Engine, Removing
Engine, Removing
• With lock carrier installed, 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
• Pry Lever - Remove Outside Mirror (80 - 200)
• Used Oil Collecting and Extracting Device (V.A.G 1782)
• Step Ladder (VAS 5085)
• Engine Bung Set (VAS 6122)
• Scissor Lift Table (VAS 6131 A) with Support Set (VAS 6131/10) and Adapters (VAS 6131/10-12) (qty. 2)
• Drip Tray for Workshop Crane (VAS 6208)
• Hose Clamp Pliers (VAS 6340)
• Hose Clamp Pliers (VAS 6362)
• Tension Strap (T10038)
• Puller (T10369)
Procedure
CAUTION!
Before removing engine, secure vehicle against tipping over. For this the luggage compartment must be empty.
CAUTION!
Observe measures when connecting battery.
• So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted.
• In order for the driveshaft to be able to rotate for removal, the electro-mechanical parking brake must be released before disconnecting battery.
- Switch off the ignition and disconnect the 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).
- Remove front engine cover - 1 - and rear - 2 - - arrows -.
CAUTION!
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.
- Open the quick-release fasteners - 1 - and - 2 - and remove noise insulation.
- Place Drip Tray for Workshop Crane (VAS 6208) under engine.
- Remove drain plug - 2 - at coolant thermostat housing and drain coolant.
- Remove coolant hoses - 1 - and - 3 -.
- Remove drain plug - arrow - at front coolant pipe and drain coolant.
- Disconnect coolant hoses at positions indicated by - arrows -.
- Drain remaining coolant.
- Unbolt Ground (GND) cable - arrow - from right longitudinal member.
• To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
- Remove bolts - 1 - and - 2 -.
- Disconnect refrigerant lines from A/C compressor.
- Seal the open connections on A/C compressor using clean plugs.
• Place a rag under separating point to catch escaping hydraulic fluid.
- Remove hydraulic hose - arrow - from line on left longitudinal member.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Disengage electrical connector - arrow - from bracket at left of lock carrier.
• Electrical connector is not disconnected.
- Disconnect electrical connector - 1 - on Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) and remove vacuum hose - 2 -.
- Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) from bracket and lay aside with hose connected.
- Remove bolts - arrows - and remove left air duct.
- Loosen hose clamp - 1 - and remove screws - 2, 3, 4 -.
- Remove the left air filter upper section.
- Disconnect electrical connector - arrow - on Mass Air Flow (MAF) Sensor 2 (G246).
- Remove air filter lower section form the side connection.
- Remove air filter lower section upward - arrow -.
- Disconnect secondary air injection electrical connector - arrow - below headlamp.
- Free up electrical wiring.
• To improve clarity, the bumper cover is shown removed.
- Remove hood seal from lock carrier and from fender edges.
- Disconnect vacuum hoses - 1 - and - 2 - and free them up.
• Place a rag under separating point to catch escaping hydraulic fluid.
- Disconnect power steering hydraulic pressure line - arrow - at front left on engine.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Disconnect air guide hoses - arrows - to secondary air injection combi-valves.
- Remove bolts - arrows - and remove right air duct.
- Disconnect vacuum hose - 5 - from air guide hose.
CAUTION!
Hose connectors - 4 - must not be opened. Move the right air filter housing upper section, with the crankcase ventilation hose still connected, to the side.
- Loosen the hose clamp - 6 - and remove screws - 1, 2 and 3 -.
- Remove the right air filter housing upper section.
- Disconnect electrical connector - arrow - on Mass Air Flow (MAF) Sensor (G70).
- Remove the air filter lower section form the side connection.
- Remove the air filter lower section upward - arrow -.
- Remove coolant hoses - 4 - and - 5 - from coolant reservoir and coolant pipe.
- Disconnect electrical connector - 1 - on Engine Coolant Level (ECL) Warning Switch (F66) at bottom of coolant expansion tank.
- Remove bolts - 2 - and - 3 - and remove coolant reservoir.
- Remove coolant hose - 1 - from radiator and right coolant pipe - 2 -.
- Lay coolant hose on engine.
- Remove coolant hoses - 1 - and - 2 - from right coolant pipe.
- Remove nut - arrow - and remove coolant pipe from right longitudinal member.
- Remove vacuum hoses - 1 - and - 2 -.
CAUTION!
Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening the connection.
- Disconnect fuel supply line - arrow - on distribution piece.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- 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 screw - 3 - clockwise until the wiper arm is pulled off the wiper axle.
- Remove nuts completely and remove wiper arms.
- Remove the cowl panel screws - arrows - - 1 -.
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 the cowl grill from the windshield.
- Remove bracket - 1 - from suspension strut transverse beam.
- Remove bolts - 2 - and - 3 - and remove suspension strut transverse beam.
- 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 Ground cable - arrow - at left in plenum chamber.
- Disconnect electrical harness connector - arrow - at Brake Booster Pressure Sensor (G294).
- Release retaining clips - arrows - and remove ECM - 1 - and - 2 -.
• The ECMs remain connected to the wiring harness.
- Remove bolts - arrows - and remove cover for E-box at right in engine compartment.
CAUTION!
The heater pump valve unit (on the left in front of the E-box) becomes very hot during operation and could cause burns.
- Unclip suppression capacitor - 5 - from bracket in E-box.
- Disconnect the electrical connection - 4 - at rear on the connector strip.
- Unbolt electrical wiring connections - 1 - and - 2 -.
- Unclip relay carrier - 3 - from bracket in E-box.
- Remove bolts - 1 - and - 2 -.
- Disconnect electrical connector - 3 - on Brake System Vacuum Pump (V192).
- Free electrical wiring up to generator using Pry Lever - Remove Outside Mirror (80 - 200).
• If necessary, use silicon-free spray lubricant to facilitate removal of wiring clips.
- Set the wiring harnesses on engine and secure Engine Control Modules (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 -.
- Remove the left and right nuts - arrows - and bolt - 2 - and then remove the crossmember together with the stabilizer bar.
• Ignore - 1 -.
- Remove stabilizer bar with cross beam.
- Disconnect electrical harness connector - 2 - at Level Control System Sensor.
- Disconnect connecting link - 1 - from control arm.
CAUTION!
Wheel bearing housing must be supported to prevent upper control arm joints from being damaged.
- Tie up wheel bearing housing with Tension Strap (T10038) as shown in illustration.
- Unbolt suspension strut from control arm - arrow -.
- Unbolt guide control arm - 1 - and control arm - 2 - from subframe.
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.
- Swing guide control arm - 1 - and control arm - 2 - outward.
- Repeat work procedure on opposite side of the vehicle.
- Unbolt 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.
- Remove electrical connectors - 1 - for Heated Oxygen Sensor (HO2S) (G39) and - 2 - for Heated Oxygen Sensor (HO2S) 3 (G285) from bracket.
- Remove subframe transverse beam - arrows -.
- Loosen clamping sleeves - 1 - and - 2 - and slide them back.
- Remove heat shield - A - for driveshaft - arrows -.
- Remove bolts on transmission/driveshaft connection.
- Slide driveshaft back to rear final drive; CV joints can move axially.
- Tie driveshaft up and to the side against heat shield - arrow -.
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.
- 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 left rear on engine/transmission as shown in illustration.
- Position support elements from (VAS 6131/10) at right on transmission 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 long members using a felt-tip marker.
- Remove bolts - 2, 3, 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.
- First lower engine/transmission assembly using Scissor Lift Platform (VAS 6131 A) only approximately by dimension - a -.
• Dimension - a - = max. 100 mm.
- Remove bolts - arrows - and remove selector lever cable heat shield.
• Mark the installation position of bracket for selector lever cable using a felt-tip marker.
- Remove the selector lever cable ball socket - 1 - from the transmission shift lever.
- Remove cable mounting bracket - 2 - from the transmission.
- Move selector lever cable clear.
- Lower engine/transmission subassembly downward.
- Push Scissor Lift Platform (VAS 6131 A) with engine/transmission subassembly under vehicle.