Part 1
Engine, removing (vehicles with manual transmission)
Note:
^ After removing the lock carrier, the engine is removed downward with transmission and subframe.
^ Drained coolant must be stored in a clean container for disposal or reuse.
^ All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
Special tools, testers and auxiliary items required
^ Oil collecting and extracting device V.A.G 1782
^ Hose clamp pliers V.A.G 1921
^ Spark plug connector pliers V.A.G 1922
^ Step ladder VAS 5085
^ Scissor lift platform VAS 6131 with support set for Audi VAS 6131/10
^ Drip tray for workshop crane VAS 6208 or drip tray V.A.G 1306
Work sequence
- Remove rubber seal for plenum chamber cover.
- Remove plenum chamber cover - 1 - toward front - arrows -.
CAUTION: Observe safety precautions when disconnecting battery.
- With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
- Discharge refrigerant circuit.
- Extract power steering fluid from reservoir using oil collecting and extracting device V.A.G 1782.
CAUTION: Cover cap of expansion tank with a rag and open carefully, as hot steam (i.e. hot coolant) may escape when opening.
- Open cap of coolant expansion tank.
- Remove both front wheels.
- Remove quick-release screws - 1 -, remove screws - 2 - and remove sound insulation.
- Remove bracket for sound insulation - arrows -.
- Remove front left and right wheelhousing liners.
- Remove front bumper cover.
- Remove left air guide - arrow - in front of auxiliary cooler.
- Remove right air guide - arrow - in front of auxiliary cooler.
- Place drip tray for workshop crane VAS 6208 or drip tray V.A.G 1306 under engine.
- Remove drain plug - arrow - on coolant regulator housing and drain coolant from engine.
- Disconnect lower coolant hose from radiator - arrow - and drain residual coolant.
- Place oil collecting and extracting device V.A.G 1782 under engine.
- Disconnect hydraulic lines to cooling coil at left rear of bumper - arrows -.
- Remove cover - 1 - in engine compartment (left side).
- Remove cover - 1 - in engine compartment (right side).
- Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- - item 1 - from air guide.
- Remove bolts - arrows -.
- Remove air guide - 2 -.
- Disconnect top coolant hose - arrow - from radiator.
- Remove electrical harness connectors - 1 - and - 2 - from bracket and disconnect them.
- Move wiring to lock carrier clear.
- Disconnect electrical harness connector - arrow - for headlights at both sides of vehicle.
- Move electrical wiring clear.
- Disconnect electrical harness connector - arrow - for left and right airbag sensors on lock carrier.
- Move electrical wiring clear.
- Remove cable for hood on lock carrier.
- Disconnect electrical harness connector - arrow - for right coolant fan.
Note: Do not bend or stretch lines or hoses as condenser and/or refrigerant lines/hoses may be damaged.
- Remove bolt and refrigerant line - arrow - leading to A/C compressor.
- Remove bolt and refrigerant line - arrow - leading to A/C evaporator.
- Remove bolts - arrows - at left and right side of bumper.
- Pull off hood seal from lock carrier and fender edges.
- Remove bolts at impact absorbers - arrows - at left and right.
Note: A second technician is required to remove the lock carrier.
- Remove lock carrier and set aside securely to prevent it from falling.
- Remove rear engine cover - arrows -.
- Remove front engine cover - arrows 1 and 2 -.
- Remove coolant hoses - 1 - and - 2 -.
- Unbolt coolant reservoir - arrow -.
- Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch -F66- at bottom of expansion tank.
- Disconnect vacuum line - arrow - to brake booster at bulkhead.
- Unclip coolant hose - arrow - from bracket on bulkhead.
- If installed, disconnect vacuum line - arrow - to vacuum reservoir.
- Disconnect vacuum hose - arrow - from intake manifold.
- Disconnect coolant hose - arrow - to heater core at rear coolant pipe on engine.
- If installed, disconnect vacuum line at area designated with - arrow -.
- Disconnect electrical harness connector - arrow - for After-Run Coolant Pump -V51- (behind auxiliary radiator at left) and move electrical wiring clear.
Note: Place a rag under separating point to catch escaping hydraulic fluid.
- Disconnect hose - 1 - from power steering fluid reservoir.
Note: Disregard - 2 -.
- Disconnect coolant hoses at positions indicated by arrows.
- Disconnect coolant hoses at positions indicated by - arrows -.
- Disconnect coolant hose to oil cooler - arrow -.
- Disconnect coolant hoses at positions indicated by - arrows -.
- Remove bolts - 1 - and - 2 -.
- Remove right auxiliary radiator together with coolant hoses.
Note: The hose - arrow - can remain connected at auxiliary cooler.
CAUTION: Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening connection.
Engine code BHF
- Unscrew fuel hose from connection on fuel rail line. To do so, counterhold using an open-end wrench at hex head - 1 - and - 3 - and unscrew union nut - 2 -.
All:
- Disconnect electrical harness connector - 2 - from Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-.
- Disconnect electrical harness connector - 3 - at Mass Air Flow (MAF) Sensor -G70-.
- Disconnect hose - 1 - to Secondary Air Injection (AIR) pump.
- Disconnect air guide hose - 4 - at Mass Air Flow (MAF) sensor.
- Move wiring harness clear at air filter housing.
- Remove clip - arrow - and remove air filter housing with Mass Air Flow (MAF) sensor.
- Disconnect air hose - arrow - from engine on right.
- Remove bracket for electrical harness connectors - 1 to 4 - at right from bulkhead.
- Remove nut - 1 - and remove fuse strip on battery positive (+) cable terminal clamp.
- Disconnect battery positive (+) cable - 2 - from battery terminal.
- Pull battery positive (+) cable through bulkhead toward front.
- Move cable harness clear.
Note: Disregard item - 3 -.
- Pry off both covers - 3 - using a screwdriver.
- Loosen hex-nuts - 4 - by several turns.
- Loosen wiper arms - 2 - by tilting slightly from respective wiper axle.
- Remove hex nuts completely and remove wiper arms.
- Disconnect securing clips - 1 - and remove cowl grille - 5 -.
- Remove cover for electronics box in plenum chamber - arrows -.
- Using a screwdriver, carefully pry off mounting bracket - arrow - and remove Engine Control Module (ECM) from electronics box.