Engine, removing and installing: Removing

NOTE:

Engine is removed downward with transmission and subframe.
Obtain radio anti-theft code.
All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
Battery is located at right in luggage compartment.
Drained coolant must be stored in a clean container for disposal or reuse.

NOTE:

Before raising the vehicle on a hoist (wheels off the ground), first activate the vehicle jack mode → 43 - Self Leveling Suspension .

Fig 1: Identifying Rubber Seal & Plenum Chamber Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove rubber seal for plenum chamber cover - 1 -.
Remove plenum chamber cover - 2 - and - 3 -.
Switch ignition on.
Carry out flick wipe function and let wiper motor run to rest position.

Turn ignition and remove ignition key.

Fig 2: Prying Off Cover Cap At Wiper Arms Using Screwdriver And Hex Nut

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pry off cover cap at wiper arms using a screwdriver - arrows - and remove hex nut.
Pull off wiper arms from wiper axles.

Fig 3: Removing Wind Deflector By Removing Bolts On Left/Right

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove wind deflector - 1 - by removing bolts on left and right - arrows - if present.

Fig 4: Removing Dust And Pollen Filter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove dust and pollen filter, to do so open quick-release screws - arrows -.

CAUTION: For vehicles with Telematic, activate service mode of Telematic Control Module before disconnecting the battery.

Observe procedures for disconnecting battery → 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

Fig 5: Removing Cover Of Right Luggage Compartment Side Trim

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove right luggage compartment side trim cover.

Fig 6: Removing Cover Above Battery

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove cover - 1 - above battery.

NOTE:

Disregard - 2 -.

Fig 7: Disconnecting Battery Ground (GND) Strap

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect Ground (GND) strap - arrow - at battery.

For vehicles with auxiliary heater

Fig 8: Removing Bolts For Exhaust Pipe Of Parking Heater/Auxiliary Heater On Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

All

Remove left and right front wheels.

Fig 9: Locating Mounting Parts And Removing Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove noise insulation, items - 1 through 4 -.
Remove front and rear parts of wheel housing liner at right front → 66 - EXTERIOR EQUIPMENT .
Remove front part of left front wheelhouse liner → 66 - EXTERIOR EQUIPMENT .
Remove front bumper → 63 - BUMPERS .

Fig 10: Disconnecting Intake Air Duct At Secondary Air Injection (AIR) Pump Motor V101

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect intake air duct - 1 - at Secondary Air Injection (AIR) Pump Motor V101.

Fig 11: Removing Engine Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove engine cover - 1 - and - 2 - upward.
Carefully open cap on coolant expansion tank (release pressure), then close again.

Fig 12: Identifying Clips & Bolt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove clips - 1 - using Pry Lever - Rmv Outside Mirror 80 - 200.
Remove bolt - 2 - and remove cover.

NOTE:

Note clips when installing - arrows -.

Fig 13: Removing Hose

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove hose - 1 -.

Fig 14: Identifying Hose & Air Intake Tube

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect hose - 1 -.
Unclip hose - 2 -.
Remove air intake tube - arrows -.

Fig 15: Identifying Mass Air Flow (MAF) Sensor Electrical Connector & Air Filter Box

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connector - 1 - from mass air flow (MAF) sensor.
Remove air filter box - arrows -.
Remove right headlight → 94 - LIGHTS, SWITCHES - EXTERIOR .

Fig 16: Depressing Locking Mechanisms And Removing Air Guide At Right Front From Lock Carrier

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Depress locking mechanisms - arrows - and remove air guide at right front from lock carrier.

Fig 17: Removing Bolts And Air Guide

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows - and remove air guide.
Pull lock carrier toward front → 50 - BODY - FRONT

Fig 18: Identifying Cable & Torque Support Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unclip cable - arrows -.
Remove bolts - 1 - for torque support.

Fig 19: Locating Bolt On Torque Support Valve N382

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate torque support - arrow - from torque support valve N382 and remove.

Fig 20: Identifying Heated Oxygen Sensor Before Catalytic Converter, Oxygen Sensor Behind Catalytic Converter & Solenoid Valve Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect connector - 1 - of heated oxygen sensor before catalytic converter (black).
Disconnect connector - 2 - of oxygen sensor behind catalytic converter (brown).
Disconnect connector - 3 - from solenoid valve and lay wiring harness to engine aside.
Disconnect hose - 4 - from solenoid valve and lay hose aside.

free up electrical wires of oxygen sensors.

Fig 21: Identifying Fuel Supply Lines

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect fuel supply line - 1 -.
Disconnect fuel return line - 2 -.
Remove right trim for A-pillar → 70 - INTERIOR TRIM .
Fold floor covering back.

Remove protective cover from above main fuse holder.

Fig 22: Identifying Cap & Nut

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Fold cap - 2 - aside.
Remove nut - 4 -.
Remove terminal 30 wire to starter.

NOTE:

Ignore - 1 - and - 3 -.

Fig 23: Pulling Wiring Harness Out From Interior

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove harness clamp - 1 - in right front wheel housing.
Pull wiring harness out from interior - arrow -.

Fig 24: Disconnecting Electrical Harness Connectors & Ground (GND) Wire On Long Member

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connectors - 1 - and - 3 -.
Remove Ground (GND) wire - 2 - on long member.
Remove bracket for wiring harness on longitudinal member - arrows - and lay wiring harness aside.
Place drip tray for workshop crane VAS 6208 under engine.

Fig 25: Identifying Coolant Hoses & Drain Plug

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect coolant hose - 1 - to drain coolant.
Disconnect coolant hose - 2 -.
Open drain plug - 3 - and drain coolant from oil filter bracket.

Fig 26: Installing Drain Plug At Oil Filter Bracket With New Gasket In Engine At Left

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Open drain plug - arrow - and drain coolant from engine.

Fig 27: Disconnecting Coolant Hoses

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect coolant hoses - 1 and 2 -.

NOTE:

Before removing toothed belt, mark running direction with chalk or felt tip marker. A reversed turning direction can cause damage to the belt under operating conditions.
Note previously marked direction of belt rotation and be sure that it is seated correctly on pulley.

Fig 28: Locating Ribbed Belt

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To loosen ribbed belt, turn tensioner clockwise in direction of - arrow - using box wrench until two holes are aligned; counter hold in position using locking pin T10060 A.
Remove ribbed belt.

Fig 29: Disconnecting Vacuum Hose To Variable-Tract Intake Manifold

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect vacuum hose - 1 - to variable-tract intake manifold.

NOTE:

For the sake of illustration, compressor is removed.

Fig 30: Disconnecting Electrical Connector From A/C Compressor And Free Up Electrical Wire

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connector - 1 - from A/C compressor and free up electrical wire.
Remove A/C compressor - arrows - and hang at side.

NOTE:

Lines remain connected.
Lines must not be bent.
Pay attention to centering sleeves for guiding A/C compressor at retainer.

Place drip tray VAS 6208 underneath vehicle to collect hydraulic fluid.

Fig 31: Identifying Banjo Bolt, Pressure Hose, And Seals

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen clamp - 4 - , pull off intake line - 3 - and lay aside.
Remove banjo fitting - 2 - for expansion hose - 1 - and lay expansion hose aside.
Seal connections of power steering pump using sealing plugs.

For vehicles without auxiliary/additional heater

Fig 32: Disconnecting Supply And Return Line To Heater Core

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect supply and return line to heater core - arrows -.

For vehicles with auxiliary/additional heater

Fig 33: Disconnecting Coolant Hose From Coolant Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect coolant hose - arrow - from coolant pipe.

All

Fig 34: Disconnecting Hose From Coolant Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect hose - arrow - from coolant pipe.

Fig 35: Removing Insulation Mat From Dome Brace

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove insulation mat from dome brace - arrows -.

Fig 36: Removing Dome Brace Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove dome brace bolts - 1 through 4 -.

NOTE:

Note spacer sleeves for - 2 -.

Fig 37: Removing Engine Control Module

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove engine control module - arrows - and lay aside.

NOTE:

The anti-theft device is not removed, the control module remains attached.

Fig 38: Disconnecting Electrical Connector & Removing E-Box Cover

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connector - 1 -.
Remove E-Box cover - arrows -.

Fig 39: Disconnecting Electrical Connectors And Exposing Wiring Harness With Control Module Up To Engine

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical connectors - arrows - and expose wiring harness with control module up to engine.

Fig 40: Disconnecting Hose For Secondary Air Injection

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect hose - arrow - for secondary air injection.

Fig 41: Disconnecting Hose To Brake Booster

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect hose - arrow - to brake booster.

Fig 42: Identifying Permanent Ventilation Hoses & Coolant Reservoir

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect hose - 1 - for permanent ventilation from coolant expansion tank.
Disconnect hose - 2 - for permanent ventilation from coolant expansion tank.
Remove coolant reservoir - arrows -.
Disconnect electrical connector for coolant level indicator.

Remove coolant hose beneath coolant reservoir.

NOTE:

Wheel bearing housing must be supported to prevent upper control arm joints from being damaged.

NOTE:

Ensure Lifting Eyebolt 3368 thread does not protrude too far toward top.

Fig 43: Positioning Lifting Eyebolt 3368 Into Hole At Suspension Strut Dome And Securing With Washer And Nut

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position Lifting Eyebolt 3368 into hole at suspension strut dome and secure with washer - 1 - and nut - 2 -.
Tie up wheel bearing housing using tensioning strap T10038 as shown in illustration.

Fig 44: Removing Collar Bolt At Left/Right Drive Axles

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Have a second technician press brake pedal.

CAUTION: To loosen collar bolt for drive axle, the wheel bearing must not be under load (vehicle must not be standing on its wheels).

Remove collar bolt - 2 - at left and right drive axles - 1 -.

Fig 45: Removing Bolts Uniformly At Left/Right

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows - uniformly at left and right.
Remove stabilizer.

Fig 46: Removing Cross Member For Noise Insulation At Subframe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove cross member - arrows - for noise insulation at subframe.

Fig 47: Identifying Left Level Control System Sensor Electrical Harness Connector & Left/Right Control Arms Coupling Rod

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect electrical harness connector - 2 - at left level control system sensor.
Remove coupling rod - 1 - at left and right control arms.

Fig 48: Removing Air Spring Damper From Control Arm

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove air spring damper from control arm - arrow -.

Fig 49: Removing Guide Control Link And Control Link On Subframe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove guide control link - 1 - and control link - 2 - on subframe.

Fig 50: Pivoting Guide Control Link And Control Link Outward

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pivot guide control link - 1 - and control link - 2 - outward.

CAUTION: Guide control link and control link must not hang free. Tie up both control arms on wheel bearing housing - arrows - as shown in illustration.

Repeat work procedure on opposite side of vehicle.

Fig 51: Removing Shielding Plate Of Drive Axles

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove shielding plate - arrows - of drive axles.

NOTE:

The left shielding plate consists of 2 parts.

Remove drive shaft from transmission flange.

CAUTION: Do not damage brake hose!

Pivot wheel bearing housing outward and remove drive axle.
Repeat work procedure on opposite side of vehicle.

Fig 52: Locating Double Clamps

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen double clamps - 1 - and - 2 - and slide toward front.
Remove front cross member - arrows -.

Fig 53: Removing Drive Shaft Heat Shield

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove drive shaft heat shield - A - - arrows -.
Remove bolts at transmission/drive shaft flange.
Push drive shaft together with rear final drive. The constant velocity (CV) joints can move axially.
Tie up drive shaft to side at body.

Fig 54: Identifying Selector Lever Cable & Bracket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pry off selector lever cable - 2 - from ball head using Pry Lever - Rmv Outside Mirror 80 - 200.
Remove securing device from bracket - 1 - and expose selector lever cable.

Prepare scissor lift platform:

Fig 55: Identifying Scissor Lift Platform VAS 6131

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Equip scissor lift table VAS 6131 with support set VAS 6131/10 and supplementary set, Audi A8 VAS 6131/11 as follows:

Platform coordinates	Support set components from VAS 6131/10 and supplementary set VAS 6131/11
B3	/10-1	/10-4	/10-5	/10-11
G3	/10-1	/10-4	/10-5	/11-4
B5	/10-1	/10-3	/10-5	/10-7
G5	/10-1	/10-3	/10-5	/10-7
B9	/10-1	/10-2	/10-5	/10-8
G9	/10-1	/10-2	/10-5	/10-8
C16	/10-1	/10-2	/10-5	/11-5
F16	/10-1	/10-2	/10-5	/11-5

Install attachments on scissor lift table by hand first.
Place scissor lift platform VAS 6131 in horizontal position.
Note bubble level (sight glass) on support platform
Drive scissor lift platform VAS 6131 under engine/transmission subassembly.

Fig 56: Placing Support Set VAS 6131/10 And Supplementary Set, Audi A8 VAS 6131/11 Attachments On Front Of Engine

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place Support Set VAS 6131/10 and Supplementary Set, Audi A8 VAS 6131/11 attachments on front of engine as shown in illustration.
Make sure threaded spindles are installed completely.

Fig 57: Positioning Attachments Of Support Set VAS 6131/10 At Left And Right On Engine Carrier And Subframe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position attachments of support set VAS 6131/10 at left and right on engine carrier and subframe, as shown in illustration.

Fig 58: Placing Support Set VAS 6131/10 And Supplementary Set, Audi A8 VAS 6131/11 Attachments On Rear Of Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place Support Set VAS 6131/10 and Supplementary Set, Audi A8 VAS 6131/11 attachments on rear of transmission as shown in illustration.
Twist all spindles of support elements upward far enough until all support pins make contact at support points.
When all attachments are positioned, lift scissor lift table far enough until engine and transmission mount are free of tension.
Tighten base plates for attachments to 20 Nm onto scissor lift table VAS 6131.

Fig 59: Removing/Installing Bolts At Tunnel Cross Member

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows - at tunnel cross member.

Fig 60: Removing/Installing Long Member Subframe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mark installation position of subframe on long member using a felt tip pen.
Remove bolts - 1 - and - 4 -.
Remove bolts - 2 - and - 3 - in diagonal sequence and in stages.

NOTE:

Verify that all hoses and lines between engine, transmission, subframe and body have been disconnected.
While lowering, carefully guide engine/transmission subassembly with subframe out of engine compartment in order to prevent damage.

Slowly lower engine/transmission subassembly downward.
Remove scissor lift table VAS 6131 under vehicle.