and remove stabilizer bar.
- Disconnect electrical harness connector - 2 - at Level Control System Sensor.
- Disconnect connecting link - 1 - at control arm.
CAUTION!
Risk of damaging axle joints on upper control arms.
• Support wheel bearing housing.
- Tie up wheel bearing housing with Tension Strap (T10038) as shown in illustration.
- Remove suspension strut from control arm - arrow -.
- Remove guide control arm - 1 - and control arm - 2 - on subframe.
- Swing guide control arm - 1 - and control arm - 2 - outward.
CAUTION!
Guide control arm and control arm must not hang free. Tie up both control arms on wheel bearing housing - arrows - as shown in illustration.
- Repeat work procedure on opposite side of the vehicle.
- Remove heat shield for drive axle - arrows -.
- Remove drive axle from transmission flanged shaft.
CAUTION!
Do not damage brake hose!
- Swing wheel bearing housing outward and remove drive axle.
- Repeat work procedure on opposite side of the vehicle.
- Loosen the clamping sleeves - 1 - and - 2 -.
- Remove front transverse beam - arrows -.
- Remove subframe transverse beam - arrows -.
Prepare scissor lift platform:
- Equip Scissor Lift Platform (VAS 6131 A) with Support Set for Audi (VAS 6131/10) as follows:
- Install attachments on scissor lift table by hand first.
- Place Scissor Lift Platform (VAS 6131 A) in horizontal position.
• Note bubble level (sight glass) on support platform.
- Drive Scissor Lift Table (VAS 6131 A) under engine/transmission subassembly.
- Position support elements from (VAS 6131/10) at front on engine as shown in illustration.
- Make sure that the threaded spindles are completely screwed in.
- Position support elements from (VAS 6131/10) at left and right on subframe as shown in illustration.
- Position support elements from (VAS 6131/10) at rear on tunnel cross member, as shown in illustration.
- Twist all spindles of support elements upward far enough until all support pins make contact at support points.
- Tighten base plates for support elements to 20 Nm on Scissor Lift Platform (VAS 6131 A).
- Remove bolts - arrows - on tunnel cross member.
- Remove bolts - 1 -.
- Mark installation position of subframe and of both engine mount brackets to longitudinal members using a felt-tip marker.
- Remove bolts - 2 -, - 3 - and - 4 - in diagonal sequence and in stages.
• Verify that all hoses and lines between engine, transmission, subframe and body have been disconnected.
• While lowering, carefully guide engine/transmission subassembly with subframe out of engine compartment in order to prevent damage.
- Slowly lower engine/transmission subassembly downward (approximately 10 cm).
- Mark selector lever cable bracket installation location.
- Remove the selector lever cable bracket bolt - 1 -.
- Remove the selector lever cable ball socket - 2 - from the transmission shift lever.
• Do not bend or kink selector lever cable.
- Completely lower Scissor Lift Table (VAS 6131 A) and remove it with engine/transmission assembly under vehicle.