Engine, Removing

Special tools and workshop equipment required 

• Engine Bung Set: VAS6122 
  Fig 1: Engine Bung Set

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• Scissor Lift Table: VAS6131B 
  Fig 2: Scissor Lift Table (VAS6131B)

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• Scissor Lift Table - Audi Set: VAS6131/10 
  Fig 3: Identifying Scissor Lift Table - Audi Set VAS 6131/10

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• Universal Supports: VAS6131/13-2  from Scissor Lift Table - Q7 Set: VAS6131/13  , quantity 2
• Shop Crane - Drip Tray: VAS6208 
  Fig 4: Identifying Drip Tray

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• Hose Clip Pliers: VAS6340 
  Fig 5: Hose Clip Pliers VAS6340

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• Hose Clip Pliers: VAS6362 
  Fig 6: Hose Clip Pliers

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• Engine and Gearbox Jack: VAS6931 
  Fig 7: Engine and Gearbox Jack VAS6931 or VAG1383A

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• Ball Joint Splitter (Kukko 129-3): VAS251805 
  Fig 8: Ball Joint Splitter (kukko 129-3)

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• Tensioning Strap: T10038 
  Fig 9: Identifying Tensioning Strap T10038

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• Commercially available Step Ladder

Procedure 

• With the lock carrier installed, the engine is removed downward with the transmission and subframe.
• Install cable ties at the same locations when installing.
• Pay attention to the guidelines for clean working conditions. Refer to CLEAN WORKING CONDITIONS .
• All chassis component bolts with bonded rubber bushings must be tightened in the control position.
• Bonded rubber bushings have a limited range of rotation. Before axle components with bonded rubber bushings are tightened, they have to be brought to a position which matches the position when the vehicle is being operated (control position). Otherwise, the bonded rubber bushing will be under stress, which will reduce the service life.

-- Before starting the procedures, determine the curb weight position (refer to WHEEL BEARING IN CURB WEIGHT POSITION, LIFTING VEHICLES WITH COIL SPRING ), or determine the standard vehicle height (refer to WHEEL BEARING AT STANDARD VEHICLE HEIGHT, LIFTING VEHICLES WITH AIR SUSPENSION ).

-- Move the front wheels so that they are in a straight-ahead position.

-- Switch off the ignition.

• The electro-mechanical parking brake must be released before disconnecting battery so the driveshaft can be rotated to remove it.

-- De-energize the 48 Volt system and disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

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

-- Open the coolant expansion tank cap -1- by releasing the catch in direction of -arrow-.

-- Remove the air filter housing. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

-- Remove the lock carrier cover. Refer to OVERVIEW - BUMPER COVER .

-- Remove the air duct pipes. Refer to AIR DUCT PIPE, REMOVING AND INSTALLING .

-- Loosen the threaded connection between the drive axle and wheel hub. Refer to DRIVE AXLE THREADED CONNECTION, LOOSENING AND TIGHTENING .

-- Remove the front wheels. Refer to WHEEL, CHANGING .

-- Remove the left and right front wheel housing liner front section. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

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

-- Remove the left and right lower longitudinal members. Refer to OVERVIEW - LOCK CARRIER .

-- Remove the right and left front muffler. Refer to FRONT MUFFLER, REMOVING AND INSTALLING .

-- Remove the driveshaft. Refer to DRIVESHAFT, REMOVING AND INSTALLING .

-- Remove the left transmission mount. Refer to LEFT TRANSMISSION MOUNT, REMOVING AND INSTALLING .

-- Remove the right transmission mount. Refer to RIGHT TRANSMISSION MOUNT, REMOVING AND INSTALLING .

-- Drain the coolant. Refer to COOLANT, DRAINING AND FILLING .

-- Release the left and right catches in direction of -arrows- and remove the retaining pin -1- for the radiator upward.

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-- Carefully push the radiator module as far forward as possible and secure using suitable service equipment.

-- Loosen the hose clamp -arrow- on the left and right sides and remove the air duct hose from the charge air cooler.

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-- Loosen the hose clamp -5- and remove the air duct hose -6-.

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-- Loosen the hose clamp -1- and remove the air duct hose -2-.

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-- Equipped on some models: loosen the screw-type clamp -1-, and remove the exhaust pipe -3- from the muffler -2- for the parking/auxiliary heater.

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-- Place a cloth underneath to catch any escaping coolant.

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-- Loosen the hose clamp -5- and remove the coolant hose -4-.

-- Disconnect the connector -7- and free up the wire.

-- Remove the coolant hose -2- to do so loosen the hose clamps -3-.

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-- Lift the clip -2- and remove the upper left coolant hose from the radiator.

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-- Remove the A/C compressor from the bracket and tie it up on the left side. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING ON BRACKET .

-- Disconnect the connector -6- and free up the wires:

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-- Remove the upper nut -1- and free up the wire -2-.

-- Release the latch in direction of -arrow- and open the cover -1-. There are different versions.

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-- Remove the nut -3- and free up the wire -2-. There are different versions.

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-- Disconnect the fuel line -2-. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

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-- Loosen the hose clamp -1- and disconnect the hose for the EVAP system.

-- Always seal off any open lines and connections with plugs that are thoroughly cleaned from the Engine Bung Set: VAS6122  .

-- Remove the engine bracket for the driving dynamic support. Refer to DRIVING DYNAMIC SUPPORT ENGINE BRACKET, REMOVING AND INSTALLING .

-- Free up the wire -1- on the wiring duct.

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-- Remove the bolt -2- and free up the ground wire.

-- Remove the bolt -3- and nut -4- and free up the wiring duct.

-- Remove the nut -4- and free up the ground wires.

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-- Remove the bolt -2-.

-- Disconnect the connector -1 and 3- and free up the wires.

-- Remove the bolt -arrow- and open the bracket -3-.

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-- Free up the wires -1 and 2-.

-- Disconnect the left and right connector -1- for the electrohydraulic engine mount solenoid valve.

-- If installed, disconnect the left and right connector -2- for the Assembly Mount Sensor 1 and 2 Assembly Mount Sensor 1 -G748- /Assembly Mount Sensor 2 -G749-.

Vehicles with a Particulate Filter:

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-- Disconnect the connectors and free them up:

1 -  For the Particulate Filter Differential Pressure Sensor -G1037-

3 -  For the Exhaust Gas Temperature Sensor 3 -G495-

Continuation for All Vehicles: 

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-- Lift the clamp -1- and disconnect the coolant ventilation line to the engine -5-.

-- If necessary, disconnect the connectors and free it up.

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1. For the Charge Air Pressure Sensor 2 -G447-
2. For the Tank Ventilation Pressure Sensor 2 -G951-

-- Press the release button and disconnect and free up the vacuum hose -3- to the reservoir.

-- Release and disconnect the connectors -2 and 5-.

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-- Free up the wiring harness and place on the engine.

Vehicles with a Particulate Filter: 

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-- Disconnect the connectors and free them up:

1 -  For the Exhaust Gas Temperature Sensor 3 Bank 2 -G497-

3 -  For the Particulate Filter Differential Pressure Sensor 2 -G1038-

Continuation for All Vehicles: 

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-- Release the catch in direction of -arrow- and remove the vacuum hose -1- at the same time do not damage it.

-- Tie up the vacuum hose to the engine.

Vehicle with Sway Stabilization Control Module -J924- in Right Front Wheel Housing 

-- Remove the right front wheel housing liner rear section. Refer to FRONT WHEEL HOUSING LINER, REMOVING AND INSTALLING .

-- Disconnect the connectors -1 and 2- for the Sway Stabilization Control Module -J924-. Free up the wires.

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Continuation for All Vehicles: 

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-- Tie up the left and right wheel bearing housing -1- as shown with the Tensioning Strap: T10038  . Use a hammer handle -2- to do this.

-- Disconnect the connector -3- on the Left Electrohydraulic Engine Mount Solenoid Valve -N144- and free up the wire.

-- Release and disconnect the left and right connector -2- for the Right Front ABS Wheel Speed Sensor - G45- /Left Front ABS Wheel Speed Sensor - G47-.

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-- Free up the wire.

-- Disconnect the connector -arrow- from the Left Front Level Control System Sensor -G78- / Right Front Level Control System Sensor -G289- and free up the wire.

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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 .

-- Loosen the threaded connection -1-.

-- Remove the joint pins in the upper control arm -2- from the wheel bearing housing.

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

-- Remove the left and right nut -4-.

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-- Remove the stabilizer bar. Refer to STABILIZER BAR, REMOVING AND INSTALLING .

-- Detach the left and right drive axles from the transmission. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

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

-- Release and disconnect the right connector on the transmission -1-.

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-- Free up the wiring harness -2- -arrows-.

-- Release and disconnect the connectors -1-.

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-- Unclip the wiring harness -2- -arrows- and free up.

-- To release turn the twist lock counter-clockwise -arrow- and disconnect the front connector -1- from the transmission.

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-- Remove the bolts -arrows- and tie up the Transmission Coolant Valve -N488- -1- with the bracket -2- to the side.

-- Remove the right coolant pipe on the transmission. Refer to COOLANT PIPES, REMOVING AND INSTALLING .

-- Release the retainers in direction of -A arrows- and slide the sleeve -1- on the emergency release cable in the direction of -arrow B-.

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-- Disengage the rear section of the emergency release cable from the front section of the emergency release cable in direction of -arrow C-.

Scissor Lift Table, Preparing:

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

Table Coordinates	Parts from Scissor Lift Table - Audi Set: VAS6131/10  and Scissor Lift Table - Q7 Set: VAS6131/13
B5	/10-1	/10-4	/10-5	/10-8
G5	/10-1	/10-4	/10-5	/10-8
B6	/10-1	/10-3	/10-5	/10-6
G6	/10-1	/10-3	/10-5	/10-6
A8	/13-4	/10-2	/10-5	/13-2
F8	/13-4	/10-2	/10-5	/13-2
C15	/10-1	/10-4	/10-5	/10-13
F15	/10-1	/10-4	/10-5	/10-13

-- Secure the mounting elements by hand on the Scissor Lift Table: VAS6131B  .

-- Position the Scissor Lift Table: VAS6131B  so it is level.

• Note the bubble level (sight glass) on support platform.

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

-- Attach mounting elements from the Scissor Lift Table - Audi Set: VAS6131/10  and Scissor Lift Table - Q7 Set: VAS6131/13  at the left and right of the control arm, as shown.

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-- Make sure the threaded spindles are completely screwed in.

-- Attach the mounting elements from the Scissor Lift Table - Audi Set : VAS6131/10  to the mounting element on the left and right front as shown.

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-- Install the internal multi-point bolt -arrow- for the subframe crossbrace all the way into the subframe on the left and right sides.

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-- Attach the mounting elements from the Scissor Lift Table - Audi Set : VAS6131/10  to the internal multi-point bolts for the subframe crossbrace on the left and right sides as shown.

-- Attach the mounting elements from the Scissor Lift Table - Audi Set : VAS6131/10  to the tunnel crossmember on the left and right sides as shown.

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

-- Fasten the mounting element base plates to 20 Nm on the Scissor Lift Table: VAS6131B  .

-- Secure the subframe. Refer to SUBFRAME, LOWERING .

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

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-- Lower the Scissor Lift Table: VAS6131B  with the engine/transmission assembly approximately 80 mm.

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

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

-- Lower the Scissor Lift Table: VAS6131B  more with the engine/transmission assembly and remove from under the vehicle.