Engine, Removing, Vehicles With Manual Transmission: Procedure

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.

NOTE:

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

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

WARNING:

When working on the whole exhaust system:

Follow the safety precautions when working on the exhaust system.

WARNING:

Risk of vehicle tipping over with engine removed.

Secure vehicle. Luggage compartment must be empty for this.

There is a risk of injury because the fuel is under very high pressure.

Reduce the fuel pressure down to residual pressure before opening high pressure area of the fuel injection system.

-- Position the front wheels so they are straight.

CAUTION:

Danger of causing damage to electronic components.

Observe the steps for disconnecting the battery.

-- Turn off the ignition.

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

-- Remove the engine cover -arrows-.

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-- Drain 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:

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.

-- Remove the cap -arrow- from the coolant reservoir.

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

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

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

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

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

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

-- Lift the clip -2- and disconnect the coolant hose from the radiator.

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

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

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

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

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NOTE:

Ignore -item 1-.

-- Open the clamps -arrows- and remove the air guide 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 cleanliness 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 -2- and remove the coolant hose.

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-- Loosen the clamp -1- and remove the vacuum connection from the plenum chamber bulkhead.

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

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-- Loosen the clamp -3- and remove the air guide hose.

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NOTE:

Ignore -items 1 and 2-.

-- 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:

Danger of causing damage to 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 set aside.

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

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-.

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

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

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

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

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

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

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

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

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

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

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

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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 carrier 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 wiring bushing -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.

-- Push the retainer back -arrow-, press the release down and disconnect the coolant fan connectors -1- and -2-, if applicable.

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-- Free up the wiring harness.

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

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-- Disconnect the connector -arrow- from the Left Front ABS Wheel Speed Sensor -G45- / Left Front ABS Wheel Speed Sensor -G47-.

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-- Disconnect the left and right connector -1- from the front vehicle level sensor -G78- / -G289- and free up the wire -arrow-.

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

CAUTION:

Risk of damaging 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 subframe crossbrace. Refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

CAUTION:

The suspension components could be damaged.

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

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

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

-- Release the safety catch -arrow-, push the retainer down and disconnect the connector from -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.

-- Remove the bolt -2- and secure the clutch slave cylinder sideways in the engine compartment.

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CAUTION:

Risk of damaging the clutch slave cylinder.

Do not operate the clutch pedal anymore after slave cylinder has been removed.

-- Remove the gearshift rod nut -1-.

-- Position the Puller - Gear Shaft Linkage :T40160 and remove the gearshift rod -1-.

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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 ENGINE AND TRANSMISSION, SEPARATING, VEHICLES WITH MULTITRONIC 0AW .

Prepare scissor lift platform:

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-- Equip the Scissor Lift Table :VAS6131B with the Scissor Lift Table - Audi Set :VAS6131/10 and Scissor Lift Table - A8 Set :VAS6131/11 , and Scissor Lift Table - Q7 Set:VAS6131/13 as follows:

Platform coordinates	Components from the Scissor Lift Table - Audi Set :VAS6131/10 , Scissor Lift Table - A8 Set :VAS6131/11 and Scissor Lift Table - Q7 Set :VAS6131/13
B4	/13-4	/10-4	/10-5	/13-1
G4	/13-4	/10-4	/10-5	/13-1
B6	/10-1	/10-2	/10-5	/11-2
G6	/10-1	/10-2	/10-5	/11-2
A8 + C8	/13-6			/13-2
F8 + H8	/13-5			/13-2
B14	/10-1	/10-3	/10-5	/11-1
G14	/10-1	/10-4	/10-5	/11-1
F17	/10-1	/10-4	/10-5	/13-2

-- First manually secure the mounting elements to the scissor lift table.

-- Position the Scissor Lift Table :VAS6131B horizontally.

Note bubble level (sight glass) on support platform.

-- Guide the Scissor Lift Table :VAS6131B under the engine/transmission subassembly.

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WARNING:

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

Do not loosen the subframe bolts -2- and -3-.

-- Remove the left and right subframe bolts -1-.

-- Attach mounting elements from the : VAS6131/10 and : VAS6131/13 at the left and right on the front of the subframe as shown in the illustration.

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-- Ensure threaded spindles are completely installed.

-- Attach the mounting elements from the : VAS6131/10 at the left and right rear on the subframe crossbrace front connecting points as shown in the illustration.

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-- Position mounting elements from the Scissor Lift Table - Q7 Set : VAS6131/13 at the lower left and right on the wheel bearing housing as shown in the illustration.

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-- Attach mounting elements from the : VAS6131/10 and : VAS6131/11 at the left and right rear of the tunnel crossmember, as shown in the illustration.

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-- Attach the mounting elements from the :VAS6131/10 and :VAS6131/13 under the front exhaust pipe, as shown.

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-- Rotate the mounting element spindles upward until all the mounting pins come into contact with the mounting points.

-- Attach mounting element base plates to Scissor Lift Table : VAS6131 B and tighten to 20 Nm.

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

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CAUTION:

Risk of damaging the decoupling element inside the front exhaust pipe.

Do not bend the decoupling element in the front exhaust pipe more than 10°.

-- Mark the location of the subframe and tunnel crossmember to the longitudinal members using a felt-tip pen.

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-- Remove the left and right subframe bolts -2- and -3- in a diagonal sequence in stages.

-- Remove the bolts -arrows- on the tunnel crossmember.

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NOTE:

Ignore -item 1-.

-- Remove the left and right bolts -2-.

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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 guide the engine/transmission sub-assembly with subframe out of engine compartment while lowering.
Carefully guide the suspension struts past the longitudinal members.

-- Next lower engine/transmission subassembly with Scissor Lift Table : VAS6131 B only by dimension -a-.

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Dimension -a- = 100 mm maximum.

-- Remove the bolts -1- and -3- for the gearshift rod and push rod.

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NOTE:

Ignore -item 2-.

-- Lower the engine/transmission subassembly further.

-- Remove the Scissor Lift Table : VAS6131 B with engine/transmission assembly from under the vehicle.