Engine, Removing: Procedure

WARNING: This page is about a different car, the 2016 Audi A3 and 2015 Audi A3. However, it is still accessible from the selected car via links, so may be relevant.

The engine is removed downward together with the transmission.
During installation, install all cable ties back at the same position.
During installation, install all heat insulation sleeves at the same locations.

CAUTION:

The cooling system is under pressure when the engine is warm. Risk of scalding due to hot steam and hot coolant.

Scalding the skin and other parts of the body is possible.

- Wear safety gloves.

- Wear protective eyewear.

- Reduce the pressure by covering the coolant expansion tank cap with a cloth and carefully opening it.

-- Open the coolant reservoir cap -arrow-.

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-- Remove the subframe -9- without the steering gear. Refer to SUBFRAME .

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-- Remove the left and right front wheel housing liner. Refer to WHEEL HOUSING LINER .

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-- Place the :VAS6208 underneath.

VEHICLES WITH VERSION 1 RADIATOR

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-- Lift the clamp -arrow-, remove the lower left coolant hose from the radiator and drain the coolant.

-- Lift the clamp -arrow-, remove the lower right coolant hose from the charge air cooling circuit cooler and drain the coolant.

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VEHICLES WITH VERSION 2 RADIATOR

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-- Lift the clamp -1-, remove the lower left coolant hose from the radiator and drain the coolant.

-- Lift the clamp -2-, remove the lower right coolant hose from the charge air cooling circuit cooler and drain the coolant.

Vehicles with Version 3 Radiator

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-- Lift the clamp -arrow-, remove the lower left coolant hose from the radiator and drain the coolant.

-- Lift the clamp -1 and 2-, remove the coolant hose from the charge air cooling circuit cooler and drain the coolant.

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-- Unlock the retaining tab in direction of -arrow-, and disengage the coolant hoses -1- from above.

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All Vehicles

-- Loosen the hose clamp -arrow- remove the lower coolant hose for the Heater Support Pump -V488- and drain the coolant.

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-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

-- Remove the bolts -1 and 3-.

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-- Open the retainer in direction of -arrow- and remove the cover -2-.

-- Free up the coolant hose -2-.

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-- Release the retainers -arrows-, and remove the air guide upper section -1-.

-- Disconnect the connector -2- from the Mass Airflow Sensor -G70-.

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-- Disconnect vacuum hose -4-.

-- Loosen the clamp -3- and remove the air guide hose.

-- Remove the air filter housing -1-.

-- Remove the left and right bolts -arrow-.

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-- Unclip and remove the air duct lower section -1-.

-- If installed: Disconnect the vacuum hose -arrow-.

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-- Press the release button on the crankcase ventilation hose -1- and remove the hose from the cylinder head.

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-- Free up the vacuum hose on the air guide pipe -arrows-.

-- Remove bolt -2- and tilt the air guide pipe with the intake tube backward and remove from the turbocharger.

-- Disconnect the connector -1-.

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-- Release the retainers in direction of -arrows-, and remove the NOx Sensor Control Module -J583- -3- from the bracket -2- and place on the engine.

-- Remove the battery tray -1-. Refer to BATTERY .

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-- Remove the vacuum hose -2- from the turbocharger vacuum diaphragm.

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-- Disconnect the vacuum hose -1- at the T-connection.

-- Open the retainer in direction of -arrow- and remove the vacuum hose -1-.

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TIP

Different equipment depending on the version.

Vehicles without Auxiliary Heater

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-- If installed: Remove the heat insulation sleeve.

-- To catch escaping coolant place a clean cloth under the separation point.

-- Lift the clamps -arrows-, remove the coolant hoses from the heater heat exchanger.

Vehicles with Auxiliary Heater

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-- Remove the heat shield boot -1-.

-- Loosen the clamp -2- and remove the coolant hose.

-- Lift the clamp -2-, open the hose clamp -1-, and remove the coolant hose.

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All Vehicles

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-- Disconnect the connectors and free up the wires.

For Exhaust Gas Temperature Sensor 4 -G648-
For Exhaust Gas Temperature Sensor 3 -G495-
For Exhaust Gas Temperature Sensor 2 -G448- Equipped Depending on the Exhaust Gas Standard

-- Remove the connector for the Heated Oxygen Sensor -G39- -4- from the bracket, disconnect it and free up the wire.

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CAUTION:

The Fuel System Is under Pressure.

Risk of Injury from Fuel Spraying Out.

- Wear protective eyewear.

- Wear safety gloves.

- Reduce the pressure: Place clean cloths around the connection point and carefully open the connection point.

-- Disconnect the fuel line -2-, to do this push the hose coupling down in direction of -arrow A - then press the release buttons in direction of -arrow B-.

-- Remove the hose coupling with the release buttons pressed.

-- Disconnect the connector -5- on the Fuel Temperature Sensor -G81-.

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-- Loosen the clamps -4 and 6- then remove the fuel supply hose and return hose.

-- Loosen the clamps -1 and 3- and remove the coolant hoses.

-- Remove the bolt -2-.

-- Remove the connector -4- from the mount, disconnect, and free up the wires.

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-- Loosen the hose clamp -1-.

-- Remove the coolant hoses -3-.

-- Free up the SCR line -2-.

-- Remove the Reducing Agent Injector -N474- and lay it to the right side.

Vehicles with Radiator Versions 1 and 2

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-- Lift the clamp -arrow- and remove the upper right coolant hose from the charge air cooling circuit cooler.

All Vehicles

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-- Lift the clamp -arrow- and remove the upper left coolant hose from the radiator.

Use the :80-200 for removing the spiral clips in the following step.

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-- Disconnect the connector -2- from the Engine Control Module -J623-. Refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

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-- Disconnect the connectors -1, 3 and 4- and remove them from the bracket.

-- Free up the wires.

-- Release the retainers in direction of -arrows-, and remove the cover -1- from the engine compartment E-box.

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-- Open the retainers with a screwdriver in direction of -arrow-, remove the cover -1- for the engine compartment E-box upward.

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-- Remove the nut -arrow-, disconnect and free up the wires.

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Vehicles with a Manual Transmission

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-- Disconnect the connector -2-.

-- Push back the B+ terminal protector -1- and disconnect the B+ wire from the starter solenoid switch.

-- Remove the nut -3- and remove the Ground (GND) wire.

-- Disconnect the left front connectors from the transmission:

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Transmission Neutral Position Sensor -G701-
Back-Up Lamp Switch -F4-

-- Remove the gearshift and the selector lever cable from the transmission, remove the cable mounting bracket and move it to the side with the cables. Refer to SELECTOR MECHANISM, REMOVING AND INSTALLING [For transmission(s) 0D9] .

Vehicles with Manual Transmission Code 02S

-- Remove the clutch slave cylinder and set aside with the hose/line assembly still connected. Refer to appropriate service information. .

-- Loosen the bolts -arrows- from the transmission mount (about 2 turns).

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Vehicles with Manual Transmission Code 02Q

-- Remove the clutch pedal if the hose/line assembly from the clutch slave cylinder breather. Refer to appropriate service information. .

-- Loosen the bolts -arrows- from the transmission mount (about 2 turns).

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VEHICLES WITH S TRONIC TRANSMISSION CODE 0CW

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-- Disconnect the connector -3-.

-- Push back the B+ terminal protector -2- and disconnect the B+ wire from the starter solenoid switch.

-- Remove the nut -4- and remove the ground wire.

CAUTION:

- Do not touch the connector terminals by hand.

- Touch a ground (for example the hoist) and discharge the static electricity.

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

-- Disconnect the connector -1- for the DSG Transmission Mechatronic -J743-, by turning screw connection counterclockwise.

-- Remove the selector lever cable from the transmission, remove the cable mounting bracket and tie it up with the selector lever cable. Refer to SELECTOR MECHANISM, REMOVING AND INSTALLING [For transmission(s) 0D9] .

-- Loosen the bolts -arrows- from the transmission mount (about 2 turns).

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Vehicles with S tronic Transmission Code 0D9

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-- Remove the selector lever cable from the transmission and pull it out of the cable bracket. Refer to SELECTOR MECHANISM, REMOVING AND INSTALLING [For transmission(s) 0D9] .

-- Disconnect the connector -2-.

-- Push back the B+ terminal protector -1- and disconnect the B+ wire from the starter solenoid switch.

-- Remove the nut -3- and remove the ground wire.

CAUTION:

- Do not touch the connector terminals by hand.

- Touch a ground (for example the hoist) and discharge the static electricity.

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

-- Disconnect the connector -4- for the DSG Transmission Mechatronic -J743-, by turning screw connection counterclockwise.

-- Loosen the bolts -2- from the transmission mount (about 2 turns).

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All Vehicles

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-- Remove the bolts -arrows- from the engine mount (about two turns).

Vehicles with Auxiliary Heater

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-- Loosen clamp -1-, remove bolt -2-, and remove the parking heater muffler.

All Vehicles

CAUTION:

Risk of damage 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.

-- Before removing the ribbed belt, mark the running direction with chalk or a felt-tip pen for reinstallation.

-- Secure the tensioning system using the :T10060A .

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-- Remove the ribbed belt.

-- Disconnect the connector -1- on the A/C Compressor Regulator Valve -N280-.

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CAUTION:

- Do not bend, twist or stretch the refrigerant lines and hoses.

-- Remove the bolts -arrows-.

-- Remove the A/C compressor from the bracket with the refrigerant hoses attached and tie up to the right side.

-- Disconnect the coolant fan electrical connector -1- by sliding the retainer back in direction of -arrow A- and pressing the release down.

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-- Press the fan shroud left and right locking tabs at the same time in direction of -arrow B- and remove the fan shroud downward from the radiator.

-- Remove the left and right drive axle -arrow- from the transmission. Refer to DRIVE AXLE and tie up toward the rear.

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-- Disconnect the on the Exhaust Door Control Unit -J883- connector -1-.

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TIP

The Exhaust Door Control Unit -J883- is not installed with engine codes CRFA and CRFC.

-- Loosen clamping sleeve -2- and push it rearward.

-- Loosen the bolt -2- and the screw-type clamp.

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-- Remove the front exhaust pipe.

Vehicles with Engine Codes CRKB, CXXB, CRLB, CRLC, CUNA, DBKA, CXXB, DGCA, DCYA and DDYA:

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-- Loosen the left center underbody trim panel to the exhaust system and push slightly downward. Refer to UNDERBODY TRIM PANEL .

-- Remove the -arrow- for the Oxygen Sensor After Three Way Catalytic Converter -G130- connector from the bracket and disconnect it, then free up the wire.

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Continuation for All Vehicles through MY 2014

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-- Disconnect the connector -4-.

-- Remove the nut -2- and the bolts -3-.

-- Push the coolant pipe -1- and Charge Air Cooling Pump -V188- -5- to the side.

Continuation for All Vehicles from MY 2015

-- Disconnect the connector -3-.

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-- Free up the coolant hoses -1-.

-- Remove the bolts -2- and push the Charge Air Cooling Pump -V188- to the side.

Continuation for All Vehicles

-- Loosen the fasteners -arrows-, and remove the oil pan noise insulation -1-.

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AWD Vehicles

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

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-- Mark position of flexible disc and the bevel box flange to each other for reinstallation.

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-- Using a lever to counterhold the triangular flange, remove the driveshaft from the bevel box -arrows-.

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-- Push the engine/transmission assembly slightly forward (direction of the front end).

-- Remove the driveshaft horizontally and push to the right side of the vehicle.

If the gasket -arrow- is damaged, the driveshaft must be replaced.

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All Vehicles

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-- Tighten the :T10497 with the :T10497/1 to the cylinder head with bolt -1- to 20 Nm, use the upper long opening "A" -1-.

-- Install the :VAS6931 on the engine bracket :T10497 and slightly lift the engine/transmission sub-assembly.

-- Remove the bolts -arrows- for the subframe mount completely, at the same time use the :VAS5085 .

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-- Completely remove the transmission mount bolts -arrows- completely.

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TIP

Depending on the transmission 2 or 3 bolts.

The illustration shows the transmission mount on a vehicle with S tronic transmission.

-- Make sure all the vacuum lines or wires between the engine, the transmission and the vehicle body are loosened.

-- Drain the engine/transmission assembly.