Engine, Removing, Audi S6/S7

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

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 -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 .

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

Fig 4: Identifying Drain Plug And Clamp

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-- Remove the drain plug -2- and drain the coolant.

-- Loosen the clamp -1-, remove the coolant hose from the left lower coolant pipe and let the coolant drain out.

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

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

Fig 5: Identifying Bolts And Air Guide

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

Fig 6: Identifying Bolts

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NOTE:

Ignore item -1-.

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

Fig 7: Hose Clamps & Air Filter Housing

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

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

Fig 8: Identifying Clamps

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

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-.

Fig 9: Identifying Release Ring To Disconnect Fuel Line -2-

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-- 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.

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

Fig 10: Identifying Clamp

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

Fig 11: Identifying Clamps

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-- Free up the coolant hoses -arrow-.

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

Fig 12: Identifying Bolts & Clamp

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-- Free up the coolant hose line.

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

-- Disconnect the connector -3-.

Fig 13: 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.

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

Fig 14: Identifying Bolts

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

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

Fig 15: Identifying Retainer

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

Fig 16: Identifying Nuts

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

-- 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.

Fig 17: Identifying Foam Wedge And Bolts

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-- Remove the bolts -arrows-.

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

Fig 18: Identifying Wiring Duct -1-

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

-- 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 19: Identifying Bolts

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

Fig 20: Engine Control Module -J623- Component Location

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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 engine compartment E-box cover -1-.

Fig 21: 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-.

Fig 22: Identifying Connectors And Nut

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

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

Fig 23: 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.

-- Remove the bolt -1- and guide the refrigerant line -2- through the left air guide -3-.

Fig 24: Identifying Bolt, Refrigerant Line -2- & Left Air Guide -3-

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-- Disconnect the connectors -1, 2- and free them up.

Fig 25: Identifying Connectors

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

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

Fig 26: Identifying Air Filter & Clamp

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

Fig 27: Identifying Clamp

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-- Remove the coolant fan electrical connectors -1, 2- from the bracket and disconnect it by sliding the retainer back in direction of -arrow- and pressing the release down.

Fig 28: Identifying Coolant Fan Electrical Connectors

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-- Free up the wiring harness.

-- Disconnect the connector -arrow-.

Fig 29: 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 30: 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 31: 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 32: 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 33: Identifying Left And Right Stabilizer Bar Bolt

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-- Free up the clip -arrow-.

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

Fig 34: Identifying Connector

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-- 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 35: Identifying Subframe Heat Shield Bolts

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

Fig 36: Identifying Left Front Muffler Nuts

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

Fig 37: 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 .

Fig 38: Identifying Steering Intermediate Shaft Bolt

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

Fig 39: Identifying Connector -1-

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

-- Free up the wiring harness.

Prepare Scissor Lift Platform:

Fig 40: 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	/10-3	/10-5	/11-1
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 41: Identifying Subframe Bolts

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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 VAS 6131/10 and VAS 6131/13 at the left and right on the front of the subframe as shown in the illustration.

Fig 42: 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 43: 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 44: 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 45: Identifying Scissor Lift Table

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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.

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

Fig 46: Identifying Subframe Bolts (Tighten To Specifications)

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

Fig 47: Identifying Bolts

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

Fig 48: 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.

-- Next lower engine/transmission subassembly with Scissor Lift Table VAS 6131B only by dimension -a-.

Fig 49: Lower Transmission To Dimension -a-

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Dimension -a- = 100 mm maximum.

-- Remove the ball socket -2- on the selector lever cable from the selector shaft lever using the Pry Lever 80-200.

Fig 50: Identifying Selector Lever Cable

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-- Press the securing clips -1- off and remove the selector lever cable from the transmission.

NOTE:

Do not bend or kink the selector lever cable.

-- Lower the engine/transmission subassembly.

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