3.2L - Engine Assembly - Engine Code(s): Bub & Cbra: Other Audi A3 8P facelift 2

ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER

Special tools and workshop equipment required

1. Lifting Tackle 3033
2. Engine Support 3269
3. Engine and Transmission Holder VAS 6095
4. Shop Crane VAS 6100

Procedure

Hook 3033 onto engine and onto VAS 6100 as shown in the illustration.

Scheme 429

Lift engine off from VAS 6100 using workshop crane.

Engine, engaging on transmission side

Secure transmission side of VAS 6095 on cylinder block as shown in illustration.

Scheme 430

Engine, engaging at sides

Secure sides of 3269 to cylinder block as shown in illustration.

Scheme 431

Secure engine to VAS 6095 with 3269.

Scheme 432

1. Bolt Transmission support to transmission Tightening specifications, refer to -item 15- in «SUBFRAME MOUNT OVERVIEW»(ref-496080-S16258932702012082100000)
2. 40 Nm plus an additional 90° ( 1 / 4 ) turn. Pendulum supports to transmission Replace
3. Engine Support
4. 45 Nm Engine support to engine
5. Engine Mount
6. 40 Nm plus an additional 90° ( 1 / 4 ) turn. Engine mount to body Replace
7. Bracket
8. 20 Nm plus an additional 90° ( 1 / 4 ) turn. Bracket to engine mount Replace
9. 20 Nm plus an additional 90° ( 1 / 4 ) turn. Bracket to body Replace
10. 40 Nm plus an additional 90° ( 1 / 4 ) turn. Engine mount to body Replace
11. 60 Nm plus an additional 90° ( 1 / 4 ) turn. Engine mount to engine support Replace
12. Pendulum Supports
13. Bolt Pendulum supports to subframe Replace
14. Bolt Transmission mount to transmission support Tightening specifications, refer to -item 14- in «SUBFRAME MOUNT OVERVIEW»(ref-496080-S16258932702012082100000)
15. 100 Nm plus an additional 90° ( 1 / 4 ) turn. Transmission mount to body Tightening specifications, refer to -item 1- in «SUBFRAME MOUNT OVERVIEW»(ref-496080-S16258932702012082100000)
16. Transmission Mount Illustration shows version for direct shift automatic transmission.
17. Bolt Transmission support to transmission Tightening specifications, refer to -item 17- in «SUBFRAME MOUNT OVERVIEW»(ref-496080-S16258932702012082100000)
18. Bolt Transmission support to transmission Tightening specifications, refer to -item 18- in «SUBFRAME MOUNT OVERVIEW»(ref-496080-S16258932702012082100000)
19. Transmission Support

SUBFRAME MOUNT, ADJUSTING

Special tools and workshop equipment required

1. Engine Support Bridge 10-222 A

Adjusting

If an insufficient or an excessive distance is measured, proceed as follows

If equipped, remove vacuum hose -2- to air guide hose.

Disconnect air guide hose -1- at throttle valve control module -J338-.

Scheme 433

Disconnect mass air flow (MAF) sensor -G70- electrical connector -3-.

Unbolt upper section of air filter housing -arrows-.

Remove filter element.

Pull off air guide cover -1-, disengage clips sideways to do so.

Scheme 434

Unclip air duct -2-.

Remove lower section of air filter housing -arrows-.

Scheme 435

Remove air filter housing bracket -arrows-.

Scheme 436

Secure shackle 10-222 A/12 at right rear engine lifting eye.

Scheme 437

Position 10-222 A with adapters 10-222 A/3 on fender attachment edge.

Engage spindles at lifting eye or shackle.

Raise engine slightly with spindles even.

Remove subframe mounting bolts at engine -arrows-.

Scheme 438

Remove subframe mounting bolts at transmission -arrows-.

Scheme 439

Replace all 5 bolts in succession (if not already done when installing engine) and hand tighten.

Loosen left and right support arm bolts approximately 2 turns.

Using a pry bar between the engine support -4- and engine mount -1-, move the engine so far until the following dimensions are set

1. Both bolts -2- must be parallel to edge of support arm -3-.
2. A distance of -x- = 16 mm must be present between engine mount -1- and engine support -4-.

Note. Distance -x- = 16 mm can also be checked with a suitable cylindrical rod.

Tighten engine-side assembly mounting bolts.

On transmission side, make sure edges of support arm -1- and transmission mount -2- are parallel.

Scheme 440

1. Dimension -x- same size on both sides of bracket.

Tighten transmission-side assembly mounting bolts.

Further installation is in reverse order.

Tightening Specifications

ENGINE, REMOVING

Pry Lever - Rmv Outside Mirror 80 - 200

Engine/Transmission Jack V.A.G 1383 A

Step Ladder VAS 5085

Drip Tray for VAS 6100 VAS 6208

Mandrel T10060 A

Assembly Tool T10118

Torque Wrench SAT 8010/3

Note. The engine is removed downward together with the transmission. All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine. Heat insulation sleeves removed during engine removal should be reinstalled in the same location when installing engine. Drained coolant must be stored in a clean container for disposal or reuse.

Remove tool formed insert under luggage compartment floor covering.

Remove cover -arrow- for battery compartment

Scheme 441

Remove formed insert from over the battery.

With ignition switched off, disconnect Battery Ground (GND) cable -arrow-.

Scheme 442

Open cap of coolant expansion tank.

Remove both front wheels.

Remove center noise insulation fasteners -1 to 3-.

Scheme 443

Remove the left and right noise insulation fasteners -1 to 3-.

Scheme 444

Disconnect electrical connector -1- at engine coolant temperature (ECT) sensor (on radiator) -G83-.

Scheme 445

Place VAS 6208 under engine.

Vehicles with drain plug

Turn drain plug -arrow- on radiator left, place assisting hose on supports if necessary.

All Vehicles

Remove lower coolant hose -2- from radiator by removing retaining clamps.

Drain coolant.

Also remove lower coolant hose to after-run coolant pump -V51- -arrow- and allow remaining coolant to drain.

Scheme 446

Note. Shown in illustration on vehicle with Direct Shift Gearbox transmission.

If equipped, remove vacuum hose -2- to air guide hose.

Disconnect air guide hose -1- at throttle valve control module -J338-.

Disconnect mass air flow (MAF) sensor -G70- electrical connector -3-.

Remove upper section of air filter housing -arrows-.

Remove filter element.

Pull off air guide cover -1-, disengage clips sideways to do so.

Unclip air duct -2-.

Remove lower section of air filter housing -arrows-.

Remove air filter housing bracket -arrows-.

Disconnect electrical connector -1- for heated oxygen sensor (HO2S) 2 -G108- and -2- for heated oxygen sensor (HO2S) -G39-.

Scheme 447

Free up electrical wiring to oxygen sensors.

Pry off the caps on the wiper arms using a screwdriver.

Scheme 448

Loosen the nuts -arrows- by several turns.

Loosen the wiper arms by gently rocking the wiper arm. Remove the nuts and remove the wiper arms.

Unclip the spray nozzles -arrow-.

Scheme 449

Push spray nozzle with lines still attached back through opening and into plenum chamber.

Remove rubber seal -1- for plenum chamber cover.

Scheme 450

Remove the plenum chamber cover -2-.

Free up the rear engine wiring harness at the partition for plenum chamber.

Remove partition for plenum chamber -arrows-.

Scheme 451

Remove Engine Control Module (ECM). Refer to Removal and Installation .

Separate the electrical connector -2- for engine wiring harness.

Scheme 452

Note. Electrical connector -1- remains connected.

Release pass-through for engine wiring harness -arrow- and pull off upward.

Scheme 453

Vehicle with E-box, old version

Press retaining clamps in direction of -arrow- and remove engine compartment E-box cover.

Scheme 454

Vehicle with E-box, new version

Press both latches in direction of -arrow- and remove engine compartment E-box cover.

Scheme 455

Remove terminal 30 wiring -arrow- at engine compartment E-box and free up.

Scheme 456

Open bracket of wiring -arrows-.

Scheme 457

Free up electrical connector -1- and disconnect.

Scheme 458

Open the underlying wiring guide bracket -2-.

Remove engine wiring harness to control module from wiring.

Note. To unclip spiral clip, use 80-200.

Disconnect secondary air hose at position indicated by -arrow-.

Scheme 459

Free up air hose to Secondary Air Injection (AIR) pump.

Disconnect electrical harness connectors -1-, -3- and -5-.

Scheme 460

Remove protective boot and remove electrical wiring -2- at starter solenoid switch.

Remove Ground (GND) cable -4-.

Remove bolts -1- for bracket -D-.

Scheme 461

Remove retaining clip -A- upward -arrow- and remove selector lever cable from transmission.

Note. Ignore items -B- and -C-.

Remove coolant hoses to heater core on bulkhead -arrows-.

Scheme 462

Disconnect coolant hoses at positions indicated by -arrows-.

Scheme 463

Disconnect electrical connection -1- at throttle valve control module -J338-.

Scheme 464

Disconnect coolant hoses at positions indicated by -arrows-.

Remove throttle valve control module -J338- from intake manifold -arrows-.

Scheme 465

Disconnect following hose connections

Scheme 466

1. Coolant hose to reservoir
2. Vacuum hose to Evaporative Emission (EVAP) Canister
3. Vacuum hose to Leak Detection Pump
4. Fuel supply line
5. Coolant hose to reservoir

Note. Depending on the construction version, low pressure connectors were used in the version shown. To disconnect, slide back rubber cap -1- and slide release button -2- to the rear.

Remove hoses and electrical connectors at indicated places

Scheme 467

1 - Electrical connector to evaporative emission (EVAP) canister purge regulator valve -N80

2 - Vacuum hose to brake booster

3 - Vacuum hose to exhaust flap, also to Leak Detection Pump

5 - Vacuum hose to evaporative emission (EVAP) canister purge regulator valve -N80

Note. Ignore -4-.

Remove wiring connection -arrows-.

Remove wiring connections with coolant and vacuum hoses.

Remove heated oxygen sensor (HO2S) 2 -G108- -1- and heated oxygen sensor (HO2S) -G39- -2-.

Scheme 468

Remove bolts -1- and -3- and remove front exhaust pipe support -2-.

Scheme 469

Remove front exhaust pipe nuts and exhaust manifolds -arrows-.

Scheme 470

Remove top mounting bolts for fan shroud -top arrows-.

Scheme 471

Note. Before removing the ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

Swing tensioning device in direction of -arrow- to relieve tension on the ribbed belt and then lock it in place using the T10060 A.

Remove ribbed belt.

Loosen subframe mounting bolts to engine -arrows- approximately 2 turns.

Loosen subframe mounting bolts to transmission -arrows- approximately 2 turns.

Remove the right vehicle underbody cover -arrows-.

Scheme 472

Disconnect electrical connector -1- to oxygen sensor (O2S) behind three way catalytic converter (TWC) -G130- and -2- to oxygen sensor (O2S) 2 behind three way catalytic Converter (TWC) -G131-.

Scheme 473

Remove connector coupling from bracket and free up wiring to oxygen sensors.

Remove front vehicle floor crossmember by removing nuts -1- and -2-.

Scheme 474

Note. Do not bend the flex joints in front of the exhaust pipe more than 30° or they may be damaged.

Separate exhaust system at clamping sleeve -3-.

Remove exhaust system bracket -arrows- and remove exhaust system.

Scheme 475

Free up coolant hose at bottom on fan shroud.

Disconnect electrical connector -3- at secondary air injection (AIR) pump motor -V101- and free up electrical wiring.

Scheme 476

On vehicles with DSG transmission, remove coolant pipe bracket -2- to transmission oil cooler.

Remove bolts -1-.

Loosen bolt -4- and remove Secondary Air Injection (AIR) pump with bracket.

Disconnect electrical harness connectors -1- for coolant fans at bottom on fan shroud.

Remove mounting bolts for fan shroud at bottom -bottom arrows-.

Pull out fan shroud downward with both fans.

Disconnect electrical harness connector -1- for A/C clutch on A/C compressor and free up electrical wire.

Remove bolts -arrow- for A/C compressor.

Scheme 477

Securely tie the A/C compressor with connected coolant hoses at front on the longitudinal member.

Remove electrical wire -1- on generator.

Scheme 478

Separate the electrical connector -2-.

Note. Ignore -3-.

Remove upper idler roller -1-.

Scheme 479

Remove mounting bolts -2- and -3- for generator.

Note. Generator can be removed from bracket only with the upper mounting bolt still installed.

Remove generator from accessory assembly bracket.

Remove generator downward and to the left.

Disconnect electrical connector -arrow- to secondary air injection (AIR) solenoid valve -N112-.

Scheme 480

Have a second technician press brake pedal.

Remove collar bolt -2- at right drive axle -1-.

Scheme 481

Remove right drive axle heat shield from bevel box -arrows-.

Scheme 482

Remove right drive axle. Refer to Removal and Installation .

Remove left drive axle from transmission flange shaft.

Position of flexible disc and bevel box flange are marked to each other.

Remove driveshaft flexible disc at bevel box -arrows-.

Scheme 483

Note. To loosen bolts, counterhold at driveshaft flange/final drive with a lever.

Press driveshaft horizontally as far back as possible.

Scheme 484

Remove bolts -1 to 3- and remove pendulum support.

Scheme 485

Disconnect electrical connector -1- at oil level thermal sensor -G266-.

Scheme 486

Unclip bracket -2- for electrical wire to oil level thermal sensor -G266- at subframe.

Disconnect electrical harness connector -arrow- at after-run coolant pump -V51-.

Scheme 487

Pull after-run coolant pump -V51-, with coolant hoses connected, downward out of rubber loops of retainer. Spray rubber loops with silicon-free lubricant if necessary.

Note. Coolant pump remains on the engine with coolant hoses connected.

Remove bolts -1 to 5- and remove accessory assembly bracket.

Screw T40074 to cylinder block -arrows- and tighten to 20 Nm.

Scheme 488

Insert V.A.G 1383 A at T40074 and raise engine/transmission slightly.

Note. Use VAS 5085 to remove bolts for assembly mounting.

Remove subframe mounting bolts at engine -arrows-.

Remove subframe mounting bolts at transmission -arrows-.

Note. Verify that all hose and line connections between engine, transmission and body have been disconnected. While lowering, carefully guide engine/transmission assembly in order to prevent damages.

Pull engine/transmission assembly as far forward as possible and slowly lower it.

ENGINE AND DSG TRANSMISSION, SEPARATING

Special tools and workshop equipment required

1. Shop Crane VAS 6100
2. Bracket T10013
3. Bolt M8x40 with nut and washer exterior dia. 30 mm

Procedure

1. Engine/transmission assembly removed and mounted on engine mount.

Remove bolts -1- and -2- at bevel box bracket -A- and remove bracket.

Scheme 489

Disconnect coolant hoses -arrows- at transmission oil cooler.

Scheme 490

Remove bolts from T10013 by releasing circlip.

Scheme 491

Secure T10013 with bolt M8x40 and a washer exterior dia. 30 mm to transmission lifting eye.

Engage VAS 6100 at T10013.

Remove bolts -1-, -2- and -5 to 10- at engine/transmission flange.

Pull transmission off from engine.

ENGINE, INSTALLING

Installation is in reverse order of removal, note the following

Note. Always replace self-locking nuts, bolts which have been tightened to tightening specifications as well as gaskets and O-rings. Secure all hose connections with hose clamps appropriate for the model.

Make sure alignment sleeves for engine to transmission are installed in cylinder block. Install if necessary.

A pilot needle bearing must be installed in the crankshaft in engines for vehicles with DSG transmission. Install needle bearing if necessary. Refer to NEEDLE BEARING IN CRANKSHAFT .

Bolt transmission to engine.

Secure with new bolts.

Note. Tightening specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts. Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not. Do not use any degreased parts. Tolerance for tightening specifications ±15%.

Securing engine/DSG transmission

Remove bevel box bracket -A- while observing the following installation sequence

First tighten bolts -1- to 3 Nm.

Tighten the bolts -2- to 35 Nm.

Finally tighten bolts -1- to 45 Nm.

Guide the engine/transmission assembly into the body.

Next, hand tighten the engine support bolts to the engine mounts -arrows-.

Next tighten the transmission mount bolts to the transmission support -arrows-.

Secure with new bolts.

Note. The bolts are first tightened to final torque after the engine mounts have been adjusted. Refer to SUBFRAME MOUNT, ADJUSTING .

Remove engine/transmission support from engine.

Install drive axles. Refer to Removal and Installation .

Note. Drive axles must be installed before any further installation.

Fasten pendulum support to transmission with new bolts items -2 and 3-.

Press engine/transmission assembly toward bulkhead, bevel box pins must be carefully guided into driveshaft flange when doing so.

Fasten pendulum support to subframe with new bolt -1-.

Fasten driveshaft with flexible disc to bevel box flange -arrows-.

Further installation is in reverse order of removal, note the following

Install exhaust system and align it free of stress. Refer to EXHAUST SYSTEM, INSTALLING .

Install selector lever cable. Refer to SELECTOR LEVER CABLE .

Install bracket for assemblies. Refer to ACCESSORY ASSEMBLY BRACKET .

To make it easier to install the generator, drive the bushings for the retaining bolts back slightly.

Install generator. Refer to Removal and Installation .

Install air conditioning compressor.

Install fan shroud. Refer to COOLANT FAN AND COOLANT FAN 2 .

Install Secondary Air Injection (AIR) pump. Refer to SECONDARY AIR INJECTION PUMP .

Install ribbed belt. Refer to RIBBED BELT .

Adjust the engine mounts. Refer to SUBFRAME MOUNT, ADJUSTING .

Install windshield wiper arms. Refer to WINDSHIELD WIPER ARMS .

Electrical connections and routing. Refer to appropriate SYSTEMS WIRING DIAGRAM.

Connect Ground (GND) wire to battery. Refer to REMOVAL AND INSTALLATION .

Check oil level. Refer to OIL LEVEL, CHECKING .

Fill with coolant: FILLING .

Note. Only reuse drained coolant if cylinder head or engine block was not replaced. Dirty coolant must not be re-used.

Tightening Specifications

Scheme 492

Special tools and workshop equipment required

1. Lifting Tackle 3033
2. Engine Support 3269
3. Engine and Transmission Holder VAS 6095
4. Shop Crane VAS 6100

Scheme 493

Special tools and workshop equipment required

1. Pry Lever - Rmv Outside Mirror 80 - 200
2. Engine/Transmission Jack V.A.G 1383 A
3. Step Ladder VAS 5085
4. Drip Tray for VAS 6100 VAS 6208
5. Mandrel T10060 A
6. Assembly Tool T10118

Special tools and workshop equipment required

Scheme 494

Scheme 495

Scheme 496

Scheme 497

1. Torque Wrench SAT 8010/3
2. Engine Support Bridge 10-222 A
3. Shop Crane VAS 6100
4. Bracket T10013