Engine, Removing, Vehicles With Manual Transmission: Procedure

WARNING: This page is about a different car, the 2012 Audi S5, 2011 Audi S5, 2010 Audi S5, 2009 Audi S5, and 2008 Audi S5. However, it is still accessible from the selected car via links, so may be relevant.

WARNING:

Risk Of Vehicle Tipping Over With Engine Removed.

Secure Vehicle. Luggage Compartment Must Be Empty For This.

There Is A Risk Of Injury Because The Fuel Is Under Very High Pressure.

Reduce The Fuel Pressure Down To Residual Pressure Before Opening High Pressure Area Of The Fuel Injection System.

-- Reduce The Fuel Pressure In The High Pressure Area. Refer To BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

NOTE:

Release The Electrical Parking Brake Before Disconnecting Battery So The Driveshaft Can Be Rotated To Remove It.

-- Position The Front Wheels So They Are Straight.

CAUTION:

Danger Of Causing Damage To Electronic Components.

Complete The Steps For Disconnecting The Battery.

-- Turn Off The Ignition And Remove The Key.

-- Disconnect The Battery Ground (GND) Cable -2-. Refer to BATTERY, DISCONNECTING AND CONNECTING .

Fig 1: Identifying Battery

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-- Discharge The Refrigerant Circuit. Refer to REFRIGERANT CIRCUIT, DISCHARGING / REFRIGERANT CIRCUIT, DISCHARGING WITH A/C SERVICE STATION .

-- Extract The Power Steering Oil From The Reservoir With The :SMN372500 .

-- Remove The Engine Cover In Direction Of -arrows-.

Fig 2: Identifying Engine Cover

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Fig 3: Coolant Reservoir for Audi Q5

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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.

-- Remove The Left And Right Front Wheels. Refer To WHEEL, CHANGING AND MOUNTING .

-- Remove The Left And Right Front Wheel Housing Liners. Refer To WHEEL HOUSING LINER .

-- Remove The Noise Insulation -1 and 2-. Refer to NOISE INSULATION, REMOVING AND INSTALLING .

Fig 4: Automatic Transmission Fluid Oil Pan

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-- Place the :VAS6208 under engine.

Fig 5: Identifying Drain Plug -Arrow- On Front Coolant Hose

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-- Remove the drain plug -arrow- on the front coolant hose and drain the coolant.

-- Remove the drain plug -arrow- on the Map Controlled Engine Cooling Thermostat -F265- and drain the coolant.

Fig 6: Identifying Drain Plug -Arrow- On Map Controlled Engine Cooling Thermostat -F265-

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-- Disconnect the coolant hose from the radiator, to do this, lift the retaining clip -2-.

Fig 7: Identifying Coolant Hose And Spring Clip

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NOTE:

Ignore items -1, 3 and 4-.

-- Disconnect the vacuum hose -1- and free up the hydraulic hose -arrow- on the bracket.

Fig 8: Disconnect Vacuum Hose And Lay Hydraulic Oil Hose To Side

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-- Remove the nuts -2- and vacuum reservoir.

-- Place the :SMN372500 under the separating point.

Fig 9: Identifying Power Steering Hydraulic Oil Feed Line -2- & Return Line -1-

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-- Disconnect the power steering hydraulic oil feed line -2- and return line -1-.

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

Fig 10: Identifying Bolts & Refrigerant Lines To A/C Compressor

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CAUTION:

Risk Of Damaging Refrigerant Lines And Hoses.

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

-- Remove the bolts -1 and 2-.

-- Disconnect the refrigerant lines from the compressor.

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

-- Remove the nut -arrow- on the right longitudinal member and free up the GND wires.

Fig 11: Disconnecting Ground Wires -Arrow- From Right Longitudinal Member

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NOTE:

Ignore item -1-.

-- Disconnect the connector -2-.

-- Place the :VAS6208 under engine.

-- Remove the coolant hoses from the After-Run Coolant Pump -V51- -arrows-.

Fig 12: Identifying Coolant Hoses -Arrows

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NOTE:

Ignore item -2-.

-- Disconnect the connector -3- on the Secondary Air Injection Pump Motor -V101-.

-- Remove the secondary air injection hose -1- and free it up.

Fig 13: Component Location Of Secondary Air Injection (AIR) Pump Motor -V101-

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

Fig 14: Identifying Coolant Fan Electrical Connectors -1 And 2-

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-- Free up the wiring harness.

-- Remove the left and right bolts -1- and nuts -3- and the lock carrier braces -2-.

Fig 15: Identifying Carrier Left Brace Components

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Fig 16: Disconnecting Fuel Line

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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.

CAUTION:

Follow The Guidelines For Cleanliness When Working On The Fuel Supply System. Refer to CLEAN WORKING CONDITIONS .

-- Disconnect The Fuel Line -arrow-.

-- Free up the fuel line and the line to the Evaporative Emission (EVAP) canister on the air guide pipe.

Fig 17: Disconnecting Electrical Connector -2- On EVAP Canister Purge Regulator Valve 1 -N80- & Disconnect Vacuum Hose -1-

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-- Disconnect the connector -2- on EVAP Canister Purge Regulator Valve 1 -N80- and disconnect the vacuum hose -1-.

-- Remove EVAP Canister Purge Regulator Valve 1 -N80- from bracket and lay aside with hose and fuel line connected.

-- Disconnect the vacuum hose leading to the Leak Detection Pump -V144- -arrow-.

Fig 18: Disconnecting Vacuum Hose Leading To Leak Detection Pump -V144- -Arrow-

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-- Remove the air duct -arrows-.

Fig 19: Identifying Air Duct

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-- Disconnect the connector -1- from the Mass Airflow Sensor -G70-.

Fig 20: Disconnecting Connector On Mass Airflow (MAF) Sensor

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-- Disconnect The Vacuum Line -3- From The Air Guide Pipe.

CAUTION:

Risk Of Violating Emissions Legislation On USA Vehicles.

Do not open hose connection -2- !

-- Lay aside air guide pipe with connected crankcase ventilation hose -2- by loosening hose clamp -4- and opening clips -arrows-.

-- Disconnect the vacuum line -1-.

Fig 21: Identifying Secondary Air System Components

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-- Remove the air filter housing and disconnect the electrical connector -2- on the rear side at the Intake Air Switch-Over Valve -N335-.

-- Remove hose -3- from the Secondary Air Injection (AIR) system.

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

Fig 22: Identifying Coolant Hose From Radiator And Right Coolant Pipe, Removal

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-- Disconnect electrical connector -1- for the Brake System Vacuum Pump -V192- and free up electrical wiring.

Fig 23: Disconnecting Vacuum Hose -2-

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-- Disconnect the vacuum hose -2-.

-- Remove the coolant hoses -1 and 3- from the coolant overflow reservoir.

Fig 24: Identifying Coolant Hose And Coolant Reservoir

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NOTE:

Ignore item -2- and -arrows-.

-- Remove the seal -arrow-.

Fig 25: Identifying Alarm Horn, Removal

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-- Remove The Plenum Chamber Cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING / OVERVIEW - PLENUM CHAMBER BULKHEAD .

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

Fig 26: Opening Terminal Box Cover

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-- Remove the nuts -1 and 2- for the electrical wires.

-- Disconnect the connectors -3 and 4-.

-- Remove the bolt -5- and the Terminal 30 Wire Junction 2 -TV22- from the tower brace in direction of -arrow-.

Fig 27: Identifying Nuts, Bolts & Connectors

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-- Release the retainers from the wheel housing side using a 5.5 mm wrench -1- and remove the wiring bushing -2- upward.

-- Free up the wiring harness -3- to the generator and starter using the :80-200 .

Fig 28: Release Retainers From Wheel Housing Side Using A 5.5 Mm Open End Wrench

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-- Free up the wiring duct by releasing the retainer in direction of -arrow B- and pulling the duct forward in direction of -arrow A-.

Fig 29: Freeing Up Wiring Duct By Releasing Retainer

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-- Remove the nut -1- and tilt the washer fluid filler neck upward in direction of -arrow A-.

-- Remove the filler neck -2- with the filler tube from the washer fluid reservoir and the opening in the body in direction of -arrow B-.

Fig 30: Identifying Filler Neck With Filler Tube From Washer Fluid Reservoir And Opening In Body

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-- Remove the bolts -1- and nuts -2- and the tower brace -3-. The procedure for doing this depends on the version.

Fig 31: Identifying Bolts, Nuts And Tower Brace

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

-- Remove the nut -1- and free up the wire.

Fig 32: Identifying E-Box Bolts & Cover

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-- Release the retainers in direction of -A arrows- and remove the Engine Control Module (ECM) in direction of -arrow B-.

Fig 33: Engine Control Module (ECM)

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-- Disconnect the connector -2-, if equipped.

-- Disconnect the connectors -4- and remove the nut -3- for the electrical wire.

-- Release the retainers in direction of -arrow- and remove the relay carrier with the fuse holder -1-.

Fig 34: Disconnect Electrical Connectors

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

-- Open the retainers in direction of -arrows A- and remove the wiring harness bushing -2- in direction of -arrow B-.

Fig 35: Disengaging Catches -Arrows A- And Remove Upper Part Of Line Pass-Through -2- Upward -Arrow B-

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-- Remove the GND pin -1- and free up the GND wire.

-- Lay the wiring harness on the engine and secure the ECM so that it cannot fall.

-- Mark and remove the coolant hoses -1 and 2- for re-installing.

Fig 36: Identifying Clamp -2- And Remove Coolant Hose

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-- Press the coolant hoses with hose guide in the engine compartment.

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

Fig 37: Identifying Speed Sensor Connector

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-- Disconnect the connector -1- Headlamp Range Control Sensor 1 -G233- electrical sensor -arrow- and free up electrical wiring.

Fig 38: Disconnect Electrical Connector On Left Front Level Control System Sensor

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-- Free up the electrical connector -2- on the bracket by pulling the retainer back in direction of -arrow A- and turning the connector approximately 90° in the direction of -arrow B-.

Fig 39: Free Up Electrical Connector

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-- Free up the electrical wiring -3- and brake line -4- on the bracket.

-- Remove the bolts -1- and secure the brake caliper, with the brake line still connected, inside the wheel housing using wire.

CAUTION:

Risk Of Damaging Brake Pistons.

Do Not Operate Brake Pedal With Brake Caliper Removed.

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

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

Fig 40: Disconnecting Upper Control Arm From Wheel Bearing Housing

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

Vehicles Through VIN 8T-8A-011200

Fig 41: Identifying Left And Right Bolts

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-- Remove the left and right stabilizer bar bolt -3-.

-- Remove the left and right nut -1-.

NOTE:

The Bolts -2- Will Be Removed Later.

Vehicles From VIN 8T-8A-011201

Fig 42: Identifying Left And Right Stabilizer Bar Bolt

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

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

NOTE:

The bolts -2- will be removed later.

Continuation For All Vehicles

Fig 43: Identifying Subframe Crossbrace

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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 Subframe Crossbrace. Refer to SUBFRAME, CROSSBRACE, DIAGONAL BRACE, STABILIZER BAR, COUPLING ROD AND SUBFRAME SHIELD OVERVIEW, FROM 09.2007 .

-- Remove the bolts -arrows- and the crossmember.

Fig 44: Identifying Bolts And Front Crossmember

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

Fig 45: Identifying Left Front Muffler Flange Nuts

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

Fig 46: Identifying Right Front Muffler Flange Nuts

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CAUTION:

The Decoupling Elements In The Front Muffler Could Be Damaged.

Do Not Bend Decoupling Elements In Front Muffler More Than 10°.

-- Loosen The Clamping Sleeves -1 And 2-, Slide Them Back And Remove The Left And Right Front Mufflers.

Fig 47: Clamps Vehicles With Dual Exhaust System

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-- Remove the bolts -arrows- and the driveshaft heat shield -1-.

Fig 48: Driveshaft Heat Shield

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-- Remove The Driveshaft From The Transmission. Refer to the appropriate service information .

Fig 49: Counterholding Driveshaft Using T10172 And T10172/5

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-- Slide The Driveshaft Toward The Rear Final Drive; The CV Joints Can Move Axially.

-- Secure The Driveshaft To The Side.

-- Remove The Steering Intermediate Shaft From The Steering Gear Push Them Upward. Refer To STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

Fig 50: Locating Steering Column Universal Joint Bolt

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-- Remove The Bolt -2- And Secure The Clutch Slave Cylinder Sideways In The Engine Compartment.

Fig 51: Identifying Bolt And Clutch Slave Cylinder Secured Sideways In Engine Compartment

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CAUTION:

Risk Of Damaging The Clutch Slave Cylinder.

Do Not Operate The Clutch Pedal Anymore After Slave Cylinder Has Been Removed.

-- Remove The Gearshift Rod Nut -1-.

-- Position the :T40160 and remove the gearshift rod -1-.

Fig 52: Position Puller T40160 And Remove Selector Rod

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Prepare Scissor Lift Platform

Fig 53: Identifying Scissor Lift Platform VAS 6131

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-- Equip the Scissor Lift Table:VAS6131B with Scissor Lift Table - Audi Set:VAS6131/10 and Scissor Lift Table - Q7 Set:VAS6131/13 as follows:

Platform Coordinates	Parts From :VAS6131/10 and :VAS6131/13
B4	/13-4	/10-4	/10-5	/13-1
G4	/13-4	/10-4	/10-5	/13-1
B6	/10-1	/10-2	/10-5	/10-11
G6	/10-1	/10-2	/10-5	/10-11
A8+C8	/13-6			/13-2
F8+H8	/13-6			/13-2
C14	/10-1	/10-3	/10-5	/10-13
F14	/10-1	/10-3	/10-5	/10-10

-- First Manually Secure The Mounting Elements To The Scissor Lift Table.

-- Position The Scissor Lift Table:VAS6131B Horizontally.

Note Bubble Level (Sight Glass) On Support Platform.

-- Guide The :VAS6131B Under The Engine/Transmission Subassembly.

Fig 54: Identifying Subframe Bolts

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WARNING:

The Subframe Could Cause An Accident If It Is Not Secured.

Do not loosen the subframe bolts -2 and 3-.

-- Remove The Left And Right Subframe Bolts -1-.

-- Attach Mounting Elements From The :VAS6131/10 And :VAS6131/13 At The Left And Right On The Front Of The Subframe As Shown In The Illustration.

Fig 55: Attach At Left And Right Front Of Subframe

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-- Ensure threaded spindles are completely installed.

-- Attach the mounting elements from the :VAS6131/10 at the left and right rear on the subframe crossbrace front connecting points as shown in the illustration.

Fig 56: Attach At Left And Right Front Of Subframe

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-- Position mounting elements from the :VAS6131/13 at the lower left and right on the wheel bearing housing as shown in the illustration.

Fig 57: Attach At Lower Left And Right Of Wheel Bearing Housing

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-- Remove the noise insulation retaining clips from the crossmember.

Fig 58: Attach At The Left And Right Rear Of The Crossmember As Shown In Illustration

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-- Attach mounting elements from the :VAS6131/10 at the left and right rear of the crossmember as shown in the illustration.

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

-- Attach mounting element base plates to : VAS6131B and tighten to 20 Nm.

NOTE:

Ignore item -1-.

-- Mark The Location Of The Subframe And Engine Carrier To The Longitudinal Members Using A Felt-Tip Pen.

-- Remove the left and right subframe bolts -2 and 3- in a diagonal sequence in stages.

Fig 59: Identifying Subframe Bolts

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-- Remove the bolts -arrows- and remove the tunnel crossmember.

Fig 60: Identifying Bolts & Tunnel Crossmember

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Vehicles Through VIN 8T-8A-011200

-- Remove the left and right bolts -2-.

Fig 61: Identifying Left And Right Bolts

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Vehicles From VIN 8T-8A-011201

Fig 62: Identifying Left And Right Stabilizer Bar Bolt

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-- Remove the left and right bolts -2-.

Continuation For All Vehicles

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.

-- Next lower engine/transmission subassembly with :VAS6131B only by dimension -a-.

Fig 63: Engine And Gearbox Jack VAS 6931

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Dimension -a- = 100 mm maximum.

-- Remove the bolts -1 and 3- for the gearshift rod and push rod.

Fig 64: Attaching Bolts And For Selector Rod And Push Rod

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NOTE:

Ignore item -2-.

-- Lower The Engine/Transmission Subassembly More.

-- Remove The :VAS6131B With Engine/Transmission Assembly From Under The Vehicle.