Engine, removing

WARNING: This page is about a different car, the 2009 Audi A4, 2008 Audi A4, 2007 Audi A4, 2006 Audi A4, and 2005 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tools - Engine, Removing

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Special tools, testers and auxiliary items required

Pry lever 80-200
Hose Clamps Up to 25 mm dia. 3094
Drip tray for workshop crane VAS 6208 or V.A.G 1306
Hose clamp pliers V.A.G 1921

Step ladder VAS 5085
Scissor Lift Table VAS 6131 with Support Set VAS 6131/10 and VAS 6131/11

NOTE:

If engine and transmission are to be separated after removal, the Supplementary Set Audi A6 (C6) VAS 6131/12 will also be required.

Work procedure

NOTE:

With lock carrier installed, engine is removed downward with transmission and subframe.
All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
Drained coolant must be stored in a clean container for disposal or reuse.

Discharge refrigerant circuit Refrigerant R134a - Servicing.

CAUTION: Observe safety precautions when disconnecting the battery → 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Fig 2: Disconnecting Battery Ground (GND) Strap

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With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.

Fig 3: Removing Rear Engine Cover

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Remove rear engine cover - arrows -.

Fig 4: Identifying Front Engine Cover

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Remove front engine cover - arrows -.

CAUTION: Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.

Open cap of coolant expansion tank.
Remove both front wheels.

Fig 5: Locating Fasteners Exhaust Pipe

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For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

Fig 6: Identifying Quick-Release Fasteners And Noise Insulation

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Loosen quick-release fasteners - 1 through 3 - and remove front and rear noise insulation.
Place drip tray for workshop crane VAS 6208 under engine.

Fig 7: Disconnecting Coolant Hose From Oil Cooler

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Disconnect coolant hose - arrow - from oil cooler and drain coolant.

Fig 8: Disconnecting Lower Right Coolant Hose From Radiator

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Disconnect lower right coolant hose from radiator - arrow - and drain residual coolant.

Fig 9: Removing/Installing Bolts At Torque Support Stop

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Remove bolts - arrows - at torque support stop.

Fig 10: Removing/Installing Bolts For Torque Support

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Remove bolts - arrows - for torque support.

NOTE:

The torque support and torque support stop will later be removed.

Fig 11: Removing Ground (GND) Strap From Right Longitudinal Member

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Remove Ground (GND) strap - arrow - from right longitudinal member.

Fig 12: Disconnecting Brake Booster Vacuum Hose From Grommet On Bulkhead

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Disconnect brake booster vacuum hose from grommet - arrow - on bulkhead.

Fig 13: Removing Ground (GND) Strap At Bulkhead

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Remove Ground (GND) strap - arrow - at bulkhead.

Fig 14: Removing Coolant Hoses At Coolant Expansion Tank

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Remove coolant hoses - 1 - and - 2 - at coolant expansion tank.
Remove coolant expansion tank - arrow -.
Disconnect electrical connection at Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant expansion tank.

Fig 15: Removing Coolant Hose From Front Coolant Line

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Remove coolant hose - arrow - from front coolant line.

Fig 16: Disconnecting Top Coolant Hose From Radiator

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Remove left front coolant hose in engine compartment - arrows -.

Fig 17: Removing Coolant Hose From Front Coolant Line

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Remove coolant hose - arrow - from front coolant line.

Fig 18: Disconnecting Vacuum Hose To Leak Detection Pump

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Disconnect vacuum hose - arrow - to leak detection pump.

NOTE:

Place a rag under hydraulic lines to catch escaping hydraulic fluid.

Fig 19: Removing Hydraulic Pressure Line At Power Steering Pump & Clamping Off Hydraulic Hose For Power Steering Pump With Hose Clamps

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Remove hydraulic pressure line - 2 - at power steering pump and set it aside on top of longitudinal member.
Clamp off hydraulic hose - 1 - for power steering pump with a Hose Clamps Up to 25 mm dia. 3094.
Remove hydraulic hose from power steering pump.

NOTE:

To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

Fig 20: Removing Bolts

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Remove bolts - arrows -.

NOTE:

The refrigerant lines will be removed from air conditioning compressor at a later point in time.

Fig 21: Identifying Bolts & Air Duct

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Remove bolts - arrows -.
Remove air duct - 1 - and - 2 -.

CAUTION: Note rules of cleanliness for working on the fuel injection system → Rules of cleanliness for performing work on fuel injection system .

CAUTION: Fuel system is under pressure! Before opening the low pressure section of the fuel injection system, wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.

Fig 22: Separating Fuel Line

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Separate fuel line - arrow - and lay aside.

Fig 23: Disconnecting Check Valve From Connection At Air Duct Hose

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Disconnect check valve - 1 - from connection at air duct hose.
Remove air duct hose, thereby loosening hose clamp - 2 - and opening clips - arrows -.

Fig 24: Removing Pin From Spreader Clips

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Remove pin from spreader clips - arrow -.
Remove air filter housing.

Fig 25: Removing Vacuum Hose To EVAP Canister At Evaporative Emission (EVAP) Canister Purge Regulator Valve N80

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Remove vacuum hose - arrow - to EVAP canister at Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.

Fig 26: Removing Coolant Hose To Heater Core On Rear Of Engine

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Remove coolant hose - arrow - to heater core on rear of engine.

Fig 27: Disconnecting Electrical Harness Connector For Oxygen Sensor (O2S) 2 Behind Three Way Catalytic Converter (TWC) G131

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Remove nuts and remove left bracket for harness connectors - 1 - and - 2 - from bulkhead.

Fig 28: Removing Rubber Seal & Plenum Chamber Cover

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Remove rubber seal - 2 - for plenum chamber cover.
Remove plenum chamber cover - 1 -.

Fig 29: Removing Nut And Fuse Strip On Plus Wire Terminal Clamp

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Remove nut - 1 - and remove fuse strip on plus wire terminal clamp.
Disconnect positive wire - 2 - on battery positive terminal.
Pull positive wire through bulkhead toward front.
Free up wiring harness lay it aside on engine.

NOTE:

Ignore - 3 -.

Fig 30: Identifying Covers, Hex-Nuts, Wiper Arm, Wiper Axle & Wiper Arms

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Pry off both covers - 3 - using a screwdriver.
Loosen hex-nuts - 4 - by several turns.
Loosen wiper arm - 2 - from wiper axle by lightly tilting.
Remove nuts completely and remove wiper arms.

Disconnect securing clips - 1 - and remove cowl grille - 5 -.

Fig 31: Removing Cover From E-Box In Plenum Chamber

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

Fig 32: Using Screwdriver To Pry Off Mounting Bracket And Remove Engine Control Module (ECM) From E-Box

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Using a screwdriver, carefully pry off mounting bracket - arrow - and remove Engine Control Module (ECM) from E-Box.

NOTE:

Engine Control Module (ECM) remains connected at wiring harness.

Fig 33: Releasing Retaining Hooks Toward Outside And Removing Retaining Bracket

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Release retaining hooks - arrows - toward outside and remove retaining bracket.

Fig 34: Disconnecting Electrical Harness Connectors On Connector Station

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Disconnect all electrical harness connectors on connector station - 2 -.
Remove electrical wire connection - 1 -.

Fig 35: Disengaging Locking Mechanisms And Removing Secondary Relay Carrier In E-Box Toward Top

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Disengage locking mechanisms - arrows - and remove secondary relay carrier in E-Box toward top.
Disengage engine wiring harness at E-Box and bulkhead.
Set wiring harness on engine and secure Engine Control Module (ECM) against falling down.
Have a second technician press brake pedal.

CAUTION: To loosen collar bolt for drive axle, the wheel bearing must not be under load (vehicle must not be standing on its wheels).

Fig 36: Identifying Collar Bolt For Right Drive Axle

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Remove collar bolt - 2 - at left and right drive axles - 1 -.

Fig 37: Removing Heat Shield For Left/Right Drive Axles

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Remove heat shield - 1 - for left and right drive axles.
Remove left and right drive axles from flange shafts of transmission.

NOTE:

The drive axles will be removed at a later time.

NOTE:

To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

Fig 38: Removing Bracket For Refrigerant Lines At Right On Oil Pan

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Remove bracket for refrigerant lines at right on oil pan - arrow -.
Remove refrigerant lines at A/C compressor.
Tie up refrigerant line, that runs to catch reservoir at right of vehicle, to body.
Seal open connections on A/C compressor using clean plugs.

Fig 39: Removing Bolts And Nuts Uniformly At Left/Right

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Remove bolts and nuts - arrows - uniformly at left and right.
Remove stabilizer.

Fig 40: Unclipping Actuator Rod For Left Front Level Control System Sensor G78 At Bottom On Link

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If equipped, disconnect electrical harness connector at Left Front Level Control System Sensor G78.
Unclip actuator rod for Left Front Level Control System Sensor G78 at bottom on link - arrow -.

Fig 41: Removing Suspension Strut From Link

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Remove suspension strut from link - arrow -.

Fig 42: Removing Nuts For Fastening Link And Guide Link

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Remove nuts - 1 - and - 2 - for fastening link and guide link.

NOTE:

The bolts will be removed from the subframe at a later point in time.

Repeat procedure on opposite side of vehicle.

Fig 43: Locating Clamping Sleeves

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Loosen clamping sleeves - arrows -.

Fig 44: Removing Heat Shield For Drive Shaft

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Remove heat shield - A - for drive shaft - arrows -.
Remove bolts at transmission/drive shaft flange.
Push drive shaft together with rear final drive. The constant velocity (CV) joints can move axially.
Lay aside drive shaft on exhaust system.

Fig 45: Identifying Scissor Lift Platform VAS 6131

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Prepare scissor lift platform:

Equip scissor lift platform VAS 6131 with support set for Audi VAS 6131/10 and VAS 6131/11 as follows:

Platform coordinates	Parts of support set for Audi VAS 6131/10 and VAS 6131/11
B4	/10-1	/10-4	/10-5	/10-11
G4	/10-1	/10-4	/10-5	/10-12
B11	/10-1	/10-2	/10-5	/10-8
G11	/10-1	/10-2	/10-5	/10-8
C15	/10-1	/10-2	/10-5	/11-2
F15	/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.

Note bubble level (sight glass) on support platform.

Drive scissor lift platform VAS 6131 under engine/transmission subassembly.

Fig 46: Positioning Support Elements From VAS 6131/10 At Front On Engine

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Position support elements from VAS 6131/10 at front on engine as shown in illustration.
Make sure that the threaded spindles are completely installed.

Fig 47: Positioning Support Elements From VAS 6131/10 At Left/Right On Subframe

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Position support elements from VAS 6131/10 at left and right on subframe as shown in illustration.

Fig 48: Positioning Support Elements From VAS 6131/10 And VAS 6131/11 At Left/Right On Tunnel Cross Member

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Position support elements from VAS 6131/10 and VAS 6131/11 at left and right on tunnel cross member as shown in illustration.
Twist all spindles of support elements 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.

Fig 49: Removing Nuts At Bottom On Left/Right Engine Mounts

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Remove nuts - A - at bottom on left and right engine mounts.

Fig 50: Starter Wiring Bracket Cable Ties

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Cut through cable ties - arrows - , open starter harness retainer and take electrical harness out.

Fig 51: Removing/Installing Bolts In Stages

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Mark installation position of subframe and of both engine mount plates to long members using a felt-tip marker.
Remove bolts - 1 to 4 - in diagonal sequence and in stages.
Remove left and right engine mount plate.

NOTE:

Verify that all hoses and lines between engine, transmission, subframe and body have been disconnected.
While lowering, carefully guide engine/transmission subassembly with subframe out of engine compartment in order to prevent damage.

Fig 52: Lowering Engine/Transmission Assembly Using Scissor Lift Platform VAS 6131 Only Approx. By Dimension

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First lower engine/transmission assembly using scissor lift platform VAS 6131 only approx. by dimension - a -.

Dimension - a - = 80 mm.

Fig 53: Removing Nuts For Fastening Link And Guide Link

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Remove bolts at guide link - 1 - and at link - 2 - from subframe.

Fig 54: Pivoting Guide Link And Link Outward

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Pivot guide link - 1 - and link - 2 - outward.

CAUTION: Guide link and link must not hang free. Tie up both links on wheel bearing housing - arrows - as shown in illustration.

Pivot wheel bearing housing outward and remove drive axle.
Repeat work procedure on opposite side of the vehicle.

Fig 55: Identifying Push Rod And Connecting Rod For Selector Rod

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Disconnect connecting rod - 2 - of shift rod.
Remove socket head bolt of pivot rod - 1 -.

Fig 56: Removing Nut And Lever From Selector Shaft

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Remove nut - arrow - and remove lever from selector shaft.

Fig 57: Slave Cylinder Bracket And Fastener

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Remove clutch slave cylinder - arrow - , do not disconnect lines.
Tie up clutch slave cylinder together with shift rods.
Push scissor lift platform VAS 6131 approx. 20 mm back and remove torque support and torque support stop.
Push scissor lift platform VAS 6131 back into removal position and lower scissor lift platform VAS 6131 completely.

Push scissor lift platform VAS 6131 with engine/transmission subassembly under vehicle.