Engine, Removing, 3.0L Engine

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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• Scissor Lift Table - A8 Set - Adapter :VAS6131/11-1  from Scissor Lift Table - A8 Set :VAS6131/11  , not illustrated
• Universal Supports :VAS6131/13-2  from Scissor Lift Table - Q7 Set :VAS6131/13 
  Fig 4: Identifying Scissor Lift Table - Q7 Set VAS 6131/13

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• Shop Crane - Drip Tray :VAS6208 
  Fig 5: Identifying Drip Tray

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• Hose Clip Pliers :VAS6340 
  Fig 6: Hose Clip Pliers VAS6340

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• Hose Clip Pliers :VAS6362 
  Fig 7: Hose Clip Pliers

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• Engine and Gearbox Jack :VAS6931 
  Fig 8: Engine and Gearbox Jack VAS6931 or VAG1383A

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• Ball Joint Splitter :VAS251805 
  Fig 9: Ball Joint Splitter (kukko 129-3)

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• Ball Joint Splitter :VAS251809  with :VAS251809/1 
  Fig 10: Ball Joint Splitter

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• Tensioning Strap :T10038 
  Fig 11: 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 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 IN CURB WEIGHT POSITION, LIFTING VEHICLES WITH COIL SPRING or determine the control position (refer to WHEEL BEARING AT STANDARD VEHICLE HEIGHT, LIFTING VEHICLES WITH AIR SUSPENSION ).

-- Move the wheels so that 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 A, DISCONNECTING AND CONNECTING, VEHICLES WITHOUT ALTERNATIVE DRIVE SYSTEM, (0K0) , or BATTERY A, DISCONNECTING AND CONNECTING, VEHICLES WITH HIGH-VOLTAGE SYSTEM, (0K3) , or BATTERY A, DISCONNECTING AND CONNECTING, VEHICLES WITH ALTERNATIVE DRIVE SYSTEM, (0K4) .

-- LHD: Remove the right cover -1- toward the rear in direction of -arrows- and remove.

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-- RHD: Remove the left cover -1- toward the rear -arrows- and remove.

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

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

-- Remove the front wheels. Refer to WHEELS AND TIRES .

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

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

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

-- Place the Shop Crane - Drip Tray :VAS6208  underneath.

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-- Disconnect the connector -3- for the Engine Coolant Temperature Sensor on Radiator Outlet -G83-.

-- Lift the clamp -2-, remove the coolant hose from the radiator and allow the coolant to drain.

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

-- 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 (shown for LHD vehicle).

-- Carefully pull the engine cover off the retaining pins one after the other in direction of -arrows-. Do not pull sharply on the engine cover or pull it to one side.

-- If the engine and transmission must be separate, remove the ball pins and bolts -arrows- and remove the heat shield -1-.

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

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

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-- Pull the air filter housing -1- upward and remove it.

-- 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 Engine Bung Set :VAS6122  .

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

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

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

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Vehicles with a Particulate Filter:

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-- Disconnect the connector -1- for the Exhaust Gas Temperature Sensor 3 -G495-.

-- If the engine and transmission are disconnected: remove the connector from the bracket and free up the wire.

Continuation for All Vehicles:

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-- Disconnect the connector -3- for the Charge Air Pressure Sensor -G31-.

-- Lift the clamp -2- and disconnect the coolant ventilation line.

-- Loosen the hose clamp -1- and remove the air duct pipe and tie up to the left side.

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

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-- Release the retainer -arrow- and remove the vacuum hose -1-.

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

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-- Release the catches in direction of -arrows- and move the Engine 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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Vehicles with a Particulate Filter:

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-- Disconnect the connector -1- for the Particulate Filter Differential Pressure Sensor - G1037-.

-- If engine and transmission are to be separated, remove the bolts -2- and free up the bracket -3- with the differential pressure sensor.

Continuation for All Vehicles:

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

-- Loosen the hose clamp -2- and remove the coolant hose from the Coolant Recirculation Pump -V50-.

-- Remove screw -1- and disconnect harness connector -2-.

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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 -arrow- on the starter generator.

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-- Loosen the hose clamp -1-, lift the clip -2-, and remove the coolant hose.

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-- Engage the left and right Engine Support Bridge - Special Hook (2 pc.) :10-222A/20  to the body, and tie up the wheel bearing housing as shown using the Tensioning Strap :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.

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

-- Remove the nut to do so if necessary counterhold on the joint pin with a 6 mm inner hex socket.

-- 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.

-- Remove the left and right guide link joint pin from the conical seat using the Ball Joint Splitter :VAS251809  with Ball Joint Splitter :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.

-- Loosen the subframe shield and push it slightly to the side. Refer to SUBFRAME SHIELD, REMOVING AND INSTALLING .

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

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

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

-- Open the spring clamp -3- using the Hose Clip Pliers :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.

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

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-- 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 .

-- Remove the ribbed belt from the A/C compressor belt pulley. Refer to RIBBED BELT, REMOVING AND INSTALLING .

-- 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 .

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-- Disconnect the connectors -1, 2 and 3-.

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

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

-- If the engine and transmission must be separated, remove the left and right bolts -2-.

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-- Remove the bolts -arrows- and move the heat shield -1- to the side.

-- Remove the bolt -2- and nut -3- 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:

-- Equip the Scissor Lift Table :VAS6131B  as follows:

Table Coordinates	Parts from the Scissor Lift Table - Audi Set :VAS6131/10  , Scissor Lift Table - A8 Set Adapter 1 :VAS6131/11-1  and Scissor Lift Table - Audi Set Universal Supports :VAS6131/13-2
C4	/10-1	/10-4	/10-5	/10-11
E4	/10-1	/10-4	/10-5	/10-11
C14	/10-1	/10-3	/10-5	/11-1
E14	/10-1	/10-3	/10-5	/10-6
E17	/10-1	/10-2	/10-5	/13-2

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

-- 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 subassembly.

-- Position the mounting element from the Scissor Lift Table - Audi Set :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 Scissor Lift Table - Audi Set :VAS6131/10  and Scissor Lift Table - A8 Set - Adapters :VAS6131/11-1  on the tunnel crossmember.

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-- Support the right front muffler with mounting element from the Scissor Lift Table - Audi Set :VAS6131/10  and Scissor Lift Table - Q7 Set Universal Supports :VAS6131/13-2  .

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

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

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

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

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

-- Tie up the drive axles.