Engine, Removing

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.

NOTE:

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

Drained coolant must be stored in a clean container for disposal or reuse.

All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

Special tools and workshop equipment required

Pry Lever 80-200
Used Oil Collecting and Extracting Device VAG 1782
Step Ladder VAS 5085
Engine Bung Set VAS 6122
Scissor Lift Table VAS 6131 A with Support Set VAS 6131/10 as well as Supplementary Set VAS 6131/11, VAS 6131/13 and qty. 3 VAS 6131/10-2
Drip Tray for Workshop Crane VAS 6208
Hose Clamp Pliers VAS 6362
Counterhold Tool T10172 with T10172/8
Ball Joint Puller T10187

Procedure

-- 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 area of the fuel injection system, fuel pressure must be relieved to residual pressure.

-- Reduce fuel pressure in high pressure area. Refer to FUEL PRESSURE TEST .

CAUTION:

Risk of destroying electrical components.

Observe measures when disconnecting battery.

NOTE:

So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted.

Place the selector lever in the "N" position and release the electromechanical parking brake before disconnecting the battery so that the driveshaft can still move freely.

-- Position driver's seat as far back and up as possible using the full seat adjustment range.

Fig 1: Identifying Cover -1-

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-- Switch off ignition.

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

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

-- Pry the cover -1- out of the floor covering using a 80 - 200.

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

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-- Raise the floor covering -2- slightly in the Ground (GND) cable area.

-- Remove nut -3- and remove GND cable -4- from Ground point.

-- Discharge refrigerant circuit. Refer to REFRIGERANT CIRCUIT, DISCHARGING WITH SERVICE STATION .

-- Extract power steering fluid from the reservoir using the VAG 1782.

WARNING:

Risk of scalding due to hot steam and hot coolant.

When the engine is warm the cooling system is under pressure.
To reduce pressure, cover coolant reservoir cap with cloth and carefully open.

-- Open the cap on the coolant reservoir.

-- Remove both front wheels.

-- Remove screws and remove front -1- and rear -2- noise insulation.

Fig 3: Locating Front/Rear Noise Insulation

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-- Remove left and right front wheel housing liners. Refer to FRONT WHEEL HOUSING LINERS, REMOVING AND INSTALLING .

-- Place VAS 6208 under engine.

-- Remove drain plug -1- on map controlled engine cooling thermostat -F265- and allow coolant to drain.

Fig 4: Identifying Drain Plug At Coolant Thermostat Housing

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NOTE:

Ignore item -2-.

-- Remove drain plug -arrow- at front coolant pipe and drain coolant.

Fig 5: Identifying Drain Plug At Front Coolant Pipe

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-- Lift the clamp to remove the lower coolant hose -arrow- and let the coolant drain.

Fig 6: Identifying Lower Right Coolant Hose For Radiator

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

Fig 7: Identifying Coolant Hose Clamps

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-- Pull rear engine cover off -arrows-.

Fig 8: Removing Rear Engine Cover

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-- Pull front engine cover off -arrows-.

Fig 9: Removing Front Engine Cover

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-- Remove cover over radiator -arrows-.

Fig 10: Cover Over Radiator -Arrows-

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-- Disconnect coolant hose -1-.

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

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-- Disconnect vacuum hose -2- to Evaporative Emission (EVAP) canister purge regulator valve 1 -N80- by pressing release button.

-- Free up vacuum hose.

WARNING:

Risk of injury from fuel.

To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.

-- Disconnect fuel supply line -3- at distribution piece.

-- Disconnect electrical connector -2- at Mass Airflow (MAF) sensor 2 -G246-.

Fig 12: Locating Electrical Connector, Air Guide Hose, And Retaining Clips

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-- Remove left air guide hose -1- from air duct.

-- Release retaining clips -3- and remove upper left section of air filter housing.

-- 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.

NOTE:

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

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

Fig 14: Identifying Hose For Power Steering Fluid Reservoir

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-- Separate the electrical connector -1-.

Fig 15: Identifying Refrigerant Lines From A/C Compressor

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CAUTION:

Risk of damaging coolant lines and hoses.

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

-- Remove refrigerant lines -2 and 3- from Air Conditioning (A/C) compressor.

-- Seal open lines and connections with clean plugs from the VAS 6122 to prevent dirt and moisture from entering.

-- Disconnect electrical connector -1- at Engine Coolant Temperature (ECT) sensor on radiator outlet -G83-.

Fig 16: Identifying Engine Coolant Temperature (ECT) Sensor (On Radiator) G83 And Upper Coolant Hose Connection

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-- Lift the retaining clip -2- and remove the upper coolant hose from the radiator.

-- Remove coolant hose -arrow- to radiator from right coolant pipe.

Fig 17: Identifying Quick Coupling On Upper Cooler And Lower Hose On Coolant Pipe

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-- Remove air guide hose -arrow- from connecting hose to Secondary Air Injection (AIR) combi-valves.

Fig 18: Identifying Air Guide Hose

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-- Unclip front differential breather line -arrow- from brake system vacuum pump -V192-.

Fig 19: Identifying Transmission Ventilation Hose

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-- Disconnect hose -1- to Secondary Air Injection (AIR) pump.

Fig 20: Identifying Hose To Secondary Air Injection Pump, Electrical Harness Connector, Right Air Guide Hose, And Retaining Clips

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-- Disconnect electrical harness connector -4- at Mass Airflow (MAF) sensor -G70-.

-- Remove right air guide hose -3- from air duct.

-- Release retaining clips -2- and remove upper right section of air filter housing from lower section.

Vehicles with Air Suspension

NOTE:

If necessary, remove electrical connector for Heated Oxygen Sensor (HO2S) 2 -G108- from bracket at right strut tower for better access.

-- Press circlip -1- forward from hose coupling.

Fig 21: Circlip, Release Ring And Ventilation Hose

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-- Press release ring -2- down -arrows- and remove vent hose -3- from upper section of air filter.

All Vehicles

-- Remove coolant hose -arrow- from coolant reservoir.

Fig 22: Coolant Hose

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-- Disconnect vacuum hose -arrow- to suction jet pump.

Fig 23: Identifying Vacuum Hose To Suction Jet Pump

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-- Remove electrical connectors -1 to 4- from bracket on right strut tower.

Fig 24: Identifying Electrical Connectors

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-- Disconnect electrical connectors and free up electrical lines.

-- Remove the windshield wiper arms -1 and 3-. Refer to WINDSHIELD WIPER ARMS SYSTEM .

Fig 25: Identifying Removal Of Windshield Wiper Arm -1- And -3-

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-- Remove rubber seal -5- and remove plenum chamber cover -4-.

CAUTION:

The plenum chamber cover could be damaged.

To prevent the cowl grille -2- from tearing when removing, coat the transition between the windshield and cowl grille with soapy water and pull the grille up vertically out of the fastening strip starting at the edge of the window.

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

-- Remove cover for E-Box in plenum chamber -arrows-.

Fig 26: Identifying Bolts To E-Box Plenum Chamber Cover -Arrows-

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-- Disconnect electrical connectors -1 to 3- at E-box plenum chamber connector station.

Fig 27: Identifying Electrical Connectors -1 Through 3-

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-- Free up the wiring harness.

-- Remove Ground (GND) connection -2-.

Fig 28: Engine Control Module (ECM) -J623- -1- And GND Wire Nut -2-

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-- Remove Engine Control Module (ECM) -1-. Refer to Engine Control Module (2007 MY)

-- Free up electrical wiring harness to engine.

-- Remove bolts -arrows- and remove partition at left rear in engine compartment.

Fig 29: Identifying Screws -Arrows- And Partition At Left Rear In Engine Compartment (2 Of 2)

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-- Remove bolts -arrows- and remove partition at right rear in engine compartment.

Fig 30: Identifying Screws -Arrows- And Partition At Left Rear In Engine Compartment (1 Of 2)

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

Fig 31: Pressing Out Upper Control Arm

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-- 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 32: Identifying Speed Sensor Connector

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-- Remove wiring harness bolts -arrows-.

Fig 33: 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 34: 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.

-- Remove bolts -arrows- at transfer case/rear driveshaft connection.

Fig 35: Identifying Bolts -Arrows- At Transfer Case/Rear Driveshaft Connection

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-- Counter hold with the T10172 with T10172/8.

Fig 36: Counterholding With T10172 With T10172/8

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

-- Remove bracket for noise insulation -arrows-.

Fig 37: Identifying Bracket For Noise Insulation

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CAUTION:

Danger of damaging the decoupling element.

Decoupling element must not be bent more than 10°.
Do not load decoupling element on cable.
Do not damage wire mesh at decoupling element.

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

Fig 38: Identifying Double Pipe Clamps Between Catalytic Converter/Front Muffler

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-- Remove exhaust system bracket at left and right from longitudinal members -arrows-.

Fig 39: Identifying Exhaust System Bracket At Left And Right From Longitudinal Members -Arrows-

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-- Remove selector lever cable heat shield -arrows-.

Fig 40: Identifying Selector Lever Cable Heat Shield/Ball Head

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-- Press the selector lever cable ball head -2- off the selector shaft lever using the 80 - 200.

Fig 41: Identifying Locking Washer & Selector Lever Cable

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

NOTE:

Do not bend or kink selector lever cable.

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

Fig 42: Identifying Electrical Connector -Arrow- On Steering Gear

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-- Remove heat shield -A- from steering gear.

Fig 43: Identifying Steering Gear Heat Shield -A-

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CAUTION:

Separate universal joint from steering gear only when front wheels are in straight ahead position.
Do not change steering wheel position and steering gear position any more, secure steering wheel with adhesive tape.

-- Remove universal joint bolt -B-. .

-- Press universal joint off of steering gear.

-- Place the VAG 1782 under the engine.

Fig 44: Identifying Hydraulic Line Hose

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-- Disconnect hydraulic line -1- to power steering cooler at left of lock carrier.

NOTE:

Ignore item -2-.

NOTE:

Observe the rules of cleanliness for working on automatic transmissions. Refer to INFORMATION ON 6-SPEED AUTOMATIC TRANSMISSION 09D .

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

Fig 45: Identifying ATF Lines And Bolt - Arrow -

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-- Remove Ground (GND) connection -1- from right longitudinal member.

Fig 46: Identifying Ground (GND) Cable On Longmember

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-- Disconnect electrical connectors -1 to 3- for automatic transmission 09D.

Fig 47: Connect Connectors -1 Through 3-

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To separate engine from transmission after remove engine/transmission assembly:

-- Remove ATF line -1- from transmission.

Fig 48: Identifying Engine Speed (RPM) Sensor G28 And ATF Line

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-- Remove the 3 lower engine/transmission connection bolts -2 to 4-.

Prepare scissor lift platform:

Fig 49: Identifying Scissor Lift Platform VAS 6131

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-- Equip VAS 6131 with VAS 6131/10 as well as VAS 6131/11 and VAS 6131/13 as follows:

Platform coordinates	Parts from Support SetVAS 6131/10, Supplementary Set VAS 6131/11 and VAS 6131/13
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

-- Install attachments on scissor lift table by hand first.

-- Place scissor lift platform VAS 6131 in horizontal position.

Fig 50: Attach Mounting Elements From VAS 6131/10 And VAS 6131/11 At Front Of Subframe

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Note bubble level (sight glass) on support platform.

-- Guide scissor lift table under engine/transmission assembly.

-- Position the support elements from the VAS 6131/10 and VAS 6131/11 on the front of the subframe as illustrated.

-- Make sure that the threaded spindles are completely screwed in.

-- Position the support elements from the VAS 6131/10 and VAS 6131/13 on the engine carrier as illustrated.

Fig 51: Attaching Mounting Elements From VAS 6131/10 And VAS 6131/13

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-- Position the support elements from the VAS 6131/13 on the suspension struts as illustrated.

Fig 52: Attaching Mounting Elements From VAS 6131/13 On Struts

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-- Position the support elements from the VAS 6131/10 on the rear of the transmission as illustrated.

Fig 53: Attach Mounting Elements From VAS 6131/10 At Rear Of Subframe

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-- Position the support elements from the VAS 6131/10 on the left and right of the subframe as illustrated.

Fig 54: Attaching Mounting Elements From VAS 6131/10 At Left And Right On Transmission Carrier

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-- Twist spindles of attachments upward far enough until all support pins make contact at support points.

-- Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131.

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

Fig 55: Identifying Right/Left Lower Bolt On Stabilizer Bar

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NOTE:

The threaded connection -2- has already been disconnected.

-- Mark installation position of subframe, engine carrier and transmission carrier to longitudinal members using a felt-tip marker.

Fig 56: Subframe, Engine Carrier, Crossmember And Bolts

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-- Remove bolts -1 to 4- in diagonal sequence and in stages.

NOTE:

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

While lowering, carefully guide engine/transmission assembly out of engine compartment in order to prevent damage.

Carefully guide suspension struts onto longitudinal members.

-- Lower engine/transmission subassembly downward.

-- Push VAS 6131 with engine/transmission subassembly under vehicle.