Engine, removing

WARNING: This page is about a different car, the 2008 Audi RS 4 and 2007 Audi RS 4. 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.
Drained coolant must be stored in a clean container for disposal or reuse.
During installation, re-install all heat insulation sleeves and heat shields at the same locations.
All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

Fig 1: Identifying Special Tools - Engine, 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
Step ladder VAS 5085
Scissor lift platform VAS 6131 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, the supplementary set VAS 6131/11 and adapter VAS 6131/10-12 (qty. 2) will be additionally required.

Work procedure

Raise luggage compartment floor covering and secure.

CAUTION: Observe safety precautions when disconnecting the battery →

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

Fig 2: Disconnecting Battery Ground (GND) Strap

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With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
Discharge refrigerant circuit Refrigerant R134a - Servicing.
Extract hydraulic oil for power-steering from reservoir using old oil collecting and extracting device V.A.G 1782.

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

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

Fig 3: 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 4: 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 5: Removing Left Air Guide In Front Of Auxiliary Cooler

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

Fig 6: Removing Bolt On Auxiliary Cooler Upper Bracket, At Left Of Lock Carrier

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Remove bolt - arrow - on auxiliary cooler upper bracket, at left of lock carrier.

Fig 7: Removing Right Air Guide In Front Of Auxiliary Cooler

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Remove right air guide - arrow - in front of auxiliary cooler.
Place old oil collecting and extracting device V.A.G 1782 under engine.
Drain engine oil.

Fig 8: Removing Bolts On Oil Cooler Lines At Upper Part Of Oil Pan

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Remove bolts - arrows - on oil cooler lines at upper part of oil pan.
Remove oil lines from upper part of oil pan.

Fig 9: 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 10: Removing Drain Plug On Front Coolant Pipe

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In addition, remove drain plug - arrow - on front coolant pipe and allow rest of coolant to drain.

Fig 11: Removing Coolant Hose Downward From Cooler

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Loosen hose clamps - arrow - and remove coolant hose downward from cooler.
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: Removing Cover In Engine Compartment (Left Side)

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

Fig 14: Removing Bolts & Air Ducts

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

Fig 15: Disconnecting Top Coolant Hose From Radiator

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Disconnect top coolant hose - arrow - from radiator.

Fig 16: Removing Electrical Harness Connectors From Bracket

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

Fig 17: 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 18: 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 electrical wiring.
Remove hood cable at lock carrier →
- 55 HOOD, LIDS
- 55 - HOOD, LIDS for BODY EXTERIOR - CABRIOLET
.

Fig 19: Disconnecting Electrical Harness Connector For Right Fan

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Disconnect right radiator fan electrical connector - arrow -.

Fig 20: Removing Bolt And Disconnecting Refrigerant Line To A/C Compressor

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NOTE:

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

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

Fig 21: Removing Bolt And Disconnecting Refrigerant Line To A/C Evaporator

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

Fig 22: Removing Right Coolant Hose

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Remove right coolant hose - arrow -.

Fig 23: 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 24: 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 25: Pulling Rear Engine Cover Off

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Pull rear engine cover off - arrows -.

Fig 26: Pulling Front Engine Cover Off

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Pull front engine cover off - arrows -.

Fig 27: Removing Coolant Hoses & Coolant Expansion Tank

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

Fig 28: Removing Ground (GND) Connection & Vacuum Lines To Brake Booster From Distribution Piece

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Remove Ground (GND) connection - 2 -.
Remove vacuum lines - 1 - and - 3 - to brake booster from distribution piece.

Fig 29: Removing Hose At Evaporative Emission (EVAP) Canister Purge Regulator Valve N80

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Remove hose at Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - arrow -.
Free up hose.

Fig 30: Disconnecting Electrical Harness Connector On Brake System Vacuum Pump V192

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Disconnect electrical harness connector - arrow - on Brake System Vacuum Pump V192.

Fig 31: Disconnecting Electrical Harness Connector For After-Run Coolant Pump V51 (Behind Auxiliary Cooler At Left)

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

Fig 32: Disconnecting Vacuum Hose

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Disconnect vacuum hose - arrow -.

Fig 33: Removing Hose At Power Steering Fluid Reservoir

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NOTE:

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

Remove hose - arrow - at power steering fluid reservoir.

Fig 34: Disconnecting Coolant Hoses

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Disconnect coolant hoses at positions indicated by - arrows -.

Fig 35: Removing Coolant Hose From Thermostat Housing

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Remove coolant hose from thermostat housing - arrow -.

Fig 36: Removing Coolant Hoses To Oil Cooler At Engine And To Generator

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Remove coolant hoses to oil cooler at engine and to generator - arrows -.

Fig 37: Disconnecting Coolant Hoses

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Disconnect coolant hoses at positions indicated by - arrows -.

Fig 38: Removing Bolts & Bracket For Front Torque Support

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Remove bolts - 1 to 3 -.
Remove bracket for front torque support.

Fig 39: Identifying Mass Air Flow (MAF) Sensor G70 Electrical Harness Connector, Secondary Air Injection (Air) Pump Hose, Vacuum Lines & Air Guide Hose

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Disconnect electrical harness connector - 4 - at Mass Air Flow (MAF) Sensor G70.
Disconnect hose - 5 - to Secondary Air Injection (AIR) pump.
Pull off vacuum lines - 1 - and - 6 -.
Disconnect air guide hose - 3 - at Mass Air Flow (MAF) sensor.

Free up electrical wiring harness at air filter housing.
Remove clip - 2 - and remove air filter housing with Mass Air Flow (MAF) sensor.

NOTE:

Ignore - arrows -.

Fig 40: Removing Hose At Secondary Air Injection Pump By Pressing Release Buttons & Disconnecting Electrical Harness Connectors

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Remove hose - 1 - at secondary air injection pump by pressing release buttons.
Disconnect electrical harness connectors - 2 - and - 3 -.
Free up electrical wiring.
Disconnect vacuum hose - 2 - from air guide hose.

Remove hose clamps - 1 - and - 3 - and lay air guide hose aside.

CAUTION: Hose connectors must not be opened.

Fig 41: Removing Bolts & Disengaging Retaining Clip & Removing Rear Engine Cover Bracket

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Remove bolts - 1 -.
Disengage retaining clip - 2 - and remove rear engine cover bracket.

Fig 42: Disconnect fuel supply line - arrow - at fuel rail

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

Disconnect fuel supply line - arrow - at fuel rail.

Fig 43: Identifying Plenum Chamber Cover & Rubber Seal

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Remove rubber seal and plenum chamber cover - 1 - forward - arrows -.

Fig 44: Removing Securing Clips And Cowl

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Pry off cover caps - 3 - from wiper arms with a screwdriver.
Loosen nuts - 4 - several turns.
Loosen wiper arms - 2 - one after another by tilting wiper axles slightly.
Remove nuts completely and remove wiper arms.

NOTE:

If wiper arm cannot be removed in this way, use a standard puller.

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

Fig 45: Removing Screws And Cover From E-Box In Plenum Chamber

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

Fig 46: 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 47: Releasing Retaining Hooks Toward Outside And Removing Retaining Bracket

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

Fig 48: Disconnecting All Electrical Harness Connectors On Connector Station & Electrical Wire Connection

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

Fig 49: 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 50: Disconnecting Electrical Connectors

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Disconnect electrical connectors - 1 - and - 2 -.
Free up wiring harness.
Set electrical wiring harness on engine and secure Engine Control Module (ECM) against falling down.

Fig 51: Removing Bolts, Ground (GND) Pins & Ground (GND) Line Underneath

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Remove bolts - arrows -.
Remove engine control module (ECM) 2 bracket.
Place ECM 2 on engine and secure it against falling down.
Remove Ground (GND) pins - 1 - and remove Ground (GND line underneath.

Remove bolt - 2 - and disengage positive terminal pick-off at mount.

Fig 52: Releasing Retaining Clip And Open Cover Over Positive Terminal Pick-Off, Cover Over Electrical Lines & Removing Nut On Positive Line

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Release retaining clip and open cover - 2 - over positive terminal pick-off.
Release cover - 3 - over electrical lines.
Remove nut - 1 - on positive line.
Pull plus wire through bulkhead toward front.

Free up the wiring harness.

NOTE:

Ignore - 4 -.

Remove heat insulation sleeve over coolant hoses to heat exchanger.

Fig 53: Removing Lower Coolant Hose At Heat Exchanger

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Remove lower coolant hose - arrow - at heat exchanger.
Slide coolant hose back down slightly through rubber sleeve.

Fig 54: Identifying Secondary Air Injection (AIR) Pump Motor V101 Electrical Harness Connector, Long Member Ground (GND) Wire & Right Engine Bracket Electrical Connectors

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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.
Disconnect - 3 - and - 4 - at right engine bracket and at Generator (D+).
Free up wiring harness upward.

Place old oil collecting and extracting device V.A.G 1782 under engine.

Fig 55: Disconnecting Hydraulic Pressure Line For Power-Steering At Left Next To Oil Pan

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Disconnect hydraulic pressure line - arrow - for power-steering at left next to oil pan.

Fig 56: Removing Bolts And Nuts Uniformly At Left/Right

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

NOTE:

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

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

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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 Bracket For Refrigerant Lines At Left Front On Oil Pan

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Remove bracket for refrigerant lines at left front on oil pan - arrow -.

Fig 59: Removing Bracket For Refrigerant Lines At Left Rear On Oil Pan

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Remove bracket for refrigerant lines at left rear on oil pan - arrow -.

Fig 60: 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 -.

Fig 61: Removing Coolant Line Retaining Clamp At Right Of Auxiliary Cooler

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Remove coolant line retaining clamp at right of auxiliary cooler - arrow -.

Fig 62: 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.
Have a second technician press foot brake.

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 63: Identifying Collar Bolt For Right Drive Axle

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

Fig 64: Disconnecting Electrical Harness Connector At Left Front Level Control System Sensor G78

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Disconnect electrical harness connector - 2 - at Left Front Level Control System Sensor G78.
Unclip securing clip - 1 - at Left Front Level Control System Sensor G78 actuating rod at bottom of control arm.

Fig 65: Removing Suspension Strut From Link

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Remove suspension strut from link - 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 Link And Link On Subframe

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Remove guide link - 1 - and link - 2 - on subframe.

Fig 68: 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.

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 Clamping Sleeves

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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 clamping sleeves - 1 - and - 2 -.

Fig 71: 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.
Tie up drive shaft to body.

Fig 72: 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 as follows:

Platform coordinates	Parts from Support Set VAS 6131/10
B4	/10-1	/10-4	/10-5	/10-12
G3	/10-1	/10-4	/10-5	/10-6
B10	/10-1	/10-2	/10-5	/10-8
G10	/10-1	/10-2	/10-5	/10-8
C14	/10-1	/10-3	/10-5	/10-7
E14	/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 73: 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 74: 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 75: Positioning Support Elements From VAS 6131/10 At Left/Right On Tunnel Cross Member

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Position support elements from VAS 6131/10 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 76: 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.

NOTE:

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

Fig 77: Lowering/Lifting 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 - = max. 100 mm.

Fig 78: 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 79: Removing/Installing Nut And Lever From/To Selector Shaft

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

Fig 80: 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.

CAUTION: Do not operate the clutch pedal anymore after slave cylinder has been removed. At a pedal pressure of approx. 300 N, the clutch slave cylinder is destroyed.

Fig 81: Removing/Installing Coolant Hose To Heater Core On Rear Coolant Pipe

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Remove coolant hose - arrow - to heater core on rear coolant pipe.
Lower engine/transmission subassembly downward.
Push scissor lift platform VAS 6131 with engine/transmission subassembly under vehicle.