Engine, removing

Lock carrier removed, see LOCK CARRIER, REMOVING .

Unplug electrical connector -5- at Charge Air Pressure Sensor -G31-.
Loosen hose clamps -3- and -4-.
Pull off hoses at air recirculation valves.
Remove bolts -1- and -2- detach air intake pipe.
Remove connecting hoses to charge air coolers.

Fig 1: Removing Connecting Hoses To Charge Air Coolers

Courtesy of AUDI OF AMERICA, INC.

Disconnect electrical harness connector (arrow) to Brake System Vacuum Pump -V192-.
Move cable clear.

Fig 2: Disconnecting Electrical Harness Connector To Brake System Vacuum Pump
Courtesy of AUDI OF AMERICA, INC.

NOTE: Place a cloth underneath connecting points to catch escaping hydraulic fluid.
Detach hose -1- from power steering reservoir.
Pull off vacuum hose -2- going to vacuum reservoir.
Place container underneath connecting points to catch escaping fluid.

Fig 3: Detaching Hose From Power Steering Reservoir

Courtesy of AUDI OF AMERICA, INC.

Unbolt hydraulic pressure line at vane pump (arrow).

Fig 4: Unbolting Hydraulic Pressure Line At Power Steering Vane Pump

Courtesy of AUDI OF AMERICA, INC.

Disconnect coolant hose (arrow) to Valve for coolant circulation -N214-.

Fig 5: Disconnecting Coolant Hose To Valve For Coolant Circulation

Courtesy of AUDI OF AMERICA, INC.

Disconnect coolant hoses -1- to -3-. See Fig 6.

Fig 6: Disconnecting Coolant Hoses

Courtesy of AUDI OF AMERICA, INC.

Disconnect electrical harness connector -3- from Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- (item -1-). See Fig 7.
Remove solenoid valve from bracket.
Disconnect vacuum hose -2- from solenoid valve.

Fig 7: Removing EVAP Canister Purge Regulator Solenoid Valve From Bracket

Courtesy of AUDI OF AMERICA, INC.

Unplug electrical connector -2- from Secondary Air Injection (AIR) Pump Motor -V101- and move wiring clear. See Fig 8.
Detach hose -3- from secondary air system combination valve. See Fig 8.
Unscrew secondary air pump with bracket -1- from body.

Fig 8: Unplugging Electrical Connector From Secondary Air Injection (Air) Pump Motor
Courtesy of AUDI OF AMERICA, INC.

NOTE: Secondary air pump with bracket remains at installation location.

WARNING: Fuel system is under pressure. Before opening system, place a cloth around connection. Then release pressure by carefully loosening connection.
Disconnect fuel supply line -2- and fuel return line -1-.

Fig 9: Disconnecting Fuel Supply Line And Fuel Return Line

Courtesy of AUDI OF AMERICA, INC.

Disconnect vacuum hose -3- from brake booster. See Fig 10.
Disconnect coolant hoses -1- and -2- between engine and heater core at bulkhead.

Fig 10: Disconnecting Vacuum Hose & Coolant Hoses

Courtesy of AUDI OF AMERICA, INC.

Disconnect electrical harness connectors -1- to -4- from right bracket at bulkhead.
Disconnect electrical harness connector -4-.

Fig 11: Disconnecting Electrical Harness Connector From Right Bracket At Bulkhead
Courtesy of AUDI OF AMERICA, INC.
Remove right bracket at bulkhead.
Remove coolant reservoir (arrows).
Disconnect electrical harness connector to Engine Coolant Level (ECL) Warning Switch -F66- at bottom of reservoir.
Move wiring harness to Engine Control Module (ECM) clear.
Disconnect coolant hose -2-.

Fig 12: Removing Coolant Reservoir

Courtesy of AUDI OF AMERICA, INC.

Unclip covers over wiring connections.
Unbolt electrical wires -1- to -3- at right in plenum chamber.

Fig 13: Unbolting Electrical Wires -1- To -3- At Right In Plenum Chamber
Courtesy of AUDI OF AMERICA, INC.
Expose wiring harness and set it on engine.
Remove cover for electronics box in plenum chamber (arrows).

Fig 14: Removing Cover For Electronics Box In Plenum Chamber

Courtesy of AUDI OF AMERICA, INC.

Carefully pry off retainer bar with a screwdriver (arrow).
NOTE: Engine control module remains connected to wiring harness.

Fig 15: Removing Retainer Bar

Courtesy of AUDI OF AMERICA, INC.

Unplug connectors (arrows) from rear of connector console.

Fig 16: Unplugging Connectors From Rear Of Connector Console

Courtesy of AUDI OF AMERICA, INC.

Release retainer (arrow) and push auxiliary relay carrier in electronics box upwards to remove.
Disengage engine wiring harness from electronics box and bulkhead.

Fig 17: Releasing Retainer And Removing Auxiliary Relay Carrier In Electronics Box

Courtesy of AUDI OF AMERICA, INC.

Disconnect electrical harness connector -2- at Brake Booster Pressure Sensor -G294-. See Fig 18.
Move cable clear.
Disconnect vacuum hose -1-. See Fig 18.

Fig 18: Disconnecting Electrical Harness Connector At Brake Booster Pressure Sensor

Courtesy of AUDI OF AMERICA, INC.

Remove Sensor -1- for exhaust temperature -G235- and Bank 2 Exhaust Gas Temperature (EGT) Sensor 1 -G236- (items -1- and -2-) from bulkhead.
Disconnect Ground (GND) connections -3-.

Fig 19: Removing Sensor For Exhaust Temperature
Courtesy of AUDI OF AMERICA, INC.
Remove bracket -4- for harness connectors from bulkhead.
Set wiring harness on engine and secure Engine Control Module (ECM) against falling down.
NOTE: Before removing ribbed belt, mark direction of rotation with chalk or a felt pen. If a used belt rotates in opposite direction when reinstalled, premature wear and breakage may occur.
To loosen ribbed belt, turn belt tensioner in direction of arrow.

Fig 20: Removing Ribbed Belt
Courtesy of AUDI OF AMERICA, INC.
Remove ribbed belt.
Unscrew alternator securing bolts (arrows).

Fig 21: Unscrewing Alternator Securing Bolts

Courtesy of AUDI OF AMERICA, INC.

Disconnect electrical wires -1- and -2- from generator.
Remove generator.

Fig 22: Disconnecting Electrical Wires And From Generator

Courtesy of AUDI OF AMERICA, INC.

Remove coolant line from engine (arrows).
NOTE: Shown in illustration with engine removed.

Fig 23: Removing Coolant Line From Engine

Courtesy of AUDI OF AMERICA, INC.

Unscrew nuts -1- to -4- for left and right stabilizer bar mountings.

Fig 24: Unscrewing Nuts For Left And Right Stabilizer Bar Mountings

Courtesy of AUDI OF AMERICA, INC.

Unscrew bolts -1- and -2-.
Loosen hose clamps (arrows) and detach left air pipe.

Fig 25: Locating Hose Clamps And Detach Left Air Pipe

Courtesy of AUDI OF AMERICA, INC.

Unscrew bolts -1-.
Loosen hose clamps (arrows) and detach right air pipe.

Fig 26: Locating Hose Clamps And Detach Right Air Pipe

Courtesy of AUDI OF AMERICA, INC.

Unbolt angle bracket for wiring harness from right engine mount.
Mark positions of threaded connections -1- and locating sleeves -2- on right engine mounting (bottom).
NOTE: Different mounting holes are provided for different engine versions.

Fig 27: Identifying Mark Positions Of Threaded Connections On Right Engine Mounting

Courtesy of AUDI OF AMERICA, INC.

Remove ground wire -2-. See Fig 28.
Unscrew nuts -1- and -3- for right engine mounting.
Unplug electrical connector at engine mounting.

Fig 28: Locating Engine Mounting

Courtesy of AUDI OF AMERICA, INC.

Remove bolts (arrows).
Set aside Valve for coolant circulation -N214- with connected electrical wire upward on longmember.

Fig 29: Removing Bolts For Coolant Circulation Valve N214

Courtesy of AUDI OF AMERICA, INC.

Mark positions of threaded connections -1- and locating sleeves -2- on left engine mounting (bottom).
NOTE: Different mounting holes are provided for different engine versions.

Fig 30: Identifying Mark Positions Of Threaded Connections And Sleeves On Left Engine Mounting

Courtesy of AUDI OF AMERICA, INC.

Unscrew nuts -1- and -2- for left engine mounting. See Fig 31.
Unplug electrical connector at engine mounting.

Fig 31: Unplugging Electrical Connector At Left Engine Mounting

Courtesy of AUDI OF AMERICA, INC.

Remove mounting for front left exhaust pipe (arrows).
NOTE: Shown in illustration with engine removed.

Fig 32: Removing Mounting For Front Left Exhaust Pipe

Courtesy of AUDI OF AMERICA, INC.

Remove mounting for front right exhaust pipe (arrows).
NOTE: Shown in illustration with engine removed.

Fig 33: Removing Mounting For Front Right Exhaust Pipe

Courtesy of AUDI OF AMERICA, INC.

Remove heat shield -1- for right drive shaft.

Fig 34: Locating Heat Shield For Right Drive Shaft
Courtesy of AUDI OF AMERICA, INC.
Unbolt left and right-hand axle shafts from transmission flange.
WARNING: To loosen drive axle collared bolt, wheel bearing must not be under load (vehicle must not be standing on its wheels).
Apply brakes (second person necessary).
Unscrew collared bolt -2- from left drive axle.

Fig 35: Unscrewing Collared Bolt From Left Drive Axle
Courtesy of AUDI OF AMERICA, INC.
Loosen nuts for left swivel joint at wheel bearing housing several turns.
Attach ball joint puller T40010 to swivel joint as shown in Fig 36.
NOTE:
- Make sure that both arms of puller are parallel to each other.
- Make sure that protective boot is not damaged.
Press left swivel joint out of wheel bearing housing.

Fig 36: Pressing Left Swivel Joint Out Of Wheel Bearing Housing
Courtesy of AUDI OF AMERICA, INC.
Remove left drive axle.
Turn securing element -1- and unplug transmission wiring harness connector. See Fig 37.
Unplug connector -2- for Multi-Function Transmission Range (TR) Switch -F125- and unbolt connector retainer.
Unplug connector for Sender for transmission output RPM -G195- -item 3-.

Fig 37: Unplugging Wiring Harness Connectors
Courtesy of AUDI OF AMERICA, INC.
Move the wiring harness clear.
NOTE: Flexible pipe connection (de-coupling element) on front exhaust pipe must not be bent more than 10° - otherwise it can be damaged.
Loosen clamps -1- and -2- and disconnect exhaust pipes.

Fig 38: Disconnect Exhausting Pipes
Courtesy of AUDI OF AMERICA, INC.
Remove rear section of exhaust system.
Remove both heat shields (arrows).

Fig 39: Removing Both Heat Shields

Courtesy of AUDI OF AMERICA, INC.

Remove heat shield for driveshaft -A- (arrows).
Unscrew bolts on transmission/driveshaft flange.
Slide driveshaft together towards rear final drive. Constant velocity joints move along their axes.
Tie up driveshaft to body on one side.

Fig 40: Removing Heat Shield For Driveshaft

Courtesy of AUDI OF AMERICA, INC.

Unscrew bolts -1-, -3- and -4- to remove heat shield. See Fig 41.
NOTE: Mark installation position of support bracket on transmission.
Unscrew bolt -2- for Bowden cable support bracket.
Press ball socket of selector lever cable off selector shaft lever -arrow-.

Fig 41: Pressing Ball Socket Of Selector Lever Cable Off Selector Shaft Lever

Courtesy of AUDI OF AMERICA, INC.

Remove bolts -1- to -6- for left and right transmission mounting.
Remove washers below nuts -3- and -4-.

Fig 42: Removing Bolts For Left And Right Transmission Mounting
Courtesy of AUDI OF AMERICA, INC.

NOTE: Transmission must not be supported on transmission oil pan.
Place support plate of engine and transmission jack V.A.G 1383 A behind automatic transmission oil pan at location marked with an -arrow- and raise transmission.

Fig 43: Placing Support Plate Of Engine And Transmission Jack V.A.G1383 behind Automatic Transmission Oil Pan

Courtesy of AUDI OF AMERICA, INC.

Remove bolts -2- and -3- first, then unscrew securing bolts -1- and -4- on carrier.

Fig 44: Removing Transmission Mounting Bolts
Courtesy of AUDI OF AMERICA, INC.
Remove both transmission mountings.
Lower transmission again slowly.
Place a piece of wooden block of height a = 50 mm between carrier and body.
Tie back right drive axle.

Fig 45: Placing Piece Of Wooden Block Between Carrier And Body

Courtesy of AUDI OF AMERICA, INC.

Engine/transmission assembly must be lifted at rear before removing. For this purpose push a floor jack -1- underneath transmission from front.
NOTE: Arrangement of floor jack and workshop crane is shown in illustration with engine/transmission assembly already removed.

Fig 46: Removing Engine/Transmission Assembly
Courtesy of AUDI OF AMERICA, INC.

NOTE: Transmission must not be supported on transmission oil pan.
Place a wooden block of suitable size on support plate of floor jack and apply floor jack at rear of automatic transmission oil pan on transmission housing at position marked with an (arrow).

Fig 47: Placing A Wooden Block On Support Plate Of Floor Jack
Courtesy of AUDI OF AMERICA, INC.
Lift transmission slightly with floor jack.
Remove harness retainer at rear left engine lifting eye.
Attach shackle 10-222 A12 to rear left engine lifting eye.

Fig 48: Attaching Shackle To Rear Left Engine Lifting Eye

Courtesy of AUDI OF AMERICA, INC.

Attach hook 10-222 A20 to rear right engine lifting eye.
WARNING: Hook 10-222 A20 must be secured with a locating pin (arrow).

Fig 49: Attaching Hook To Rear Right Engine Lifting Eye

Courtesy of AUDI OF AMERICA, INC.

Attach lifting tackle 3033 to shackles 10-222 A12 and hook onto workshop crane VAS 6100, as shown in this figure.

Fig 50: Attaching Lifting Tackle 3033 To Shackles And Hook Onto Workshop Crane
Courtesy of AUDI OF AMERICA, INC.

WARNING: Support weight of engine/transmission assembly with the VAS 6100 workshop crane before removing the torque reaction support.
Remove securing bolts -1- to -3- and remove torque reaction support.

Fig 51: Removing Securing Bolts -1- To -3- Of Torque Reaction Support
Courtesy of AUDI OF AMERICA, INC.
Lift engine carefully.
Remove both engine mountings.
NOTE:
- Check that all hoses, lines and other connections between engine/transmission and body have been detached.
- When lifting engine, make sure that lines at rear of engine are not trapped against bulkhead.
Pull engine/transmission assembly slightly forward.
Lift engine/transmission assembly further and pull out of engine compartment from front.