Engine, Removing, Vehicles With DSG Transmission: Procedure

WARNING: This page is about a different car, the 2015 Audi A7 Quattro, 2014 Audi A7 Quattro, 2013 Audi A7, and 2012 Audi A7. 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:

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 .

-- Position the front wheels so they are straight.

NOTE: Release the electro-mechanical parking brake before disconnecting the battery so the driveshaft can be rotated to remove it.

CAUTION:

Danger of causing damage to electronic components.

Complete the steps for disconnecting the battery.

-- Turn off the ignition and remove the key.

-- 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 o .

-- Remove the engine covers -1- and -2- upward.

Fig 1: Identifying Engine Cover -1- And -2-

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Fig 2: 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 left and right front wheels, refer to WHEELS AND TIRES .

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

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

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

Fig 3: Identifying Drain Plug

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

Fig 4: Identifying Clamp

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NOTE: Ignore item -2-.

-- Loosen the hose clamps -1- and -3-, remove the left front coolant hoses from the coolant pipes and drain any remaining coolant.

Fig 5: Identifying Hose Clamps

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NOTE:

The installed position is shown in the illustration with the engine removed.

Ignore item -2-.

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

NOTE: Ignore item -2-.

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

Fig 6: Identifying Bolts And Air Guide

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-- Free up the fuel hose -1- and the EVAP canister hose -2- on the air duct pipe.

Fig 7: Identifying Clamps

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-- Remove the vacuum hose -3- from the air guide pipe connection.

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

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

Fig 8: Identifying Air Filter Housing

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-- Remove the secondary air hose -arrow- by pressing the release buttons.

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

Fig 9: Identifying Clamp

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-- Disconnect the connector -2- on EVAP Canister Purge Regulator Valve 1 -N80- and disconnect the vacuum hose -3-.

-- Disengage the EVAP Canister Purge Regulator Valve 1 -N80- from the bracket and lay it aside with the hoses connected.

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 .

-- Remove the fuel line -1-, refer to CONNECTOR COUPLINGS, SEPARATING .

Fig 10: Identifying Fuel Line

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

-- Lift the clamp -arrow- and remove the coolant hose leading to the back of the heater core on the engine.

Fig 11: Identifying Coolant Hose Clamp

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NOTE: The installed position is shown in the illustration with the engine removed.

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

Fig 12: Identifying Clamp And Right Front Coolant Hose To Front Coolant Pipe

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

Fig 13: Identifying Bolt

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-- Remove the bolt -1- and free up the refrigerant line.

-- Lift the clamp -arrow-, free up the coolant hose and remove the left coolant hose from the coolant pipe.

Fig 14: Identifying Coolant Hose From Front Coolant Pipe By Lifting Retaining Clamp

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Fig 15: Identifying Bolt

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CAUTION:

Risk of damaging refrigerant lines and hoses.

Do not stretch, kink or bend refrigerant lines and hoses.

-- Remove the bolt -2- and then remove the refrigerant line from the A/C compressor.

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

NOTE: Ignore items -1 and 3-.

-- 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 16: Identifying Retainer

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

Fig 17: 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 18: Identifying Foam Wedge And Bolts

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-- Remove the bolts -arrows-.

-- Open the retainers -arrows- and free up the wiring guide -2-.

Fig 19: Identifying Retainers

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-- Remove the cap nut -1- and free up the ground cables.

-- 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 20: 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 21: Engine Control Module -J623-

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

Fig 22: Identifying Bolts And Cover

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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 from the plenum chamber E-box and free it up.

Fig 23: Identifying Connectors And Nut

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

Fig 24: 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.

-- Disconnect the connector -2- from the Charge Air Cooling Pump -V188- and free it up.

Fig 25: Location Charge Air Cooling Pump -V188-

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NOTE: Ignore item -1- and -arrows-.

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

Fig 26: Identifying Coolant Fan Connectors

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-- Free up the wiring harness.

-- Disconnect the connector -4- on the Secondary Air Injection Pump Motor -V101-.

Fig 27: Secondary Air Injection Pump Motor -V101- Component Location

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-- Press the release buttons and remove the secondary air hose -2-.

NOTE: Ignore items -1 and 3-.

-- 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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-- Disconnect the connector -1- from the left and right front speed sensors -2- -G45- / -G47-.

Fig 29: ABS/Electronic Stabilization Program Speed Sensor Assembly Overview

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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 30: Identifying 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 -arrows-.

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

Fig 31: Identifying Nut And Bolt

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NOTE: The bolts -2- will be removed later.

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

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

Fig 32: Identifying Left And Right Stabilizer Bar Bolt

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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 remove the subframe heat shield -1-.

Fig 33: Identifying Subframe Heat Shield Bolts

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

Fig 34: Identifying Left Front Muffler Nuts

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

Fig 35: 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 .

-- Open the retainer -arrow- and push it down and then disconnect the connector -2- from the steering gear.

Fig 36: Identifying Connector

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-- Disconnect the connector -1-.

-- Free up the wiring harness.

Prepare Scissor Lift Platform:

Fig 37: 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 38: 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 VAS 6131/10 and VAS 6131/13 at the left and right on the front of the subframe as shown in the illustration.

Fig 39: 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 VAS 6131/10 at the left and right rear on the subframe crossbrace front connecting points as shown in the illustration.

Fig 40: 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 41: 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 42: 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.

Fig 43: 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 44: Identifying Bolts

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

Fig 45: 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 46: Lower The Transmission

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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 47: 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 more.

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