Engine (vehicles with automatic transmission), removing

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2009 Audi S4, 2008 Audi S4, 2007 Audi S4, 2006 Audi S4, and 2005 Audi S4. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

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

Fig 1: Identifying Special Tools - Engine (Vehicles With Automatic Transmission), Removing

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Special tools, testers and auxiliary items required

Old oil collecting and extracting device V.A.G 1782
Hose clamp pliers V.A.G 1921
Spark plug connector pliers V.A.G 1922
Step ladder VAS 5085

Scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10
Drip tray for workshop crane VAS 6208

NOTE:

If engine and transmission are to be separated after removal, Supplementary Set, Audi A8 > 2002 VAS 6131/11 and Supplementary Set, Audi A6 > 2005 VAS 6131/12 will also be required.

Special tools, testers and auxiliary items required

Fig 2: Lifting Eyebolt 3368

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Lifting Eyebolt 3368

Fig 3: Tension Strap T10038

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Tension strap T10038

Work procedure

NOTE:

All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
Drained coolant must be stored in a clean container for disposal or reuse.

Remove plenum chamber cover rubber seal.

Fig 4: Identifying Plenum Chamber Cover & Removing Rubber Seal

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Remove plenum chamber cover - 1 - toward front - arrows -.

CAUTION: Observe safety precautions when disconnecting battery →

27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL for ELECTRICAL EQUIPMENT, CABRIOLET

Fig 5: Disconnecting Battery Ground (GND) Strap

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With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
Discharge refrigerant circuit → 87 - AIR CONDITIONING .
Extract hydraulic oil for power-steering from reservoir using old oil collecting and extracting device V.A.G 1782.

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 6: Removing Quick-Release Fasteners, Screws And Noise Insulation

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Remove quick-release fasteners - 1 - , remove screws - 2 - and remove noise insulation.

Fig 7: Removing Bracket For Noise Insulation

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Remove bracket for noise insulation - arrows -.
Remove left and right front wheel housing liners →
- 66 EXTERIOR EQUIPMENT
- 66 - EXTERIOR EQUIPMENT for BODY EXTERIOR - CABRIOLET
.
Remove front bumper cover →
- 63 BUMPER
- 63 - BUMPERS for BODY EXTERIOR - CABRIOLET
.

Fig 8: Removing Left Air Guide In Front Of Auxiliary Cooler

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Remove left air guide - arrow - in front of auxiliary cooler.

Fig 9: Removing Right Air Guide In Front Of Auxiliary Cooler

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Remove right air guide - arrow - in front of auxiliary cooler.

Fig 10: Removing Drain Plug On Coolant Thermostat Housing

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Place drip tray for workshop crane VAS 6208 under engine.
Remove drain plug - arrow - on coolant thermostat housing and drain coolant from engine.

Fig 11: Disconnecting Lower Coolant Hose From Radiator

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Disconnect lower coolant hose from radiator - arrow - and drain residual coolant.
Place old oil collecting and extracting device V.A.G 1782 under engine.

Fig 12: Disconnecting Hydraulic Lines To Cooling Coil At Left Rear Of Bumper

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Disconnect hydraulic lines to cooling coil at left rear of bumper - arrows -.

Fig 13: Locating Union Nuts And Disconnecting ATF Lines

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NOTE:

Observe the rules of cleanliness for working on automatic transmissions → 00 TECHNICAL DATA .

Place old oil collecting and extracting device V.A.G 1782 under engine.
Loosen union nuts - arrows - and disconnect ATF lines.

Fig 14: Removing Cover In Engine Compartment (Left Side)

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Remove cover - 1 - in engine compartment (left side).

Fig 15: Removing Cover In Engine Compartment (Right Side)

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Remove cover - 1 - in engine compartment (right side).

Fig 16: Identifying Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct

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Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 - from air guide.
Remove bolts - arrows -.
Remove air duct - 2 -.

Fig 17: Disconnecting Top Coolant Hose From Radiator

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Disconnect top coolant hose - arrow - from radiator.

Fig 18: Removing Electrical Harness Connectors And From Bracket

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Remove electrical harness connectors - 1 - and - 2 - from bracket and disconnect them.
Free up wires to lock carrier.

Fig 19: Disconnecting Electrical Harness Connector For Headlights At Both Sides Of Vehicle

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Disconnect electrical harness connector - arrow - for headlights at both sides of vehicle.
Free up electrical wiring.

Fig 20: Disconnecting Electrical Harness Connector For Left/Right Airbag Sensors On Lock Carrier

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Disconnect electrical harness connector - arrow - for left and right airbag sensors on lock carrier.
Free up cables.
Remove hood cable at lock carrier →
- 55 HOOD, LIDS
- 55 - HOOD, LIDS for BODY EXTERIOR - CABRIOLET
.

Fig 21: Disconnecting Electrical Harness Connector For Right Fan

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Disconnect electrical harness connector - arrow - for right fan.

Fig 22: Removing Refrigerant Line Leading To A/C Compressor

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NOTE:

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

Remove refrigerant line - arrow - leading to A/C compressor.

Fig 23: Removing Refrigerant Line Leading To A/C Evaporator

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Remove refrigerant line - arrow - leading to A/C evaporator.

Fig 24: Removing Bolts At Left/Right Side Of Bumper

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Remove bolts - arrows - at left and right side of bumper.
Pull off hood seal from lock carrier and fender edges.

Fig 25: Removing Bolts At Impact Absorbers At Left/Right

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Remove bolts at impact absorbers - arrows - at left and right.

NOTE:

A second technician is required to remove the lock carrier.

Remove lock carrier and set aside so it cannot topple.

Fig 26: Removing Rear Engine Cover

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Remove rear engine cover - arrows -.

Fig 27: Removing Front Engine Cover

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Remove front engine cover - arrows 1 and 2 -.

Fig 28: Removing Coolant Hoses & Coolant Expansion Tank

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

Fig 29: Disconnecting Brake Booster Vacuum Hose From Grommet On Bulkhead

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Disconnect vacuum line - arrow - to brake booster at bulkhead.

Fig 30: Unclipping Coolant Hose From Bracket On Bulkhead

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Unclip coolant hose - arrow - from bracket on bulkhead.

Fig 31: Disconnecting Vacuum Line To Vacuum Reservoir

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If installed, disconnect vacuum line - arrow - to vacuum reservoir.

Fig 32: Disconnecting Vacuum Hose From Intake Manifold

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Disconnect vacuum hose - arrow - from intake manifold.

Fig 33: Disconnecting Coolant Hose To Heater Core At Rear Coolant Pipe On Engine

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Disconnect coolant hose - arrow - to heater core at rear coolant pipe on engine.

Fig 34: Disconnecting Vacuum Line

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If installed, disconnect vacuum line at area designated with - arrow -.

Fig 35: Disconnecting Electrical Harness Connector For After-Run Coolant Pump V51

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If installed, disconnect electrical harness connector - arrow - for After-Run Coolant Pump V51 (behind auxiliary cooler at left) and free up electrical wire.

Fig 36: Disconnecting Hose From Power Steering Fluid Reservoir & Vacuum Hose To Vacuum Reservoir

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NOTE:

Place a rag under separating point to catch escaping hydraulic fluid.

Disconnect hose - 1 - from power steering fluid reservoir.

NOTE:

Ignore - 2 -.

Fig 37: Disconnecting Coolant Hoses

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Disconnect coolant hoses at positions indicated by - arrows -.

Fig 38: Disconnecting Coolant Hoses

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Disconnect coolant hoses at positions indicated by - arrows -.

Fig 39: Disconnecting Coolant Hose To Oil Cooler

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Disconnect coolant hose to oil cooler - arrow -.

Fig 40: Disconnecting Coolant Hoses

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Disconnect coolant hoses at positions indicated by - arrows -.

Fig 41: Removing Bolts & Right Auxiliary Cooler Together With Coolant Hoses

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Remove bolts - 1 - and - 2 -.
Remove right auxiliary cooler together with coolant hoses.

NOTE:

The hose - arrow - can remain connected at auxiliary cooler.

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

CAUTION: Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening connection.

Fig 42: Installing/Removing Fuel Hose To/From Connection On Fuel Rail Line

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Remove fuel hose from connection on fuel rail line. To do so, counter hold using an open-end wrench at hex head - 1 - and - 3 - and remove union nut - 2 -.

Fig 43: Identifying Electrical Harness Connectors, Secondary Air Injection (AIR) Pump Hose, Air Guide Hose & Mass Air Flow (MAF) Sensor

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Disconnect electrical harness connector - 2 - from Evaporative Emission (EVAP) Canister Purge Regulator Valve N80.
Disconnect electrical harness connector - 3 - at Mass Air Flow (MAF) Sensor G70.
Disconnect hose - 1 - to Secondary Air Injection (AIR) pump.
Disconnect air guide hose - 4 - at Mass Air Flow (MAF) sensor.

Move wiring harness clear at air filter housing.
Remove clip - arrow - and remove air filter housing with Mass Air Flow (MAF) sensor.

Fig 44: Disconnecting Air Hose At Right On Engine

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Disconnect air hose - arrow - at right on engine.

Fig 45: Removing Bracket For Electrical Harness Connectors At Right From Bulkhead

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Remove bracket for electrical harness connectors - 1 to 4 - at right from bulkhead.

Fig 46: 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 battery positive (+) cable - 2 - on battery positive terminal.
Pull battery positive (+) cable through bulkhead toward front.
Free up the wiring harness.

NOTE:

Disregard item - 3 -.

Fig 47: Removing Securing Clips And Cowl

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

CAUTION: To prevent the cowl grille - 5 - from tearing when removing, coat transition between windshield and cowl grille with a soapy solution and pull grille up vertically out of fastening strip beginning at edge of window.

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

Fig 48: Removing Screws And Cover From E-Box In Plenum Chamber

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

Fig 49: Using Screwdriver To Remove Retainer Bar And Engine Control Module (ECM) J623

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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 50: Releasing Retaining Hooks Toward Outside And Removing Retaining Bracket

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

Fig 51: Disconnecting All Electrical Harness Connectors On Connector Station Using Spark Plug Connector Pliers V.A.G 1922

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Disconnect all electrical harness connectors on connector station - 2 - using spark plug connector pliers V.A.G 1922.
Remove electrical wire connection - 1 -.

Fig 52: 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.

Fig 53: Removing Ground (GND) Connection

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Remove Ground (GND) connection - arrow -.

Fig 54: Removing Bracket For Electrical Harness Connectors At Left From Bulkhead

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Remove bracket for electrical harness connectors - 1 to 4 - at left from bulkhead.
Free up wiring harness.
Set electrical wiring harness on engine and secure Engine Control Module (ECM) against falling down.

Fig 55: Disconnecting Electrical Harness Connector At Secondary Air Injection (AIR) Pump Motor V101 & Removing Ground (GND) Wire On Long Member

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Disconnect electrical harness connector - 1 - at Secondary Air Injection (AIR) Pump Motor V101.
Remove Ground (GND) wire - 2 - on long member.

Fig 56: Disconnecting Hydraulic Pressure Line For Power-Steering At Left Next To Oil Pan

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Place old oil collecting and extracting device V.A.G 1782 under engine.
Disconnect hydraulic pressure line for power-steering - arrow - at left next to oil pan.

Fig 57: Removing Bolts & Right Refrigerant Line From A/C Compressor

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NOTE:

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

Remove bolts - 1 - and - 2 -.
Remove right refrigerant line from A/C compressor.

NOTE:

The left refrigerant line will be removed at a later point in time.

Seal open connections on A/C compressor using clean plugs.

Fig 58: Removing Left Bracket For Refrigerant Line

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Remove left bracket for refrigerant line - arrows -.

Fig 59: Removing Refrigerant Line On Bracket

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Remove refrigerant line on bracket - arrow -.

Fig 60: Removing Bolt And Disconnecting Refrigerant Line To A/C Compressor

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Remove bolt - arrow - and disconnect refrigerant line to A/C compressor.

Fig 61: Identifying Collar Bolt For Right Drive Axle

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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).

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

Fig 62: 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 63: Disconnecting Electrical Harness Connector At Left Front Level Control System Sensor G78

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Disconnect electrical harness connector at Level Control System Sensor.
Unclip operating rod for Left Front Level Control System Sensor G78 at bottom on control arm.
Remove outer suspension strut bolt from left and right of engine compartment.

Fig 64: Rotating Lifting Eyebolt 3368 At Left/Right In Suspension Strut Mount Hole From Below

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Rotate Lifting Eyebolt 3368 at left and right in suspension strut mount hole from below.

CAUTION: Only install Lifting Eyebolt 3368 until it is flush with upper edge of suspension strut mount so that hood is not damaged when closed.

Tie up wheel bearing housing at left and right with Tensioning Strap T10038 as shown in illustration.

CAUTION: To prevent upper control arm joints from being damaged, wheel bearing housing must be supported before loosening lower suspension strut bolts.

Fig 65: Removing Bolt And Suspension Strut From Control Arm

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Remove bolt and remove suspension strut from control arm - arrow -.

Fig 66: Removing Expanding Clips, Nut And Cover Behind Wheel Housing

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Remove expanding clips - arrows -.
Remove nut - 1 - and remove cover behind wheel housing.

Fig 67: Removing Guide Control Arm And Control Arm On Subframe

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Remove guide control arm - 1 - and control arm - 2 - on subframe.

Fig 68: Pivoting Guide Control Arm And Control Arm Outward

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Pivot guide control arm - 1 - and control arm - 2 - outward.

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

Repeat work procedure on opposite side of vehicle.

Fig 69: Removing Heat Shield For Left Drive Axle

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Remove heat shield - 1 - for left drive axle.
Remove drive axle from transmission flanged shaft.
Swing left wheel bearing housing outward and remove drive axle.
Repeat work procedure on opposite side of vehicle.

Fig 70: Disconnecting Exhaust System At Double Clamps

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NOTE:

Flex joint in front exhaust pipe must not be bent more than 10 ° , otherwise it may be damaged.

Disconnect exhaust system at double clamps - arrows -.

Fig 71: Removing Heat Shield For Driveshaft

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Remove heat shield - A - for drive shaft - arrows -.
Remove bolts at transmission/driveshaft flange.
Push driveshaft together with rear final drive. The constant velocity (CV) joints can move axially.
Tie up driveshaft to body.

NOTE:

Mark the installation position of bracket for selector lever cable using a felt-tip marker.

Fig 72: Pressing Ball Socket Of Selector Lever Cable From Selector Shaft Lever & Removing Bracket On Transmission

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Press ball socket - 1 - of selector lever cable from selector shaft lever.
Remove bracket on transmission - arrows -.
Move selector lever cable clear.

NOTE:

To improve clarity, the transmission supports are shown removed in the illustration.

Fig 73: Identifying Scissor Lift Platform VAS 6131

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Prepare scissor lift platform:

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

Platform coordinates	Parts of support set for Audi VAS 6131/10
B4	/10-1	/10-4	/10-5	/10-11
G3	/10-1	/10-4	/10-5	/10-11
B10	/10-1	/10-2	/10-5	/10-8
G10	/10-1	/10-2	/10-5	/10-8
C15	/10-1	/10-3	/10-5	/10-12
F15	/10-1	/10-3	/10-5	/10-12

Install attachments on scissor lift table by hand first.
Place scissor lift platform VAS 6131 A in horizontal position.

Note bubble level (sight glass) on support platform.

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

Fig 74: 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.

Fig 75: 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 76: Positioning Support Elements From VAS 6131/10 At Rear On Transmission

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Position support elements from VAS 6131/10 at rear on transmission as shown in illustration.
Turn 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 A.

Fig 77: Positioning Support Elements From VAS 6131/10 At Left/Right On Subframe

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Turn both spindles at subframe 2 rotations upward.

Fig 78: Positioning Support Elements From VAS 6131/10 At Rear On Transmission

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Turn both spindles at transmission 4 rotations upward.

Fig 79: Removing/Installing Bolts In Stages

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Remove bolts - 1 -.
Mark installation position of subframe and of both engine mount plates to long members using a felt-tip marker.
Remove bolts - 2 - , - 3 - and - 4 - in diagonal sequence and in stages.

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.

Slowly lower engine/transmission subassembly downward.
Push scissor lift platform VAS 6131 A with engine/transmission subassembly under vehicle.