Engine, Removing, Audi RS6/RS7

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2015 Audi S7, 2015 Audi RS 7, 2015 Audi A7 Quattro, 2014 Audi S7, and 2014 Audi RS 7. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools And Workshop Equipment Required

Pry Lever 80-200
Step Ladder VAS 5085
Engine Bung Set VAS 6122
Scissor Lift Table VAS 6131B 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
Hose Clip Pliers VAS 6340
Used Oil Collection and Extraction Unit SMN372500

Procedure

NOTE:

The engine is removed downward with transmission and subframe.

When installing, bring all cable ties back to same positions.

All bolts on suspension components must be equipped with bonded rubber bushings and tightening in curb weight position (no load).

Bonded rubber bushings have a limited range of motion. Axle components with bonded rubber bushings must be brought into the position they will be in during driving before tightening (curb weight position). Otherwise, the bonded rubber bushing will have tension, which will reduce the service life.

Measure dimension -a- from the center of the wheel to the lower edge of the wheel housing before beginning work, for example, using a tape measure.

Fig 1: Measuring Dimension From Center Of Wheel To Lower Edge Of Wheel Housing Using Tape Measure

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The measurement must be taken with the vehicle in curb weight position (no load).

Note the measurement. This number will be needed when tightening the bolts/nuts.

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.

-- Reduce the fuel pressure in the high pressure area, refer to HIGH FUEL PRESSURE, REDUCING .

NOTE:

To be able to turn the drive axle to remove it, shift the transmission to "N" and release the electromechanical parking brake before disconnecting the battery.

-- Position the front wheels so they are straight.

CAUTION:

Danger of causing damage to electronic components.

Complete the steps for disconnecting the battery.

-- Disconnect the ground cable from the battery terminal, refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Empty the coolant circuit, refer to A/C System with Refrigerant R134a.

-- Remove the lock carrier cover, refer to LOCK CARRIER COVER, REMOVING AND INSTALLING .

-- Remove the driveshaft, refer to REMOVAL AND INSTALLATION or REMOVAL AND INSTALLATION .

-- Remove the engine cover in direction of -arrows-.

Fig 2: Remove Engine Cover

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WARNING:

Fire hazards and risk of damage for a faulty engine cover.

The engine cover must be always be installed before the hood is closed.
The engine may neither be started nor driven without an engine cover.

Fig 3: Identifying Coolant Reservoir Cap

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

-- Remove the left and right front wheel spoiler, refer to FRONT WHEEL SPOILER, REMOVING AND INSTALLING, AUDI A7/S7 or FRONT WHEEL SPOILER, REMOVING AND INSTALLING, AUDI RS7 .

-- Remove the noise insulations, refer to NOISE INSULATION, REMOVING AND INSTALLING .

-- Remove the front bumper cover end plate, refer to BUMPER COVER END PLATE, REMOVING AND INSTALLING, AUDI A7/S7 .

-- Free up the wiring harness -arrow-.

Fig 4: Identifying Nut And Clamp

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-- Remove the nuts -1, and 2-, and free up coolant line.

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

-- Loosen the hose clamps -3, and 4- drain the coolant to remove the coolant hoses.

-- Lift the clamp -1- and loosen hose clamp -2- to disconnect the coolant hose and drain the coolant.

Fig 5: Identifying Clamp

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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-.

Fig 6: Identifying Bolts And Air Guide

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-- Remove bolt -arrows-, and free up the air guide -2- at the lock carrier.

Fig 7: Identifying Bolts

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NOTE:

Ignore item -1-.

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

Fig 8: Hose Clamps & Air Filter Housing

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

-- Remove the right and left attachments -arrows- and unclip the cover -1-.

Fig 9: Identifying Bolts

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

-- Remove heat shield -1- from above in direction of -arrow-.

Fig 10: Removing Heat Shield

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-- Loosen the clamp -2- and remove the vacuum connection from the plenum chamber bulkhead.

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

Fig 11: Identifying Clamps

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WARNING:

Risk of injury from fuel.

To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.

CAUTION:

There is a risk of contamination.

Follow the guidelines for cleanliness when working on the fuel supply system, refer to CLEAN WORKING CONDITIONS .

-- Press the release ring and disconnect the fuel line -2-.

-- Loosen the clamp -1- and disconnect the hose from the EVAP canister.

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

Fig 12: Identifying Release Ring To Disconnect Fuel Line -2-

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-- Disconnect the coolant hose by lifting the retaining clamps -2- and loosening the hose clamp -1-.

Fig 13: Identifying Clamp

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-- Loosen the hose clamps to remove the coolant hoses from the charge air cooling circuit radiator -1-.

-- Free up the coolant hoses -arrow-.

Fig 14: Identifying Clamps

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-- Open the clamp -2- to remove the coolant hose line.

-- Free up the coolant hose line.

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

Fig 15: Identifying Bolts & Clamp

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-- Disconnect the connector -3-.

Fig 16: Identifying Vacuum Hose, Secondary Air Hose & Connector

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-- Disconnect the vacuum hose -1-.

-- Disconnect the secondary air hose -2- by pressing the release buttons.

-- Release the retainer in direction of -arrow A- and open the cover in direction of -arrow B-.

Fig 17: Identifying Retainer

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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.

Fig 18: Identifying Nuts

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-- Remove the nuts -arrows- and then remove Terminal 30 Wire Junction -TV2- from the plenum chamber bulkhead.

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

-- Remove the bolts -arrows-.

Fig 19: Identifying Foam Wedge And Bolts

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

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

Fig 20: Identifying Wiring Duct -1-

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-- 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.

Fig 21: Identifying Bolts

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

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

Fig 22: Engine Control Module -J623- component location

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-- Remove the bolts -arrows- and the engine compartment E-box cover -1-.

Fig 23: Identifying E-Box Cover & Bolts

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

-- Release the retainers in direction of -arrows- and remove the relay carrier with the fuse panel -3-.

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

Fig 24: Identifying Connectors And Nut

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-- Release the retainers in direction of -arrows A- and remove the wiring bushing -1- upward in direction of -arrow B-.

Fig 25: Identifying Wiring Bushing

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

-- Unclip the lower air duct -1- from underneath -arrow-.

-- Remove the bolt -2- and free up the refrigerant line.

Fig 26: Identifying Air Guide

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NOTE:

the Installed position is shown with the front bumper cover removed for better illustration.

-- Free up the connectors -1, 2-.

Fig 27: Identifying Connectors

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-- Remove the left and right bolts -arrows- and the lower front longitudinal member -1-.

Fig 28: Identifying Lower Front Longitudinal Member With Bolts

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-- Remove the air filter -2- from the mount in direction of -arrow-.

Fig 29: Identifying Clamp & Air Filter

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

NOTE:

The illustration shows the Installed position on an Audi S6/S7.

-- Open the clamp -arrow- to remove the coolant hose.

Fig 30: Identifying Clamp

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-- Disconnect the coolant fan connectors -1, 2- to do this, push the clamp to the rear in direction of -arrow- and push the release down.

-- Free up the wiring harness.

Fig 31: Identifying Coolant Fan Electrical Connectors

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-- Place the Used Oil Collection and Extraction Unit SMN372500 under the engine.

-- Remove the nut -1- and the bolts -arrows-.

-- Remove and free up the oil lines from the engine oil cooler.

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

Fig 32: Identifying Nut And Bolts

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-- Disconnect the connector -arrow-.

Fig 33: Identifying Connector

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NOTE:

If the engine must be removed from the scissor lift table for future procedures, remove the connector from the mount and guide it through the subframe.

-- Disconnect the electrical connectors -arrow- at the left and right on the front speed sensors -G45- / -G47-.

Fig 34: Identifying Speed Sensor Connector

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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-.

Fig 35: Identifying Left And Right Connector

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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 SYSTEM - MECHANICAL COMPONENTS .

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-.

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

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

Fig 36: Identifying Nut And Bolt

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

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

NOTE:

The bolts -2- will be removed later.

Fig 37: Identifying Left And Right Stabilizer Bar Bolt

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-- Free up the clip -arrow-.

Fig 38: Identifying Connector

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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:

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-.

Fig 39: Identifying Subframe Heat Shield Bolts

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-- Remove the nuts -arrows- and the left front muffler.

Fig 40: Identifying Left Front Muffler Nuts

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-- Remove the nuts -arrows- and the right front muffler.

Fig 41: Identifying Right Front Muffler Nuts

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-- Remove the steering intermediate shaft from the steering gear and the push the splines together, 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-.

Fig 42: Identifying Connector -1-

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

-- Free up the wiring harness.

-- Remove bolts -arrows- and then remove the heat shield.

Fig 43: Identifying Heat Shield & Bolts

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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.

Fig 44: Identifying Selector Lever Cable

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NOTE:

Do not bend or kink the selector lever cable.

Prepare Scissor Lift Platform:

Fig 45: Identifying Scissor Lift Platform VAS 6131

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-- Equip the Scissor Lift Table VAS 6131B with the Scissor Lift Table - Audi Set VAS 6131/10 and Scissor Lift Table - A8 Set VAS 6131/11, and VAS 6131/13 as follows:

Table coordinates	Components from the 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
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	/10-11
G6	/10-1	/10-2	/10-5	/10-11
A8+C8	/13-6	-	-	/13-2
F8+H8	/13-5	-	-	/13-2
B14	/10-1	/10-4	/10-5	/10-7
G14	/10-1	/10-4	/10-5	/11-1

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

-- Position the Scissor Lift Table VAS 6131B horizontally.

Note bubble level (sight glass) on support platform.

-- Guide the Scissor Lift Table VAS 6131B under the engine/transmission subassembly.

Fig 46: Identifying Subframe Bolts (Tighten To Specifications)

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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 Scissor Lift Table - Audi Set VAS 6131/10 and Scissor Lift Table - Q7 Set VAS 6131/13 at the left and right on the front of the subframe as shown in the illustration.

Fig 47: Attach At Left And Right Front Of Subframe As Shown In Illustration

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-- Ensure threaded spindles are completely installed.

-- Attach the mounting elements from the Scissor Lift Table - Audi Set VAS 6131/10 at the left and right rear on the subframe crossbrace front connecting points as shown in the illustration.

Fig 48: Attach At Left And Right Front Of Subframe As Shown In Illustration

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-- Position mounting elements from the Scissor Lift Table - Q7 Set VAS 6131/13 at the lower left and right on the wheel bearing housing as shown in the illustration.

Fig 49: Attach At Lower Left And Right Of Wheel Bearing Housing As Shown In Illustration

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-- Attach mounting elements from the Scissor Lift Table - Audi Set VAS 6131/10 and Scissor Lift Table - A8 Set VAS 6131/11 at the left and right rear of the tunnel crossmember, as shown in the illustration.

Fig 50: Identifying Mounting Elements

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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 VAS 6131B and tighten to 20 Nm.

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

Fig 51: Identifying Subframe Bolts (Tighten To Specifications)

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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.

Fig 52: Identifying Tunnel Crossmember Bolts

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

Fig 53: Identifying Left And Right Stabilizer Bar Bolt

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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.

Danger of causing damage to the front coolant pipe.

When lowering push the engine/transmission subassembly slightly toward the rear.

-- Lower the engine/transmission subassembly.

-- Remove the Scissor Lift Table VAS 6131B with engine/transmission assembly from under the vehicle.