Engine, Removing

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

NOTE:

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

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

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

Special tools and workshop equipment required

Pry Lever - Rmv Outside Mirror 80 - 200
Oil Collecting and Extracting Device V.A.G 1782
Step Ladder VAS 5085
Engine Bung Set VAS 6122
Scissor Lift Table VAS 6131 A with Support Set VAS 6131/10 and Supplementary Set VAS 6131/11 and VAS 6131/13
Drip Tray for VAS 6100 VAS 6208
Hose Clip Pliers VAS 6362

Procedure

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 the high pressure area of the fuel injection system.

-- Reduce fuel pressure in high pressure area. Refer to General Information .

-- Position the front wheels so they are straight.

NOTE:

Release the electro-mechanical parking brake before disconnecting the battery so the drive axle can be rotated to remove it.

Fig 1: Identifying Battery

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CAUTION:

Risk of destroying electrical components.

Observe measures for disconnecting battery.

-- Turn off the ignition and remove the key.

-- Disconnect the Ground (GND) cable -2- from the battery post. Refer to BATTERY .

-- Empty coolant circuit. Refer to the appropriate service information .

Vehicles with Hydraulic Power Steering

Fig 2: Identifying Reservoir Bracket To Body

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-- Extract the power steering fluid from the power steering reservoir using the V.A.G 1782 -3-.

NOTE:

Ignore -1, 2 and 4-.

All Vehicles

Fig 3: Engine Cover -1- And -2-

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

Fig 4: Identifying Coolant Reservoir Marking

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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 in the system.

-- Open the coolant reservoir cap.

-- Remove the left and right front wheels. Refer to WHEELS AND TIRES .

Fig 5: Identifying Noise Insulation

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

-- Remove the noise insulation -1 and 2-. Refer to NOISE INSULATION .

-- Place VAS 6208 under engine.

Fig 6: Identifying Drain Plug And Draining Coolant

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-- Remove the drain plug -1- and drain the coolant.

-- Lift the clip -2- and disconnect the coolant hose from the radiator.

-- Loosen the hose clamp -arrow-, remove the coolant hose from the oil cooler and drain the coolant.

Fig 7: Disconnecting Coolant Hose From Oil Cooler

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NOTE:

The engine is not shown in the following illustrations.

Vehicles with Left Front Coolant Pipes, Version 1

Fig 8: Identifying Hose Clamps -1 And 3- & Left Front Coolant Hose

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-- Loosen the hose clamps -1 and 3-, remove the left front coolant hoses from the coolant pipes and drain any remaining coolant.

NOTE:

Ignore -2-.

Vehicles with Left Front Coolant Pipes, Version 2

Fig 9: Locating Lower Coolant Pipe Bolt

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-- Loosen the clamps -arrows-, drain any remaining coolant and then remove the coolant hoses from the left front coolant pipes.

NOTE:

Ignore -1-.

All Vehicles

Fig 10: Charge Air Cooling Pump -V188-, Tightening Specifications

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-- Disconnect and free up the connector -3- on the charge air cooling pump -V188-.

NOTE:

Ignore -1 and 2-.

Vehicles with Hydraulic Power Steering

Fig 11: Disconnecting Power Steering Hydraulic Oil Supply Line

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-- Place the V.A.G 1782 under the disconnection point.

-- Disconnect the power steering hydraulic oil supply line -2- and return line -1- in the left front wheel housing and free them up.

-- Seal any open lines and connections with a clean plug from the VAS 6122.

All Vehicles

Fig 12: Identifying ATF Line Bracket

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-- Place the V.A.G 1782 under the disconnection point.

-- Mark the locations of the ATF lines -1 and 2- so they can be installed later and then disconnect them.

-- Seal any open lines and connections with a clean plug from the VAS 6122.

NOTE:

Ignore -arrow-.

Vehicles with Coolant Recirculation Pump -V50-, Version 1

Fig 13: Identifying Coolant Recirculation Pump Components

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-- Disconnect the connector -2-.

-- Place the VAS 6208 under the engine.

-- Loosen the hose clamp -1- and remove the coolant hose from the coolant recirculation pump.

NOTE:

Ignore -3 and 4-.

All Vehicles

Fig 14: Freeing Up Electrical Wiring Harness

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-- Disconnect the radiator fan electrical connectors -1 and 2-, to do this, push the clamp to the rear -arrow- and push the release down.

-- Free up the wiring harness.

Vehicles with Secondary Air Injection (AIR) Pump Motor -V101-, Version 1

Fig 15: Component Location Of Secondary Air Injection (AIR) Pump Motor -V101-

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-- Disconnect the connector -3- on the AIR pump motor.

-- Press the release buttons and remove the secondary air hose -1-.

NOTE:

Ignore -2-.

Vehicles with Secondary Air Injection (AIR) Pump Motor -V101-, Version 2

Fig 16: Identifying Secondary Air Injection (AIR) Pump Motor Components

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-- Disconnect the connector -2- on the AIR pump motor.

-- Press the release buttons and remove the secondary air hose -1-.

NOTE:

Ignore -3-.

All Vehicles

Fig 17: Identifying Carrier Left Brace Components

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-- Remove the left and right bolt -1- and nut -3- and the lock carrier brace -2-.

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

Fig 18: Disconnecting Ground Wires -Arrow- From Right Longitudinal Member

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-- Remove the seal from the plenum chamber bulkhead.

Fig 19: Identifying Plenum Chamber Cover

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-- Remove the plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

-- Remove the air duct -arrows-.

Fig 20: Identifying Air Duct

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-- Free up the fuel hose -1- and the EVAP canister hose -2- on the air duct pipe.

Fig 21: Identifying Air Duct Pipe

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-- Remove the vacuum hose -3- from the air guide pipe connection.

-- Remove the air guide pipe by loosening the hose clamp -4- and opening the clips -arrows-.

-- Remove the air filter housing and where equipped, disconnect the connector -arrow- on the intake air switch-over valve -N335-.

Fig 22: Identifying Intake Air Switch-Over Valve Connector

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-- Disconnect the vacuum connection -2- from the plenum chamber bulkhead. Remove the vacuum hose -1- on the back.

Fig 23: Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80- -3- Connector

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-- Disconnect the connector -3- on Evaporative Emission (EVAP) canister purge regulator valve 1 -N80- and disconnect the vacuum hose -4-.

-- Disengage the EVAP canister purge regulator valve 1 from the bracket and lay it aside with the hoses connected.

-- Disconnect the vacuum hose leading to the leak detection pump -V144- -arrow-.

Fig 24: Identifying Leak Detection Pump Vacuum Hose

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All Vehicles

Fig 25: Identifying Fuel Supply Hose

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WARNING:

Risk of injury from fuel.

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

CAUTION:

There is a risk of contamination.

Follow the guidelines for cleanliness when working on the fuel supply system. Refer to CLEAN WORKING CONDITIONS .

-- Remove the fuel supply line from the high pressure pump -arrow- and lay it aside.

-- Seal any open lines and connections with a clean plug from the VAS 6122.

Vehicles with Version 1

Fig 26: Identifying Coolant Hose Clamp

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-- Lift the clamp -arrow- and remove the coolant hose leading to the back of the heater core on the engine.

NOTE:

To provide a better illustration, component location is shown from behind with engine removed.

-- Remove the vacuum hose -1- for the climatronic refrigerant shut-off valve -N422-.

Fig 27: Disconnecting Connector & Vacuum Hoses

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NOTE:

Ignore -2 and 3-.

Vehicles with Version 2

Fig 28: Identifying Version 2 Cylinder Bank 1 (Right)

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WARNING:

Risk of injury from fuel.

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

CAUTION:

There is a risk of contamination.

Follow the guidelines for cleanliness when working on the fuel supply system. Refer to CLEAN WORKING CONDITIONS .

-- Press the release buttons and disconnect the fuel hose -1-.

-- Seal any open lines and connections with a clean plug from the VAS 6122.

NOTE:

Ignore -arrows-.

-- Lift the clamp -2- and remove the coolant hose leading to the heater core on the plenum chamber bulkhead.

Fig 29: Identifying Coolant Hose Clamps

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NOTE:

Ignore -1-.

All Vehicles

Fig 30: Identifying Clamp And Right Front Coolant Hose -Arrow- To Front Coolant Pipe

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-- Open the clamp and remove the right front coolant hose -arrow- from the front coolant pipe.

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

Fig 31: Engine Coolant Temperature (ECT) Sensor -G62- Location

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NOTE:

Ignore -1 and 2-.

-- Lift the clamp -arrow- and remove the coolant hose from the front coolant pipe

Fig 32: Identifying Coolant Hose From Front Coolant Pipe By Lifting Retaining Clamp

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Vehicles with Hydraulic Power Steering

Fig 33: Identifying Coolant Overflow Reservoir

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

-- Remove the bolts -arrows-, disconnect the connector on the engine coolant level warning switch -F66- and remove the coolant reservoir.

-- Disconnect the connector -arrow- from the power steering pump, if applicable.

Fig 34: Disconnecting Connector -Arrow- From Power Steering Pump

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-- Press the hydraulic hose down slightly.

All Vehicles

Fig 35: Identifying Bolts

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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 -arrows- and the refrigerant lines from the Air Conditioning (A/C) compressor.

-- Seal any open lines and connections with a clean plug from the VAS 6122.

-- Release the retainer -arrow A- and open the cover -arrow B-.

Fig 36: Opening Terminal Box Cover

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-- Remove the nuts -1- from the electric wires.

Fig 37: Identifying Terminal Box Wire Components

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-- Remove the electrical connector -2- from the bracket and disconnect it.

-- Remove the bolt -3- and the terminal 30 wire junction 2 -TV22- from the tower brace -arrow-.

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

Fig 38: Releasing Retainers From Wheel Housing Side Using A 5.5 Mm Open End Wrench

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

-- Wiring duct version 1: Free up the wiring harness by releasing the retainer -arrow B- and pulling the duct forward -arrow A-.

Fig 39: Freeing Up Wiring Duct By Releasing Retainer

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-- Wiring duct version 2: Open the catch -arrow-, free up the wiring harness and open the wiring duct -1-.

Fig 40: Freeing Up Wiring Harness And Open Wiring Duct

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-- Remove the nut -1- and tilt -arrow A- the washer fluid reservoir filler neck -2- upward slightly.

Fig 41: Identifying Filler Neck With Filler Tube From Washer Fluid Reservoir And Opening In Body

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

-- Remove the bolts -1- and nuts -2- and remove the tower brace -3-.

Fig 42: Identifying Bolts, Nuts And Tower Brace

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

Fig 43: Identifying E-Box Bolts & Cover

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

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

Fig 44: Engine Control Module (ECM)

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-- Disconnect the connector -2- if applicable.

Fig 45: Disconnecting Electrical Connectors

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

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

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

-- Release the retainers -A arrows- and remove the wiring bushing -2- upward -arrow B-.

Fig 46: Disengaging Catches -Arrows A- And Remove Upper Part Of Line Pass-Through -2- Upward -Arrow B-

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-- Remove the ground pin -1- and free up the wiring harness.

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

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

Fig 47: Identifying Speed Sensor Connector

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-- Disconnect the connector -1- from the left front level control system sensor -G78- and from the right front level control system sensor -G289- and free up the wires -arrow-.

Fig 48: Disconnecting 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 -arrow A- and turning the connector approximately 90° clockwise -arrow B-.

Fig 49: Freeing 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 when the brake caliper is removed.

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

Fig 50: Identifying Nut And Bolt

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

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

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

Fig 51: Identifying Left And Right Stabilizer Bar Bolt

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

NOTE:

The bolts -2- will be removed later.

-- Remove the subframe cross brace. Refer to OVERVIEW - SUBFRAME .

Fig 52: Locating Power Steering Hydraulic Line

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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 cross brace are not installed correctly.

Audi A5 Cabriolet

Fig 53: Identifying Clamping Sleeve

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-- Remove diagonal braces. Refer to the appropriate Service Information .

Vehicles with Electro-Mechanical Power Steering

Fig 54: Identifying Power Steering Control Module

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-- Release the safety catch -arrow-, push the retainer down and disconnect the connector from -2- from the power steering control module -J500-.

-- Free up the wiring harness.

NOTE:

Ignore -1-.

All Vehicles

Fig 55: Locating Left Bolts & Heat Shield

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

-- Remove the bolts -arrows- and the front crossmember, if applicable.

Fig 56: Identifying Bolts And Front Crossmember

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

Fig 57: Identifying Left Front Muffler Nuts

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

Fig 58: Identifying Right Front Muffler Nuts

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Fig 59: Identifying Bolts Vehicles With Dual Exhaust System

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CAUTION:

The decoupling elements in the front muffler could be damaged.

Do not bend decoupling element in front muffler more than 10°.

-- Loosen the clamping sleeves -1 and 2-, slide them back and remove the left and right front mufflers.

Vehicles with a Bolted Driveshaft

Fig 60: Counterholding Driveshaft Using T10172 And T10172/5

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-- Remove the driveshaft from the transmission. Refer to the appropriate service information .

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

-- Secure the driveshaft to the side.

Vehicles with an Attached Driveshaft

-- Remove the driveshaft. Refer to the appropriate service information .

All Vehicles

Fig 61: Locating Universal Joint Bolt

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-- Remove the steering intermediate shaft from the steering gear push them upward. Refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

Prepare Scissor Lift Platform

Fig 62: Identifying Scissor Lift Platform VAS 6131

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-- Equip the VAS 6131 A with the VAS 6131/10, VAS 6131/11 and VAS 6131/13 as follows:

Table Coordinates	Parts from VAS 6131/10, VAS 6131/11 and VAS 6131/13
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	/10-4	/10-5	/10-7
F14	/10-1	/10-4	/10-5	/11-1

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

-- Position the VAS 6131 A horizontally.

Note bubble level (sight glass) on support platform.

-- Move the VAS 6131 A under the engine/transmission subassembly.

Fig 63: Identifying Subframe Bolts (Tighten To Specifications)

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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 the mounting elements from the VAS 6131/10 and VAS 6131/13 at the left and right front of the subframe as shown in the illustration.

Fig 64: Attaching Mounting Elements At Left And Right Front Of Subframe

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-- Ensure threaded spindles are completely installed.

-- Attach the mounting elements from the VAS 6131/10 at the left and right rear on the subframe cross brace front connecting points as shown in the illustration.

Fig 65: Attaching VAS 6131/10 At Left And Right Rear On Subframe Crossbrace Front Connecting Points

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-- Attach mounting elements from the VAS 6131/13 at the lower left and right of the wheel bearing housing as shown in the illustration.

Fig 66: Attaching Mounting Elements From VAS 6131/13 At Lower Left And Right Of Wheel Bearing Housing

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-- Attach the mounting elements from the VAS 6131/10 and VAS 6131/11 at the left and right rear of the tunnel crossmember as shown in the illustration.

Fig 67: Attaching VAS 6131/10 And VAS 6131/11 At Left And Right Rear Of Tunnel Crossmember

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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 VAS 6131 A and tighten to 20 Nm.

-- Mark the location of the subframe and engine carrier to the longitudinal members using a felt-tip pen.

Fig 68: Identifying Subframe Bolts (Tighten To Specifications)

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

-- Remove the bolts -arrows- on the tunnel crossmember.

Fig 69: Identifying Bolts & Tunnel Crossmember

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

Fig 70: Identifying Left And Right Stabilizer Bar Bolt

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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 engine-transmission assembly with subframe out of engine compartment while lowering.

-- Next lower engine/transmission subassembly with VAS 6131 A only by dimension -a-.

Fig 71: Lowering Transmission

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Dimension -a- = 100 mm maximum.

-- Remove the ball socket -2- on the selector lever cable from the selector shaft lever using the 80 - 200.

Fig 72: Identifying Selector Lever Cable

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-- Press the securing clips -1- off and remove the selector lever cable from the transmission.

NOTE:

Do not bend or kink the selector lever cable.

-- Lower the engine/transmission subassembly more.

-- Remove the VAS 6131 A with the engine/transmission subassembly under vehicle.