Engine, Removing, Vehicle With Generator

WARNING: This page is about a different car, the 2020 Audi A5 Quattro. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Engine Support Bridge:10-222A
Engine Support Bridge - Spindle:10-222A/11
Engine Sling:2024A
Shop Crane:VAS6100
Engine Support Bridge Adapter:3147
Ring Wrench 7-Piece Set:3337
Torque Wrench 1332 Insert - Ring Wrench - 16mm:VAG1332/14
Shop Crane:VAS6100
Engine Bung Set:VAS6122
Coolant Collection System:VAS5014 or Shop Crane - Drip Tray:VAS6208
Hose Clip Pliers:VAS6362
Torque Wrench Adapter:VAS6948
Locking Pin:T10060A
Engine Support - Supplement Kit - Adapter:T40093/6 from the Engine Support - Supplement Kit:T40093B
Wrench - 21mm:T40263
Adapter:T40314
Protective Eyewear
Safety Gloves

Procedure

Remove the engine upward without the transmission.
During installation, all cable ties must be installed at the same location.

-- Observe the guidelines for clean working conditions. Refer to Guidelines For Clean Working Conditions .

-- Disconnect the battery. Refer to Battery, Disconnecting And Connecting .

-- Engage the 4th gear on versions with a manual transmission.

-- Carefully pull the engine cover off the retaining pins one after the other in direction of -arrows-. Do not remove the engine cover on one side or in a jerking manner.

Fig 1: Engine Cover 2.0L TFSI

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CAUTION:

The Cooling System Is Under Pressure When the Engine Is Warm. There Is a 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 expansion tank cap -1- by releasing the catch in direction of -arrow- if necessary.

Fig 2: Coolant Expansion Tank

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-- Remove the front wheels. Refer to Wheels And Tires .

-- Remove the noise insulation. Refer to Noise Insulation, Removing And Installing .

-- Remove the left and right wheel spoiler as well as the right front wheel housing liner. Refer to Front Wheel Housing Liner, Removing And Installing .

-- Equipment version: disconnect the connector -2- for the Intake Air Switch-Over Valve -N335- and remove the water drain -1- downward in direction of -arrow-.

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-- Remove the lock carrier cover. Refer to Front Bumper .

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-- Remove the bolts -arrows- and the air guide -2-.

-- Remove the vacuum hose -3-.

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-- Loosen the hose clamp -2- and remove the air duct hose.

-- Pull the air filter housing -1- upward.

-- Release the latch in direction of -arrow B- and open the E-box -1- in direction of -arrow A-.

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-- Remove the nut -2- and free up the B+ wire.

-- Free up the upper wiring duct.

-- Remove the nuts -1- from the front muffler accessible from the top. (Nut -2- and bolt -3- are removed later.)

Fig 3: Threaded Connection - Front Muffler, Vehicle without Particulate Filter

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-- Disconnect the connector -1- for the Charge Air Pressure Sensor -G31-.

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-- Loosen the screw-type clamp -2- and remove the air duct pipe from the Throttle Valve Control Module -J338-.

-- Place the container of the :VAS5014 or the :VAS6208 underneath.

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-- Open the drain plug -1- on the connection and drain the coolant.

-- Loosen the left front wheel housing liner in the front area and push slightly toward the rear. Refer to Front Wheel Housing Liner, Removing And Installing .

-- Loosen the hose clamp -1- and remove the air duct hose and remove downward.

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Fig 4: Ribbed Belt For Vehicles With Electro-Mechanical Power Steering

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CAUTION:

Risk of Destroying a Used Ribbed Belt by Reversing the Running Direction

- Mark the running direction before removal.

- Pay attention to the running direction when reinstalling.

-- Pivot the tensioner counter-clockwise in direction of -arrow- and remove the ribbed belt from the A/C compressor ribbed belt pulley.

-- Secure the tensioner using the :T10060A .

-- Remove the A/C compressor from the bracket. Refer to A/C Compressor, Removing And Installing From Bracket .

-- Remove the left and right bolt -1- for the support bearing -2-.

Fig 5: Identifying Bolts & Support Bearing

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-- Remove the bolt -arrow- and remove the wiring duct -1- from the oil pan upper section toward the front and push it downward.

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-- Loosen the hose clamp -arrow- and remove the air duct hose at the right from the turbocharger.

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-- Remove the connector -2- from the bracket and disconnect it.

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-- Release the retainers in direction of -arrows- and free up the wiring duct -1-.

-- Free up the wiring harness to the engine.

-- Remove the nut -arrow- and free up the ground wire.

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-- Remove the right drive axle heat shield. Refer to Drive Axle Heat Shield, Removing And Installing .

-- Remove the left and right drive axles from the transmission. Refer to Drive Axle, Removing And Installing .

-- Remove the nut -2- and bolt -3- for the front muffler.

Fig 6: Threaded Connection - Front Muffler, Vehicle without Particulate Filter

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Fig 7: Identifying Bolts

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CAUTION:

Risk of Damaging the Coupling Due to Improper Handling

- Coupling must not be bent more than 10°.

- Do not load the coupling on the cable.

-- Remove the bolts -arrows-.

-- Loosen the threaded connections -arrows- and slide the clamping sleeves toward the rear.

Fig 8: Identifying Bolts

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-- Remove the front muffler.

-- Remove the nut -2- from below. (The nuts -1- will be removed later.)

Fig 9: Identifying Turbocharger Catalytic Converter & Nuts

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-- Remove the lower cover -1- from the transmission in direction of -arrow-.

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-- To loosen the bolts for the flywheel, counterhold the crankshaft using the :T40263 and :T40314 .

Fig 10: Using T40263 & T40314

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CAUTION:

Risk of Damaging the Engine by the Timing Mechanism Skipping

- Only let the engine turn in the direction of engine rotation.

-- Turn the crankshaft an additional 120° respectively in the direction of engine rotation -arrow-.

-- Remove the three bolts -arrow- for the flywheel -1-.

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Vehicle with Manual Transmission:

Fig 11: Engine To Transmission Bolts (1 through 10)

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-- Loosen the bolt -1- using the : VAG1332/14 and :VAS6948 .

-- Remove the bolts -6 through 10- that attach the engine to the transmission.

Vehicle with Dual-Clutch Transmission:

Fig 12: Transmission Mounting Bolts and Alignment Sleeves (4-Cylinder FSI Engine)

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-- Loosen the bolt -1- using the : VAG1332/14 and :VAS6948 .

-- Remove the bolts -6 through 10- that attach the engine to the transmission.

Continuation for All Vehicles:

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-- Remove the left and right bolt -2- from the engine mount.

-- Disconnect the connector -1- for the Oxygen Sensor after Catalytic Converter -G130- -2- and free up the wires. (There are different installation positions.)

Fig 13: Oxygen Sensor 1 after Catalytic Converter -GX7- Component Location

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-- Remove the connector -1- from the bracket and disconnect it.

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-- Remove the Heated Oxygen Sensor -G39- -2- using a tool from the :3337 .

-- Remove the nuts -1- and the catalytic converter upward.

Fig 14: Identifying Turbocharger Catalytic Converter & Nuts

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-- Disconnect the fuel hose -1-. Refer to Connector Couplings .

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-- Loosen the hose clamp -2- and disconnect the hose for the EVAP system.

-- Pull back the heat shield slightly.

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-- Lift the clamp -arrow- and remove the coolant hose.

-- Lift the clamps -arrows-, remove and free up the coolant hoses.

Fig 15: Coolant Expansion Tank.

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-- Disconnect the connector -1- for the Engine Coolant Level Warning Switch -F66-.

-- Remove the bolt -2- and remove the coolant expansion tank -3-.

-- Lift the clamp -1 and 3-, and remove the coolant hoses.

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Vehicle with Dual-Clutch Transmission:

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

-- Loosen the hose clamp -arrow- on the left coolant pipe and remove the coolant hose.

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Vehicle with Manual Transmission:

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-- Lift the clamp -1- and remove the coolant hose.

Continuation for All Vehicles:

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-- Remove the connector -2- from the bracket and disconnect it.

-- Disconnect the connector -1- from the engine control module.

-- Free up the wiring harness and place on the engine.

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

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Vehicle with Manual Transmission:

Fig 16: Engine To Transmission Bolts (1 through 10)

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-- Remove -2 to 5- that are accessible from above that connect the engine to the transmission.

-- Remove the starter slightly from the transmission and leave it in the installation position.

Vehicle with Dual-Clutch Transmission:

Fig 17: Transmission Mounting Bolts and Alignment Sleeves (4-Cylinder FSI Engine)

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-- Remove the bolts -2 to 5- that are accessible from above that connect the engine to the transmission.

Continuation for All Vehicles:

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-- Position the :10-222A with the :10-222A/22 on the left and right fender bolting edges as shown.

-- Connect the transmission and :10-222A/11 with the :3147 . (Shown with the engine removed.)

-- Slightly pre-tension the transmission using the spindle.

-- Engage the :2024A on the engine and on the :VAS6100 as shown.

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CAUTION:

There Is a Risk of Injury from the Lifted Engine Falling.

Parts of the Body Could Be Crushed.

- Secure the mounting hooks and pins on the lifting tackle with a securing pin.

-- Lift the engine until the engine mount is free.

-- Turn the :10-222A/11 .

CAUTION:

Risk of Damaging the Lines and Hoses and the Engine Compartment When Removing the Engine

- Make sure all connections between the engine, transmission, subframe and body have been disconnected.

-- Remove the engine from the transmission and lift it upward out of the engine compartment.