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 - RMV Outside Mirror (80 - 200)
• Lifting Eyebolt (3368)
• Used Oil Collecting and Extracting Device (V.A.G 1782)
• Spark Plug Connector Pliers (V.A.G 1922)
• Hose Clip Pliers (VAS 6340)
• Hose Clip Pliers (VAS 6362)
• Step Ladder (VAS 5085)
• Scissor Lift Platform (VAS 6131 A) with Support Set for Audi (VAS 6131/10)
• Drip Tray (VAS 6208)
• Tensioning Strap (T10038); quantity: 2
• Puller (T40039)
• Engine Bung Set (VAS 6122)
• Puller (T10369)
Procedure
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.
• In order for the driveshaft to be able to rotate for removal, the electro-mechanical parking brake must be released before disconnecting battery.
- With the ignition switched off, disconnect the ground (GND) cable - arrow - on the battery.
- Discharge refrigerant circuit.
- Remove front engine cover - 1 - and rear - 2 - - arrows -.
- Remove cover above coolant reservoir - arrows -.
CAUTION!
Cover the coolant reservoir cap with a cloth and open carefully because steam or hot coolant may escape when opening.
- Open the cap on the coolant reservoir.
- Remove both front wheels.
- For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.
- Open the quick-release fasteners - 1 - and - 2 - and remove noise insulation.
- Remove front and rear part of left and right front wheel housing liner.
- Place (VAS 6208) under engine.
- Remove drain plug - arrow - at coolant thermostat housing and drain coolant.
- Remove drain plug - arrow - at front coolant pipe and drain coolant.
- Remove coolant hoses - 1 to 3 - and drain coolant.
- Disconnect coolant hose next to left drive axle from coolant pipe - arrow - and drain the coolant.
- Remove the bolts - 2 - and - 3 -.
- Remove front lower coolant pipe from hoses - 1 - and - 4 -.
- Remove hoses - 1 - and - 2 - from secondary air injection connecting pipes.
- Remove coolant hoses - 1 - and - 2 - from right auxiliary cooler and drain remaining coolant.
- Remove nut - 1 - and remove coolant hose - 2 - from right auxiliary cooler.
- Disconnect electrical connector - 1 - on EVAP canister purge regulator valve 1 (N80) and remove vacuum hose - 2 -.
- Remove EVAP canister purge regulator valve 1 from bracket and lay aside with hose connected.
- Remove the coolant hose - arrow - from the coolant pipe leading to the coolant reservoir.
- Disconnect electrical connector - 2 - for Mass airflow sensor 2 (G246).
- Disconnect air duct hose - 1 - from intake manifold.
- Remove the bolts - arrows - and remove the left air filter housing upper section.
- Remove the air duct - 1 -.
- Remove the bolts - arrows -.
- Tilt air filter housing lower section and remove the air flap vacuum hose.
- Remove the left air filter housing lower section.
- Extract the power steering oil from the reservoir with the (V.A.G 1782).
• 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 (VAS 6122).
- Remove hood seal from lock carrier and from fender edges.
- Disconnect vacuum hoses - 1 - and - 2 - and free them up.
- Separate the electrical connector - 1 - for mass airflow sensor (G70).
- Disconnect vacuum hose - 2 - from air guide hose.
- Loosen hose clamps and lay aside air guide hose - 4 -.
CAUTION!
Hose connectors - 3 - must not be opened.
- Remove the bolts - arrows - and remove the right air filter housing upper section.
- Remove the lower air guide hose - arrow - from the right air filter housing lower section.
- Disconnect both vacuum hoses - 1 -.
- Remove the air duct - 2 -.
- Remove the bolts - arrows -.
- Tilt the air filter housing lower section and disconnect the connector - 3 - on the intake air switch-over valve (N335).
- Remove the right air filter housing lower section.
- Disconnect coolant hose - arrow - at right on engine.
- Remove bolt - arrow - at torque support mount.
- Remove oxygen sensor electrical connectors - 1 - and - 2 - from right bracket in engine compartment.
- Disconnect vacuum hoses - 1 - and - 2 - and free them up.
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 (VAS 6122).
- Disconnect crankcase ventilation hose - 2 -.
- Disconnect the connectors - 1 - and - 5 -.
- Remove the bolts - 3 - and - 4 -.
- Disconnect electrical connectors to ignition coils in cylinder bank 1 (right) and free up electrical wiring harness.
- Remove the ignition coils using the ignition coil puller (T40039).
- Loosen bolts in - 16 to 1 - sequence and remove them.
- Remove right cylinder head cover.
- Cover open valvetrain with a clean cloth.
- Remove rubber seal - 1 - and remove plenum chamber covers - 2 - and - 3 -.
- Pry out cover caps on windshield wiper arms with a screwdriver and loosen nuts - arrows - a few turns.
- Position the puller for removing wiper arms (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 dust and pollen filter by opening the 4 quick-release fasteners.
• Cover the air duct at air conditioning housing with a clean rag so that nothing can fall in.
- Remove the left and right cowl grill screws - arrows - - 1 -.
CAUTION!
To prevent the cowl grille 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.
- Carefully pull the cowl grill off from the retainers on the windshield.
- Remove suspension strut crossmember - arrow -.
- Remove bolts - 1 - and - 2 - and remove retaining bracket.
- Release the retaining tabs - arrows - and remove both engine control modules (ECM).
• Electrical harnesses remains connected.
- Remove air quality sensor (G238) by rotating approximately 90° counter-clockwise - arrow - and removing from bracket.
- Release the retaining clips - 1 to 4 -.
- Fold the cover for the E-box in the plenum chamber open slightly and pull off toward the front.
- Disconnect the multi-pin harness connectors - arrows - using spark plug connector pliers (V.A.G 1922).
- Disengage engine wiring harness at E-Box and at bulkhead.
- Lay the wiring harness aside on the engine with engine control modules (ECM) connected.
• Protect the engine control modules from falling off.
- Remove the right A-pillar trim.
- Fold back the carpet.
- Remove protective cover from above the main fuse holder.
- Fold the cap - 2 - aside.
- Remove nut - 4 -.
- Remove terminal 30 wire to starter.
• Ignore - 1 - and - 3 -.
- Unfasten the harness clamp - 1 - in right front wheel housing.
- Pull the wiring harness out from the interior - arrow -.
- Separate the electrical connector - 2 -.
- Remove Ground (GND) wire - 1 - on longitudinal member.
- Remove wiring harness bracket on longitudinal member - arrows -.
- Free up the wiring harness.
- Disconnect electrical harness connector - 2 - at level control system sensor.
- Disconnect connecting link - 1 - from control arm.
- Repeat procedure on opposite side of the vehicle.
• To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
- Remove the bolts - 1 - and - 2 -.
- Disconnect refrigerant lines from A/C compressor.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
- Remove bolts - arrows - on climate control system reservoir bracket.
• Climate control system reservoir remains in installation location.
• Place a rag under separating point to catch escaping hydraulic fluid.
- Remove hydraulic hose - arrow - from power steering fluid reservoir.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
- 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 bolts - arrows - uniformly at left and right.
- Remove stabilizer.
- Insert left and right (3368) from below into hole in strut tower.
- Secure (3368) with a nut - 2 - with washer - 1 - over several threads (do not install nut all the way down on threads).
- Tie up wheel bearing housing at left and right with (T10038) as shown in illustration.
CAUTION!
To prevent upper control arm joints from being damaged, wheel bearing housing must be supported before loosening lower suspension strut bolts.
- Remove air spring damper from control arm - arrow -.
- Remove guide control arm - 1 - and control arm - 2 - from subframe.
- Pivot 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 drive axle from transmission flanged shaft.
CAUTION!
Do not damage brake hose!
- Pivot wheel bearing housing outward and remove drive axle.
- Repeat work procedure on opposite side of the vehicle.
- Remove front transverse beam - arrows -.
• Do not bend the flex joint in front of the exhaust pipe more than 10° or it could be damaged.
- Loosen the clamping sleeves - 1 - and - 2 -.
- 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 (VAS 6131 A) in horizontal position.
• Note bubble level (sight glass) on support platform.
- Drive (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 engine carrier and subframe as shown in illustration.
- Remove bracket for oxygen sensor electrical connectors - 1 - and - 2 - from tunnel crossmember - arrows -.
• Electrical connectors remain connected.
- Position support elements from (VAS 6131/10) at rear on transmission as shown in illustration.
- Twist all spindles of support elements upward far enough until all support pins make contact at support points.
- When all attachments are positioned, lift scissor lift table far enough until engine and transmission mounts are free of tension.
- Tighten the base plates for attachments to 20 Nm on the (VAS 6131 A).
- Remove bolts - arrows - at tunnel cross member.
- Mark the installation position of the subframe on the longitudinal member with a felt tip pen.
- Remove the bolts - 1 - and - 4 -.
- Remove bolts - 2 - and - 3 - 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 (VAS 6131 A) only approximately by dimension - a -.
• Dimension - a - = approximately 300 mm.
- Remove the selector lever cable ball socket - 2 - from the transmission shift lever using the (80 - 200).
- Unclip the locking plate - 1 - from the selector lever cable bracket.
- Remove selector lever cable.
- Lower engine/transmission subassembly downward.
- Push (VAS 6131 A) with engine/transmission subassembly under vehicle.