Engine, Removing, Vehicles With Manual Transmission

WARNING: This page does not describe the selected car, but rather 12 other vehicles, including the 2017 Audi S5, 2016 Audi S5, 2016 Audi S4, 2015 Audi S5, and 2015 Audi S4. 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 80-200
Used Oil Collection and Extraction Unit SMN372500
Step Ladder VAS5085
Engine Bung Set VAS6122
Scissor Lift Table VAS6131B with Scissor Lift Table - Audi Set VAS6131/10 and Scissor Lift Table - Q7 Set VAS6131/13
Shop Crane - Drip Tray VAS6208
Hose Clip Pliers VAS6362
Puller - Gear Shaft Linkage T40160

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 high pressure area of the fuel injection system.

-- Reduce the fuel pressure in the high pressure area. Refer to PRESSURE, REDUCING IN HIGH PRESSURE AREA .

-- Position the front wheels so they are straight.

NOTE:

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

Fig 1: Identifying Battery And Ground Cable

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CAUTION:

Danger of causing damage to electronic components.

Observe the steps for disconnecting the battery.

-- Switch the ignition off and remove the ignition key.

-- Disconnect the battery Ground (GND) cable -2-. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Discharge the refrigerant circuit. Refer to USING SERVICE STATION , and REFRIGERANT CIRCUIT .

Vehicles with Hydraulic Power Steering

Fig 2: Identifying Reservoir Bracket To Body

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-- Extract the power steering fluid from the reservoir -4- with the Used Oil Collection and Extraction Unit SMN372500.

NOTE:

Ignore -1, 2 and 3-.

Continuation for All Vehicles

Fig 3: Engine Covers

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

Fig 4: Identifying Coolant Reservoir Markings

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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.

-- Open the coolant reservoir cap.

-- Remove the left and right front wheels.

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

Fig 5: Noise Insulation Panels

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

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

Fig 6: Identifying Coolant Drain Plug

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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.

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

Fig 7: Identifying Coolant Hose Clamp At 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 item -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 item -1-.

Continuation for All Vehicles

Fig 10: Charge Air Cooling Pump -V188-, Connections And Clamp

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-- Disconnect the connector -3- from the Charge Air Cooling Pump -V188- and free it up.

NOTE:

Ignore items -1 and 2-.

Vehicles with Hydraulic Power Steering

Fig 11: Disconnect Power Steering Hydraulic Oil Supply Line

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-- Place the Used Oil Collection and Extraction Unit SMN372500 under the separating 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 the open lines and connections with clean plugs from the Engine Bung Set VAS6122.

Vehicles with Coolant Recirculation Pump -V50-, Version 1

Fig 12: Identifying Coolant Recirculation Pump Components

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-- Disconnect the connector -2-.

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

-- Loosen the hose clamp -1- and remove the coolant hose from the Coolant Recirculation Pump -V50-.

NOTE:

Ignore items -3 and 4-.

Continuation for All Vehicles

Fig 13: Disconnecting Coolant Fan Connectors

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-- Disconnect the coolant fan 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 Pump Motor -V101-, Version 1

Fig 14: Component Location Of Secondary Air Injection (AIR) Pump Motor -V101-

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

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

NOTE:

Ignore item -2-.

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

Fig 15: Identifying Secondary Air Injection (AIR) Pump Motor Components

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-- Disconnect the connector -2- from the Secondary Air Injection Pump Motor -V101- and free up the wire.

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

NOTE:

Ignore item -3-.

Continuation for All Vehicles

Fig 16: 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 17: Disconnecting Ground Wires -Arrow- From Right Longitudinal Member

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-- Remove the seal from the plenum chamber bulkhead.

Fig 18: 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 19: Identifying Air Duct

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

Fig 20: 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-.

-- Press the release buttons, remove the air filter housing and remove the secondary air hose -arrow-.

Fig 21: 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 22: Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80- -3- Connector

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-- Disconnect the connector -3- from the EVAP Canister Purge Regulator Valve 1 -N80- and disconnect the vacuum hose -4-.

-- Disengage the EVAP Canister Purge Regulator Valve 1 -N80- from the bracket and lay it aside with the hoses connected.

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

Fig 23: Identifying Leak Detection Pump Vacuum Hose

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Vehicles with Version 1

Fig 24: 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 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 the open lines and connections with clean plugs from the Engine Bung Set VAS6122.

Vehicles without the Coolant Recirculation Pump -V50- :

Fig 25: 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.

Vehicles with the Coolant Recirculation Pump -V50- :

Fig 26: View Of Coolant Hose At Plenum Chamber Bulkhead

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-- Lift the clamp -arrow - and disconnect the coolant hose at the plenum chamber bulkhead.

Continuation for All Vehicles

Fig 27: Disconnecting Connector & Vacuum Hoses

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-- Disconnect the vacuum hose -1- and free it up.

NOTE:

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

NOTE:

Ignore the -arrows-.

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

Fig 29: Identifying Coolant Hoses Leading To Heater Core

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NOTE:

Ignore item -1-.

Continuation for 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 items -1 and 2-.

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

Fig 32: Identifying Coolant Hose From Front Coolant Pipe

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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 expansion tank.

-- Remove the bolts -arrows-, disconnect the connector from the Engine Coolant Level Warning Switch -F66- and remove the coolant expansion tank.

-- 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.

Continuation for All Vehicles

Fig 35: Identifying Refrigerant Line Bolts

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CAUTION:

Danger of causing damage to the refrigerant lines and hoses.

Do not bend, twist or stretch the refrigerant lines and hoses.

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

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

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

Fig 36: Opening Terminal Box Cover

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

Fig 37: Identifying Terminal Box Wire Components

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-- Remove the 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: Release 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 Pry Lever 80-200.

-- Wiring duct version 1: unlock the retainer and free up the wiring duct in direction of -arrow B- and pull the duct forward in direction of -arrow A-.

Fig 39: Freeing Up Wiring Duct By Releasing Retainer

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-- Wiring duct version 2: unlock the retainer in direction of -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 in direction of -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 in direction of -arrow B-.

-- Remove the bolts -1- and nuts -2- and 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 in direction of -A arrows- and remove the Engine Control Module (ECM) in direction of -arrow B-.

Fig 44: Engine Control Module (ECM)

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

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 in direction of -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 in direction of -A arrows- and remove the wiring bushing -2- upward in direction of -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 (GND) 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 connector -1- on the left and right from the front speed sensors -2-.

Fig 47: ABS/Electronic Stabilization Program Speed Sensor Assembly Overview

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-- If equipped, 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 wire -arrow-.

Fig 48: Disconnecting Electrical Connector On Left Front Level Control System Sensor

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-- Free up the connector -2- on the bracket by pulling the retainer back in direction of -arrow A- and turning the connector approximately 90° clockwise in direction of -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: Disconnecting Upper Control Arm From Wheel Bearing Housing

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-- Remove the upper control arm upward from the wheel bearing housing in direction of -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 crossbrace. Refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

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 crossbrace are not installed correctly.

Audi A5 Cabriolet/Sportback

Fig 53: Diagonal Brace Bolts

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-- Remove the diagonal braces. Refer to OVERVIEW - SUBFRAME .

Vehicles with Electro-Mechanical Power Steering

Fig 54: Power Steering Control Module & Connectors

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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 item -1-.

Continuation for 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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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.

Fig 59: Identifying Bolts - Vehicles With Dual Exhaust System

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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 DRIVESHAFT, REMOVING AND INSTALLING for 0BC, 0BD, 0BE and 0BF, or 39 FINAL DRIVE, DIFFERENTIAL for 0BF and 0BE - with Sport Differential .

-- 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 DRIVESHAFT, REMOVING AND INSTALLING for 0BC, 0BD, 0BE and 0BF, or 39 FINAL DRIVE, DIFFERENTIAL for 0BF and 0BE - with Sport Differential .

Continuation for 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 .

-- Remove the bolt -2- and secure the clutch slave cylinder sideways in the engine compartment.

Fig 62: 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 Puller - Gear Shaft Linkage T40160 and remove the gearshift rod -1-.

Fig 63: Position Puller T40160 And Remove Selector Rod

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Prepare Scissor Lift Platform

Fig 64: 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:

Table Coordinates	Parts from Scissor Lift Table - Audi SetVAS6131/10 and Scissor Lift Table - Q7 SetVAS6131/13
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 Scissor Lift Table VAS6131B under the engine/transmission subassembly.

Fig 65: 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 Scissor Lift Table - Audi Set VAS6131/10 and Scissor Lift Table - Q7 Set VAS6131/13 at the left and right on the front of the subframe as shown in the illustration.

Fig 66: Attach At Left And Right Front Of Subframe

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-- Ensure threaded spindles are completely installed.

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

Fig 67: Attaching VAS 6131/10 At Left And Right Rear On Subframe Crossbrace Front Connecting Points

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-- Position mounting elements from the Scissor Lift Table - Q7 Set VAS6131/13 at the lower left and right on the wheel bearing housing as shown in the illustration.

Fig 68: Attaching VAS 6131/13 At Lower Left And Right Of Wheel Bearing Housing

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

Fig 69: Attaching Mounting Elements From VAS 6131/10 At Left And Right Rear Of Crossmember

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-- Attach mounting elements from the Scissor Lift Table - Audi Set 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 Scissor Lift Table VAS6131B and tighten to 20 Nm.

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

Fig 70: Identifying Subframe Bolts

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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 71: Identifying Bolts & Tunnel Crossmember

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

Fig 72: 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 the engine/transmission sub-assembly with subframe out of engine compartment while lowering.

-- Next lower engine/transmission subassembly with Scissor Lift Table VAS6131B only by dimension -a-.

Fig 73: Lowering/Raising Engine/Transmission Subassembly To Dimension -A-

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Dimension -a- = 100 mm maximum.

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

Fig 74: 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 Scissor Lift Table VAS6131B with engine/transmission assembly from under the vehicle.