Engine Through 05.2010, Removal

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Pry Lever 80-200
Used Oil Collection And Extraction Unit SMN372500
Step Ladder VAS 5085
Engine Bung Set VAS6122
Scissor Lift Table VAS6131A with Scissor Lift Table - Audi Set VAS6131/10 and Scissor Lift Table - A8 Set VAS6131/11, Scissor Lift Table - Q7 Set VAS6131/13 and qty. 3 Scissor Lift Table - Audi Set - Mounting Pin VAS6131/10-2
Shop Crane - Drip Tray VAS6208
Hose Clamps - Up To 25mm 3094
Hose Clip Pliers VAS6362
Puller - Ball Joint T10187

Procedure

NOTE:

With lock carrier installed, engine is removed downward with transmission and subframe.

When Installation, bring all cable ties back to same positions.

Collect escaping coolant in a clean container for disposal or reuse.

-- On a vehicle with air suspension, activate vehicle lift mode. Refer to VEHICLE LIFT MODE .

NOTE:

To rotate the driveshaft freely, move the selector lever into "N".

Fig 1: Pry Cover -1- With 80 - 200 From Floor Covering.

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CAUTION:

Danger of causing damage to other electronic components when disconnecting the battery.

Complete the steps for disconnecting the battery.
Pay attention the to waiting period for vehicles with urea injection.

-- Disconnect the ground cable -4- from the battery terminal. Refer to GROUND CABLE WITH Battery Monitoring Control Module -J367- FROM MY 09, REMOVING AND INSTALLING .

-- Empty the coolant circuit. Refer to A/C System with Refrigerant R134a.

-- Extract the power steering oil from the reservoir with the Used Oil Collection And Extraction Unit SMN372500.

WARNING:

Risk of scalding due to hot steam and hot coolant.

The coolant system is under pressure when the engine is warm.
Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure.

-- Open the coolant reservoir cap.

-- Remove the left and right front wheels.

Fig 2: Locating Front/Rear Noise Insulation

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-- Remove the noise insulation -1- and -2-. Refer to NOISE INSULATION, REMOVING AND INSTALLING .

-- Remove left and right front wheel housing liners. Refer to Wheel Housing Liners .

Fig 3: Left Front Wheel Housing Liner And Fasteners

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-- Place the Shop Crane - Drip Tray VAS6208 under the engine.

Fig 4: Identifying Coolant Hose -Arrow- To Left Coolant Pipe

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-- Remove the coolant hose from the left coolant pipe by loosening the hose clamp -arrow- and letting the coolant drain out.

-- Disconnect the connector -2- from the Engine Coolant Temperature Sensor on Radiator Outlet -G83-.

Fig 5: Engine Coolant Temperature (ECT) Sensor On Radiator Outlet -G83- -2-

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-- Remove the right lower coolant hose from the radiator by lifting the clamp -1- and let the coolant drain out.

-- Loosen the hose clamps, remove the coolant hoses from the heat exchanger -arrows- and let the coolant drain out.

Fig 6: Identifying Coolant Hose Clamps

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-- Remove the coolant hose from the right coolant pipe by loosening the hose clamp -arrow- and letting any remaining coolant drain out.

Fig 7: Identifying Coolant Hose -Arrow- And Connector Coupling To Right Coolant Pipe

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-- Carefully pull the engine cover off the 4 bolts one after the other -arrows-.

Fig 8: Removing Engine Cover

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-- Pull the cover over the radiator -arrows-, to do this disconnect the lower coolant hose.

Fig 9: Cover Over Radiator -Arrows-

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-- Loosen the clamp -1- and remove the coolant hose.

Fig 10: Removing Coolant Hose At Hose Clamp -1-

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NOTE:

Ignore -item 2-.

Fig 11: Fuel Hoses, Fuel Filter And Mounting Bolts

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WARNING:

Very hot fuel can burn your skin.

In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
Wear safety gloves
Wear protective eyewear.

-- Remove the bolts -1- and -2- as well as the nuts -4-.

-- Move the fuel filter to the side, with the fuel hoses still connected -3, 5 and 6-.

-- Remove the bolts -1 through 4- and move the fuel system cooler to the side.

Fig 12: Fuel System Cooler Bracket Mounting Bolts -1 Through 4

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NOTE:

The fuel filter bracket remains in its installation position.

-- Open the cover over the Terminal 30 Wire Junction 2 -TV22- -arrow-.

Fig 13: Battery Jump Start Terminal -U6- Pins

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-- Remove the bolts -1- for the Battery Jump Start Terminal -U6- and free up the electrical wire.

-- Remove the air guide hose by loosening the hose clamps -arrows-.

Fig 14: Identifying Charge Air Hose Clamps -Arrows- And Hose

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-- Disconnect the connector -3-.

Fig 15: Throttle Valve Control Module -J338- From Intake Tube, Remove/Install

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-- Remove the screws -1- and -2-, remove the Throttle Valve Control Module -J338- from the intake tube.

NOTE:

Place a cloth underneath to soak up any escaping power steering fluid.

Fig 16: Removing Power Steering Fluid Hose

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-- Disconnect the power steering pump fluid line and Hose Clamps - Up To 25mm 3094.

-- Loosen the hose clamp -1- and remove the power steering fluid hose.

-- Seal any open lines and connections with a clean plug from the Engine Bung Set VAS6122.

NOTE:

Ignore -item 2-.

Fig 17: A/C Compressor Refrigerant Lines And Electrical Connector -2-, Remove/Install

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CAUTION:

Risk of damaging refrigerant lines and hoses.

Do not stretch, kink or bend refrigerant lines and hoses.

-- Remove the clamp screws -1- and -5-.

-- Remove the screws -3- and -4- and then remove the refrigerant lines from the A/C compressor.

-- Seal any open lines and connections with a clean plug from the Engine Bung Set VAS6122.

NOTE:

Ignore -item 2-.

-- Unclip the coolant hose on the air filter housing upper section.

Fig 18: Air Filter Housing, Mass Airflow Sensor -G70- And Intake Duct

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-- Unclip the front final drive vent hose -1- from the air filter housing.

-- Disconnect the connector -3- from the Mass Airflow Sensor -G70-.

-- Remove the air duct hose form the turbocharger by loosening the hose clamps -4-.

-- Unlock the clips -2-.

-- On vehicles with air suspension, push the securing ring -1- forward off the hose coupling, press the release ring -2- downward -arrows- and remove the ventilation hose -3- from the air filter housing upper section.

Fig 19: Circlip, Release Ring And Ventilation Hose

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-- Remove the air filter housing upper section and the air filter.

-- Pry off the air guide -2- from the air filter housing lower section -1- starting on the wheel housing side using Pry Lever 80-200.

Fig 20: Locating Air Filter Housing

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-- Remove the bolts -1- and -2-.

Fig 21: Air Filter Housing Mounting Screws

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-- Remove the air filter housing lower section; to do this, slightly push on the windshield washer fluid reservoir to the side.

-- Remove the air duct hoses by loosening the hose clamps -1, 2 and 3-.

Fig 22: Air Duct Hoses And Hose Clamps -1, 2 And 3-

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-- Disconnect the connector -arrow-.

Fig 23: Disconnecting Connector -Arrow- On Right Side From Engine

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-- Disconnect the vacuum hose -arrow- leading to the brake booster.

Fig 24: Identifying Vacuum Hose -Arrow

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WARNING:

Very hot fuel can burn your skin.

In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.
Wear safety gloves
Wear protective eyewear.

There is a risk of injury because the fuel is under pressure.

To reduce pressure in fuel system, lay a clean cloth around the connector and carefully loosen connector.

-- Disconnect the fuel supply line -1- and return line -2- on the bulkhead.

Fig 25: Identifying Fuel Supply Hose -1-

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-- Disconnect the -1- Exhaust Gas Temperature Sensor 2 -G448- and -2- Heated Oxygen Sensor -G39- connectors.

Fig 26: Component Location On Plenum Chamber Bulkhead

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-- Free up the electric wires.

NOTE:

Ignore -items 3 and 4-.

-- Remove the Heated Oxygen Sensor -G39- -5-.

Fig 27: Locating Primary Catalytic Converter And Sensors, Catalyst Temperature Sensor 1 -G20- (2), EGT 3 -G495- (1), EGT 2 -G448- (3) & NOx Sensor -G295- (4)

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-- Remove the NOx Sensor -G295- -4- and free up the electrical wire.

-- Secure the NOX sensor to the body.

NOTE:

Ignore -item 1, 2 and 3-.

-- Remove the windshield wiper arms -1- and -3-. Refer to WINDSHIELD WIPER ARM, REMOVING AND INSTALLING .

Fig 28: Identifying Removal Of Windshield Wiper Arm -1- And -3-

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CAUTION:

Danger of causing damage to the plenum chamber cover.

Coat the transition area between the windshield and plenum chamber cover with soapy water and carefully pull the cover vertically up out of the retainers on the windshield, beginning at the edge of the window.

-- Remove gasket -5-.

-- Carefully remove the plenum chamber covers -2- and -4- from the retainers on the windshield.

-- Remove cover for E-box, plenum chamber -arrows-.

Fig 29: Identifying Bolts To E-Box Plenum Chamber Cover -Arrows-

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-- Disconnect the connectors -1, 2 and 3- at E-box plenum chamber coupling station and free up the wiring harness.

Fig 30: Identifying Electrical Connectors -1 Through 3-

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-- Disconnect the connector -arrow-.

Fig 31: Identifying Electrical Connector -Arrow-

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-- Remove the ground connection nut -2-.

Fig 32: Identifying Engine Control Module (ECM) -J623- -1- And GND Wire Nut -2-

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-- Remove the engine control module -1-. Refer to Engine Control Module -J623-, REMOVING AND INSTALLING .

-- Free up electrical wiring harness to engine.

-- Loosen upper control arm nut a few turns and pull joint off with Puller - Ball Joint T10187.

Fig 33: Pressing Out Upper Control Arm

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-- Completely remove upper control arm nut.

-- Repeat procedure on opposite side of vehicle.

-- Disconnect the connectors -arrow- at the left and right on the front speed sensors.

Fig 34: Identifying Speed Sensor Connector

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-- Remove wiring harness bolts -arrows-.

Fig 35: Identifying Wire Harness Bolts

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-- Remove brake caliper bolts -1-.

NOTE:

Do not change brake line bend shape.

-- Engage brake caliper in wheel housing with wire.

CAUTION:

Risk of damaging brake pistons.

Do not operate brake pedal with brake caliper removed.

-- Repeat procedure on opposite side of vehicle.

-- Disconnect lower threaded connection -2- at left and right on stabilizer bar.

Fig 36: Identifying Right/Left Lower Bolt On Stabilizer Bar

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-- Remove nuts from bolts -1- at left and right on strut.

NOTE:

Bolts -1- are removed later.

-- Disconnect the exhaust system at the clamping sleeve -arrows-.

Fig 37: Disconnect Exhaust System At Clamping Sleeve -Arrows-

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-- Remove NOx Sensor 2 -G687- -item 3-.

Fig 38: Locating NOx Sensor 2 -G687- -3-

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-- Disconnect the connector -5- and free up the electrical wire.

-- Loosen the clamp -arrow- and remove the Reducing Agent Injector -N474-.

-- Move the nuts -1- and screws -2- and -4- and remove the SCR catalytic converter.

-- Remove the bolts -arrows- that attach the rear driveshaft to the transfer case. Refer to TRANSFER CASE .

Fig 39: Identifying Bolts -Arrows- At Transfer Case/Rear Driveshaft Connection

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-- Slide rear driveshaft toward rear final drive; CV joints can move axially.

-- Secure the driveshaft to the side.

-- Remove the nuts and bolts -arrows- then remove the noise insulation bracket.

Fig 40: Identifying Bracket For Noise Insulation

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-- Remove the exhaust system bracket bolts -arrows- on the longitudinal member.

Fig 41: Identifying Exhaust System Bracket At Left And Right From Longitudinal Members -Arrows-

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-- Remove the Exhaust Gas Temperature Sensor 4 -G648- -arrow-.

Fig 42: Identifying Exhaust Gas Temperature Sensor 4 -Arrow-

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-- Remove the Differential Pressure Sensor -G505- hoses from the pressure lines on the particulate filter; to do this, loosen the hose clamps -arrows-.

Fig 43: Disconnect Differential Pressure Sensor Hoses -Arrows

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-- Disconnect electrical connector -arrow- on steering gear.

Fig 44: Identifying Electrical Connector -Arrow- On Steering Gear

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-- Remove the 2 bolts and then remove the steering gear heat shield -A-.

Fig 45: Identifying Steering Gear Heat Shield -A-

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CAUTION:

Risk of distorting airbag spiral spring.

Separate universal joint from steering gear only when front wheels are in straight ahead position.
Secure steering wheel with adhesive tape to prevent position of steering wheel and steering gear from changing.

-- Remove the bolt -B- for the universal joint. .

-- Remove universal joint from steering gear.

-- Place the Used Oil Collection And Extraction Unit SMN372500 under the disconnection point.

Fig 46: Identifying Hose Clamp -Arrow

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-- Loosen the hose clamp -arrow- and disconnect the left fluid line on the lock carrier leading to the power steering cooler.

-- Seal any open lines and connections with a clean plug from the Engine Bung Set VAS6122.

-- Remove the screw -arrow-, free up the coolant hose and move the Fuel Cooler Pump -V166- to the side.

Fig 47: Identifying Fuel Cooler Pump Screw -Arrow-

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NOTE:

Observe the rules of cleanliness for working on automatic transmissions. Refer to INFORMATION ON 6-SPEED AUTOMATIC TRANSMISSION 0AT .

Fig 48: Identifying ATF Lines And Bolt - Arrow -

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-- Remove the bolt -arrow- and disconnect the ATF lines from the ATF thermostat.

-- Seal any open lines and connections with a clean plug from the Engine Bung Set VAS 6122.

-- Remove the nut -1- on the right longitudinal member and disconnect the ground wire form the threaded pin.

Fig 49: Identifying Ground (GND) Cable On Longmember

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-- Disconnect the automatic transmission connectors -1, 2 and 3-.

Fig 50: Connect Connectors -1 Through 3-

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Prepare scissor lift platform:

Fig 51: Identifying Scissor Lift Platform VAS 6131

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-- Equip Scissor Lift Table VAS6131A with Scissor Lift Table - Audi Set VAS6131/10 and Scissor Lift Table - A8 Set VAS6131/11 and Scissor Lift Table - Q7 Set VAS6131/13 as follows:

Platform Coordinates	Parts from Scissor Lift Table - Audi Set VAS6131/10, Scissor Lift Table - A8 Set VAS6131/11 and Scissor Lift Table - Q7 Set VAS6131/13
B2	/10-1	/10-2	/10-5	/11-1
G2	/10-1	/10-2	/10-5	/11-1
A4 and C4	/13-5	-	-	/13-2
F4 and H4	/13-6	-	-	/13-2
B5	/13-4	/10-2	/10-5	/13-1
G5	/13-4	/10-2	/10-5	/13-1
C7	/10-1	/10-2	/10-5	/10-8
F7	/10-1	/10-2	/10-5	/10-8
B14	/10-1	/10-3	/10-5	/10-7
G14	/10-1	/10-3	/10-5	/10-7

-- First manually secure the mounting elements to the Scissor Lift Table VAS6131A.

Fig 52: Attach Mounting Elements From VAS 6131/10 And VAS 6131/11 At Front Of Subframe

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-- Position the scissor lift table horizontally.

Note bubble level (sight glass) on support platform.

-- Guide the scissor lift table under the engine/transmission subassembly.

-- Attach mounting elements from Scissor Lift Table - Audi Set VAS6131/10 and Scissor Lift Table - A8 Set VAS6131/11 at front of subframe as shown in illustration.

-- Ensure threaded spindles are completely installed.

-- Attach mounting elements from the Scissor Lift Table - Audi Set VAS6131/10 and Scissor Lift Table - Q7 Set VAS6131/13 at the left and right on the transmission carrier as shown in the illustration.

Fig 53: Attaching Mounting Elements From VAS 6131/10 And VAS 6131/13

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-- Position mounting elements Scissor Lift Table - Q7 Set VAS6131/13 at the left and right on the suspension struts as shown in the illustration.

Fig 54: Attaching Mounting Elements From VAS 6131/13 On Struts

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-- Attach mounting elements from Scissor Lift Table - Audi Set VAS6131/10 at the left and right on the subframe as shown in the illustration.

Fig 55: Attach Mounting Elements From VAS 6131/10 At Rear Of Subframe

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-- Attach mounting elements from Scissor Lift Table - Audi Set VAS6131/10 at left and right on transmission carrier as shown in illustration.

Fig 56: Attaching Mounting Elements From VAS 6131/10 At Left And Right On Transmission Carrier

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-- Rotate mounting element spindles upward until all mounting pins come in contact with mounting points.

-- Attach mounting element base plates to Scissor Lift Table VAS6131A and tighten to 20 Nm.

-- Mark position of subframe, engine carrier and transmission carrier to longitudinal members with a felt-tip pen.

Fig 57: Subframe, Engine Carrier, Crossmember And Bolts

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-- Remove the bolts -1 to 4- in a diagonal sequence in steps.

CAUTION:

Risk of damaging hose and wiring connections as well as engine compartment.

Make sure all the hoses and lines between the engine, transmission, subframe and body have been disconnected.
Carefully guide engine-transmission assembly with subframe out of engine compartment while lowering.
Carefully guide the suspension struts past the longitudinal members.

-- Next lower engine/transmission subassembly with Scissor Lift Table VAS6131A only by dimension -a-.

Fig 58: Identifying Dimension -a- Between Subframe And Body

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Dimension -a- = 200 mm.

-- Remove the bolts -1 through 4- and remove the selector lever cable heat shield.

Fig 59: Identifying Selector Lever Cable Heat Shield - Tightening Specification

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-- Remove the selector lever cable ball head -2- from the transmission shift lever using the Pry Lever 80-200.

Fig 60: Identifying Locking Washer & Selector Lever Cable

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-- Remove securing clips -1- and remove selector lever cable from transmission.

NOTE:

Do not bend or kink the selector lever cable.

-- Lower the engine/transmission subassembly further.

-- Remove the Scissor Lift Table VAS6131A with engine/transmission assembly from under the vehicle.