Engine, removing

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2004 Audi A6, 2003 Audi S6, 2003 Audi A6, 2002 Audi S6, and 2002 Audi A6. However, it is still accessible from the selected car via links, so may be relevant.

See Caution before beginning repairs on the electrical system . See ENGINE, REMOVING AND INSTALLING

NOTE:

Remove engine together with transmission from the front.
Replace all cable ties detached or cut when removing the engine in the same position when installing.
The battery is located behind a cover on the right side of the luggage compartment.

With ignition switched off, disconnect battery ground strap.
Unscrew grille on left side -arrow-, unclip on right side.

Fig 1: Identifying Screw On Left Side Of Grille

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Remove noise insulation.

Fig 2: Removing Noise Insulation
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Remove both front wheels.
Remove both front wheel housings.
Remove front bumper behind wheel housings.
Unbolt bumper on left and right sides.
Vehicles with headlight washers:

Fig 3: Identifying Bumper Bolt On Left And Right Sides
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Clamp off washer hose for headlight washers with clamp 3094.
Disconnect hose to jets at bumper in right air intake grille.
Disconnect hoses for headlight washers (in right grille).

WARNING: The cooling system is under pressure when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection. Cover the cap with a rag and open carefully to relieve pressure slowly.

Open cap of coolant expansion tank.
Place drip tray VAG 1306 under engine.
Drain coolant from radiator (bottom left) -arrow-. Install drain hose if necessary.

Fig 4: Installing Drain Hose On Bottom Of Radiator

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Open drain plugs -arrows- and drain coolant.

Fig 5: Identifying Coolant Drain Plug In Engine

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CAUTION: Dispose of used coolant properly.

Disconnect coolant hose connection -arrow-.

Fig 6: Disconnecting Coolant Hose Connection

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Remove radiator shroud at left and right sides -arrows-

Fig 7: Removing Radiator Shroud At Left And Right Sides

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Remove engine cover -arrows-

Fig 8: Removing Engine Cover

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Remove air intake duct for air cleaner -arrows-.

Fig 9: Removing Air Intake Duct For Air Cleaner

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Remove bracket for hydraulic oil lines -arrow-.

Fig 10: Removing Bracket For Hydraulic Oil Lines

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Disconnect temperature sensor -1-. See Fig 11.
Remove long loop for hydraulic oil -arrows- and move aside.

Fig 11: Disconnecting Temperature Sensor

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Disconnect connector -1- for pressure switch.

Fig 12: Disconnecting Connector -1- For Pressure Switch
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CAUTION: The A/C refrigerant circuit must only be opened by specially trained technicians using proper tools and equipment.

DO NOT open air conditioning refrigerant circuit.
Disconnect A/C refrigerant line brackets and support points only.
Set A/C compressor carefully aside. Avoid damage from bending lines or kinking hoses. Refrigerant lines kink easily.

Remove condenser and hang up with wire.
Disconnect left and right headlights
Disconnect connectors for left and right indicator lights.

Automatic transmission only

Disconnect ATF lines for automatic transmission -arrows-.

Fig 13: Disconnecting ATF Lines For Automatic Transmission

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All vehicles

Remove coolant hose at upper right radiator -arrow-.

Fig 14: Removing Coolant Hose At Upper Right Radiator

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Disconnect thermal switch -arrow-.

Fig 15: Disconnecting Thermal Switch
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Disconnect connectors at horns.
Remove cover -1- in front of ABS unit.

Fig 16: Removing Cover In Front Of ABS

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Disconnect connectors in front of ABS unit -arrows-.

Fig 17: Disconnecting Connectors In Front Of ABS Unit

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Remove bolt -arrow- on left and right sides.

Fig 18: Removing Bolt On Left And Right Sides

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Remove left and right impact absorbers -arrows-.

Fig 19: Removing Left And Right Impact Absorbers

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Disengage hood release cable.
Remove air shroud bolts -arrows- on left and right sides.

Fig 20: Removing Air Shroud Bolts
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Remove air shroud with radiator.
Remove hose -1-.
Remove hose -2- to throttle body.

Fig 21: Removing Hose 1 To Throttle Body

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Remove hose -1- from air cleaner by turning it in direction of arrow. See Fig 22.
Remove bracket for frequency valve -2- from air cleaner housing.. See Fig 22.
Disconnect connector from mass air flow sensor -3-.
Remove bolt -arrow- and remove air cleaner housing together with mass air flow sensor and air intake duct.

Fig 22: Removing Air Cleaner Housing

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Disconnect connector -1- from oil level sensor and move wiring aside.

Fig 23: Disconnecting Connector From Oil Level Sensor

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Counter-hold pulley for viscous fan with pin wrench 3212 and remove fan with wrench 3312 (FAN HAS LEFT HAND THREAD).

Fig 24: Removing Viscous Fan With Wrench 3312

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CAUTION:

Mark the running direction of the belt with crayon or marker before removing. Reinstalling a used belt in reversed running direction could damage the belt
When installing a used ribbed belt be sure the belt runs in the right direction and is seated correctly on the belt pulleys.

To loosen ribbed belt, turn belt tensioner with 19mm wrench in direction of arrow until both holes are aligned. Insert 3204 to hold tensioner in position.

Fig 25: Inserting 3204 To Hold Ribbed Belt Tensioner In Position
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Remove ribbed belt.
Remove pulley of hydraulic pump using pin wrench 3212 to counter-hold.
NOTE: Be aware of washers behind belt pulley. Install washers again when pulley is reinstalled.
Remove hydraulic pump from bracket and move it aside.

Fig 26: Removing Hydraulic Pump From Bracket

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Remove clamp for refrigerant line -arrow-.

CAUTION: The A/C refrigerant circuit must only be opened by specially trained technicians using proper tools and equipment.

DO NOT open air conditioning refrigerant circuit.
Disconnect A/C refrigerant line brackets and support points only.
Set A/C compressor carefully aside. Avoid damage from bending lines or kinking hoses. Refrigerant lines kink easily.

Fig 27: Removing Clamp For Refrigerant Line

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Remove A/C compressor and hang up with wire. Watch out for centering dowels to locate A/C compressor on bracket.

Fig 28: Removing A/C Compressor

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Automatic transmission only

Remove bolts -arrow- for bracket for ATF lines at engine.

Fig 29: Removing Bolts For Bracket For ATF Lines At Engine

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All vehicles

Remove torque support -arrows-.

Fig 30: Removing Torque Support

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Disconnect connector -1- for oxygen sensor after Three Way Catalytic Converter (TWC) and free wiring to oxygen sensor.
Disconnect connector -2- for oxygen sensor after Three Way Catalytic Converter (TWC) and free wiring to oxygen sensor.
Disconnect connector -3- for right oxygen sensor and free wiring.

Fig 31: Disconnecting Connectors For Oxygen Sensors

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WARNING:

Fuel lines are under pressure. Keep anything away that could ignite fuel or fumes.
Before disconnecting fuel lines, clean connections.
Cover connections with rag to protect against fuel spray.

Disconnect fuel supply and return lines.

Fig 32: Disconnecting Fuel Supply And Return Lines
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Remove hose -2- and move it aside.
Remove hoses -arrows- from coolant expansion tank
Remove coolant expansion tank.
Disconnect connector from coolant level sensor at expansion tank.

Fig 33: Removing Hoses From Coolant Expansion Tank

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Disconnect connector for left oxygen sensor -arrow- and set wiring aside.

Fig 34: Disconnecting Connector For Left Oxygen Sensor And Set Wiring

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Remove coolant hose -1-. See Fig 35.
Disconnect connector -2-.
Disconnect ground wire -3-at cylinder head.
Disconnect connector -4-.
Disconnect connector -5-.

Fig 35: Disconnecting Electrical Connectors And Coolant Hose

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Disconnect connector -1- from Camshaft Position (CMP) sensor.
Disconnect connector -2-.
Disconnect connector -3-.

Fig 36: Disconnecting Connector From Camshaft Position (CMP) Sensors

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Disconnect connector -3-.

Fig 37: Disconnecting Connector At CMP Sensor

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Disconnect connector -4- from ignition coils.
Disconnect connector -6-.

Fig 38: Disconnecting Connectors From Ignition Coils

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Disconnect connector -1- for knock sensor at cylinder bank 5-8.
Disconnect connectors -arrows- from fuel injectors of cylinder bank 5-8 and set wiring harness aside.
Disconnect connectors for knock sensor at cylinder bank 1-4.
Disconnect connectors from fuel injectors of cylinder bank 1-4

Fig 39: Disconnecting Connector For Knock Sensor And Fuel Injectors At Cylinder Bank 5-8

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Remove clamp -arrow-from coolant line and set wiring harness aside.

Fig 40: Removing Clamp From Coolant Line And Set Wiring Harness

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CAUTION: DO NOT bend swivel joint of exhaust pipe by more than 10° to prevent damage.

Remove upper exhaust pipe bolts, left and right.
Remove exhaust pipe bolts -arrows-at left from below.

Fig 41: Removing Exhaust Pipe Bolts

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Remove exhaust pipe from retainer -arrow-.

Fig 42: Removing Exhaust Pipe From Retainer

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Loosen double clamp-1-and push it forward.
Carefully remove exhaust pipe.

CAUTION: DO NOT bend swivel joint of exhaust pipe by more than 10° to prevent damage.

Fig 43: Locating Double Clamp

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From below, remove bolts -arrow- between exhaust pipe and exhaust manifold.

Fig 44: Removing Bolts Between Exhaust Pipe And Exhaust Manifold

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Remove exhaust pipe from retainer -arrow-.

Fig 45: Removing Exhaust Pipe From Retainer

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Loosen double clamp -2- and push forward.
Carefully remove exhaust pipe with Three Way Catalytic (TWC) converter.

CAUTION: DO NOT bend swivel joint of exhaust pipe by more than 10° to prevent damage.

Fig 46: Locating Double Clamp

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Disconnect cable -1- from generator.
Disconnect cable -2- from generator.
Remove bracket -3-.

Fig 47: Disconnecting Cable From Generator

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Remove bracket for protective cover.
Remove oil filter.

Fig 48: Removing Bracket For Protective Cover

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Disconnect ground cable -arrow-.

Fig 49: Disconnecting Ground Cable

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Remove bracket for starter motor.
Disconnect electrical wiring from starter motor.
Remove starter motor.

Fig 50: Removing Bracket For Starter Motor

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NOTE: Before unbolting torque converter, mark alignment with drive plate.

Remove bolts of torque converter -arrow-(three bolts).
Tightening torque: 85 Nm (63 ft lb)

If engine or transmission are replaced separately:

With engine separated, turn crankshaft to TDC and align markings on torque converter and bell housing.

Fig 51: Removing Bolts Of Torque Converter

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Remove left and right engine mounts.

Fig 52: Removing Left And Right Engine Mounts

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Attach engine sling VAG 3033 at two engine lifting points shown.
Position workshop crane VAG 202A and hook up sling VAG 3033.

Fig 53: Positioning Workshop Crane VAG 202A And Hook Up Sling VAG 3033 To Engine
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WARNING:

To properly balance the engine assembly, install the hooks in the correct notches of the sling, exactly as shown in the illustration.
Assure that hooks are firmly connected with the lifting eyes.

Carefully lift engine and transmission and remove toward front.