Engine, Removal

WARNING: This page is about a different car, the 2010 Audi Q7, 2009 Audi Q7, 2008 Audi Q7, and 2007 Audi Q7. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Used Oil Collection And Extraction Unit SMN372500
Hose Clip Pliers VAG1921
Step Ladder VAS5085
Scissor Lift Table VAS6131 with Scissor Lift Table - Audi Set VAS6131/10, Scissor Lift Table - A8 Set VAS6131/11, Scissor Lift Table - Q7 Set VAS6131/13 and 3 - Scissor Lift Table - Audi Set - Mounting Pin VAS6131/10-2
Shop Crane - Drip Tray VAS6208
Pry Lever 80-200
Hose Clip Pliers VAS6340
Puller - Ball Joint T10187

NOTE:

If the engine and transmission are to be separated after removal, the Scissor Lift Table - A6 Set VAS6131/12 will also be required.

Procedure

Proceed as follows:

NOTE:

Remove engine downward together with transmission and subframe with lock carrier installed.

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 .

WARNING:

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

Before opening high pressure components of the fuel injection system, pressure must be relieved to residual pressure.

-- Reduce the fuel pressure in the high pressure area, refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

CAUTION:

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

Complete the steps for disconnecting the battery.

NOTE:

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

-- Position driver's seat as far back and high as possible by using the entire seat adjustment range.

-- Turn off the ignition.

-- Grasp under seat and release retaining clips on back side of cover -1- in -direction of arrow A-.

Fig 1: Removing Under Seat Cover -1-

Courtesy of AUDI OF AMERICA, LLC

-- Remove cover in -direction of arrow B- from driver's seat console.

-- Pry cover -1- out of carpet with Pry Lever 80-200.

Fig 2: Pry Cover -1- With 80 - 200 From Floor Covering.

Courtesy of AUDI OF AMERICA, LLC

-- Lift the floor covering -2- in slightly in area of ground wire.

-- Remove nut -3- and remove ground wire -4- from ground point.

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

-- Extract power steering fluid from reservoir with 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 both front wheels.

Fig 3: Identifying Front/Rear Noise Insulation

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts and the front -1- and rear -2- noise insulation.

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

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

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

Courtesy of AUDI OF AMERICA, LLC

-- Remove coolant hose from front coolant pipe -arrow- and drain coolant.

Vehicles with 2-Zone Climate Control:

Fig 5: Identifying Coolant Hoses -1 And 2- To Heat Exchanger

Courtesy of AUDI OF AMERICA, LLC

-- Detach the coolant hoses -1 and 2- to the heater heat exchanger from the plenum chamber bulkhead.

Vehicles with 4-Zone Climate Control:

Fig 6: Identifying Coolant Hose Clamps

Courtesy of AUDI OF AMERICA, LLC

-- Remove coolant hoses -arrows- from coolant pipes and drain remaining coolant.

All Vehicles:

Fig 7: Air Guide Pipe And Vacuum Hose

Courtesy of AUDI OF AMERICA, LLC

-- If present, remove the vacuum hose -1-.

-- Remove air guide pipe -arrows-.

Vehicles without Mechanical Vacuum Pump:

Fig 8: Identifying Vacuum Lines On Intake Manifold

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect brake booster vacuum line -arrow-.

-- On a USA vehicle, disconnect the vacuum hose -4- to the Leak Detection Pump -V144- by pressing the release buttons.

NOTE:

Ignore -items 1, 2 and 3-.

-- Disconnect vacuum hose -1- to EVAP Canister Purge Regulator Valve 1 -N80- by pressing release button.

Fig 9: Identifying Electrical Harness Connector -1-

Courtesy of AUDI OF AMERICA, LLC

-- Free up vacuum hose.

WARNING:

Risk of injury from fuel.

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

-- Disconnect the fuel supply line -2-, refer to.

Vehicles with mechanical vacuum pump:

Fig 10: Identifying Vacuum Lines From Intake Manifold

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect brake booster vacuum line -arrow-.

NOTE:

Ignore -items 1, 2 and 3-.

-- Disconnect vacuum hose -1- to EVAP Canister Purge Regulator Valve 1 -N80- by pressing release button.

Fig 11: Identifying Vacuum Hose -1- To Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80-

Courtesy of AUDI OF AMERICA, LLC

-- Free up vacuum hose.

-- On a USA vehicle, disconnect the vacuum hose -2- to the Leak Detection Pump -V144-.

WARNING:

Risk of injury from fuel.

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

-- Disconnect the fuel supply line -3-, refer to.

All Vehicles:

Fig 12: Disconnecting Heated Oxygen Sensor Electrical Harness Connectors

Courtesy of AUDI OF AMERICA, LLC

-- Remove the oxygen sensor connectors -1 to 4- from the bracket on the right strut tower and disconnect them.

-- Unclip the front differential vent hose from the air filter housing -arrows-.

Fig 13: Bleed Hose From Air Filter Housing -Arrows-

Courtesy of AUDI OF AMERICA, LLC

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

Fig 14: Identifying Coolant Hoses -1 And 2- To Coolant Reservoir

Courtesy of AUDI OF AMERICA, LLC

-- Remove coolant hoses -1 and 2-.

Fig 15: Identifying Upper Coolant Hose -1-

Courtesy of AUDI OF AMERICA, LLC

-- Remove coolant hose -arrow- from front coolant pipe.

Fig 16: Identifying Coolant Hose -Arrow- From Front Coolant Pipe

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore -Item 1- Hose Clamps - Up To 40mm 3093.

-- Open cover over B+ distributor -arrow-.

Fig 17: Identifying B+ Wires

Courtesy of AUDI OF AMERICA, LLC

-- Remove positive wires:

To to generator
To the starter

-- Free up the electric wires.

NOTE:

Place a cloth under separating point to catch escaping hydraulic fluid.

Fig 18: Identifying Hose For Power Steering Fluid Reservoir

Courtesy of AUDI OF AMERICA, LLC

-- Remove hose from power steering reservoir -arrow-.

Fig 19: Identifying A/C Compressor Lines

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Risk of damaging refrigerant lines and hoses.

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

-- Remove refrigerant lines -2 and 3- from A/C compressor.

NOTE:

To prevent dirt and moisture from entering, seal off open lines and connections to A/C compressor with clean plugs or protective caps.

Ignore -Item 1-.

-- Pry cover caps off windshield wiper arms with screwdriver.

Fig 20: Identifying Removal Of Windshield Wiper Arm -1- And -3-

Courtesy of AUDI OF AMERICA, LLC

-- Loosen nuts -1 and 3- a few turns.

-- Loosen wiper arms in succession by tilting wiper axles slightly.

-- Remove nuts completely and remove wiper arms.

NOTE:

If wiper arms cannot be removed in this way, use a standard puller.

-- Remove rubber seal -5-.

-- Carefully remove plenum chamber cover -2- from retainer on windshield.

NOTE:

Ignore -Item 4-.

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

Fig 21: Identifying Bolts To E-Box Plenum Chamber Cover -Arrows-

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the connectors -1, 2 and 3- at the E-box plenum chamber connector station.

Fig 22: Identifying Electrical Connectors -1 Through 3-

Courtesy of AUDI OF AMERICA, LLC

-- Free up electrical wiring harness.

-- Remove ground connection -2-.

Fig 23: Identifying Engine Control Module (ECM) -J623- -1- And GND Wire Nut -2-

Courtesy of AUDI OF AMERICA, LLC

-- Remove the engine control module -1-, refer to ENGINE CONTROL MODULE .

-- 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 24: Pressing Out Upper Control Arm

Courtesy of AUDI OF AMERICA, LLC

-- Completely remove upper control arm nut.

-- Repeat procedure on opposite side of vehicle.

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

Fig 25: Identifying Speed Sensor Connector

Courtesy of AUDI OF AMERICA, LLC

-- Remove wiring harness bolts -arrows-.

Fig 26: Identifying Wire Harness Bolts

Courtesy of AUDI OF AMERICA, LLC

-- 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 27: Identifying Right/Left Lower Bolt On Stabilizer Bar

Courtesy of AUDI OF AMERICA, LLC

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

NOTE:

Bolts -1- are removed later.

-- Remove bolts -arrows- at drive shaft connection at rear of transfer case.

Fig 28: Identifying Bolts -Arrows- At Transfer Case/Rear Driveshaft Connection

Courtesy of AUDI OF AMERICA, LLC

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

-- Remove the noise insulation bracket -arrows-.

Fig 29: Identifying Bracket For Noise Insulation

Courtesy of AUDI OF AMERICA, LLC

Fig 30: Identifying Clamping Sleeves -1 And 2-

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

Risk of damaging decoupling elements.

Do not bent decoupling elements in front exhaust pipe more than 10°.

-- Disconnect exhaust system at clamping sleeves -1 and 2-.

-- Remove exhaust system brackets -1 and 3- from longmember.

Fig 31: Identifying Bolts -1, 2, 3- On Main Catalytic Converter Brackets

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore -Item 2-.

Vehicles with a Manual Transmission:

Fig 32: Identifying Lower Engine/Transmission Bolts

Courtesy of AUDI OF AMERICA, LLC

-- If engine and transmission are to be separated after Removal engine/transmission assembly, remove lower bolts -arrows- from engine to transmission connection.

-- Disconnect electrical connector -arrow- at Back-Up Lamp Switch -F4-.

Fig 33: Removing Bolt

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolt -arrow-.

Fig 34: Removing Clutch Slave Cylinder

Courtesy of AUDI OF AMERICA, LLC

-- Remove clutch slave cylinder and secure sideways in engine compartment.

CAUTION:

Risk of damaging clutch slave cylinder.

Do not operate the clutch pedal anymore after slave cylinder has been removed.

Vehicles with Automatic Transmission:

Fig 35: Identifying ATF Lines And Bolt - Arrow -

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Observe the rules of cleanliness for working on automatic transmissions, refer to REPAIR INFORMATION .

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

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

-- Remove selector lever cable ball head -2- from selector shaft lever with Pry Lever 80-200.

Fig 36: Identifying Locking Washer & Selector Lever Cable

Courtesy of AUDI OF AMERICA, LLC

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

NOTE:

Do not bend or kink selector lever cable.

Fig 37: Turning Screw Connection Counter-Clockwise -Arrow-

Courtesy of AUDI OF AMERICA, LLC

CAUTION:

There is a risk of destroying the transmission control module (Mechatronic) with static discharge.

Do not touch contacts in transmission connector with hands.

-- To discharge static electricity, touch vehicle ground with hand (without gloves).

-- Turn the twist lock counter-clockwise -arrow- and disconnect the connector from the transmission.

-- If engine and transmission are to be separated after Removal engine/transmission assembly, remove ATF line -1- from transmission and remove lower bolts -arrows- in engine-transmission connection.

Fig 38: Identifying Lower Bolts -Arrows- For Engine To Transmission Connection

Courtesy of AUDI OF AMERICA, LLC

All vehicles:

Fig 39: Identifying Electrical Connector -Arrow- On Steering Gear

Courtesy of AUDI OF AMERICA, LLC

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

Fig 40: Identifying Universal Joint Bolt -Arrow-

Courtesy of AUDI OF AMERICA, LLC

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 -arrow- for the universal joint, refer to Removing .

-- Remove universal joint from steering gear.

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

Fig 41: Identifying Lock Carrier On Left Hydraulic Line -Arrow- To Left Power Steering Pump Cooler

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect left hydraulic line -arrow- to left power steering pump cooler at lock carrier.

NOTE:

Ignore Hose Clamps - Up To 25mm 3094.

-- Remove ground connection -1- from right longitudinal member.

Fig 42: Identifying Ground (GND) Cable On Longmember

Courtesy of AUDI OF AMERICA, LLC

Prepare Scissor Lift Platform:

Fig 43: Identifying Scissor Lift Platform VAS 6131

Courtesy of AUDI OF AMERICA, LLC

-- Equip Scissor Lift Table VAS6131 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

-- Next secure mounting elements to scissor lift table by hand.

Fig 44: Attach Mounting Elements From VAS 6131/10 And VAS 6131/11 At Front Of Subframe

Courtesy of AUDI OF AMERICA, LLC

-- Position the Scissor Lift Table VAS6131 horizontally.

Note bubble level (sight glass) on support platform.

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

-- Position the support elements from the Scissor Lift Table - Audi Set VAS6131/10 and Scissor Lift Table - A8 Set VAS6131/11 on the front on the door components carrier as illustrated.

-- Ensure threaded spindles are completely installed.

-- Attach mounting elements from theScissor 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 45: Attaching Mounting Elements From VAS 6131/10 And VAS 6131/13

Courtesy of AUDI OF AMERICA, LLC

-- 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 46: Attaching Mounting Elements From VAS 6131/13 On Struts

Courtesy of AUDI OF AMERICA, LLC

-- 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 47: Attach Mounting Elements From VAS 6131/10 At Rear Of Subframe

Courtesy of AUDI OF AMERICA, LLC

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

Fig 48: Attaching Mounting Elements From VAS 6131/10 At Left And Right On Transmission Carrier

Courtesy of AUDI OF AMERICA, LLC

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

-- Attach mounting element base plates to Scissor Lift Table VAS6131 and tighten to 20 Nm.

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

Fig 49: Identifying Bolts -4- And Engine Carrier Bolts -3-

Courtesy of AUDI OF AMERICA, LLC

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

-- Remove bolt -1- at left and right.

Fig 50: Identifying Right/Left Lower Bolt On Stabilizer Bar

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore -Item 2-.

Verify that all hoses and lines between engine/transmission subassembly and body have been disconnected.

To avoid damage, guide the engine/transmission subassembly carefully into the engine compartment when lowering.

Carefully guide suspension struts onto longitudinal members.

Vehicles with a manual transmission:

Fig 51: Identifying Dimension -a- Between Subframe And Body

Courtesy of AUDI OF AMERICA, LLC

-- Next lower engine/transmission subassembly with Scissor Lift Table VAS6131 only by dimension -a-.

Dimension -a- = 100 mm maximum.

-- Pry cable cover caps -1- upward.

Fig 52: Removing Lock Washers From Cable Bracket

Courtesy of AUDI OF AMERICA, LLC

-- Remove the lock washer -2- and remove the cable -3- from the pins -4- on the selector lever or shift relay lever.

-- Remove the lock washers -A- from the cable bracket -D-.

Fig 53: Removing Shifter Cable And Selector Lever Cable From Cable Bracket

Courtesy of AUDI OF AMERICA, LLC

-- Remove the shifter cable -B- and selector lever cable -C- from the cable bracket.

All Vehicles:

-- Lower engine/transmission assembly.

-- Remove the Scissor Lift Table VAS6131 with engine/transmission assembly from under the vehicle.