Engine, Removing, AUDI RS6/RS7: Procedure

WARNING: This page is about a different car, the 2018 Audi S6, 2017 Audi S6, and 2016 Audi S6. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

The engine is removed downward with transmission and subframe.

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

All bolts on suspension components must be equipped with bonded rubber bushings and tightening in curb weight position (no load).

Bonded rubber bushings have a limited range of motion. Axle components with bonded rubber bushings must be brought into the position they will be in during driving before tightening (curb weight position). Otherwise, the bonded rubber bushing will have tension, which will reduce the service life.

Measure dimension -a- from the center of the wheel to the lower edge of the wheel housing before beginning work, for example, using a tape measure.

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The measurement must be taken with the vehicle in curb weight position (no load).

Note the measurement. This number will be needed when tightening the bolts/nuts.

WARNING:

Risk of vehicle tipping over with engine removed.

NOTE:

To be able to turn the drive axle to remove it, shift the transmission to "N" and release the electromechanical parking brake before disconnecting the battery.

-- Position the front wheels so they are straight.

CAUTION:

Risk of damaging the electronic components.

Follow the steps for disconnecting the battery.

-- Disconnect the ground cable from the battery terminal. Refer to BATTERY .

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

-- Remove the lock carrier cover. Refer to ATTACHMENTS, REMOVING AND INSTALLING .

-- Remove the driveshaft. Refer to REMOVAL AND INSTALLATION .

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

WARNING:

Fire hazards and risk of damage for a faulty engine cover.

The engine cover must be always be installed before the hood is closed.
The engine may neither be started nor driven without an engine cover.

WARNING:

The cooling system is under pressure when the engine is warm. Risk of scalding due to hot steam and hot coolant.

Scalding the skin and other parts of the body is possible.

Wear safety gloves.
Wear protective eyewear.
Reduce the pressure by covering the coolant expansion tank cap with a cloth and carefully opening it.

-- Remove the cap -arrow- from the coolant reservoir.

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-- Remove the front left and right wheel housing liners. Refer to WHEEL HOUSING LINER .

-- Remove the left and right front wheel spoiler. Refer to WHEEL HOUSING LINER .

-- Remove the noise insulations. Refer to NOISE INSULATION .

-- Remove the front bumper cover end plate. Refer to ATTACHMENTS, REMOVING AND INSTALLING .

-- Free up the wiring harness -arrow-.

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-- Remove the nuts -1 and 2-, and free up coolant line.

-- Place the :VAS6208 under engine.

-- Loosen the hose clamps -3 and 4- drain the coolant to remove the coolant hoses.

-- Lift the clamp -1- and loosen hose clamp -2- to disconnect the coolant hose and drain the coolant.

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-- Remove the plenum chamber cover. Refer to BULKHEAD .

-- Remove the bolts -arrows- and air guide -1-.

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-- Remove bolt -arrows-, and free up the air guide -2- at the lock carrier.

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NOTE:

Ignore item -1-.

-- Loosen the hose clamps -arrows- and remove the air guide hose.

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-- Remove the air filter housing -1- upward.

-- Remove the right and left fasteners -arrows- and remove the cover -1-.

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-- Remove the tower brace. Refer to SUSPENSION STRUT AND UPPER CONTROL ARM .

-- Remove heat shield -1- from above in direction of -arrow-.

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-- Loosen the clamp -2- and remove the vacuum connection from the plenum chamber bulkhead.

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

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WARNING:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

Wear protective eyewear.
Wear safety gloves.
Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Place a clean cloth around the connection location. Loosen the union nuts -arrows- and reduce the fuel pressure, while at the same time counterhold on the hex fitting of the corresponding connection.

NOTE:

Do not change the shape of the high pressure pipe.

Ignore -1 through 5-

-- Press the release ring and disconnect the fuel line -2-.

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-- Loosen the clamp -1- and disconnect the hose from the EVAP canister.

-- Seal the open lines and connections with clean plugs from the :VAS6122 .

-- Disconnect the coolant hose by lifting the retaining clamps -2- and loosening the hose clamp -1-.

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-- Loosen the hose clamps -1- to remove the coolant hoses from the charge air cooling circuit radiator.

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-- Free up the coolant hoses -arrow-.

-- Open the clamp -2- to remove the coolant hose line.

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-- Free up the coolant hose line.

WARNING:

Danger of frostbite due to refrigerant escaping under pressure.

There is a risk of frostbite to the skin or other parts of the body.

Wear safety gloves.
Wear protective eyewear.
Extract the refrigerant or drain and immediately open the refrigerant circuit.
If evacuating or extraction has taken place more than 10 minutes ago and the refrigerant circuit was not opened, evacuate or drain the refrigerant again. Pressure can be created in the refrigerant circuit by evaporation.

-- Remove the bolts -1- and free up the refrigerant lines.

-- Disconnect the connector -3-.

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-- Disconnect the vacuum hose -1-.

-- Disconnect the secondary air hose -2- by pressing the release buttons.

-- Release the retainer in direction of -arrow A- and open the cover in direction of -arrow B-.

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-- Remove the nuts -2 and 3- and free up the wire.

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-- Remove the connector -1- from the bracket and disconnect it.

-- Remove the nuts -arrows- and then remove Terminal 30 Wire Junction -TV2- from the plenum chamber bulkhead.

-- Move the foam wedge -1- to the side.

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-- Remove the bolts -arrows-.

-- Remove the nut -2- on the right longitudinal member and free up the ground wires.

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-- Unlock the retainer in direction of -arrow- and free up the wiring harness to open the wiring duct -1-.

-- Remove the bolts -arrows-, pull the filler tube -1- out of the windshield washer fluid reservoir and out of the opening in the body and move it to the right.

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-- Remove the cap nut -2- and free up the ground cable.

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-- Open the retainer in direction of -arrow- and remove the Engine Control Module -J623- -1- from the bracket and move it to the side.

-- Remove the bolts -arrows- and the engine compartment E-box cover -1-.

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-- Disconnect the connectors -1- and remove the nut -2- for the wire.

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-- Release the retainers in direction of -arrows- and remove the relay carrier with the fuse panel -3-.

-- Disengage the engine wiring harness at the engine compartment E-box and free it up.

-- Release the retainers in direction of -arrows A- and remove the wiring bushing -1- upward in direction of -arrow B-.

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-- Lay the wiring harness on the engine and secure the Engine Control Module -J623- so that it cannot fall.

-- Unclip the lower air duct -1- from underneath in direction of -arrows-.

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-- Remove the bolt -2- and free up the refrigerant line.

NOTE:

The Installed position is shown with the front bumper cover removed for better illustration.

-- Free up the connectors -1 and 2-.

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-- Remove the left and right bolts -arrows- and the lower front longitudinal member -1-.

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-- Remove the nut -arrow- and free up the coolant pipe.

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-- Remove the clamp -1- and loosen hose clamp -3- to disconnect the coolant hoses and drain the coolant.

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-- Remove the bolt -4- and remove the supports from the coolant pump.

-- Loosen hose clamp -arrow-, and remove the front coolant pipes toward the right side.

-- Remove the air filter -2- from the mount in direction of -arrow-.

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

NOTE:

The illustration shows the Installed position on an Audi S6/S7.

-- Open the clamp -arrow- to remove the coolant hose.

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-- Disconnect the coolant fan connectors -1 and 2- to do this, push the clip to the rear in direction of -arrow- and push the release down.

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-- Free up the wiring harness.

-- Place the :SMN372500 under the engine.

-- Remove the nut -1- and the bolts -arrows-.

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-- Remove and free up the oil lines from the engine oil cooler.

-- Seal the open lines and connections with clean plugs from the :VAS6122 .

-- Disconnect the connector -arrow-.

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NOTE:

If the engine must be removed from the scissor lift table for future procedures, remove the connector from the mount and guide it through the subframe.

-- Disconnect the electrical connectors -arrow- at the left and right on the front speed sensors -G45- / -G47-.

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-- Disconnect the left and right connector -1- from the front vehicle level sensor -G78- / -G289- and free up the wire -arrow-.

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-- Remove the brake caliper and secure the brake caliper with the brake hoses still attached inside the wheel housing with wire. .

CAUTION:

Risk of damaging brake pistons.

Do not operate brake pedal when the brake caliper is removed.

-- Remove the nut -2- and the bolt -1-.

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-- Remove the upper control arm upward from the wheel bearing housing in direction of -arrows-.

-- Repeat the procedure on the other side of the vehicle.

NOTE:

The bolts -2- will be removed later.

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-- Remove the left and right stabilizer bar bolt -1-.

-- Remove the left and right nuts -3-.

-- Free up the clip -arrow-.

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-- Disconnect the connector -1- and free up the wire.

-- Remove the subframe crossbrace. Refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

CAUTION:

The suspension components could be damaged.

Do not rest the vehicle on its wheels if the subframe mount, the steering gear or the subframe crossbrace are not installed correctly.

-- Remove the left and right bolts -arrows- and the heat shield -1-.

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-- Remove the nuts -arrows- and the left front muffler.

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-- Remove the nuts -arrows- and the right front muffler.

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-- Remove the steering intermediate shaft from the steering gear and the push the splines together. Refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

-- Release the safety catch -arrow-, push the retainer down and disconnect the connector from -2- from the Power Steering Control Module -J500-.

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-- Disconnect the connector -1- from the Power Steering Control Module -J500-.

-- Free up the wiring harness.

-- Remove bolts -arrows- and then remove the heat shield.

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-- Remove the ball socket -1- on the selector lever cable from the selector shaft lever using the :80-200 .

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NOTE:

Do not bend or kink the selector lever cable.