Engine, Removing

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 such as Step Ladder VAS5085
Engine Bung Set VAS6122
Scissor Lift Table VAS6131B with Scissor Lift Table - Audi Set VAS6131/10, Scissor Lift Table - A8 Set VAS6131/11, Scissor Lift Table - Q7 Set VAS6131/13 and Scissor Lift Table - Audi Set - Mounting Pin VAS6131/10-2 quantity: 3
Shop Crane - Drip Tray VAS6208
Hose Clip Pliers VAS6362
Locking Pin T10060A
Puller - Ball Joint T10187

Procedure

NOTE:

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

During installation, cable ties must be installed at the same location.

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

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

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CAUTION:

Risk of damaging electronic components when disconnecting the battery.

Complete the steps for disconnecting the battery.

-- Disconnect the Ground (GND) cable -4-. Refer to GROUND CABLE WITH Battery Monitoring Control Module -J367- FROM MY 09, REMOVING AND INSTALLING .

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

Fig 2: Locating Front/Rear Noise Insulation

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

Fig 3: Front Wheel Housing Liners And Fasteners

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-- Remove the rear driveshaft. Refer to REAR DRIVESHAFT .

Fig 4: Identifying Tunnel Support And Bolts

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NOTE:

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

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

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

Fig 5: Locating Lower Right Coolant Hose For Radiator

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-- Free up the coolant hose.

-- Open the clamps -1 and 2-, drain the coolant and then remove the coolant hoses from the coolant pipes.

Fig 6: Identifying Coolant Hose Clamps

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-- Open the clamps -arrows-, drain the coolant and remove the coolant hoses from the coolant pipes on the left longitudinal member.

Fig 7: Identifying Coolant Hose Clamps

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-- Open the clamp -1-, drain the coolant and remove the coolant hose from the coolant pipe on the lock carrier.

Fig 8: Identifying Coolant Hose And Clamp

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

-- Open the clamp and remove the hydraulic hose -2-.

-- Seal the open lines and connections with clean plugs from the Engine Bung Set VAS6122.

-- Remove the coolant hose from the engine oil cooler by loosening the hose clamp -arrow- and letting the coolant drain out.

Fig 9: Disconnecting Coolant Hose From Oil Cooler

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-- Remove the engine covers -1 and 2- upward.

Fig 10: Engine Cover

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CAUTION:

Danger of defects caused by dirt.

Follow the guidelines for cleanliness when working on the fuel supply system. Refer to FUEL SUPPLY, INJECTION SYSTEM AND CHARGING SYSTEM, CLEAN WORKING CONDITIONS .

-- Free up the fuel supply line in the center of the plenum chamber bulkhead.

Fig 11: Pushing Hose Coupling -2- On Fuel Line -Arrow A- And Then Pressing Release Buttons -Arrows B-

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WARNING:

Risk of injury from fuel.

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

-- Roll up the protective boot to disconnect the fuel supply line -1-.

-- Push the hose coupling -2- on the fuel line in direction of -arrow A- and then press the release buttons in direction of -arrows B-.

-- Remove the hose coupling with the release buttons pressed.

-- Unlock the brackets -3 and 4-, lay them on the engine and free up the fuel supply hose.

-- Press the release buttons and disconnect the hose -1- from the Evaporative Emission (EVAP) canister.

Fig 12: Identifying Brake Booster Vacuum Line -2- And EVAP Canister Hose -1-

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-- Disconnect the brake booster vacuum line -2-, free it up and lay it on the right side of the vehicle.

-- Remove the vacuum hose -1- from the air guide pipe connection.

Fig 13: Identifying Air Guide Pipe And Clamps

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

-- Remove coolant hoses by loosening the hose clamps -1 and 2-.

Fig 14: Identifying Coolant Hoses And Clamps

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-- Remove the connectors -1 through 4- from the bracket on the right suspension strut tower, disconnect them and free up the wires.

Fig 15: Identifying Electrical Connectors

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-- Open the clamps -1 and 2- and the clips -3- and then remove the coolant hoses.

Fig 16: Identifying Coolant Hose Clamps -1 And 2- And Clips -3-

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CAUTION:

Risk of damage due to reversed running direction on a used ribbed belt.

Before removing ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later.

-- To release the tension on the ribbed belt, swivel the tensioner clockwise in direction of -arrow- and then lock the tensioner using a Locking Pin T10060A.

Fig 17: Swivel Tensioner Clockwise -Arrow- And Then Lock Tensioner Using T10060 A

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-- Remove the ribbed belt from the Air Conditioning (A/C) compressor.

NOTE:

Place a cloth underneath to catch the draining hydraulic fluid.

-- Remove the banjo bolt -1-.

Fig 18: Power Steering Pump Pressure And Return Lines

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-- Loosen the hose clamp -2- and remove the power steering fluid hose.

-- Open the tab -4- and open the cover -5- in direction of -arrow-.

Fig 19: Opening Tab -4- And Open Cover -5- -Arrow-

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-- Remove the nut -3- and free up the B+ wire on the plenum chamber bulkhead.

NOTE:

Ignore items -1 and 2-.

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

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

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-- Remove gasket -5-.

CAUTION:

Danger of causing damage to the plenum chamber cover.

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 retainer on windshield.

-- Remove the bolts -arrows- and the engine compartment E-box plenum chamber.

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

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

Fig 22: Identifying Electrical Connectors -1 Through 3-

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-- Free up the wiring harness.

-- Remove the nut -2- and remove the GND wire.

Fig 23: Identifying 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 -J623-, REMOVING AND INSTALLING .

-- Free up the wiring harness.

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

Fig 24: Pressing Out Upper Control Arm

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-- Completely remove upper control arm nut.

-- Repeat procedure on opposite side of vehicle.

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

Fig 25: Identifying Speed Sensor Connector

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-- Remove wiring harness bolts -arrows-.

Fig 26: Identifying Wire Harness Bolts

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-- Remove brake caliper bolts -1-.

NOTE:

Do not change the shape of the brake lines.

-- Secure the brake caliper with the brake line still attached inside the 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

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

NOTE:

The bolts will be removed later.

-- Remove the bolts -arrows- and the noise insulation bracket.

Fig 28: Identifying Bracket For Noise Insulation

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-- Remove the nut -2- on the right longitudinal member and disconnect the GND wire.

Fig 29: Ground Connection On Right Longitudinal Member

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-- Press the release buttons and remove the hose -1- from the Secondary Air Injection Pump Motor -V101-.

-- Remove the bolts -1- and -arrows- and remove the right bracket -2- for the catalytic converter.

Fig 30: Identifying right bracket -2- And Bolts

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NOTE:

The bolt -1- is accessible from the top.

-- Remove the ball head -1- on the selector lever cable from the selector shaft lever using the Pry Lever 80-200.

Fig 31: Identifying Selector Lever Cable Ball Head -1- And Cable Mounting Bracket Bolt -2-

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-- Remove the bolt -2- and remove the cable mounting bracket from the transmission.

NOTE:

Do not bend or kink the selector lever cable.

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

Fig 32: 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 33: Steering Gear Heat Shield -A-

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CAUTION:

The airbag spiral spring could be damaged.

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 the bolt -B- for the universal joint.Tightening specifications: 35 Nm + 90° .

-- Remove universal joint from steering gear.

NOTE:

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

Fig 34: Identifying ATF Lines And Bolt - Arrow -

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

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

Fig 35: Connect Connectors -1 Through 3-

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Prepare Scissor Lift Platform

Fig 36: Identifying Scissor Lift Platform VAS 6131

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-- Equip the Scissor Lift Table VAS6131B with the 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	Components from the Scissor Lift Table - Audi Set VAS6131/10, Scissor Lift Table - A8 Set VAS6131/11 and Scissor Lift Table - Q7 Set VAS6131/13
B3	/10-1	/10-2	/10-5	/11-1
G3	/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
B13	/10-1	/10-3	/10-5	/10-7
G13	/10-1	/10-3	/10-5	/10-7

-- First manually secure the mounting elements to the scissor lift table.

-- Position the scissor lift table horizontally.

Note bubble level (sight glass) on support platform.

-- Guide the Scissor Lift Table VAS6131A under the engine/transmission subassembly.

Fig 37: Attach Mounting Elements From VAS 6131/10 And VAS 6131/11 At Front Of Subframe

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

-- Ensure threaded spindles are completely installed.

-- Attach mounting elements from Scissor Lift Table - Audi Set VAS6131/10 and Scissor Lift Table - Q7 Set VAS6131/13 on the engine support as shown in illustration.

Fig 38: Attaching Mounting Elements From VAS 6131/10 And VAS 6131/13

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

Fig 39: 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 rear on the subframe as shown in the illustration.

Fig 40: Attach Mounting Elements From VAS 6131/10 At Rear Of Subframe

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-- Position mounting elements Scissor Lift Table - Audi Set VAS6131/10 at the left and right on the transmission support as shown in the illustration.

Fig 41: Attaching Mounting Elements From VAS 6131/10 At Left And Right On Transmission Carrier

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

-- Attach mounting element base plates to Scissor Lift Table VAS6131B and tighten to 20 Nm.

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

Fig 42: Identifying Right/Left Lower Bolt On Stabilizer Bar

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NOTE:

The threaded connection -2- has already been disconnected.

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

Fig 43: 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 the engine/transmission sub-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 44: Lifting Engine/Transmission Subassembly Using Scissor Lift Platform VAS 6131 Until Dimension Is Reached

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Dimension -a- = 180 mm maximum.

-- Disconnect the connector -1- to the A/C Compressor Regulator Valve -N280-.

Fig 45: Connector For Wiring To Air Conditioning Compressor Clutch Solenoid & Compressor Mounting Bolts

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WARNING:

Refrigerant can cause serious personal injury.

Do not open the air conditioning refrigerant circuit.

-- Remove A/C compressor bolts -arrows-.

CAUTION:

Danger of damaging the refrigerant lines and hoses.

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

-- Remove the A/C compressor from the bracket and with the refrigerant lines still connected to the left longitudinal member, tie it up.

-- Lower the engine/transmission subassembly more.

-- Remove the Scissor Lift Table VAS6131B with engine/transmission assembly from under the vehicle.