Engine, Removing, Vehicles With BITURBO Engine: Notes

WARNING: This page is about a different car, the 2016 Audi A6 Quattro. However, it is still accessible from the selected car via links, so may be relevant.

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Special tools and workshop equipment required

Pry Lever :80 - 200
Commercially Available Step Ladder or :VAS 5085
Engine Bung Set :VAS 6122
Scissor Lift Table :VAS 6131 B with Scissor Lift Table - Audi Set :VAS 6131/10 , Scissor Lift Table - A8 Set :VAS 6131/11 and Scissor Lift Table - Q7 Set :VAS 6131/13
Shop Crane - Drip Tray :VAS 6208
Hose Clip Pliers :VAS 6362

Special tools and workshop equipment required

Hose Clip Pliers :VAS 6340

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Procedure

NOTE:

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

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

WARNING:

When working on the entire exhaust system:

Follow the safety precautions when working on the exhaust system.

WARNING:

Risk of vehicle tipping over with engine removed.

The luggage compartment must be empty to secure the vehicle.

Risk of injury due to the fuel being under very high pressure.

The fuel pressure must be reduced to residual pressure before opening the high pressure area of the fuel injection system.

-- Position the front wheels so they are straight.

CAUTION:

Risk of destroying the electronic components.

Follow the steps for disconnecting the battery.

-- Switch off the ignition.

-- Disconnect the ground cable from the battery terminal. Refer to BATTERY .

-- Remove the engine cover -arrows-.

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-- Discharge the refrigerant circuit. Refer to A/C System with Refrigerant R134a.

-- Remove the lock carrier cover. Refer to ATTACHMENTS, REMOVING AND INSTALLING .

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WARNING:

There is a risk of scalding due to hot steam and hot coolant.

The cooling system is under pressure when the engine is warm.
Cover the coolant expansion tank cap with a cloth and carefully open it to reduce the pressure.

-- Open the coolant reservoir cap -arrow-.

-- Remove the left and right front wheels. Refer to WHEELS AND TIRES .

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

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

-- Remove the noise insulation. Refer to NOISE INSULATION .

-- Remove the right air intake grille. Refer to ATTACHMENTS, REMOVING AND INSTALLING .

-- If equipped, remove the right cover -1- to do this release the catches -arrows-.

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NOTE:

Collect dripping coolant in a clean container for disposal or reuse.

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-- Place the Shop Crane - Drip Tray :VAS 6208 under the engine.

-- Remove the drain plug -1- and allow the coolant to drain.

-- Then lift the clamp -2- and disconnect the coolant hose from the radiator.

-- Loosen the clamp -arrow-, remove the coolant hose from the lower left coolant pipe and let the coolant drain out.

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-- Remove the right coolant hose from behind, lift the clamp -arrow-, and drain the coolant.

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-- Remove the plenum chamber cover. Refer to PLENUM CHAMBER COVER, REMOVING AND INSTALLING .

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

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

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NOTE:

Ignore -item 1-.

-- Loosen the hose clamps -arrows- and remove the air duct pipe -1-.

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-- Disconnect and free up the connector -2- from the Mass Airflow Sensor -G70-.

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-- Remove the air filter housing -1- upward.

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CAUTION:

There is a risk of contamination.

Follow the guidelines for clean working conditions when working on the fuel supply system

-- Loosen the clamps and remove the fuel hoses.

Blue Fuel Hose
Yellow Fuel Hose
White Fuel Hose

-- Open the clamp -1- and remove the coolant hose.

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-- Loosen the hose clamp -2- and remove the vacuum hose.

-- Loosen the clamp -arrow- and remove the coolant hose from the front coolant pipe.

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-- Open the hose clamp -3- and remove the air duct hose.

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NOTE:

Ignore -items 1 and 2-.

-- Disconnect the vacuum hose -arrow-.

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

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-- Remove the bolts -1- and free up the refrigerant lines.

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CAUTION:

Risk of damaging the refrigerant lines and hoses.

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

-- Remove bolt -2-, remove the refrigerant line from the A/C compressor and move to the side.

-- Seal the open lines and connections with clean plugs from the Engine Bung Set :VAS 6122 .

NOTE:

Ignore -items 1 and 3-.

-- Disconnect the connector -2- for Charge Air Pressure Sensor -G31- / Intake Air Temperature Sensor -G42- and free up the wire.

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NOTE:

Ignore -item 1-.

Vehicles with an SCR system:

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-- Remove the NOx Sensor -G295- -arrow-, free it up and set to the left side.

Continuation for All Vehicles:

-- Remove the tower brace. Refer to TOWER BRACE, REMOVING AND INSTALLING .

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

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Vehicles without an SCR system:

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-- Remove the nuts -2, 3 and 4- and free up the wire.

-- Remove the connector -1- from the bracket and disconnect it.

Vehicles with an SCR system:

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-- Remove the nuts -2 and 3- and free up the wire.

-- Remove the connector -1- from the bracket and disconnect it.

-- Remove the bolts -arrows- and then remove the Terminal 30 Wire Junction 2 -TV22- from the plenum chamber bulkhead.

-- Disconnect the connectors -arrows- on the Catalytic Converter Heating Control Module 1 -J1021- and free up the wiring harness.

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Continuation for All Vehicles:

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-- Move the foam wedge -1- to the side.

-- Remove the bolts -arrows-.

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

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

-- Remove the bolts -arrows-, pull the filler neck -1- out of the windshield washer fluid reservoir and out of the opening in the body and move it to the right side.

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-- Remove the cap nut -2- and free up the ground wire.

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-- Open the retainer -arrow-, remove the Engine Control Module -J623- -1- from the bracket and move it to the side.

-- Remove the bolts -arrows- and the plenum chamber E-box cover -1-.

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-- Disconnect the connectors -1- and remove the nut -2- for the wire.

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-- Release the retainers -arrows- and remove the relay panel with the fuse panel -3-.

-- Disengage the engine wiring harness from the plenum chamber E-box and free it up.

-- Release the retainers -A arrows- and remove the cable grommet -1- upward -arrow B-.

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-- Lay the wiring harness on the engine and secure the Engine Control Module -J623- so that it cannot fall.

-- Slide the clamp toward the rear -arrow-, press the release downward and remove the radiator fan connectors -1 and 2-.

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-- Free up the wiring harness.

NOTE:

Ignore -item 3-.

-- Remove the air duct hose from the air duct pipe by loosening the hose clamp -arrow-.

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-- Loosen the left and right nuts -arrows- on the crossbrace. Leave the crossbrace -1- in its installation position.

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-- Remove the bolts -arrow- and press the torque support stop -1- towards the engine.

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-- Disconnect the connector -arrow- from the Left and Right Front ABS Wheel Speed Sensors -G45- / -G47-.

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-- If equipped, disconnect the connector -1- on the left and right sides from the Left Front Level Control System Sensor -G78- / Right Front Level Control System Sensor -G289- and free up the wire -arrow-.

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-- Remove the brake caliper and secure it with the brake hose still attached inside the wheel housing with wire. Refer to BRAKE CALIPER, REMOVING AND INSTALLING .

CAUTION:

Risk of damaging the brake pistons.

Do not operate brake pedal when the brake caliper is removed.

-- Remove the nut -2- and the bolt -1-.

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-- Remove the upper control arm upward from the wheel bearing housing -arrows-.

-- Repeat the procedure on the other side of the vehicle.

-- Remove the left and right stabilizer bar bolt -1-.

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-- Remove the left and right nuts -3-.

NOTE:

The bolts -2- will be removed later.

-- Remove the steering intermediate shaft from the steering gear and the push the splines together. Refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

-- Free up the clip -arrow-.

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-- Disconnect the connector -1- and free up the wire.

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

CAUTION:

There is a risk of damaging the suspension components.

If the subframe mount, steering gear or subframe crossbrace are not installed correctly, do not rest the vehicle on its wheels.

-- Remove the left and right bolts -arrows- and remove the heat shield -1-.

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-- Remove the driveshaft. .

-- Release the safety catch -arrow-, push the retainer down and disconnect the connector -2- from the Power Steering Control Module -J500-.

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-- Disconnect the connector -1- from the Power Steering Control Module -J500-.

-- Free up the wiring harness.

-- If installed, remove the bolts -arrows- and then remove the heat shield.

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-- Remove the ball socket -1- on the selector lever cable from the selector shaft lever using the Pry Lever :80 - 200 .

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-- Press the lock washer -2- off and remove the selector lever cable from the transmission.

NOTE:

Do not bend or kink the selector lever cable.

-- Disconnect the connector -arrow-.

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NOTE:

If the engine and transmission are to be separated, remove the connectors from the bracket.

Vehicles with an SCR system:

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-- Disconnect the connector -2- and free up the wiring harness.

-- Loosen the clip -1- and free up the Reducing Agent Injector -N474- with the metering line -3- on the tunnel crossmember and tie up to the underbody.

NOTE:

If the engine and transmission are to be separated for the subsequent work, separate the drive plate threaded connection at the flywheel/torque converter. Refer to.