Removing engine - vehicles with four-wheel drive with engine codes BMN, BUY — AUDI

Audi
Audi A3
2004
Power unit
4-cylinder TDI unit injector engine (2.0 ltr. 4-valve), mechanics
Edition
12.2009
Removing engine - vehicles with four-wheel drive with engine codes BMN, BUY
Special tools and workshop equipment required
Removal lever
80 - 200
Hose clamps, up to 25 mm
3094
(only for vehicles with manual gearbox)
Engine and gearbox jack
V.A.G 1383 A
Hose clip pliers
V.A.G 1921
Stepladder
VAS 5085
Drip tray for workshop hoist
VAS 6208
Engine bracket
T10012
Tool set for wiper arms
T10369
Procedure
Note
The engine is removed from underneath together with the gearbox.
All cable ties which are released or cut open when removing must be fitted in the same position when installing.
Collect drained coolant in a clean container for re-use or disposal.
Lift off engine cover panel (outside
1
and inside
2
) by pulling up evenly.
Remove cover
1
over battery; to do so, press release tab
arrow
.
Caution
Observe notes on procedure for disconnecting the battery
Rep. Gr.
27
.
With ignition switched off, disconnect battery earth cable
arrow
.
WARNING
Hot steam or hot coolant can escape when expansion tank is opened; cover filler cap with cloth and open carefully.
Open filler cap on coolant expansion tank.
Remove both front wheels.
Remove centre noise insulation
fasteners 1 ... 3
.
Remove noise insulation (left and right)
fasteners 1 ... 3
.
Remove air intake hose (left-side) by lifting retaining clips
arrows
slightly.
Remove air intake hose (right-side) by lifting retaining clips
arrows
slightly.
Caution
Seal opening of charge air cooler with a piece of clean foam or similar to prevent coolant from entering.
Place
drip tray for workshop hoist
VAS 6208
under engine.
Pull out retaining clip at the bottom
arrow
, disconnect coolant hose from radiator and drain off coolant.
Move coolant hose clear at air pipe.
Pull cover off air duct (release clips on sides)
arrows
.
Unclip air duct at the bottom by releasing clips
arrows
.
Detach air duct (bottom) together with air hose.
Unplug electrical connector
1
at
air mass meter
G70
.
Detach vent hose
3
and air hose
2
.
Unscrew bolt
4
and remove air cleaner housing.
Disconnect coolant hose at bottom of oil cooler
arrow
and drain off remaining coolant.
Remove battery
Rep. Gr.
27
.
Remove battery tray
arrows
.
Unclip securing clips
1
and
2
on both selector cables.
Pull selector cable end-pieces off selector shaft lever and relay lever.
Remove selector cable support bracket
arrows
from gearbox and place to one side.
Clamp off pressure hose to clutch slave cylinder using a
hose clamp
3094
.
Detach pressure hose
1
from hose connector by pulling securing clip
arrow
upwards.
Caution
Do not operate clutch pedal with slave cylinder removed.
Detach coolant hoses at the connections indicated
arrows
.
Disconnect vacuum hose
arrow
from brake servo.
Remove crankcase breather hose
2
.
Move vent hose
4
and vacuum hoses
3
clear at air intake hose.
Slacken hose clip
1
.
Swing air hose to rear and detach from turbocharger.
Disconnect electrical connector
1
at
charge pressure control solenoid valve
N75
.
Unscrew nuts and place
charge pressure control solenoid valve
N75
on engine (hoses remain connected).
Note
Disregard
items 2, 3, 4 and 5
.
Detach coolant hoses going to to heat exchanger at bulkhead
arrows
.
Unclip
change-over valve for exhaust gas recirculation cooler
N345
item 2
from bracket.
Unplug electrical connector
1
and move wiring clear.
Remove bolts
arrows
.
Note
Disregard
items 3, 4, 5 and 6
.
Unplug electrical connector
3
for
exhaust gas temperature sender 1
G235
and electrical connector
4
for
Lambda probe
G39
.
Move wiring clear.
Note
Disregard
items 1, 2 and 5
.
Unscrew Lambda probe
3
Rep. Gr.
23
.
Remove
temperature sender before particulate filter
G506
item 5
and move wiring clear.
Unbolt bracket
2
for pressure pipes.
Detach pressure pipe
4
from particulate filter.
Remove
exhaust gas pressure sensor 1
G450
together with pressure pipes.
Slacken and remove retaining clamp
1
for particulate filter.
Detach coolant hose
arrow
at coolant expansion tank.
Caution
Rules for cleanliness when working on the injection system
Chapter
.
WARNING
In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with unit injector engine. Allow the fuel to cool down before disconnecting the lines - danger of scalding.
Wear protective gloves.
Wear safety goggles.
Disconnect fuel supply pipe
2
and fuel return pipe
1
by pulling release tabs.
Detach coolant hose
2
at front of engine.
Note
Disregard
item 1
.
Detach fuel supply hose
2
and fuel return hose
1
from fuel pipes.
Slacken bolt
1
one turn.
Remove bolt
2
and nut
3
.
Remove fuel filter with hoses attached.
Pull out oil dipstick
4
.
Disconnect vacuum hose
1
.
Remove bolts
2
and
3
and place engine lifting eye with
intake manifold flap valve
N316
on engine.
Note
Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage.
Turn the tensioner in the direction of the
arrow
to slacken the poly V-belt.
Remove poly V-belt.
Unscrew bolts
arrows
and remove alternator.
Note
If alternator sticks in its bracket, screw bolt back in again down to the last 2 turns.
Tap carefully on bolt heads with flat side of hammer to release bushes of alternator mountings.
Swivel alternator towards right side of vehicle with wiring connected.
Unplug electrical connector
2
.
Unscrew wire
1
and wire clamp
3
at alternator.
Lift out alternator.
Unscrew top bolts
upper arrows
for radiator cowl.
Lever off caps on windscreen wiper arms with a screwdriver.
Loosen nuts
arrows
several turns.
Apply
puller
T10369/1
onto wiper arm
1
as shown illustration.
Apply thrust piece
2
onto wiper shaft.
Turn bolt
3
in clockwise direction until wiper arm is pulled off wiper shaft.
Remove nuts completely and take off wiper arms.
Unclip washer jets
arrow
.
Push washer jet through assembly opening back into plenum chamber, leaving hoses connected.
Pull off rubber seal
1
on plenum chamber cover.
Detach plenum chamber cover
2
.
Detach engine wiring harness at rear plenum chamber panel.
Remove plenum chamber intermediate plate
arrows
.
Remove engine control unit
Rep. Gr.
23
.
Unplug electrical connector
2
for engine wiring harness and move connector clear.
Note
The electrical connector
1
remains connected.
Release wiring protector for engine wiring harness
arrow
and lift off.
Press the two clips in direction of the
arrows
and remove cover from electronics box in engine compartment.
Unscrew terminal 30 wire
arrow
from electronics box in engine compartment and move it clear.
Open wiring duct brackets
arrows
.
Unclip electrical connector
1
from bracket and unplug it.
Open wiring duct bracket located below.
Unclip engine control unit wiring harness from wiring duct.
Note
Disregard
item 2
.
Note
Use
removal lever
80 - 200
to lever out the wiring clips.
Disconnect earth cable
1
.
Unplug electrical connector
2
.
Push back protective cover and unscrew B+ wire
3
from starter solenoid switch.
Unplug electrical connector
2
for reversing light switch.
Unscrew nut
1
and remove bracket with wiring from stud.
Unplug electrical connector
arrow
at longitudinal member (bottom left).
Loosen bolts
arrows
of assembly mounting for engine approx. 2 turns.
Loosen bolts
arrows
of assembly mounting for gearbox approx. 2 turns.
Unscrew air duct at lock carrier
arrows
.
Unplug electrical connector
1
.
Unscrew the bottom bolts
bottom arrows
and remove radiator cowl from below.
Unscrew bolts
1
for lock carrier (right-side).
WARNING
The air conditioner refrigerant circuit must not be opened.
Note
To prevent damage to the air conditioner compressor and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.
Unscrew bolts
2
and
3
at brackets for refrigerant pipes.
Remove bolts
4
and move crash sensor (right-side) with wiring to one side.
Note
Disregard items marked
1, 2, 3
and
arrows
.
Unscrew bolts
arrows
on backside of radiator.
Lift out radiator from above.
Unplug electrical connector
3
at air conditioner compressor.
Note
Disregard items marked
1
and
2
.
Unplug electrical connector
2
at
charge pressure sender
G31
/
intake air temperature sender
G42
.
Remove bolts
1
and
3
.
Disconnect air pipe from air hose
4
and remove pipe downwards.
WARNING
The air conditioner refrigerant circuit must not be opened.
Note
To prevent damage to the air conditioner compressor and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.
Unscrew bolts
1
and
2
and tie air conditioner compressor up to lock carrier.
Note
Disregard
item 3
.
Unplug electrical connector
1
at
oil level and oil temperature sender
G266
.
Unclip bracket
2
for wire to
oil level and oil temperature sender
G266
from subframe.
Remove front cross-piece for underbody
arrows
.
Note
To avoid damage, the flexible joints in the front exhaust pipe must not be bent more than 10°.
Loosen nuts on clamp
1
.
Push clamp back and tie up front exhaust pipe to underbody.
To support propshaft, position
engine and gearbox jack
V.A.G 1383 A
underneath with a piece of wood
A
placed in between.
Remove bolts
arrows
securing heat shield and propshaft centre bearing and detach heat shield.
Fit bolts
arrows
for propshaft centre bearing again.
Unbolt flexible coupling for propshaft at bevel box
arrows
(counterhold using a suitable lever at the triangular flange).
Check whether markings
arrow A
and
arrow B
are visible on constant velocity joint and propshaft. Apply markings if necessary.
Remove bolts
arrows
.
Caution
Take care to bend the front section of the propshaft tube downwards as little as possible when detaching.
Push front section of propshaft tube towards the front and swivel it out of rear section of propshaft tube.
Note
Avoid damaging the seal
arrow
in the propshaft flange when removing and installing.
Pull front section of propshaft tube off centring pin on bevel box horizontally, swivel downwards and detach.
Unscrew
temperature sender after particulate filter
G527
item 1
from exhaust pipe behind particulate filter.
Unscrew pressure pipe
2
going to
exhaust gas pressure sensor 1
G450
.
Remove
exhaust gas pressure sensor 1
G450
together with pressure pipes.
Unbolt drive shaft (left-side) from gearbox flange and drive shaft (right-side) from bevel box flange.
Unbolt heat shield for drive shaft (right-side)
arrows
.
Tie up drive shaft (left-side), push back drive shaft (right-side).
Remove nuts
1
and
3
and bolt
2
and detach bracket for particulate filter.
Unscrew bolts
1 ... 3
and remove pendulum support.
Unbolt bracket for exhaust system
arrows
.
Place particulate filter to rear in engine compartment.
Attach
engine bracket
T10012
with securing nut and bolt to cylinder block: approx. 20 Nm.
Apply
engine and gearbox jack
V.A.G 1383 A
to
engine bracket
T10012
and raise engine/gearbox assembly slightly.
Note
To unscrew bolts for assembly mounting use
stepladder
VAS 5085
.
Loosen and remove bolts
arrows
of assembly mounting on engine.
Loosen and remove bolts
arrows
of assembly mounting on gearbox.
Note
Check that all hoses, pipes and wiring connections between engine, gearbox and body have been detached.
Carefully guide engine/gearbox assembly when lowering to avoid damage.
Make sure there is sufficient clearance from air conditioner compressor.
First lower engine/gearbox assembly only slightly.
Then swing gearbox end of engine/gearbox assembly forwards and only then lower further.