Engine, removing: Notes

NOTE:

All cable ties opened or cut during engine removal must be reinstalled at the same locations.
Remove engine without transmission toward the front.
Drained coolant must be stored in a clean container for disposal or reuse.
Always replace seals and gaskets.
Do not open coolant circulation system.

See Caution before beginning repairs on the electrical system under ENGINE, REMOVING AND INSTALLING .

Remove plenum cover.
Switch ignition off and disconnect battery Ground (GND) strap.
Remove bolts (arrows) and remove engine covers -A- and -C-.
Remove cover above air filter.

Fig 1: Removing Engine Covers
Courtesy of AUDI OF AMERICA, INC.
Remove sound-proofing material (arrows).
Remove bracket for sound-proofing at unit support.
Drain engine coolant. See COOLING SYSTEM, DRAINING AND FILLING .
Remove bumper:
See FRONT BUMPER .
Remove lock carrier:
LOCK CARRIER WITH ATTACHMENTS, REMOVING AND INSTALLING .

Fig 2: Removing Sound-Proofing Material
Courtesy of AUDI OF AMERICA, INC.
Remove viscous fan counter-hold using 3212 wrench.
NOTE: The viscous fan has a LEFT-HANDED thread.

Fig 3: Removing Viscous Fan Using 3212 Wrench
Courtesy of AUDI OF AMERICA, INC.
Mark direction of rotation of ribbed belt
To loosen ribbed belt, turn clockwise using 17 mm box wrench until two holes are aligned (arrow). Counter-hold in position using 3204 drift.
NOTE: Mark direction of rotation of ribbed belt. Reversing the direction in which it runs can ruin it.
Remove ribbed belt.

Fig 4: Turning Ribbed Belt Tensioner Clockwise
Courtesy of AUDI OF AMERICA, INC.
Cut coolant hoses -1- and -2-
Remove coolant reservoir (arrows).
Disconnect connector for coolant level display.
Remove valve cover (cylinder bank 4-6).

Fig 5: Removing Coolant Reservoir
Courtesy of AUDI OF AMERICA, INC.
Remove hose -1- to vacuum reservoir.

Fig 6: Removing Hose From Vacuum Reservoir
Courtesy of AUDI OF AMERICA, INC.
Remove air distributor (arrows).

Fig 7: Removing Air Distributor
Courtesy of AUDI OF AMERICA, INC.

WARNING: Fuel system is under pressure! Before opening the system place a rag around the connection. Then release pressure by carefully loosening the connection.
Disconnect fuel supply and return lines -1- and -2- and move aside.
Remove hose from Evaporative Emission (EVAP) canister purge regulator valve -3-.

Fig 8: Disconnectur Fuel Supply Lines And Hose From EVAP Canister Purge Regulator Valve
Courtesy of AUDI OF AMERICA, INC.
Disconnect connector -1- at Mass Air Flow (MAF) sensor. See Fig 9
Disconnect connectors -2- from power output stage and move cables aside.
Remove air filter.

Fig 9: Removing Air Filter
Courtesy of AUDI OF AMERICA, INC.
Disconnect connector -1- for oxygen sensor at bulkhead. See Fig 10.
Disconnect connector -2- for knock sensor.
Disconnect harness connector -3-.
Move cables clear.

Fig 10: Disconnecting Harness Connectors At Bulkhead
Courtesy of AUDI OF AMERICA, INC.
Remove pressure hoses (arrows) from charge air cooler to left and right pressure lines.

Fig 11: Removing Pressure Hoses (Arrows) From Charge Air Cooler To Left And Right Pressure Lines
Courtesy of AUDI OF AMERICA, INC.

See Caution before beginning repairs on the electrical system under ENGINE, REMOVING AND INSTALLING .
Disconnect cable at B+ on battery.
Disconnect B+ battery cable.
Move cables to starter aside together with cable channels (arrows).

Fig 12: Moving Cables To Starter Aside Together With Cable Channels
Courtesy of AUDI OF AMERICA, INC.
Remove pressure lines -1-.
NOTE: Watch position of retaining strips -2-.

Fig 13: Removing Pressure Lines
Courtesy of AUDI OF AMERICA, INC.
Disconnect hose from power steering reservoir to power steering pump with special tool 3094. See Fig 14.
Disconnect power steering hose (arrow).

Fig 14: Disconnecting Power Steering Hose (Arrow)
Courtesy of AUDI OF AMERICA, INC.
Disconnect hydraulic line (arrow).
Disconnect harness connector from vehicle speed sensor.
Disconnect harness connector from reverse gear switch.

Fig 15: Disconnecting Hydraulic Line (Arrow)
Courtesy of AUDI OF AMERICA, INC.
Unscrew heat sensor -1- from right-hand turbocharger using 3035.
Detach heat shield -2- from left and right turbochargers.
Unscrew upper bolts -3- from front exhaust pipes at left and right turbochargers.

Fig 16: Detaching Heat Shield -2- From Left And Right Turbochargers
Courtesy of AUDI OF AMERICA, INC.
Remove wiper arms (arrows).
Disconnect retaining clip -1- at water deflector.
Pull off left and right retaining clips -3- on water deflector.
Remove water deflector.
Remove cover -2- from E-box (electronics box).
Open E-box in plenum.

Fig 17: Removing Wiper Arms
Courtesy of AUDI OF AMERICA, INC.
Unclip ECM retaining bracket.
Remove ECM, disconnect harness connectors -2- and -3- and remove.
Disconnect harness connectors -1-.

Fig 18: Removing ECM Of Disconnect Harness Connectors
Courtesy of AUDI OF AMERICA, INC.
Remove hose -1- to power brake booster at bulkhead.
Disconnect ground (GND) -3-. See Fig 19.
Disconnect connectors -2- and -5- at bulkhead and remove lower part of connectors from bracket.
Pull connector -4- out of bracket and move wiring clear.
Remove bracket for cable plug.
Remove both coolant hoses to heat exchanger at engine by un-clipping retaining clips on flange.

Fig 19: Locating Power Brake Booster And Connectors At Bulkhead
Courtesy of AUDI OF AMERICA, INC.
Remove both coolant hoses to heat exchanger at engine by un-clipping retaining clips on flange.
Release hose clamp -arrow-.
Remove intake line -1-.
Remove water line -2-.

Fig 20: Removing Both Coolant Hoses To Heat Exchanger At Engine
Courtesy of AUDI OF AMERICA, INC.
Remove pressure hoses -arrows- between turbocharger and charge air cooler (left and right sides).

Fig 21: Removing Pressure Hoses -Arrows- Between Turbocharger And Charge Air Cooler (Left And Right Sides)
Courtesy of AUDI OF AMERICA, INC.
Move aside cable -1- to starter by cutting cable tie and unclipping bracket (arrow).
Remove hose -2- for cooling generator.

Fig 22: Removing Hose -2- For Cooling Generator
Courtesy of AUDI OF AMERICA, INC.
Disconnect ground (GND) (arrow) from engine support.

Fig 23: Disconnecting Ground (Arrow) From Engine Support
Courtesy of AUDI OF AMERICA, INC.
Remove torque support -1-.
Remove hose clamps (arrows).
Remove coolant line -2-. See Fig 24.
Place VAG 1306 Drip Tray beneath engine.
Remove oil filter.

Fig 24: Removing Hose Clamps At Front Of Engine
Courtesy of AUDI OF AMERICA, INC.
Remove hose clamps (arrow).
Remove oil cooler -1-.

Fig 25: Removing Oil Cooler
Courtesy of AUDI OF AMERICA, INC.
Remove heat shield (arrows) above left and right drive axle to transmission.

Fig 26: Removing Heat Shield Above Left And Right Drive Axle
Courtesy of AUDI OF AMERICA, INC.
Remove hose clamp -1- from left and right heat shield for turbocharger.
Unbolt left and right exhaust pipes -2- from turbocharger.

Fig 27: Removing Hose Clamp -1- From Left And Right Heat Shield For Turbocharger
Courtesy of AUDI OF AMERICA, INC.
Detach air conditioner line from oil pan -arrow-.
CAUTION: Do not open the refrigerant circuit of the AC system.

Fig 28: Detaching Air Conditioner Line From Oil Pan
Courtesy of AUDI OF AMERICA, INC.
Remove A/C compressor -1...2-.
Attach A/C compressor (with refrigerant hoses attached) to vehicle using wire.

Fig 29: Removing A/C Compressor
Courtesy of AUDI OF AMERICA, INC.
NOTE:
- When installing pay attention to guide bushings.
- When installing first insert bolt -1- in A/C compressor.
- Do not bend or stretch lines or hoses as condenser and/or refrigerant lines/hoses may be damaged.
Vehicles with automatic transmission:
Remove right charge air cooler by disconnecting upper hose connection; charge air cooler supported in 3x rubber bearings.
Disconnect air guide at generator support -3-.
Unbolt cable at terminal 30/B+ -1-. Tightening torque: 16 Nm
Unbolt cable at terminal D+ -2-. Tightening torque: 4 Nm

Fig 30: Disconnecting Air Guide At Generator Support
Courtesy of AUDI OF AMERICA, INC.
Remove hex socket bolt -1-, retaining nut -2-. Tightening torque: 45 Nm. See Fig 31.
Remove bolt -3-. Tightening torque: 22 Nm
Remove generator -4- downward and out.

Fig 31: Removing Generator
Courtesy of AUDI OF AMERICA, INC.

- Remove air intake -1-.
- Securing points for oil and A/C lines
- Securing point to engine block
- Remove hose clamp

Fig 32: Removing Air Intake

Courtesy of AUDI OF AMERICA, INC.

Unbolt cable for terminal 30/B+ -1-. Tightening torque: 16 Nm
Disconnect connector for terminal 50 -2-.

Fig 33: Unbolting Cable For Starter Terminals
Courtesy of AUDI OF AMERICA, INC.
Remove right wheel.
Remove upper bolt -1- through right wheelhousing. Tightening torque: 65 Nm. See Fig 34.
Remove lower bolt from engine side. Tightening torque: 65 Nm
Remove starter forward and out.

Fig 34: Removing Upper Bolt -1- Through Right Wheelhousing
Courtesy of AUDI OF AMERICA, INC.
Using special tool V175 disconnect torque converter from drive plate.

Fig 35: Disconnecting Torque Converter From Drive Plate
Courtesy of AUDI OF AMERICA, INC.