Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Pry Lever - Rmv 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 Supplementary Set (VAS 6131/11) and (VAS 6131/13)
• Drip Tray (VAS 6208)
• Hose Clip Pliers (VAS 6340)
• Hose Clip Pliers (VAS 6362)
Procedure
• With lock carrier installed, engine is removed downward together with the transmission and the subframe.
• During installation, cable ties must be installed at the same location.
Risk of vehicle tipping over with engine removed.
• Secure vehicle. Luggage compartment must be empty for this.
There is a risk of injury because the fuel is under very high pressure.
• Before opening high pressure area of the fuel injection system, fuel pressure must be relieved to residual pressure.
- Reduce fuel pressure in high pressure area.
• To be able to turn the drive axle to remove it, shift the transmission to "N" and release the electromechanical parking brake before disconnecting the battery.
- Position the front wheels so they are straight.
Risk of destroying electrical components.
• Complete the steps for disconnecting the battery.
- Switch off ignition and remove ignition key.
- Disconnect the ground (GND) cable - 2 - from the battery post.
- Empty coolant circuit.
- Extract the power steering oil from the reservoir with the (V.A.G 1782).
- Remove the engine cover - arrows -.
- Remove the lock carrier cover.
Risk of scalding due to hot steam and hot coolant.
• The coolant system is under pressure when the engine is warm.
• Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system.
- Open the coolant reservoir cap.
- Remove the left and right front wheel housing liner..
- Remove the noise insulation - 1 - and - 2 -..
- Remove the driveshaft.
• Collect escaping coolant in a clean container for disposal or reuse.
- Place (VAS 6208) under engine.
- Remove the drain plug - arrow - on the front coolant hose and drain the coolant.
- Remove the drain plug - arrow - on the map controlled engine cooling thermostat (F265) and drain the coolant.
- Loosen the clamp - 1 - and remove the coolant hose from the left lower coolant pipe.
• Ignore - 2 -.
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.
Danger of defects caused by dirt.
• Follow cleanliness precautions when working on the fuel supply system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Pull down the boot - 1 - and disconnect the fuel line.
- First push the hose coupling - 2 - downward - arrow A -, then press the release buttons - arrow B -.
- Remove the hose coupling with the release buttons pressed.
- Free up the fuel line and the line to the EVAP canister on the air guide pipe.
- Disconnect the electrical connector - 2 - on evaporative emission (EVAP) canister purge regulator valve 1 (N80) and disconnect the vacuum hose - 1 -.
- Remove evaporative emission (EVAP) canister purge regulator valve 1 from bracket and lay aside with hose and fuel line connected.
- Open the clamps - 1 and 3 - and remove the air guide pipe.
• Ignore - 2 -.
- Remove bolts - 1 and 3 - and then remove the upper right - 2 - longitudinal member.
- Remove the windshield wiper arms.
- Remove the seal - 1 - near the plenum chamber cover.
The plenum chamber cover could be damaged.
• Coat the bond between the windshield and the plenum chamber cover with soapy water.
- Carefully remove the plenum chamber cover - 2 - starting upward starting at the edge of the window - arrows -.
- Lift the plenum chamber cover and disengage it from the guide tabs - 4 - and then disengage it from the side covers - 3 -.
- Release the cover - 2 - and swivel it to the side - arrow -.
- Remove the nut - 4 - and free up the positive cable.
- Remove the nut - 3 - and remove the positive cable - 1 -.
- Open the tabs - 1 and 3 - and swivel the positive terminal - 2 - out of the mount.
- Remove the bolts - arrows - and the engine compartment E-box cover - 1 -.
- Disconnect the connectors - 1, 2 and 3 - and free up the wires.
- Release the retainers - arrows - and remove the relay carrier with the fuse panel - 4 -.
- Open the release - 5 - and remove the condenser - 6 -.
- Disengage and free up the engine wiring harness on the engine compartment E-box and then lay it on the engine.
- Open the clamps - 1 - and - 2 - and remove the coolant hoses.
- Disconnect the right, upper coolant hose from the radiator, to do this, lift the retaining clip - 1 -.
• Ignore - 2 -.
- Open the clamp - 2 -, free up the coolant hose - arrow - and remove it from the coolant reservoir.
- Open the clamps - 1 - and - 3 - and remove the air guide pipe.
- Disconnect the vacuum hose - 1 - and free it up - arrow -.
- Release the retainers - arrows - and free up the left and right wiring harness on the plenum chamber bulkhead.
- Remove the electrical connector - 1 - from the bracket and disconnect it.
- Free up the wiring harness on the tower brace using the (80 - 200).
- Remove the bolts - 1, 2 and 3 - and - arrows - and remove the tower brace.
- Open the clamps - arrows -, remove the engine control module (J623) - 2 - and lay it on the engine.
• Ignore - 1, 3 and 4 -.
- Loosen the clamp - 2 - and remove the muffler - 1 - for the auxiliary heater.
- Remove the bolts - 1 - and remove the deflector plate forward - arrow -.
- Remove the left and right air intake grilles - 1 - from the bumper cover - arrow -.
- Release the latch - arrow - and open the cover - 4 -.
- Disconnect the wires - 1 - and - 2 -.
- Remove the bolt - 3 -.
- Push the fuse panel upward and disengage is on the lock carrier.
- Free up the wires.
- Free up the hose - 3 - and the wires - 4 -.
- Remove the bolts - 1, 2 and 5 - and remove the right rear longitudinal member.
- Remove the bolt - 4 - for the battery positive cable - 3 - and the bolt - 2 - for the ground (GND) cable - 1 - and free up the cables.
- Press the release buttons and remove the air guide hose - arrow -.
- Free up the coolant hose - 1 -.
- Remove the bolts - 2 - and remove the deflector plate forward - arrow -.
- Remove the bolts - 1, 2 and 3 - and the left lower longitudinal member.
- Remove the coolant hose; to do so, loosen the hose clamp - 3 -.
• Ignore - 1, 2 and 4 -.
- Place the (V.A.G 1782) under the disconnection point.
- Loosen the clamp - arrow - and remove the hydraulic hose.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
• Place a cloth below to catch the draining hydraulic fluid.
- Loosen the clamp - arrow - and remove the hydraulic hose.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
Risk of damaging coolant lines and hoses.
• Do not stretch, kink or bend coolant lines and hoses.
- Remove the bolt - 1 - and remove the refrigerant lines from the A/C compressor.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
- Disconnect the left and right connector - arrow - from the left front level control system sensor (G78) / right front level control sensor (G289) and free up the wires.
- Disconnect the electrical connectors - arrow - at the left and right on the front speed sensors.
- Free up the electrical connector - 2 - on the bracket by pulling the retainer back - arrow A - and turning the connector approximately 90° in the direction of - arrow B -.
- Free up the electrical wiring - 3 - and brake line - 4 - on the bracket.
- Remove the bolts - 1 - and secure the brake caliper in the wheel housing using wire.
Risk of damaging brake pistons.
• Do not operate brake pedal with brake caliper removed.
- Remove the nut - 2 - and bolt - 1 -.
- Remove the upper control arm upward from the wheel bearing housing - arrows -.
- Repeat the procedure on the other side of the vehicle.
- Remove the left and right stabilizer bar bolt - 1 -.
- Remove the left and right nuts - 3 -.
• The bolt - 2 - will be removed later.
- Remove the left and right bolts - 3 -.
• Ignore - 1 and 2 -.
- Remove the subframe crossbrace.
Suspension components could be damaged.
• Do not rest the vehicle on its wheels if the subframe mount, steering gear or subframe crossbrace are not installed correctly.
The airbag spiral spring could be damaged.
• Separate universal joint from steering gear only when front wheels are in straight ahead position.
• Do not change steering wheel position and steering gear position any more, secure steering wheel with adhesive tape.
- Remove universal joint bolt - arrow -.
- Press the CV joint off the steering gear and slide it all the way up.
- Remove the nuts - 1 - and the bolts - 2 - and then remove the left front muffler.
- Remove the nuts - 4 - and the bolts - 3 - and then remove the left front muffler.
- Squeeze the retainers - arrows A - and pull the sleeve - 1 - on the emergency release cable in direction of - arrow B -.
- Disengage the rear section of the emergency release cable from the front section of the emergency release cable - arrow C -.
- Remove electrical connectors from bracket and disconnect:
1. For the left electrohydraulic engine mount solenoid valve (N144) / right electrohydraulic engine mount solenoid valve (N145)
2. For the servotronic solenoid valve (N119)
- Remove the bolt - arrow - from the auxiliary heater bracket, if equipped.
Prepare Scissor Lift Platform:
- Equip the scissor lift platform (VAS 6131 A) with the support set for Audi (VAS 6131/10) , adapter set (VAS 6131/11) and (VAS 6131/13) as follows:
- Next secure mounting elements to scissor lift table by hand.
- Position the (VAS 6131 A) horizontally.
• Note bubble level (sight glass) on support platform.
- Move the (VAS 6131 A) under the engine/transmission subassembly.
The subframe could cause an accident if it is not secured.
• Do not loosen the subframe bolts - 2 - and - 3 - yet.
- Remove the left and right subframe bolt - 1 -.
- Attach the mounting elements from the (VAS 6131/10) and (VAS 6131/13) at the left and right in front of the subframe as shown in the illustration.
- Ensure threaded spindles are completely installed.
- Attach the mounting elements from the (VAS 6131/10) at the left and right rear on the subframe crossbrace front connecting points as shown in the illustration.
- Attach mounting elements from the (VAS 6131/13) at the lower left and right of the wheel bearing housing as shown in the illustration.
- Attach the mounting elements from the (VAS 6131/10) and (VAS 6131/11) at the left and right rear of the tunnel crossmember as shown in the illustration.
- Rotate the mounting element spindles upward until all the mounting pins come into contact with the mounting points.
- Attach mounting element base plates to (VAS 6131 A) and tighten to 20 Nm.
- Mark the location of the subframe and engine carrier to the longitudinal members using a felt-tip pen.
- Remove the left and right subframe bolts - 2 and 3 - in steps.
- Remove the bolts - arrows - on the tunnel crossmember.
- Remove the left and right bolts - 2 -.
Risk of damaging hose and wiring connections as well as engine compartment.
• Make sure all the hoses and lines between the engine, transmission, subframe and body have been disconnected.
• Carefully guide engine-transmission assembly with subframe out of engine compartment while lowering.
- Lower the engine/transmission subassembly using the (VAS 6131 A).
- Remove the (VAS 6131 A) with the engine/transmission subassembly under vehicle.