Note: The engine is removed downwards together with the gearbox and subframe. For disposal or reuse, the coolant must be drained into a clean container. When reassembling, install all binders in the places where they were originally installed. Risk of vehicle rollover when the engine is removed. Secure the vehicle by leaving the luggage compartment empty. Risk of damage to electronic components when disconnecting battery terminals. Follow the instructions when disconnecting battery terminals.
Set the front wheels to the straight ahead position. To turn the propeller shaft for removal, it is necessary to release the electromechanical parking brake before disconnecting the battery. Switch off the ignition. Remove the trunk tray "3". Remove the Bassbox "2" if present. Unscrew the floor mat "1" above the cover.
Unlock the "arrow" fasteners and install cover "1".
Remove cover "1" over the negative terminal of the battery. Disconnect the ground wire "arrow" from the battery terminal. Drain the air conditioning system circuit. Pump out the hydraulic oil of the power steering using a device for pumping oil out of the reservoir.
Remove the engine casing "arrows". Open the expansion tank cap.
Remove the front wheels: right and left. Remove the front right and left mudguard. Remove noise insulation screens "1" and "2".
Install the tray for the service cranes "VAS 6208" under the engine. Unscrew the plug "arrow" of the drain hole on the connecting nipple and drain the coolant. Remove the connecting nipple from the radiator, to do this, loosen the clamp.
Remove the coolant hose from the left coolant pipe by loosening the hose clamp "arrow" and drain the coolant.
Disconnect the coolant hose from the radiator by pressing the clamp "arrow" and drain the coolant.
Install a device for pumping and collecting oil under the disconnection point. Disconnect the return oil line "arrow" of the power steering.
Disconnect plug connector "1" of boost pressure sensor "G31" and release the connector. Ignore "Pos. 2".
Loosen the "arrow" nut on the right side member and release the ground cables.
Disconnect electrical connector "1" of the radiator fan, move the lock back "arrow" and press the stopper down. Release the wiring harness from the fasteners on the side member.
Remove the air duct hose from the air duct tube and set the hose aside by loosening the "arrow" clamp.
Unscrew bolts "1" and nuts "3" on the left and right and remove the radiator frame cross member "2".
Install a device for pumping out and collecting used oil under the disconnection point. Disconnect the ATF lines "arrows" at the disconnection points on the right side of the engine.
Remove the air duct "arrow".
Disconnect plug connector "1" of air flow meter "G70". Unscrew bolt "3" and release pressure sensor 1 EG "G450" "pos. 4" on air duct pipe. Disconnect and release plug connector "2-sensor" ka EG temperature 4 "G648" on air duct pipe. Remove air hose with air flow meter "G70", for this purpose loosen hose clamp "5" and loosen clamps "arrows".
Unscrew bolts "1" and nuts "3" on the left and right and remove the radiator frame cross member "2".
Disconnect the vacuum line "1". Remove the air filter housing and disconnect the plug connector "2" of the air filter bypass valve "N₂75" on the back side.
Disconnect the supply "1" and return "2" fuel lines.
Remove plug "1". Remove air duct hose by loosening hose clamp "3". Disconnect electrical connector "4". Loosen bolts "2" and remove throttle module "J338" "pos. 5". Place rag under disconnection point to collect escaping hydraulic oil.
Clamp the hydraulic oil hose with clamp "3094" and remove it from the vane pump "arrow". Do not take "Pos. 1" into account.
Unscrew bolt "2", remove the refrigerant line from the air conditioner compressor and put it aside. "Pos. 1, 3" do not take into account.
Remove coolant hose "3" from the radiator, for which lift the clamp. "Pos. 1,2" and "arrows" do not take into account.
Unscrew bolts "1", as well as nuts "2" and "3", remove the tensioner.
Remove the gasket "3". Release the fastening clamps "1" from the fasteners and remove the cover of the water drainage box "2".
Unlock the lock "arrow A" and open the cover "arrow B".
Unscrew nuts "1, 2, 3" of the electric wires. Remove connector "4" from the bracket and disconnect it. Unscrew bolt "5" and remove branch pipe 2 cl. 30 "TV22" from the front wall of the water drainage box "arrow".
Remove foam block "1" upwards. Ignore "Pos. 2".
Unlock the wheel arch latches with a 5.5 union wrench "pos. 1" and remove the cable gland "2" in the upward direction. Release the wiring harness "3" going to the alternator and starter with the "80-200" release lever.
Release the cable channel by unlocking the lock "arrow B" and pulling the cable channel upwards "arrow A".
Disconnect coolant hose "1". Remove vacuum pipe "2" from the end wall of the water drain box, for this disconnect vacuum hose "3" on the back side "arrow".
Insert refrigerant lines "A" and "C" into connection module "B" with internal heat exchanger by hand until they stop. Spray the area around the refrigerant lines with silicone-free grease. Push puller "T40149/1" onto refrigerant line "A" and puller "T40149/2" onto refrigerant line "C" until you hear a click, thus releasing the fasteners. Use puller to remove refrigerant lines "A" and "C" from branch pipe -B with coolant line with internal heat exchanger.
If the refrigerant lines cannot be removed, twisting them in the connection module "C" is prohibited. In this case, the connecting elements "B" should be cut and the fastening rings "A" should be removed. When cutting the connecting elements, do not damage the connection module "C" with the internal heat exchanger.
Unscrew nut "3" and bolt "3". Remove filler neck "1" with filler tube from washer reservoir, passing it through body opening "arrow".
Unscrew bolts "1,2,4" and remove cover "3" of the engine compartment switching unit. Unscrew nut "5" and release the ground wire.
Unlock the clamps "arrow A" and remove the engine control unit - arrow B.
Disconnect (if available) plug connector "2". Disconnect plug connectors "4" and unscrew electrical wiring "3". Unlock the clamps - arrow ■ and remove fuse block B "SB" "pos. 1". Remove and release the engine wiring harness secured in the switching block.
Unlock the clamps "arrow A" and remove the cable guide "1" in the upward direction "arrow B". Unscrew the ground bolt "2" and release the wiring harness. Place the wiring harness on the engine and secure the engine control unit from falling out.
Unscrew nuts "2" of the intake pipe from above. Unscrew nut "1" and bolt "3" last.
Disconnect the "arrow" plug connector from the front speed sensors on the left and right.
If available, disconnect electrical connectors "1" of the front left vehicle level sensor "G78" and the front right vehicle level sensor "G289" and release the electrical cable "arrow".
Disconnect plug connector "2" from bracket by pulling lock back "arrow A" and turning plug connector approx. 90° clockwise "arrow B". Release electric wire "3" and brake hose "4" on bracket. Loosen bolts "1" and hang brake caliper on wheel arch with wire. Risk of damage to brake cylinder pistons. Do not press brake pedal when brake caliper is removed.
Unscrew nut "2" and remove bolt "1". Remove the upper suspension arm from the wheel hub bearing housing in the upward direction "arrows". Repeat the entire process of performing work on the other side of the car.
Unscrew the stabilizer bolts "1" on the left and right. Unscrew the nuts "3" on the left and right. Unscrew the bolts "2" last.
Loosen nut "1" of the hydraulic line of the power steering. Risk of damage to the chassis components. If the engine mounts, steering gear or subframe crosspiece are not installed properly, the car must not be placed on wheels. It is prohibited to support the car by the subframe or subframe crosspiece (for example, with a jack, etc.)! Unscrew the "arrow" bolts and remove the subframe brace.
Risk of damage to the coil spring contact of the Airbag. Disconnect the universal joint with the crosspiece from the steering gear only when the front wheels are in the straight-ahead position. Do not change the position of the steering wheel or the position of the steering gear. Unscrew the bolt "arrow" of the universal joint with the crosspiece. Press the universal joint with the crosspiece away from the steering gear and move the joint up to the stop.
Unscrew nut "1" and bolt "3" of the intake pipe. Nuts "2" have already been unscrewed.
Unscrew the threaded connections "arrows", move the clamping sleeve back and remove the exhaust pipe.
Press the ball head "2" of the gearbox selector cable with the "80 - 200" lever away from the shift shaft lever. Remove the latch "1". Release the gearbox selector cable. The gearbox selector cable must not be bent or kinked.
If present, unscrew the "arrow" bolts and remove the heat shield "1" of the cardan shaft.
Loosen the bolts securing the propeller shaft to the gearbox; to do this, hold the propeller shaft from turning with the support "T10172" with "T10172/5". Move the propeller shaft toward the rear main gear housing; The CV joints are movable in the axial direction. Secure the cardan shaft at the top.
Prepare the lifting table: Prepare the lifting table "VAS 6131 A" with a set of fasteners for Audi "VAS 6131 /10", as well as an additional set "VAS 6131 /11" and "VAS 6131 /13" as follows. First, screw the conductors to the lifting table by hand. Set the lifting table "VAS 6131 A" horizontally. Monitor the level (with a peephole) on the receiving platform. Place the lifting table "VAS 6131 A" under the power unit. Unscrew the bolts "1" of the subframe on the left and right.
Install conductors from "VAS 6131/10" and "VAS 6131/13" left and right on the front of the subframe as shown in the picture. Make sure the lead screws are fully screwed in.
Install conductors from "VAS 6131/10" at the rear left and right on the front threaded connections of the subframe brace, as shown in the figure.
Install conductors from "VAS 6131/13" left and right on the lower part of the wheel hub bearing housing, as shown in the figure.
Install conductors from "VAS 6131/10" and "VAS 6131/11" rear left and right on the tunnel crossbar, as shown in the picture; Turn all the running screws of the conductors upwards so that all the mounting protrusions enter the fastening points. Screw the support plates of the fastening elements to the lifting table "VAS6131 A" with a torque of 20 Nm.
Mark the mounting position of the subframe on the side members with a felt-tip pen. Crosswise unscrew bolts "2" and "3" of the subframe in several stages. Bolts "1" have already been unscrewed.
Loosen the tunnel crossmember arrow bolts.
Loosen bolt "2" on the left and right. Bolts "1" and nuts "3" have already been loosened. Risk of damage to hose and wire connections, as well as the engine compartment. Make sure that all hose and wire connections between the engine, gearbox, subframe and body are disconnected. Carefully remove the power unit with the subframe from the engine compartment when lowering.
Lower the power unit down. Pull the lifting table "VAS 6131 A" with the power unit out from under the vehicle.