Engine, removing and installing Audi A4 B6

Engine, removing and installing

Scheme 103

Special tools and equipment

1. 10-222A Engine support bridge
2. 2024A Engine Sling
3. 3147 Engine support adapter
4. 3299 Ribbed belt installation tool with 3299/1 claw for tensioner

1. VAG1306 Drip tray for VAG1202A
2. VAG1383A Engine/transmission hoist

Scheme 104

1. VAG1202A Workshop crane

or

1. VAS 6100 Workshop crane

Scheme 105

1. T10062 Support
2. Oil receptacle

Removing

Note. Engine is removed toward the front without transmission and with the lock carrier removed. All cable ties opened or cut during engine removal must be reinstalled at the same locations. Heat boots, which are removed during engine removal must be reinstalled at the same locations when re-installing engine. Drained coolant must be stored in a clean container for disposal or reuse.

Vehicles with automatic transmission

1. Shift selector lever into position "N".

All

Scheme 106

1. Pull off rubber seal of plenum chamber cover in direction of arrow.
2. Remove cover -1- toward front.

See Caution before beginning repairs on the electrical system. Refer to Engine, removing and installing

Scheme 107

1. Disconnect battery Ground (GND) strap (arrow) with ignition switched off.

1. Open cap of coolant expansion tank.
2. Remove both front wheels.

Scheme 108

1. For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of auxiliary heater on sound insulation.

Scheme 109

1. Remove bolts or quick-release screws -1- and -2- and remove front sound insulation.
2. Remove quick-release screws -3- and remove rear sound insulation, if present.

Scheme 110

1. Remove bracket for sound insulation (arrows).
2. Remove front bumper

Refer to

1. «63 BUMPER»(/audi/a4/b6-2000-2006/remont/door-locks-anti-theft-systems/#body-exterior)
2. «63 - BUMPERS»(/audi/a4/b6-2000-2006/remont/door-locks-anti-theft-systems/#body-exterior-cabriolet) for BODY EXTERIOR - CABRIOLET

1. Place VAG1306 drip tray beneath engine.

Vehicles with drain plug

Scheme 111

1. Turn radiator drain plug -2- counterclockwise, if needed attach accessory hose to connection flange and drain coolant.

Vehicles without drain plug

1. Remove retaining clamp for Engine Coolant Temperature (ECT) sensor (on radiator) -G83-.
2. Remove Engine Coolant Temperature (ECT) sensor from outlet and drain coolant.

All

1. Pull off retaining clip -1- for lower coolant hose and disconnect coolant hose from radiator.

Scheme 112

1. Disconnect left coolant hose from radiator (arrow).

Scheme 113

1. In addition, disconnect coolant hose at oil cooler (arrow) and drain remaining coolant.
2. Place oil pan underneath.

Scheme 114

1. Disconnect hydraulic lines to cooling coil at rear of bumper (arrows).

Vehicles with automatic transmission

Note. Observe the rules of cleanliness for working on automatic transmissions

Refer to

1. «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J
2. «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING

Refer to 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

1. Place oil pan underneath.

Scheme 115

1. Remove union nuts -3- and disconnect ATF lines.
2. Remove bracket for ATF lines, to do so remove nuts -1- and -2-.

All

Scheme 116

1. Remove cover -1- in engine compartment (right side).

Scheme 117

1. Remove bolts (arrows).
2. Detach Evaporative Emission (EVAP) canister purge regulator valve -N80- -1- at air guide.
3. Remove air guide -2-.

Scheme 118

1. Remove cover -1- in engine compartment (left side).

Scheme 119

1. Disconnect top coolant hose -1- from radiator.
2. Remove electrical harness connector -2- for left and right airbag sensors on bumper.....
3. ....and move cables clear.

Scheme 120

1. Remove electrical harness connectors -1- and -2- from bracket and disconnect them.

Scheme 121

1. Disconnect electrical harness connector (arrow) for headlights at both sides of vehicle.

Scheme 122

1. Remove air guides from left and right of radiator (arrows).

Scheme 123

1. Unclip temperature sensor -2- for outside temperature display from bracket.
2. Unscrew bolts -3- and -4- and remove power steering cooling coil.
3. Disconnect harness connector -1- at High pressure sensor -G65-.

1. Remove condenser mounting bolts (arrows).

Note. Do not bend or stretch lines or hoses as condenser and/or refrigerant lines/hoses may be damaged.

1. Carefully swing condenser downward and move aside.

Scheme 124

1. Remove bolts (arrows) on left and right sides of bumper.
2. Unhook hood cable from lock and move cable free.

Scheme 125

1. Unscrew bolts at impact absorbers (arrows) at left and right.

Note. A second technician is required to remove the lock carrier.

1. Remove lock carrier and set aside so it cannot topple.

1. Remove rear engine cover (arrows).

Scheme 126

1. Remove bolts for holding plate -3- for solenoid valves (arrows).
2. Disconnect intake air hose -1- at Mass Air Flow (MAF) sensor.
3. Remove hose -4- of crankshaft housing ventilation from air duct -2-.

Scheme 127

1. Remove bolt (arrow) and disconnect air duct -2- at throttle valve control module.
2. Disconnect hose -1- from air guide if installed.

Note. Illustration depicts air guide with the removed engine from rear.

Scheme 128

1. Remove coolant hoses -1- and -2-.

Note. Coolant hose -3- remains connected.

1. Remove coolant reservoir (arrow)
2. Disconnect electrical wiring to Engine Coolant Level (ECL) warning switch -F66- at bottom of expansion tank.

Scheme 129

1. Disconnect ground (GND) -2-.
2. Disconnect vacuum hoses -1- and -3-.

Scheme 130

1. Disconnect vacuum line (arrow) to leak detection pump at throttle valve control module.

Vehicles with automatic transmission

Scheme 131

1. Disconnect electrical harness connector (arrow).

All

1. Place oil pan underneath.

Scheme 132

1. Disconnect hose -1- from power steering fluid reservoir.
2. Disconnect vacuum hose -2- to vacuum reservoir.

Scheme 133

1. Disconnect electrical harness connector (lower arrow) at Secondary Air Injection (AIR) pump motor -V101- and move cable free.
2. Disconnect hose at tube to combination valve for Secondary Air Injection (AIR) (upper arrow).

Vehicles up to 06.03

Scheme 134

1. Disconnect fuel supply line -1- and fuel return line -2- and set aside.

Vehicles as of 07.03

Scheme 135

1. Unscrew fuel hose from connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head -1- and -3- and unscrew union nut -2-.

All

Scheme 136

1. Remove the following lines/harness connectors

1 - At Evaporative Emission (EVAP) canister purge regulator valve -N80

2 - Vacuum hose at Evaporative Emission (EVAP) canister purge regulator valve -N80

3 - at Mass Air Flow (MAF) sensor -G70

1. Disconnect hose connections, move wires free and remove air filter housing (arrows).

Note. Place a rag under the hydraulic pressure lines, to catch escaping hydraulic fluid.

Scheme 137

1. Unbolt hydraulic pressure line for power steering at rear coolant pipe -1- and disconnect line at height of right cylinder head -2-.

Scheme 138

1. Pry off both covers -3- using a screwdriver.
2. Loosen hex-nuts -4- by several turns.
3. Loosen wiper arm -2- by lightly tilting from wiper axle.
4. Remove hex nuts completely and remove wiper arms.

1. Disconnect securing clips -1- and remove cowl grill -5-.

Vehicles with automatic transmission

Scheme 139

1. Disconnect electrical harness connector (arrow) at Brake booster pressure sensor -G294-.

All

Scheme 140

1. Remove heater core E-box cover (arrows).

Scheme 141

1. Using a screwdriver, pry off retaining bracket (arrow).

Scheme 142

1. Disengage connector catches (arrows) and disconnect harness connectors -1- and -2- from Engine Control Module (ECM).

Vehicles with automatic transmission 01V

1. Unclip Transmission Control Module (TCM) retaining bracket.

Scheme 143

1. Disengage harness connector (arrow) and disconnect it from Transmission Control Module (TCM).

All

Scheme 144

1. Disconnect rear connectors -2- on connector strip and set wiring harness aside.
2. Unbolt electrical wire connection -1-.

Scheme 145

1. Disengage locking mechanisms (arrows) and remove secondary relay carrier in E-box toward top.
2. Unhook engine wiring harness at E-box and at bulkhead and move it free.
3. Remove heat shield for harness connectors at left of bulkhead, if installed.

Scheme 146

1. Remove harness connectors -1 to 4- from bracket at left of bulkhead.
2. Disconnect electrical harness connectors -1- and -4-.
3. Expose oxygen sensor wires.
4. Remove bracket for harness connectors.

Scheme 147

1. Remove harness connectors -1 to 4- from bracket at right of bulkhead.
2. Disconnect electrical harness connectors -1-, -3- and -4-.
3. Expose oxygen sensor wires.
4. Remove bracket for harness connectors.

Scheme 148

1. Remove nut -2- for left exhaust pipe/exhaust manifold which is accessible from top.

Note. Illustration is shown with engine removed.

Scheme 149

1. Remove nut -2- for right exhaust pipe/exhaust manifold which is accessible from top.

Note. Illustration is shown with engine removed.

1. Disconnect coolant hoses to heater core at rear coolant pipe and at right coolant pipe. To do so, remove wiring harness screw clip on right side of vehicle.
2. Remove upper mounting bolts for engine/transmission. One bolt remains tightened by hand.

1. Remove front engine cover (arrows).

Note. Before removing ribbed belt, mark direction of rotation with chalk or felt-tip marker. Reversing the direction of rotation of a run-in belt can destroy the belt.

Scheme 150

1. Swing ribbed belt tensioner in direction of arrow to release tension on ribbed belt using 3299 ribbed belt installation tool and 3299/1 claw for tensioner.
2. Remove ribbed belt from pulley of power steering pump.
3. Place engine oil drip tray beneath engine.
4. Drain engine oil.

Scheme 151

1. Remove oil filter -2-.
2. Place VAG1306 drip tray beneath engine.
3. Remove coolant hose -3- from oil cooler.
4. Remove oil cooler -1-.

Scheme 152

1. Unbolt bracket for refrigerant line at oil pan (arrow).

Note. Depicted in illustration for a vehicle with manual transmission.

Scheme 153

1. Disconnect harness connector -1- of electrical wire to A/C compressor clutch.

1. Unbolt A/C compressor from bracket (arrows).
2. Hang A/C compressor together with condenser with connected lines at right side of vehicle.
3. Disconnect electrical lines from generator.

Scheme 154

1. Unscrew bolts (arrows) and remove generator.

Scheme 155

1. Remove left and right heat shields for drive axles -1-.

Scheme 156

1. Remove electrical wires -1- and -2- from starter.
2. Disconnect Ground (GND) wire -3-.

Scheme 157

1. Remove heat shield -1- from solenoid.
2. Unscrew bolts -2- and -3- and remove starter.

Vehicles with automatic transmission 01V

Scheme 158

1. Unscrew 3 Torx bolts (arrow) of torque converter in opening of removed starter (turn crankshaft 1/3 rotation in each case).

Note. To loosen the torque converter bolts counterhold the main harmonic balancer bolt.

Scheme 159

1. Remove bolts for front vehicle floor crossmember -1- to -4-.

All

Note. Flex joint in front exhaust pipe must not be bent more than 10°, otherwise it may be damaged.

Scheme 160

1. Disconnect exhaust system at double clamps (arrows).

1. Remove nuts -1- and -3- for front exhaust pipe/left exhaust manifold which are accessible from bottom.

Note. Illustration is shown with engine removed.

1. Pull front exhaust pipe off of left exhaust manifold.

1. Remove nuts -1- and -3- for front exhaust pipe/right exhaust manifold which are accessible from bottom.

Note. Illustration is shown with engine removed.

1. Pull front exhaust pipe off of right exhaust manifold.
2. Where installed, unbolt heat shield for engine speed (RPM) sensor.

Scheme 161

1. Remove Engine Speed (RPM) sensor -G28- on left of transmission (arrow) and lay to side.

Vehicles with manual transmission

Scheme 162

1. Disconnect harness connector for back-up light switch at right of transmission and set aside electrical wire.

Note. Depicted in illustration for a vehicle with manual transmission 01E all wheel drive.

Scheme 163

1. Disconnect harness connector (arrow) from Speedometer Vehicle Speed Sensor (VSS) -G22- at left of transmission.

Note. Depicted in illustration for a vehicle with manual transmission 01E all wheel drive.

Vehicles with automatic transmission 01J

Scheme 164

1. Disengage harness connector -A- in direction of arrow and disconnect it from transmission.
2. Move wiring harness clear.

Vehicles with automatic transmission 01V

Scheme 165

1. Swing securing lever and disconnect harness connector for transmission wiring harness -1-.
2. Disconnect harness connector -2- on Speedometer Vehicle Speed Sensor (VSS) -G22-.
3. Disconnect harness connector -3- from wire for multi-function switch.

All

Scheme 166

1. Mark installation positions for threaded assemblies -1- and positioning sleeves -2-.

Note. Different mounting holes are available depending upon the installed engine.

1. Remove lower nuts -1- on left and right engine mounts.

Scheme 167

1. Slightly loosen upper nuts (arrow) on left and right engine mounts.

Scheme 168

1. Unbolt torque support (arrows).

Scheme 169

1. Tighten T10062 support on threaded holes for torque support to 20 Nm.
2. Lift engine using VAG1383A engine/transmission jack just far enough so that lower connecting bolts at engine/transmission can be removed.

Note. When working on a vehicle with all wheel drive, make sure the front constant velocity joint of driveshaft is not damaged when lifting engine.

Scheme 170

1. Remove bottom engine/transmission connecting bolts (arrows).
2. Lower engine again.

Vehicles with manual transmission and automatic transmission 01J

Scheme 171

1. Position 10-222A engine support bridge on bolted flanges of fenders behind gas-filled strut. Spindle is at front.
2. Hook 3147 engine support adapter into bolt hole at left of transmission housing.
3. Connect 3147 engine support adapter and 10222A engine support bridge with 10222A/2 additional hook.

Note. Illustration is shown with engine removed. If the engine support adapter 3147 can not be inserted far enough into the hole on transmission bell housing due to a change in wire routing, use a long bolt M10 and additional hook 10-222 A/2 in place of engine support adapter.

Vehicles with automatic transmission 01V

Scheme 172

1. Position 10-222A engine support bridge on bolted flanges of fenders behind gas-filled strut. Spindle is at front.
2. Hook 3147 engine support adapter into middle bolt hole in transmission housing.
3. Connect engine support adapter 3147 using engine support bridge 10-222 A.

Note. Illustration is shown with engine removed.

All

Scheme 173

1. Hook in 2024A engine sling at engine and at VAS6100 or 1202A workshop crane as depicted in illustration.

Note. To properly balance assembly, mounting hooks must be inserted in rails as shown in illustration.

1. Remove final mounting bolt.

Note. Verify that all hoses and lines between engine and body have been disconnected.

1. Using VAS6100 or VAG1202A workshop crane, lift engine far enough until threaded bolts of engine mount are free.
2. Turn 10-222A engine support bridge shaft.

Note. Make sure no lines are damaged at bulkhead.

Vehicles with automatic transmission 01V

Scheme 174

1. Press transmission off engine, while pressing torque converter off of drive plate.

All

1. Pull engine off of transmission and lift it out of engine compartment toward front.

Vehicles with automatic transmission 01V

1. If necessary, secure torque converter in transmission from falling out using wire.

Installing

Installation is reverse of removal, note the following

Note. During installation, all cable ties must be re-installed at the same locations. Heat boots, which are removed during engine removal must be reinstalled at the same locations when re-installing engine. Secure all hose connections using hose clamps appropriate for the model type Replace self-locking nuts and bolts during assembly work. Always replace bolts that are secured with tightening torque as well as O-rings and gaskets.

1. Make sure centering sleeves for engine to transmission are correctly installed in cylinder block. Install or replace if necessary.
2. Slide intermediate plate or intermediate panel onto sleeves.

Vehicles with manual transmission

1. Clean input shaft splines and (in case of used clutch plates) clean hub splines. Remove corrosion and apply only a very thin coating of lubricant G 000 100 on splines. Do not grease guide sleeve.
2. Check centering of clutch disc.
3. Check clutch release bearing for wear and replace if necessary.

Scheme 175

1. If plastic ring of release bearing is loose, adhere it to bearing ring again using adhesive AMV-195-KD1-01.

1. 3 rectangular tabs (arrows) of plastic ring reach into cutouts of bearing ring.
2. If grooves with depth of more than 0.5 mm are present, release bearing must be replaced.

Vehicles with SAC clutch pressure plate

When installing a new clutch disc in combination with a used SAC pressure plate (self-adjusting pressure plate), the adjustment ring of the pressure plate must be turned back to impact. Otherwise the pressure plate works with decreased contact pressure (clutch slips).

Refer to 30 CLUTCH

If the clutch disc is not replaced, the adjustment ring does not have to be turned back.

New SAC pressure plates are already pre-adjusted and must not be turned back.

Vehicles with automatic transmission 01V

Scheme 176

1. Drive plate is bolted to crankshaft with a centering bushing (arrow).
2. Use original bolts when securing torque converter to drive plate

Scheme 177

When torque converter is installed correctly, distance between lower contact surface of threaded holes at torque converter and contact surface of converter housing on Automatic Transmission 01V is approx. 23 mm.

If the torque converter is not inserted completely, this distance will be approx. 11 mm.

All

1. Carefully guide engine with transmission into chassis.
2. Set engine onto engine mounts.

1. Bolt transmission to engine, from. Refer to «Tightening torques»(/audi/a4/b6-2000-2006/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__tightening-torques) .

1. Tighten T10062 support on threaded holes for torque support to 20 Nm.
2. Lift engine using VAG1383A engine/transmission jack just far enough so that lower connecting bolts at engine/transmission can be installed.

Note. When working on a vehicle with all wheel drive, make sure the front constant velocity joint of the driveshaft is not damaged when lifting the engine.

1. Tighten lower engine/transmission connecting bolts (arrows).
2. Lower engine again.
3. Install and align exhaust system free of tension. Refer to «Exhaust system, aligning free of stress (vehicles with front wheel drive)»(/audi/a4/b6-2000-2006/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__exhaust-system-aligning-free-of-stress) or «Exhaust system, aligning free of stress (vehicles with all wheel drive)»(/audi/a4/b6-2000-2006/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__exhaust-system-aligning-free-of-stress) .
4. Install starter.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

1. Install generator. Refer to «Ribbed belt for power steering pump, generator and A/C system»(/audi/a4/b6-2000-2006/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .
2. Install A/C compressor. Refer to «Ribbed belt for power steering pump, generator and A/C system»(/audi/a4/b6-2000-2006/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn) .
3. Install ribbed belt. Refer to «Installing»(/audi/a4/b6-2000-2006/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__installing) .
4. Install lock carrier. Refer to «Lock carrier, moving into service position»(/audi/a4/b6-2000-2006/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__lock-carrier-moving-into-service-position) .

Vehicles up to 06.03

1. Tighten union nut of fuel supply line -1- to 22 Nm.
2. Secure fuel return line -2- with a hose clamp.

Vehicles as of 07.03

1. Secure fuel hose to connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head -1- and -3- and tighten union nut -2- to 22 Nm.

Vehicles with automatic transmission

1. Secure ATF lines

Refer to

1. «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J
2. «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING

Refer to 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

All

1. Check harness connectors and routing

Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations

See Caution for connecting Telematics battery. Refer to Engine, removing and installing

1. Observe safety precautions after connecting battery.

Refer to 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

1. Check engine oil level before starting engine.
2. Top off coolant. Refer to «Filling»(/audi/a4/b6-2000-2006/remont/cooling-fan/#30l-6-cyl-5v-engine-mechanical-engine-codes-avk-bgn__filling) .

Note. Only reuse drained coolant if cylinder head or engine block were not replaced. Dirty coolant cannot be reused.

1. Fill up power steering fluid and bleed steering system

Refer to 48 - STEERING

Vehicles with automatic transmission

1. Check ATF level

Refer to

1. «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J
2. «37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING»(/audi/a4/b6-2000-2006/remont/differentials-drive-axles/#continuously-variable-transmission-cvt-01j-internal-components-servicing) for CONTINUOUSLY VARIABLE TRANSMISSION (CVT) 01J - INTERNAL COMPONENTS, SERVICING

Refer to 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING

All

1. Adjust headlights

Refer to 94 LIGHTS, SWITCHES - EXTERIOR .