Part 1
Engine, Removing
• With lock carrier removed, engine is removed downward with transmission and subframe.
• Drained coolant must be stored in a clean container for disposal or reuse.
• During installation, reinstall all heat insulation sleeves and heat shields at the same locations.
• All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
Special tools, testers and auxiliary items required
• Used Oil Collecting and Extracting Device (V.A.G 1782)
• 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)
• Hose Clamp Pliers (VAS 6362)
Procedure
- Raise luggage compartment floor covering and secure.
CAUTION!
Observe safety precautions when disconnecting the battery.
- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.
- Discharge refrigerant circuit.
- Extract the power steering oil from the reservoir with the Used Oil Collection and Extraction Device (V.A.G 1782).
CAUTION!
Cover cap of coolant expansion tank with rag and open carefully, as hot steam or hot coolant may escape when opening.
- Open cap of coolant expansion tank.
- Remove both front wheels.
- Open the quick-release fasteners - 1 -, remove the screws - 2 - and then remove the noise insulation.
- Remove bracket for noise insulation - arrows -.
- Remove front left and right wheel housing liners.
- Remove front bumper cover.
- Remove left air guide - arrow - in front of auxiliary cooler.
- Remove bolt - arrow - on auxiliary cooler upper bracket, at left of lock carrier.
- Remove right air guide - arrow - in front of auxiliary cooler.
- Drain the engine oil.
- Place the Used Oil Collection and Extraction Device (V.A.G 1782) under the disconnection point.
- Remove bolts - arrows - on oil cooler lines at upper section of oil pan.
- Remove oil lines from upper part of oil pan.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Place Drip Tray for Workshop Crane (VAS 6208) under engine.
- Remove drain plug - arrow - on coolant thermostat housing and drain coolant from engine.
- In addition, remove drain plug - arrow - on front coolant pipe and allow rest of coolant to drain.
- Loosen hose clamps - arrow - and remove coolant hose downward from cooler.
- Place the Used Oil Collection and Extraction Device (V.A.G 1782) under the engine.
- Disconnect hydraulic lines to cooling coil at left rear of bumper - arrows -.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Remove cover - 1 - in engine compartment (left side).
- Remove bolts - arrows -.
- Remove the air duct - 1 - and - 2 -.
- Disconnect the coolant hose from the radiator by raising the retaining clip - arrow -.
- Remove electrical harness connectors - 1 - and - 2 - from bracket and disconnect them.
- Free up electrical wires to lock carrier.
- Disconnect electrical harness connector - arrow - for headlamps at both sides of the vehicle.
- Free up electrical wiring.
- Disconnect electrical harness connector - arrow - for left and right airbag sensors on lock carrier.
- Free up electrical wiring.
- Remove the engine hood cable from the lock carrier.
- Disconnect right radiator fan electrical connector - arrow -.
• To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
- Remove bolt - arrow - and disconnect refrigerant line to A/C compressor.
- Remove bolt - arrow - and disconnect refrigerant line to A/C evaporator.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Remove right coolant hose - arrow -.
- Remove bolts - arrows - at left and right side of bumper.
- Pull off hood seal from lock carrier and fender edges.
- Unthread bolts at impact absorbers - arrows - at left and right.
• A second technician is required to remove the lock carrier.
- Remove lock carrier and set aside so it cannot topple.
- Pull rear engine cover off - arrows -.
- Pull front engine cover off - arrows -.
- Remove the coolant hoses - 1 - and - 2 -.
- Remove coolant expansion tank - arrow -.
- Disconnect the electrical line at Engine Coolant Level (ECL) Warning Switch (F66) at bottom of coolant expansion tank.
- Unbolt Ground (GND) connection - 2 -.
- Remove vacuum lines - 1 - and - 3 - to brake booster from distribution piece.
- Remove hose at Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) - arrow -.
- Free up hose.
- Disconnect electrical harness connector - arrow - on Brake System Vacuum Pump (V192).
- Disconnect electrical harness connector - arrow - for After-Run Coolant Pump (V51) (behind auxiliary cooler at left) and free up electrical wire.
- Disconnect the vacuum hose - arrow -.
• Place a rag under separating point to catch escaping hydraulic fluid.
- Remove hose - arrow - at power steering fluid reservoir.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Disconnect coolant hoses at positions indicated by - arrows -.
- Remove coolant hose from thermostat housing - arrow -.
- Remove coolant hoses to engine oil cooler at engine and to generator - arrows -.
- Disconnect coolant hoses at positions indicated by - arrows -.
- Remove bolts - 1 to 3 -.
- Remove bracket for front torque support.
- Disconnect electrical harness connector - 4 - at Mass Air Flow (MAF) Sensor (G70).
- Disconnect hose - 5 - to Secondary Air Injection (AIR) pump.
- Pull off the vacuum lines - 1 - and - 6 -.
- Disconnect air guide hose - 3 - at Mass Air Flow (MAF) sensor.
- Free up electrical wiring harness at air filter housing.
- Remove clip - 2 - and remove air filter housing with Mass Air Flow (MAF) sensor.
• Ignore - arrows -.
- Remove hose - 1 - at secondary air injection pump by pressing release buttons.
- Disconnect the connectors - 2 - and - 3 -.
- Free up electrical wiring.
- Disconnect vacuum hose - 2 - from air guide hose.
- Remove hose clamps - 1 - and - 3 - and lay air guide hose aside.
CAUTION!
Hose connectors - 4 - must not be opened.
- Remove bolts - 1 -.
- Disengage retaining clip - 2 - and remove rear engine cover bracket.
CAUTION!
Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening the connection.