Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Engine Support Bridge (10-222 A)
• Shackle (10-222 A/12)
• Lifting Tackle (2024 A)
• Hose Clamps up to 25 mm Diameter (3094)
• Engine Support Adapter (3147)
• Engine/Transmission Jack (V.A.G 1383 A) for Audi Cabriolet
• Old Oil Collecting And Extracting Device (V.A.G 1782 )
• Hose Clamp Pliers (V.A.G 1921)
• Spark Plug Connector Pliers (V.A.G 1922)
• Shop Crane (VAS 6100) or Shop Crane (V.A.G 1202 A)
• Drip Tray For Workshop Crane (VAS 6208) or Drip Tray (V.A.G 1306)
• 15 mm Socket (Matra V/175) for vehicles with automatic transmission 01V
Procedure
• Engine is removed without transmission toward the front with the lock carrier removed.
• All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
• Drained coolant must be stored in a clean container for disposal or reuse.
- On a vehicle with Multitronic/automatic transmission, shift the selector lever to position "N".
CAUTION!
Observe procedures for disconnecting battery.
- Pull rubber seal off plenum chamber cover in direction of - arrow -.
- Remove plenum chamber cover - 1 - if equipped.
- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.
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.
- Loosen quick-release fasteners - 1 - and - 2 - and remove front noise insulation.
- Remove quick-release fasteners - 3 - and remove rear noise insulation, if installed.
- Remove bracket for noise insulation - arrows -.
- Remove front bumper cover.
- Remove air guide in front of the charge air cooler - arrows -.
- Place Drip Tray for Workshop Crane (VAS 6208) or Drip Tray (V.A.G 1306) under engine.
Vehicles with coolant drain plug:
- Open the coolant drain plug to coolant line at bottom of cooler.
- Disconnect connector on the Engine Coolant Temperature (ECT) Sensor (on Radiator) (G83) and free up the wire.
Vehicles without coolant drain plug:
- Remove retaining clip - 1 - on the Engine Coolant Temperature (ECT) Sensor (on Radiator) (G83) - 2 -.
- Remove Engine Coolant Temperature (ECT) Sensor (on Radiator) (G83) from its supports and drain coolant.
- Free up electrical wiring.
All:
- Disconnect lower coolant hose from radiator - arrow -.
- Remove lower air guide hose - 1 - on the charge air cooler.
CAUTION!
The air conditioning refrigerant circuit must not be opened.
- Unhook refrigerant line from bracket - 2 -.
- Remove air guide hose - 1 - to the lower right turbocharger on the lock carrier.
- Clamp off the hydraulic hoses to the power steering system cooling coil using Hose Clamps up to 25 mm Diameter (3094).
- Place Old Oil Collecting and Extracting Device ( V.A.G 1782) under connection.
- Disconnect hydraulic hoses - arrows -.
Vehicles with automatic transmission:
- Place old oil collecting and extracting device ( V.A.G 1782) under connection.
• Observe the rules of cleanliness for working on automatic transmissions.
- Remove union nuts - 1 - and - 2 - and disconnect the ATF lines.
- Remove ATF line bracket - arrow - on the engine.
All:
- Open quick-release fasteners - arrows - and remove engine cover.
- Remove right cover - 1 - in the engine compartment, if equipped.
- Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) from the air guide.
- Remove bolts - arrows -.
- Remove air duct - 2 -.
- Remove cover - arrow - at power steering fluid reservoir.
- Disconnect coolant hose - 1 - at top of radiator.
- Disconnect electrical harness connector - 2 - for left and right airbag sensors on lock carrier.
- Disconnect electrical harness connector - arrow - for headlamps at both sides of the vehicle.
- Remove electrical harness connectors - 1 - and - 2 - from bracket.
- Disconnect electrical connectors and free up electrical lines.
- Remove left and right air guides - arrows - at radiator.
- Unclip Outside Air Temperature Sensor (G17) - 2 - from the bracket.
- Remove bolts - 3 - and - 4 - and remove the power steering system cooling coil.
- Disconnect electrical harness connector - 1 - at High Pressure Sensor (G65).
CAUTION!
The air conditioning refrigerant circuit must not be opened.
- Remove bolts - arrows - for the condenser.
• To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
- Pivot condenser downward with lines connected.
- Remove bolts - arrows - at left and right side of bumper.
- Unhook cable for hood release at the lock.
- Remove hood seal on lock carrier and on the bolted fender flanges.
- Remove bolts - arrows - at left and right impact absorbers.
• A second technician is required to remove the lock carrier.
- Remove lock carrier and set aside so it cannot topple.
- Disconnect vacuum line - 3 - leading to the brake booster on the bulkhead.
- Remove vacuum hose leading to the Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) - 1 -.
- Remove Ground (GND) connection - 2 - from the bulkhead.
- Remove coolant hoses - 1 - and - 2 - and remove the coolant expansion tank - arrow -.
- Disconnect electrical connection at Engine Coolant Level (ECL) Warning Switch (F66) at bottom of coolant expansion tank.
- Place Drip Tray for Workshop Crane (VAS 6208) or Drip Tray (V.A.G 1306) under engine.
- Remove coolant hose from oil cooler - arrow - and drain any remaining coolant.
- Remove left coolant hose - arrow - to heater core on rear coolant pipe.
- Remove right coolant hose leading to the heater core at the cylinder head connection.
- Remove coolant hose from the thermostat connection - arrow -.
- Remove coolant hose - 1 - at upper coolant pipe.
• Ignore - 2 -.
- Disconnect air guide hose - 1 - at the intake manifold.
- Disconnect connector - 2 - on the Charge Air Pressure Sensor (G31) and free up the electrical wire.
- Disconnect vacuum hose - arrow - leading to the vacuum reservoir and free up the vacuum hose.
• Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed turning direction can cause damage to the ribbed belt under operating conditions.
- Move tensioning element in direction of - arrow - to release the tension on the ribbed belt.
- Remove ribbed belt.
- Remove front bolts - arrows - on the power steering pump.
- Remove rear bolt - arrow - on the power steering pump.
- Move power steering pump to the side onto the longitudinal member. Lines remain connected.
- Disconnect connector - bottom arrow - on the Secondary Air Injection Pump Motor (V101) and free up the electrical wire.
- Disconnect hose - upper arrow - on the pipe leading to the secondary air combination valve.
- Disconnect connector - 3 - on the Evaporative Emission Canister Purge Regulator Valve (N80) and the connector - 5 - on the Mass Air Flow (MAF) Sensor (G70).
- Disconnect hoses - 1 -, - 4 -, - 6 -, - 7 -.
- Remove air filter housing by removing the expanding clip - 2 -.
CAUTION!
Fuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.
- Disconnect fuel line - 1 - and free it up.
• Ignore - 2 -.
- Pry off both covers - 3 - using a screwdriver.
- Loosen hex-nuts - 4 - by several turns.
- Loosen wiper arm - 2 - from wiper axle by lightly tilting.
- Remove nuts completely and remove wiper arms.
- Disconnect securing clips - 1 - and remove cowl grille - 5 -.
- Remove cover for E-Box in plenum chamber - arrows -.
- Pry off retainer bar with a screwdriver - arrow -.
- Loosen connector catches - arrows - and disconnect control module electrical connectors - 1 - and - 2 -.
• The connectors remain connected to the engine control module - 1 - with a protective housing - 4 -.
• Place ECM on engine and secure it against falling down.
- Disconnect all electrical harness connectors on connector station - 2 - using Spark Plug Connector Pliers (V.A.G 1922 ).
- Unbolt electrical wire connection - 1 -.
- Disengage locking mechanisms - arrows - and remove secondary relay carrier in E-Box toward top.
- Disengage and free up engine wiring harness at E-Box and bulkhead.
- Remove connectors - 2 - and - 5 - from the left retainer on the bulkhead and disconnect the connectors.
- Remove retainer for connectors on the bulkhead.
- Remove front exhaust pipe/catalytic converter nuts - arrows -.
- Remove heat shield - 1 - for right drive axle.
- Remove nut - arrow - and on the front exhaust pipe strap.
- Remove threaded connections on the front clamping sleeves - arrows -.
- Push clamping sleeve rearward to separate the exhaust system.
• Do not bend the flex joint in front of the exhaust pipe more than 10° or it could be damaged.
- Remove catalytic converter and exhaust pipe from the turbocharger.
- Disconnect connector on the Speedometer Vehicle Speed Sensor (G22) - bottom arrow - on the left side of the transmission.
- If the vehicle has a manual transmission, disconnect the back-up light switch (F4) connector on the transmission - top arrow -.
- Free up electrical wiring.
- Disconnect electrical harness connector - arrow - at Oil Level Thermal Sensor (G266).
- Remove bracket for refrigerant line on oil pan - arrow -.
- 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 the vehicle.
- Remove the Ground (GND) cable - 1 - on the right engine support.
- Disconnect electrical wires - 2 - and - 3 - on the starter.
- Remove insulator on the starter positive connection.
- Remove harness clamp - 4 -.
- Remove starter bracket - 5 -.
- Remove starter on the transmission.
Vehicles with automatic transmission 01V:
- Remove the 3 torque converter bolts - arrow - inside the transmission opening using a 15 mm socket wrench (Matra V/175); to do this turn the crankshaft at the toothed belt sprocket bolt 1/3 turn.
All:
- Mark installed position of threaded connection - 1 - and lower locating sleeve - 2 - on left and right engine mounts.
• Depending on the engine version, different fastening holes are utilized.
- Remove nuts - 1 - at bottom on left and right engine mounts.
- Remove bolts - arrows - on the engine/transmission flange, accessible from underneath.
• Be sure to make a note of the bolt lengths and their order of removal.
Audi Cabriolet:
Do not remove the lower bolts on the engine/transmission flange.
- Lift the engine/transmission to the torque bracket using the Engine/Transmission Jack (V.A.G 1383 A).
- Make sure the wires at the top of the bulkhead do not get damaged.
CAUTION!
Make sure the support is secure otherwise this could cause personal injury.
- Lower engine again.
All:
- Loosen upper nut - arrow - on the left engine mount a few turns.
- Remove the upper bolts on the engine/transmission flange; one bolt remains install just hand-tight.
- Position Engine Support Bridge (10-222 A) behind gas-filled strut on bolted fender flange. The spindle is positioned forward.
- Install the Engine Support Adapter (3147) into the upper threaded holes in the transmission housing as illustrated.
- Join the Engine Support Adapter (3147) and Engine Support Bridge (10-222 A) together using the Additional Hooks (10-222 A/2).
• To improve clarity, the removed engine is shown.
- Lightly tension engine with Engine Support Bridge (10-222 A) spindles.
- Free up the rear lifting eyelet on the engine.
- Attach the Lifting Tackle (2024 A) to the engine and to the Workshop Crane (V.A.G 1202 A ) or (VAS 6100).
• To be aligned to the center of gravity of the engine assembly, the hole rails of the lifting hook must be inserted as shown in the illustration.
CAUTION!
Lifting hooks and alignment pins on lifting tackle must be secured with securing pins - arrows -.
- Remove the last bolt on the engine/transmission flange.
• Verify that all hose and line connections between engine and body have been disconnected.
- Lift the engine by the threaded bolts out of the engine mounts.
- Turn Engine Support Bridge (10-222 A) spindle back.
• Make sure the wires at the top of the bulkhead do not get damaged.
Vehicles with automatic transmission 01V:
- Separate the automatic transmission from the engine by pushing the torque converter from the drive plate.
All:
- Pull the engine off from transmission and guide it forward and out of the engine compartment.
Vehicles with automatic transmission 01V:
- Secure the torque converter inside the transmission from falling out.