Engine, Removing

WARNING: This page is about a different car, the 2022 Audi RS 7 Sportback. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Engine Bung Set: VAS6122
Scissors Lift: VAS6131B
Scissor Lift Table - Audi Set: VAS6131/10
Scissor Lift Table - A8 Set - Adapter: VAS6131/11-1 from Scissor Lift Table - A8 Set: VAS6131/11
Shop Crane - Drip Tray: VAS6208
Hose Clip Pliers: VAS6340
Hose Clip Pliers: VAS6362
Scraper no. 1 from the Scraper Set: VAS6845
Engine and Gearbox Jack: VAS6931
Ball Joint Splitter (Kukko 129-3): VAS251805
Ball Joint Splitter: VAS251809 with : VAS251809/1
Tensioning Strap: T10038
Body Socket: T40078
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 GUIDELINES FOR CLEAN WORKING CONDITIONS .
All chassis component bolts with bonded rubber bushings on vehicles with coil spring in the curb weight position (unloaded condition) or on vehicles with air suspension must be tightened in control position.
Bonded rubber bushings have a limited range of rotation. Axle components with bonded rubber bushings must be brought into the position they will be in when driving before they are tightened (curb weight position or 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, LIFTING TO CURB WEIGHT POSITION, VEHICLES WITH COIL SPRING or determine the control position (refer to WHEEL BEARING AT STANDARD VEHICLE HEIGHT, LIFTING VEHICLES WITH AIR SUSPENSION ).

-- Position the front wheels so they are straight.

-- 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 .

-- Remove the plenum chamber bulkhead. Refer to PLENUM CHAMBER BULKHEAD, REMOVING AND INSTALLING .

Fig 1: Coolant Expansion Tank

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CAUTION:

The cooling system is under pressure when the engine is warm. There is a risk of scalding due to hot steam and hot coolant.

Scalding the skin and other parts of the body is possible.

- Wear safety gloves.

- Wear protective eyewear.

- Reduce the pressure by covering the coolant expansion tank cap with a cloth and carefully opening it.

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

-- Discharge the refrigerant circuit. Refer to Refrigerant Circuit or REFRIGERANT CIRCUIT, DISCHARGING .

-- Remove the left and right front cover for the fender. Refer to OVERVIEW - FENDER .

-- Unclip the left and right headlamp covers -2- at the position shown with a wedge from the : VAS6845 in direction of -arrow A-.

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-- Bend the headlamp cover carefully upward and remove it from under the air filter housing -1- in direction of -B arrows-.

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

-- Remove the front wheels. Refer to WHEEL, CHANGING or to the appropriate service information. .

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

-- Remove the left and right wheel housing liner as well as the wheel spoiler. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

-- Remove the left and right subframe shield upper section. Refer to SUBFRAME SHIELD, REMOVING AND INSTALLING .

-- Remove the driveshaft. Refer to the appropriate service information. .

-- Remove the left and right nuts -arrows- and the bolt -1-, then remove the front muffler.

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

-- Remove the right drive axle heat shield. Refer to DRIVE AXLE HEAT SHIELD, REMOVING AND INSTALLING .

-- Remove the connector -arrow- for the Oxygen Sensor 1 After Catalytic Converter -GX7- from the bracket, disconnect it and free up the wire.

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-- Loosen the hose clamp -3- and remove the air duct hose from the bottom right charge air cooler.

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-- Place the : VAS6208 underneath.

CAUTION:

There is a risk of damaging the straps on the plastic coolant pipes if they are handled incorrectly.

- Counterhold at the coolant pipe when disconnecting and connecting the coolant hose.

-- Loosen the hose clamps -1 and 2-, remove the coolant hoses from the front coolant pipe and let the coolant drain out.

-- Open the hose clamp -arrow-.

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-- Remove the coolant hose from the right coolant pipe, hold it downward, and allow the coolant to drain.

-- Carefully pull the engine cover off the ball pins one after the other in direction of -arrows-. Do not remove the engine cover on one side or in a jerking manner.

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-- Remove the ball pins -arrows- and then remove the heat shield -1-.

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-- Loosen the hose clamps -2- and remove the air duct pipes.

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-- Remove the bolts -arrows- and the air filter housing -1- upwards.

-- Disconnect the fuel hose -1-. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

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-- Loosen the hose clamp -2- and disconnect the hose for the EVAP system.

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

-- Loosen the hose clamp -arrow- and remove the upper right air duct hose.

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Versions with Parking/Auxiliary Heater:

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-- Disconnect the connectors -2- and free up the wires.

-- Remove the nuts -arrows- using the : T40078 , then remove the parking/auxiliary heater -3- from the rubber bushing -1- and push slightly to the side.

Continuation for All Vehicles:

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-- Release the catch through the opening -6- using a small screwdriver and open the cover -1- in direction of -arrow-.

-- Remove the nut -3- and free up the electrical wire.

-- Remove the bolts -2 and 5- and move the Terminal 40 Wire Junction - TV66- to the side.

-- Release the catch in direction of -arrow A- and open the E-box -1- in direction of -arrow B-.

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-- Remove the nut -2- and free up the B+ wire.

-- If installed, disconnect the connector -arrow- for the Tank Ventilation Pressure Sensor 1 -G950-, then free up the wire.

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Equipment version with particulate filter:

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-- Disconnect the left and right connector -3- for the particulate filter pressure difference.

-- Remove the left and right bolt -arrow-, and remove the particulate filter differential pressure sensor from the bracket and free it up.

-- Remove the Exhaust Gas Temperature Sensor 3 -G495- connector -2- (black) from the bracket, disconnect it and free up the wire.

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-- Remove the connector -1- for the Exhaust Gas Temperature Sensor 3 Bank 2 -G497- from the bracket, disconnect it and free up the wire.

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Continuation for All Vehicles:

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-- Remove the electrical connector -2- for the Oxygen Sensor 2 after Catalytic Converter -G131- from the bracket, disconnect it and free up the wire.

-- Loosen the screw-type clamps -1 and 2-, then remove the catalytic converter to the left and right.

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-- Lift the clamp -1- and disconnect the coolant ventilation line.

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-- If installed, disconnect the connector -2- for the Tank Ventilation Pressure Sensor 2 -G951-, then free up the wire.

-- Disconnect the vacuum hose -3- without damaging it.

-- Loosen the screw-type clamp -arrow- and remove the left upper air duct hose.

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-- Lift the clip -1- and remove the upper left coolant hose from the radiator.

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-- Unlock the catch in direction of -arrow A- and release in direction of -arrow B-, and remove the vacuum hose.

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-- Disconnect the connectors -2- and free up the wires.

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-- Release the catches -arrows- and move the Engine/Motor Control Module -J623- -3- to the side.

-- Remove the connector -arrow- from the bracket and disconnect them and then free up the wires.

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-- Lift the clamp -2- and remove the coolant hose.

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-- Remove the bolts -arrows- and the coolant pipe 2 - 1-.

-- Remove the expanding rivet -1- then disconnect the connector -2- and free up the wire.

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-- Remove the connectors -2 and 3- from the bracket and disconnect.

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-- Remove the nuts -1 and 4- and free up the ground wires.

-- Disconnect the connector -2- for the Starter Generator - C29-.

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-- Disconnect the connector -1- for the Starter Generator Coolant Pump -V621-.

-- Remove the nuts -arrows- and free up the ground wire.

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

-- Loosen the screw-type clamps -arrows- and remove the air duct hose -1-.

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-- Remove the refrigerant lines from the A/C compressor. Refer to SYSTEM OVERVIEW - REFRIGERANT CIRCUIT .

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

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CAUTION:

There is a risk of damaging the joints on the upper control arm with a load that is too heavy.

- Support the wheel bearing housing.

-- Engage the left and right : 10-222A/20 to the body, and tie up the wheel bearing housing as shown using the : T10038

-- To protect the threads, remove the nut -arrow- on the left and right side from the tie rod end joint pin until it is flush with the joint pin threads.

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To prevent damage to the ball joint puller, both pry arms on the pull must be parallel to each other when the most force is applied.

CAUTION:

Abruptly loosening the tie rod end when removing increases the risk of injury.

It is possible that parts of the body may become bruised.

- Secure the tool with the engine and gearbox jack placed underneath.

-- Remove the left and right tie rod end with the : VAS251805 from the wheel bearing housing.

-- Remove the nut by counterholding at the ball joint with a 6 mm inner hex socket if necessary.

-- To protect the threads, remove the nut -arrow- on the left and right from the guide link joint pin just until it is flush with the joint pin threads. If necessary counterhold the joint pin.

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To prevent damage to the ball joint puller, both pry arms on the pull must be parallel to each other when the most force is applied.

CAUTION:

Abruptly loosening the ball joint when removing increases the risk of injury.

It is possible that parts of the body may become bruised.

- Secure the tool with the engine and gearbox jack placed underneath.

-- Remove the left and right guide link joint pin from the conical seat using the : VAS251809 with : VAS251809/1 . Do not damage the CV boot while doing this.

-- Remove the nut and free up the guide link on the wheel bearing housing. If necessary, counterhold the joint pin with a TX 40 socket to do this.

-- Equipped on some models: disconnect the left and right connector -3- for the level control system sensor and free up the wire.

Fig 2: Identifying Nuts

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-- Remove the nut -2- and free up the coupling rod.

-- Clean the steering gear and the subframe near the boot.

Fig 3: Identifying Power Steering Gear Boot

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-- Open the spring clamp -3- using the : VAS6362 .

-- Remove the clamp -1- and remove the boot -2- outward from the steering gear.

-- Disconnect the threaded connections -1 and 3- for the control arm.

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-- Pivot the control arm toward the front.

To remove the bolt -1-, push the steering all the way to the left or right.

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

-- Bring the boot into the installation position.

-- Remove the left and right nut -3- and the bolt -1- for the coupling rod -2-.

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

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CAUTION:

Risk of destroying due to electrostatic discharge.

- Do not touch the connector terminals by hand.

- Touch a ground (for example the hoist) and discharge the static electricity.

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

-- If the engine and the transmission are supposed to be parted afterwards, then free up the connectors at the tunnel crossmember -arrows- and the connectors to the subframe crossbrace.

-- Remove the bolts -arrows- and free up the parking lock emergency release cable -1-.

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-- Loosen the front area of the left and right center underbody trim panel. Refer to OVERVIEW - UNDERBODY TRIM PANELS .

Scissor Lift Table, Preparing:

Fig 4: Scissor Lift Chart

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-- Set up the Scissor Lift Table: VAS6131B as follows:

Table Coordinates	Components from the Scissor Lift Table - Audi Set: VAS6131/10 and Scissor Lift Table - A8 Set - Adapters: VAS6131/11-1 .
B3	/10-1	/10-4	/10-5	/10-11
G3	/10-1	/10-4	/10-5	/10-11
C15	/10-1	/10-2	/10-5	/11-1
F15	/10-1	/10-3	/10-5	/10-7

-- Secure the mounting elements to the scissor lift table by hand.

-- Position the : VAS6131B horizontally.

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

-- Guide the : VAS6131B under the engine/transmission assembly.

-- Position the mounting element from the : VAS6131/10 on the left and right on the engine.

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

-- Place the mounting element from the : VAS6131/10 and : VAS6131/11-1 on the tunnel crossmember.

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-- Rotate the remaining 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 : VAS6131B .

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

-- If the engine and the transmission are supposed to be parted, then remove the bolts -1-.

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

CAUTION:

Risk of damaging the lines and hoses, as well as the engine compartment by lowering the engine/transmission assembly.

- Make sure all connections between the engine, transmission, subframe and body have been disconnected.

- Carefully guide the engine/transmission assembly with the subframe out of engine compartment when lowering.

-- Lower the : VAS6131B with the engine/transmission assembly a maximum of 25 mm.

-- Tilt the scissor table as far to the rear as possible, at the same time pay attention to the : T40327 .

-- Lower the scissor lift table step by step and push to the rear, at the same time pay attention that there is clearance to the lock carrier and the plenum chamber bulkhead.

-- Tie up the drive axles.