Engine, Removing, Hybrid Vehicles

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2017 Audi Q5, 2016 Audi Q5, 2015 Audi Q5, 2014 Audi Q5, and 2013 Audi Q5. However, it is still accessible from the selected car via links, so may be relevant.

NOTE:

Follow all warnings when working on a vehicle with a high voltage system, refer to HIGH VOLTAGE VEHICLES SAFETY PRECAUTIONS , HIGH VOLTAGE SYSTEM GENERAL WARNINGS and WORKING ON HIGH VOLTAGE VEHICLESWORKING ON HIGH VOLTAGE VEHICLES .

WARNING:

The engine could start unexpectedly.

For general work performed on the high voltage system the ignition must be switched off and the key must be kept outside of the vehicle interior.

WARNING:

Handling the high voltage cables:

Do not stand on or place tools on the high voltage cables or their components. This may damage the insulation.
Do not bend or kink high voltage cables as this may damage the insulation.
The round high voltage connectors are color coded with an exterior colored ring and mechanically coded with guide or code tabs. Observe the coding when connecting the round high voltage connector in order to avoid mechanical damage to the high voltage connector.

CAUTION:

High voltage components have hazardous voltage.

Note the following when working near high voltage components and high voltage cables:

Cutting, deformed, and sharp edged tools or heat sources such as welding, solder, hot air and thermal glue are forbidden.
Visually inspect the work area before working on high voltage components.
When working in the engine compartment, perform a visual inspection of the Electric Drive Power and Control Electronics -JX1-, the Electro-Drive Drive Motor -V141-, the Electrical A/C Compressor -V470- and the high voltage cables.
Visually inspect the high voltage cables and the covers when working on the underbody.
Visually inspect the high voltage cables and the electronics box with the High Voltage System Maintenance Connector -TW- when working in the rear area of the vehicle.
Visually inspect all potential equalization cables.

Observe the following when performing the visual inspection:

None of the components appear to have any external damage.
The high voltage cable insulation and the potential equalization cable insulation are not damaged.
The high voltage cables must not have any unusual deformations.
Each high voltage component must be marked with a red warning label.

Special tools and workshop equipment required

Engine Support Bridge 10-222A
Engine/Gearbox Support Shackle (2 pc.)10-222A/12
Pry Lever 80-200
Engine Sling 2024A
Tensioning Strap T10038
Counterhold - Vibration Damper T10355
Shop Crane VAS6100
Lift Arm Extension VAS6101
Engine Bung Set VAS6122
Shop Crane - Drip Tray VAS6208
Hose Clip Pliers VAS6340
Hose Clip Pliers VAS6362
Transmission Lift Hook T40013

Procedure

NOTE:

Remove the engine upward without the transmission.

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

-- Disconnect the Ground (GND) cable from the battery terminal, refer to Battery -A- AND Auxiliary Battery -A1-, DISCONNECTING AND CONNECTING, VEHICLES WITH HIGH VOLTAGE SYSTEM for engine code CHJA .

CAUTION:

Hazardous high voltage

Severe bodily injury or death by electrocution.

The high voltage system may only be turned off by a qualified person (Audi high voltage technician).
It must be certain that the voltage for the high voltage system is turned off. The voltage is guaranteed to be off exclusively with the Vehicle Diagnostic Tester via the "Guided Fault Finding".
The qualified technician (Audi high voltage technician) will make sure the voltage is turned off and that the system cannot turn back on again using Service Disconnect Lock T40262. The qualified technician should make sure the system cannot turn on again by keeping the key and the High Voltage System Maintenance Connector -TW- in a safe place.
The qualified personnel (Audi high voltage technicians) mark the vehicle with a label.

NOTE:

De-energizing the high voltage system:

Connect the Vehicle Diagnostic Tester

Select the Guided Fault Finding mode

Using the Go To button, move through the following menu points

Function/Component Selection

Body

Electrical Equipment

OBD-Capable System

8C - Hybrid Battery Management -J840

8C - Hybrid Battery Management, Functions

51 - De-Energize the High Voltage (Repair Group 93) 93)

-- Carefully pull the engine cover off the ball pins one after the other -arrows-. Do not remove the engine cover on one side or in a jerking manner.

Fig 1: Remove Engine Cover

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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 air duct -arrows-.

Fig 2: Identifying Air Duct -Arrows-

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-- Disconnect the connector -3- from the Mass Airflow Sensor -G70-.

Fig 3: Removing Air Filter Housing

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

-- Open the clamp -4- and remove the air guide hose from the Mass Airflow Sensor -G70-.

-- Remove the air filter housing -2- upward.

-- Remove the nuts -arrows- from the catalytic converter accessible from the top.

Fig 4: Identifying Nuts

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-- Loosen the hose clamps -arrows- and remove the air guide hose.

Fig 5: Identifying Air Intake Hose Components

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-- Disconnect the connector -A- to the Drive Motor High Voltage Wiring Harness -PX2- and the connector -B- from the Drive Motor Rotor Position Sensor 1 -G713- on the left upper side of the transmission.

Fig 6: Connecting Connector To The Drive Motor High Voltage Harness

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-- Disconnect the connector -C- from the Oxygen Sensor After Three Way Catalytic Converter -G130- and remove the cable tie -arrow-.

-- Remove the left and right front wheels, refer to WHEEL, CHANGING AND MOUNTING .

-- Remove the left and right front wheel housing liners, refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Remove the noise insulation, refer to OVERVIEW - NOISE INSULATION .

-- Remove the subframe crossbrace, refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

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

Fig 7: Coolant Hose Connection And Clamp

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-- Open the clamp -2-, remove the coolant hose and drain the coolant.

-- Open the clamp -1- and remove the connection from the radiator.

-- Free up the coolant hose on the longitudinal member.

-- Remove the nuts -arrows- and move the air guide pipe -1- to the side.

Fig 8: Air Guide Pipe

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-- Free up the electric wires on the crossmember -3-.

Fig 9: Crossmember -3- & Bolts

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-- Remove the bolts -1- and then remove the torque support from the crossmember.

-- Remove the bolts -2-.

Fig 10: Identifying Bolts

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WARNING:

The subframe could cause an accident if it is not secured.

Do not remove the subframe bolts completely.

-- Loosen the bolts -2- on the subframe just enough until it is possible to free up the crossmember -1- in direction of -arrow-.

-- Move the crossmember -1- to the left side -arrow-.

Fig 11: Moving Crossmember To The Left

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-- Move the ATF hoses -2- to the side and remove the crossmember.

-- Loosen the hose clamp -arrow-, pull of the air guide hose and move it to the side.

Fig 12: Identifying Hose Clamp

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-- Remove the secondary air hose -arrow- by pressing the release buttons.

Fig 13: Secondary Air Hose (Hybrid Vehicles)

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

Fig 14: Ground (GND) Wire to Longitudinal Member

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-- Disconnect the left and right connectors -arrow- from the engine mount and then free up the electric wires.

Fig 15: Disconnect Left Electrohydraulic Engine Mount Solenoid Valve

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-- Remove the left and right bolts -1- from the engine mount.

-- Remove the nut -2- and free up the electrical wiring bracket.

-- Disconnect the connectors and free up the electric wires.

Fig 16: Electrical Connectors

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for Secondary Air Injection Pump Motor -V101-
for Low Temperature Circuit Coolant Pump -V468-

-- Remove the coolant fan connector -1- from the bracket and disconnect it by sliding the retainer back -arrow- and pressing the release down.

Fig 17: Disconnecting Coolant Fan Electrical Connector -1- From Bracket

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-- Free up the electrical wiring harness to the coolant fan control module.

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

Fig 18: Identifying Right Front Muffler Nuts

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-- Loosen the threaded connections -arrows- and slide the clamping sleeves to the rear.

Fig 19: Identifying Clamping Sleeve Components

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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°.

-- Remove the front muffler.

-- Remove the nuts -arrows- from the catalytic converter accessible from under.

Fig 20: Identifying Nuts

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-- Remove the bolt -2- and then remove the catalytic converter toward the rear.

Fig 21: Identifying Catalytic Converter

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NOTE:

Ignore item -1-.

-- Disconnect the connector -arrow- from the Transmission Fluid Auxiliary Hydraulic Pump 1 -V475- from the right side of the transmission and free up the electric wire.

Fig 22: Transmission Fluid Auxiliary Hydraulic Pump 1 -V475- Component Location

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-- Loosen bolts -arrows- one turn.

Fig 23: Identifying Crossmember & Bolts

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-- Secure the Tensioning Strap T10038 to the transmission mount and to the tunnel crossmember as shown.

Fig 24: Securing Tensioning Strap T10038

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NOTE:

Use two tensioning straps, if necessary.

-- Disconnect the connector -1- from the Power Steering Control Module -J500- and free up the wire.

Fig 25: Identifying Connector

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NOTE:

Ignore item -2- and -arrow-.

Fig 26: Disconnecting Connector On Transmission

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CAUTION:

There is a risk of destroying the transmission control module (Mechatronic) with static discharge.

Do not touch contacts in transmission connector with hands.

-- To discharge static electricity, touch the transmission housing (without wearing gloves).

-- Turn the twist lock counter-clockwise -arrow- and disconnect the connector from the transmission.

-- Free up electrical wiring harness.

-- Remove the ATF line bolts from the engine -1- and transmission -2-.

Fig 27: Loosening Bolts From ATF Pipe On Engine -1- & Transmission -2-

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-- Remove the bolt -arrow- from the ATF pipe bracket.

Fig 28: ATF Pipe Bracket

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NOTE:

Place a cloth underneath to soak up any escaping ATF.

-- Remove the bolts -arrows- and tie up the ATF lines -1-.

Fig 29: ATF Lines And Bolts

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NOTE:

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

-- Remove the lower cover -1- from the transmission -arrow-.

Fig 30: Identifying Transmission Lower Cover

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-- To loosen the bolts for the Electro-Drive Drive Motor -V141-, counterhold the crankshaft using the Counterhold - Vibration Damper T10355 on the vibration damper.

Fig 31: Identifying Vibration Damper "TDC" Position With Special Tool T10355

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-- Continue turning the crankshaft 120° in the direction of engine rotation to remove the three Electro-Drive Drive Motor -V141- bolts -arrow-.

Fig 32: Identifying Clutch Module First Bolt Installation Location

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-- Remove the bolts -1, 6, 7, 8, 9 and 10- connecting the transmission to the engine.

Fig 33: Engine To Transmission Bolts

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NOTE:

Ignore -item A-.

-- Loosen the clamps -1 and 3- and remove the coolant lines.

Fig 34: Identifying Clamps -1- & -3- & Remove Coolant Hoses

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NOTE:

Ignore item -2- and -arrows-.

-- Open the clamp -2- and remove the coolant hose.

Fig 35: Identifying Clamp

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NOTE:

Ignore item -1-.

-- Remove the Electrical A/C Compressor -V470- from the auxiliary components bracket and tie it up on the left side, refer to A/C COMPRESSOR, REMOVING AND INSTALLING, ELECTRICALLY-DRIVEN A/C COMPRESSOR .

WARNING:

Refrigerant can cause serious personal injury.

Do not open the A/C system refrigerant circuit.

CAUTION:

Risk of damaging refrigerant lines and hoses.

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

-- Free up the wiring harness.

Fig 36: Front Coolant Pipe

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-- Remove the bolts -1 and 2- and then move the coolant pipe, with the coolant hoses still connected -arrows-, upward.

-- Free up the coolant hose.

NOTE:

The illustration shows a non-hybrid vehicle.

-- Disconnect the connectors -1 and 2- from the Oil Pressure Switch -F22- and Reduced Oil Pressure Switch -F378-

Fig 37: Locating Oil Pressure Switch -F22- And Reduced Oil Pressure Switch -F378-

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NOTE:

The illustration shows a non-hybrid vehicle.

CAUTION:

Risk of contamination to the fuel system.

Note the rules of cleanliness for working on the fuel injection system, refer to CLEAN WORKING CONDITIONS .

-- Press the release ring and disconnect the fuel supply hose -1-.

Fig 38: Disconnecting Fuel Supply Hose -1-

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-- Remove the hose -2- from the Evaporative Emission (EVAP) canister.

-- Remove the left and right foam block -1 and 2-.

Fig 39: Removing Left And Right Foam Block

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-- Remove the seal -3-.

Fig 40: Identifying Clips -1- & Remove Plenum Chamber Cover -2-

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-- Open the clips -1- and remove the plenum chamber cover -2-.

-- Press the release buttons and remove the vacuum line -3- from the tower brace.

Fig 41: Removing Vacuum Line

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-- Disconnect the vacuum connection -2- from the plenum chamber bulkhead by remove the vacuum hose -1- on the back side -arrow-.

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

Fig 42: Strut Tower Brace And Fasteners

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-- Remove the bolt -2- and the nut -3-.

Fig 43: Removing Filler Neck -1- With Filler Tube From Washer Fluid Reservoir & Opening In Body -Arrow-

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-- Remove the filler neck -1- with the filler tube from the washer fluid reservoir and the opening in the body -arrow-.

-- Remove the nut -5- and free up the GND wire.

Fig 44: Identifying E-Box Cover & Bolts

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-- Remove the bolts -1, 2 and 4- and remove the E-box cover -3- in the engine compartment -arrow-.

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

Fig 45: Release Retainers And Remove Engine Control Module

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-- Disconnect the connector -2- if applicable.

Fig 46: Disconnect Electrical Connector If Applicable

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-- Disconnect the connectors -4- and the wire -3-.

-- Open the tabs -arrow- and Fuse Panel B -SB- -1-.

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

-- Open the cover -1- -arrow A-.

Fig 47: Wire Guide -3- Nut

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-- Remove the nut -2-, guide the electric wire through the wire guide -3- and free it up on the plenum chamber bulkhead.

-- Remove the nut -arrows B-.

-- Disconnect the connector -arrow- from the Brake Booster Pressure Sensor -G294-.

Fig 48: Brake Booster Pressure Sensor Harness Connector

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

Fig 49: Opening Terminal Box Cover

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-- Remove the connector -5- from the bracket and disconnect it.

Fig 50: Wiring Harness Connections

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-- Disconnect the connector -3-.

-- Remove the nut -1- and free up the GND wire -2-.

-- Remove the nuts -4- and free up the electric wires.

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

Fig 51: Release Retainers From Wheel Housing Side Using A 5.5 Mm Open End Wrench And Remove Wiring Bushing Upward

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-- Free up the wiring harness -3-.

-- Remove the nut -2- on the right longitudinal member and free up the GND wires.

Fig 52: Identifying Retainer

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-- Unlock the retainer -arrow-, open the wiring duct -1- and free up the wiring harness.

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

Fig 53: Disengaging Catches -Arrows A- And Remove Upper Part Of Line Pass-Through -2- Upward -Arrow B-

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-- Lay the wiring harness on the engine and secure the ECM against falling down.

NOTE:

Ignore item -1-.

-- Remove the high voltage cables -arrows- from the Electric Drive Power and Control Electronics -JX1-, refer to OVERVIEW - HIGH VOLTAGE CABLES .

Fig 54: Electric Drive Power And Control Electronics -JX1- High Voltage Cables

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-- Remove the left clip -arrow- from the plenum chamber bulkhead.

Fig 55: Identifying Clip

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-- Remove the nut -1-.

Fig 56: Removing Plenum Chamber Bulkhead

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-- Remove the coolant hoses -3- through the plenum chamber bulkhead.

-- Free up the electric wire -2- and guide it out through the plenum chamber bulkhead.

-- Free up the high voltage cables on the plenum chamber bulkhead.

-- Lower the plenum chamber bulkhead slightly, open the retainers with a screwdriver -4- -arrow- and pull the wire holder -5- off the plenum chamber bulkhead.

-- Remove the plenum chamber bulkhead.

-- Disconnect the connectors -2 and 3- and free up the wires.

Fig 57: Removing Coolant Hoses

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-- Remove the bolt -arrow-.

-- Open the clamps -1- and remove the coolant hoses.

-- Loosen the hose clamps -2 and 3- and remove the coolant hoses.

Fig 58: Pump Unit Bracket Bolts

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-- Remove the bolts -1 and 4- and remove the pump unit.

NOTE:

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

Make sure all hoses and lines are sealed off properly so no fluid can leak out.

-- Remove the transmission/engine bolts -2... 5-.

Fig 59: Engine To Transmission Bolts

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NOTE:

Ignore item -A-.

-- Remove the starter from the transmission and leave it in the installation position.

Fig 60: Identifying Bolt & Spacer Sleeve

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NOTE:

The bolt -2- attaches the starter to the transmission and has an additional spacer sleeve -arrow-.

-- Install Transmission Lift Hook T40013 on the transmission and close locking device.

Fig 61: Installing T40013 On Transmission

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-- Position the Engine Support Bridge 10-222A on the left and right suspension strut towers as illustrated.

-- Attach the transmission and spindle to the Engine/Gearbox Support Shackle (2 pc.)10-222A/12 and Transmission Lift Hook T40013.

NOTE:

The installation location is shown with the engine removed.

-- Engage the Engine Sling 2024A on the engine and on the Shop Crane VAS6100 with Lift Arm Extension VAS6101 as shown in the illustration.

Fig 62: Attaching -2024 A- To Engine & To - VAS 6100- With - VAS 6101-

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NOTE:

To be aligned to the center of gravity of the engine assembly, the hole rails of the lifting hook must be inserted as shown in the illustration.

WARNING:

Loose engine support bridge components could cause an accident.

Secure the mounting hooks and pins on the engine support bridge using securing pins -arrows-.

-- Lift the engine until the engine mount is free.

-- Re-tension the Tensioning Strap T10038.

-- Turn the Engine Support Bridge - Spindle10-222A/11.

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 lift and guide the engine out of the engine compartment.

NOTE:

A second technician is needed while removing the engine to make sure the hood is opened all the way.

Fig 63: Identifying Strut -1- And Ball Pin -2-

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-- Lift the left and right locking springs -arrow- with a small screwdriver and remove the top of the gas-filled strut -1- from the ball pin -2-.

-- Remove the engine from the transmission and lift it out of the engine compartment.

-- Press the gas-filled struts back onto the ball studs.