Engine, Removing

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Drip Tray VAS 6208
Engine/Transmission Jack V.A.G 1383 A
Hose Clip Pliers V.A.G 1921
Step Ladder VAS 5085
Engine/Trans. Support T10012
Pry Lever - Rmv Outside Mirror 80 - 200
Ring Spanner 7-Piece Set 3337
Locking Pin T10060A
Puller T10369
Engine Bung Set VAS 6122

Procedure

NOTE:

Assemble engine with transmission downward.

During installation, cable ties must be installed at the same location.

Collect escaping coolant in a clean container for disposal or reuse.

WARNING:

There is a risk of injury because the fuel is under very high pressure.

When removing the engine, the high pressure area of the fuel injection system is not opened.
If the engine is removed and the high pressure area is opened for the following steps, the fuel pressure in the injection system must be reduced to a residual pressure before opening the high pressure area.

-- Reduce fuel pressure in high pressure area. Refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

CAUTION:

Danger of causing damage to electrical components when disconnecting the battery.

Complete the steps for disconnecting the battery.

-- Remove luggage compartment floor covering.

-- If the battery negative post cover is under the rear cross panel trim, remove rear cross panel trim. Refer to Removal and Installation .

Fig 1: Battery Cover

Courtesy of AUDI OF AMERICA, LLC

-- Release retaining clips -arrows- and remove negative post cover.

-- Loosen nut a few turns and remove terminal clamp -arrow- on the ground (GND) cable from battery post.

Fig 2: Identifying Ground Wire Terminal Clamp

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Risk of scalding due to hot steam and hot coolant.

The coolant system is under pressure when the engine is warm.
Reduce pressure by covering coolant reservoir cap with a cloth and carefully open.

-- Open the coolant reservoir cap.

-- Remove both front wheels.

-- Remove the front noise insulation -1-. Refer to Removal and Installation .

Fig 3: Front Noise Insulation -1 And 2-

Courtesy of AUDI OF AMERICA, LLC

-- Remove left and right noise insulation -arrows-.

Fig 4: Identifying Noise Insulation Frame

Courtesy of AUDI OF AMERICA, LLC

-- Remove the noise insulation frame -arrow- and the rear noise insulation. Refer to Removal and Installation .

Fig 5: Identifying Noise Insulation Frame

Courtesy of AUDI OF AMERICA, LLC

-- Place the VAS 6208 under the engine.

-- Remove the lower coolant hose -arrow- from the radiator by lifting the clamp and let the coolant drain out.

Fig 6: Identifying Coolant Hose Quick Acting Coupling

Courtesy of AUDI OF AMERICA, LLC

-- Remove lower coolant hose to after-run coolant pump -V51- -arrow- and allow coolant to drain.

Fig 7: Identifying Coolant Recirculation Pump Coolant Hose

Courtesy of AUDI OF AMERICA, LLC

-- Remove the air guide hose by loosening hose clamps -1- and -2-.

Fig 8: Air Cooler Air Duct

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the connector -2-.

Fig 9: Fan Shroud Bolts And Electrical Connector

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -3-.

-- Remove the engine cover -arrows-.

Fig 10: Identifying Engine Cover

Courtesy of AUDI OF AMERICA, LLC

-- Remove the coolant hoses -1- and -2-.

Fig 11: Coolant Hoses

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Risk of injury from fuel.

To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.

CAUTION:

Follow the guidelines for cleanliness when working on the fuel supply system. Refer to CLEAN WORKING CONDITIONS .

-- Remove the protective boot -2- and disconnect the fuel hose by pressing the release ring.

Fig 12: Releasing EVAP Canister -Arrow B-, Remove Upward -Arrow A-

Courtesy of AUDI OF AMERICA, LLC

-- Remove the hose -1-.

-- Release the EVAP canister -B arrow-, remove it upward -A arrow- and lay it aside.

-- Remove the bolts -arrows- and air guide.

Fig 13: Identifying Bolts -Arrows- And Air Guide

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -1- and remove the fan shroud upward.

Fig 14: Fan Shroud Bolts And Electrical Connector

Courtesy of AUDI OF AMERICA, LLC

-- Remove the upper coolant hose -arrow- from the radiator by removing the retaining clip.

Fig 15: Identifying Upper Coolant Hose

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -arrows- on the rear side of the radiator.

Fig 16: Identifying Radiator Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Remove the radiator downward.

Vehicles with Air Conditioning (A/C):

Fig 17: Identifying Method To Relieve Tension On Poly V-Belt

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Risk of destroying due to reversed running direction on a used ribbed belt.

Before removing ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later.

-- Pivot the tensioner clockwise -arrow- to release the tension on the ribbed belt.

-- Secure the tensioning element with the T10060 A.

Fig 18: Identifying Lock Tensioner With Locking Pin T10060 A

Courtesy of AUDI OF AMERICA, LLC

-- Remove ribbed belt.

-- Remove the bolts -arrows- and remove the generator from the accessory assembly bracket.

Fig 19: Identifying Bolts For Generator

Courtesy of AUDI OF AMERICA, LLC

NOTE:

If generator is stuck in its bracket, screw in mounting bolt again up to 2 rotations.

Carefully strike on bolt heads using flat side of hammer - doing this loosens the bushings on the generator mount.

-- Move the generator, the electrical wires still connected, to the right side of the vehicle.

-- Disconnect the connector -2-.

Fig 20: Identifying Connector, Electrical Wire And Wiring Clamp On Generator

Courtesy of AUDI OF AMERICA, LLC

-- Remove the wire -1- and the clamp -3- from the generator.

-- Remove the generator upward.

-- Disconnect solenoid clutch electrical connector -1- on A/C compressor.

Fig 21: Identifying A/C Compressor Components

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Risk of damaging refrigerant lines and hoses.

Do not stretch, kink or bend refrigerant lines and hoses.

-- Remove the bolts -arrows-.

-- Remove the A/C compressor from the accessory assembly bracket and tie it up on the right side.

All Vehicles:

-- Remove the coolant pipe by loosening the hose clamp -1-.

Fig 22: Disconnecting Mass Air Flow Sensor

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the connector -2- from the Mass Airflow (MAF) Sensor -G70-.

-- Detach upper section of the air filter housing -arrow- and remove air filter insert.

-- Remove the bolts -arrows- and the lower section of the air filter housing.

Fig 23: Identifying Screws For Lower Portion Of Air Cleaner Housing

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -arrows- and the air filter housing bracket.

Fig 24: Air Filter Housing Bracket

Courtesy of AUDI OF AMERICA, LLC

-- Remove the connector -arrow- for the Heated Oxygen Sensor (HO2S) -G39- from the bracket, disconnect it and free it up.

Fig 25: Disconnecting Heated Oxygen Sensor (HO2S) G39 Harness Connector

Courtesy of AUDI OF AMERICA, LLC

-- Remove the heated oxygen sensor -arrow- with a socket taken from the 3337.

Fig 26: Oxygen Sensor

Courtesy of AUDI OF AMERICA, LLC

-- Remove bolt -arrow-.

Fig 27: Identifying Air Guide Pipe

Courtesy of AUDI OF AMERICA, LLC

-- Remove the hose clamp -1- and lay the air guide pipe with the hose still connected -2- on the engine.

NOTE:

Ignore -3-.

-- Remove the bolts -arrows- and nuts -1- and then remove the heat shield.

Fig 28: Locating Heat Shield Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Remove the nuts -arrows- on the front exhaust pipe/turbocharger connection from the top.

Fig 29: Front Exhaust Pipe/Turbocharger Nuts

Courtesy of AUDI OF AMERICA, LLC

-- Remove the heat exchanger coolant hoses -arrows-.

Fig 30: Disconnecting Coolant Hoses To Heater Core At Bulkhead

Courtesy of AUDI OF AMERICA, LLC

-- Remove the vacuum hose -1- from the non-return valve.

Fig 31: Identifying Non-Return Valve Vacuum Hose

Courtesy of AUDI OF AMERICA, LLC

-- Remove the non-return valve -arrow- from the brake booster.

-- Pry cover caps off windshield wiper arms with screwdriver.

Fig 32: Wiper Arm Nuts

Courtesy of AUDI OF AMERICA, LLC

-- Loosen nuts -arrows- a few turns.

-- Position the puller for removing wiper arms T10369/1 on the windshield wiper arm -1- as illustrated.

Fig 33: Removing Windshield Wiper Arm With Puller T10369/1

Courtesy of AUDI OF AMERICA, LLC

-- Mount the pressure piece -2- on the wiper axle.

-- Turn the bolt -3- clockwise until the wiper arm is pulled off the wiper axle.

-- Remove the nuts completely and remove wiper arms.

-- Remove gasket -1-.

Fig 34: Rubber Seal & Plenum Chamber Cover

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

The plenum chamber cover could be damaged.

Coat the transition area between the windshield and plenum chamber cover -2- with soapy water and carefully pull the cover vertically up out of the retainers on the windshield, beginning at the edge of the window.

-- Remove plenum chamber cover -2- by carefully pulling cover out of retainer on windshield.

-- Free up rear engine wiring harness on plenum chamber partition.

-- Remove the Engine Control Module (ECM). Refer to Removal and Installation .

-- Disconnect the engine wiring harness electrical connector -1- -arrow-.

Fig 35: Disconnecting Engine Wiring Harness Electrical Connector

Courtesy of AUDI OF AMERICA, LLC

-- Release the engine wiring harness feed -1- through and remove upward -arrow-.

Fig 36: Release Engine Wiring Harness Feed

Courtesy of AUDI OF AMERICA, LLC

-- Remove E-box cover by slide both latches in direction of -arrow-.

Fig 37: Identifying E-Box Cover And Latches

Courtesy of AUDI OF AMERICA, LLC

-- Open wiring router bracket -arrows-.

Fig 38: Opening Wiring Router Bracket

Courtesy of AUDI OF AMERICA, LLC

-- Unclip electrical connector -1- from bracket and disconnect.

Fig 39: Opening Wiring Router Bracket

Courtesy of AUDI OF AMERICA, LLC

-- Open wiring router bracket below.

-- Unclip engine wiring harness to engine control module from wiring router.

-- Place engine wiring harness with engine control module on engine.

-- Secure engine control module against falling down.

-- Unclip electrical connector -2- from bracket and disconnect.

-- Remove the terminal 30 wire -arrow- at the engine compartment E-box and free it up.

Fig 40: Locating Engine Compartment E-Box Nut

Courtesy of AUDI OF AMERICA, LLC

NOTE:

To unclip spiral clip, use 80 - 200.

Fig 41: Free Electrical Wiring Up To Generator Using Pry Lever - Rmv Outside Mirror 80-200

Courtesy of AUDI OF AMERICA, LLC

-- Cut off cable ties -arrow- for protective boot -1-.

Fig 42: Disconnecting Ground (Gnd) Wire -3-

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the connector -2-.

-- Fold back protective boot and remove battery positive wire from starter solenoid.

-- Remove ground (GND) wire -3-.

CAUTION:

Risk of destroying control module (Mechatronic) with static discharge.

Do not touch contacts in transmission connector with hands.

-- To discharge static electricity, touch vehicle ground with hand (without gloves).

-- Disconnect electrical connector -4- by turning twist lock counterclockwise.

-- Disconnect the connector -1-.

Fig 43: Identifying Wiring Harnesses And Connector On Hot Side Charge Air Pipe

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore -arrows-.

-- Remove the subframe bolts -arrows- on the engine side 2 turns.

Fig 44: Identifying Mounting Bolts Of Subframe Mount/Engine Bracket

Courtesy of AUDI OF AMERICA, LLC

-- Remove the subframe bolts -arrows- on the transmission side 2 turns.

Fig 45: Identifying Engine Mount To Engine Mount Bracket Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Mark position of flexible disc to bevel box flange for reinstallation.

-- Remove the driveshaft flexible disc bolts -arrows- from the bevel box while counterholding at the triangular flange with a lever.

Fig 46: Driveshaft Flexible Disc

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

The shaft seal -arrow- in the driveshaft flange could be damaged.

Press driveshaft horizontally as far back and to the right side of vehicle as possible.

Fig 47: Identifying Driveshaft Flange Shaft Seal

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -1- and -2- on the bracket for the oxygen sensor electrical connector under the vehicle floor. Remove the cover.

Fig 48: Removing Retaining Screws And Cover

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolt -3- and free up the electrical wire to the oxygen sensor.

-- Remove the connector coupling -arrow- from the bracket.

Fig 49: Electrical Connector -arrow-

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the connector from the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- and free it up.

-- Remove the bolts -arrows-, exhaust system bracket and tunnel brace.

Fig 50: Identifying Crossbrace Bolts -Arrows-

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Risk of damaging decoupling elements.

Do not bend decoupling element in front exhaust pipe by more than 10°.

-- Loosen the nuts -arrows- at the clamping sleeve and separate the exhaust system.

Fig 51: Clamping Sleeve -Arrows-

Courtesy of AUDI OF AMERICA, LLC

-- Remove the front exhaust pipe with the catalytic converter and front muffler.

-- Remove bracket bolts -1-.

Fig 52: Selector Lever Cable Bracket Bolts And Locking Washer

Courtesy of AUDI OF AMERICA, LLC

-- Remove locking washer -3- -arrow- and remove selector lever cable from the transmission.

NOTE:

Ignore -2-.

CAUTION:

Risk of damaging sealing ring in driveshaft flange.

Engine/transmission swings forward slightly when pendulum support/subframe bolts are loosened.

-- Remove bolts -1, 2, 3- and remove pendulum support.

Fig 53: Identifying Pendulum Support & Bolts

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the connector -1- from the oil level thermal sensor -G266-.

Fig 54: Identifying Oil Level Thermal Sensor G266 Wire On Subframe

Courtesy of AUDI OF AMERICA, LLC

-- Unclip bracket -2- for electrical wiring to oil level thermal sensor from subframe.

-- Remove the right drive axle heat shield from bevel box -arrows-.

Fig 55: Identifying Right Drive Axle Heat Shield

Courtesy of AUDI OF AMERICA, LLC

-- Remove the left drive axle from the transmission flange and the right drive axle from the bevel box flange.

-- Remove the air guide hose from the charge air cooler by loosening the hose clamp -arrow-.

Fig 56: Charge Air Cooler Air Guide Pipe

Courtesy of AUDI OF AMERICA, LLC

-- Free up the coolant hose -2-.

Fig 57: Removing Bolt -3- And After-Run Coolant Pump -V51-

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -4- and lay the after-run coolant pump -V51- with the coolant hoses still connected -arrows- to the side.

NOTE:

Ignore -1 and 3-.

-- Fasten the T10012 to the cylinder block with bolt -1- and nut -2- to approximately 20 Nm.

Fig 58: Attaching Engine Support T10012 On Engine

Courtesy of AUDI OF AMERICA, LLC

-- Place the V.A.G 1383 A on the T10012 and raise engine/transmission assembly slightly.

NOTE:

To remove subframe mounting bolts, use VAS 5085.

-- Remove the subframe bolts -arrows- on the engine side.

Fig 59: Identifying Mounting Bolts Of Subframe Mount/Engine Bracket

Courtesy of AUDI OF AMERICA, LLC

-- Remove the subframe bolts -arrows- on the transmission side.

Fig 60: Identifying Engine Mount To Engine Mount Bracket Bolts

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Verify that all hose and line connections between engine, transmission and body have been disconnected.

To prevent damage, carefully guide engine/transmission assembly when lowering.

-- Pull the engine/transmission as far as possible to the front and left and slowly lower it while paying attention to the drive axles.