Engine, Removing

WARNING: This page is about a different car, the 2011 Audi A6 and 2010 Audi A6. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Pry Lever 80-200
Used Oil Collecting and Extracting Device VAG 1782
Step Ladder VAS 5085
Engine Bung Set VAS 6122
Scissor Lift Table VAS 6131 A with Support Set VAS 6131/10, VAS 6131/11 and VAS 6131/12
Drip Tray for Workshop Crane VAS 6208
Hose Clamps Up to 25 mm Dia.3094
Hose Clamp Pliers VAS 6362
Tension Strap T10038

Procedure

NOTE:

With lock carrier installed, engine is removed downward with transmission and subframe.

During installation, all cable ties must be re-installed at the same location.

Collect escaping coolant in a clean container for disposal or reuse.

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.

Before opening high pressure area of the fuel injection system, fuel pressure must be relieved to residual pressure.

-- Reduce fuel pressure in high pressure area. Refer to Before Opening High Pressure Fuel Injection System .

NOTE:

So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted.

CAUTION:

Risk of destroying electrical components when battery is disconnected.

Observe measures when disconnecting battery.

-- Turn off ignition and remove ignition key.

-- Disconnect the Ground (GND) cable -arrow- from the battery terminal. Refer to BATTERY, DISCONNECTING AND CONNECTING .

Fig 1: Disconnecting Ground (GND) Cable At Battery

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-- Remove the engine covers -arrows-.

Fig 2: Engine Covers -1- & -2-

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WARNING:

Risk of scalding due to hot steam and hot coolant.

When the engine is warm the cooling system is under pressure.
Reduce pressure by covering coolant reservoir cap with a cloth and carefully opening.

-- Open coolant reservoir cap.

CAUTION:

Risk of destroying due to reversed running direction on a used ribbed belt.

Before removing the ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later.

-- Pivot the tensioner clockwise -arrow- to release the tension on the ribbed belt.

Fig 3: Identifying Pivoting Tensioning Device To Relieve Tension On Ribbed Belt

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-- Remove ribbed belt and release tensioning device.

-- Remove the left and right front wheels.

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

Fig 4: View Of Front Noise Insulation And Mounting Fasteners

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-- Place VAS 6208 under engine.

Fig 5: Identifying Drain Plug & Coolant Hose

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-- Open the drain plug -1- and drain the coolant.

-- Disconnect the right, lower coolant hose from the radiator, to do this, lift the retaining clip -2-.

-- Remove the coolant hose from the engine oil cooler by loosening the hose clamp -arrow- and letting the coolant drain out.

Fig 6: Disconnecting Coolant Hose From Oil Cooler

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-- Disconnect the connector -1- on the A/C compressor regulator valve -N280-.

Fig 7: Connector For Wiring To Air Conditioning Compressor Clutch Solenoid & Compressor Mounting Bolts

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WARNING:

Risk of injury from refrigerant.

The air conditioning refrigerant circuit must not be opened.

-- Remove Air Conditioning (A/C) compressor bolts -arrows-.

CAUTION:

Danger of damaging the refrigerant lines and hoses.

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

-- Attach the A/C compressor with the lines still attached to the left side of the vehicle.

NOTE:

To collect escaping power steering fluid, lay a cloth under the separating point.

-- Clamp off the power steering pump hydraulic hose -1- with a 3094.

Fig 8: Identifying Hydraulic Hose, Hydraulic Pressure Line & Hose Clamps 3094

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-- Remove the hydraulic oil hose from the power steering pump.

-- Disconnect the hydraulic pipe -2- from the power steering pump and lay it on top of the longitudinal member.

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

-- Disconnect electrical connector -3- at Secondary Air Injection (AIR) pump motor -V101- and free up electrical wiring.

Fig 9: Component Location Of Secondary Air Injection (AIR) Pump Motor -V101-

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NOTE:

Ignore -1 and 2-.

-- Remove the bolts -arrows- and remove the torque support from the engine.

Fig 10: Removing Bolts And Torque Support From Engine

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NOTE:

Follow the rules for clean working conditions when working on the multitronic transmission. Refer to TRANSMISSION, CLEAN WORKING CONDITIONS .

Fig 11: Loosening Union Nuts And Disconnecting ATF Lines

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-- Place the VAG 1782 under the separating point.

-- Loosen the union nuts and remove the ATF pipes -2 and 3-.

NOTE:

Ignore -1-.

-- Remove the nut -arrow- for the Ground (GND) cable on the right longitudinal member.

Fig 12: Ground (GND) Strap From Right Longitudinal Member, Removing/Installing

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-- Remove the coolant hose leading to the back of the heater core; to do this, lift the retaining clamps -arrow-.

Fig 13: Disconnecting Coolant Hose To Heater Core On Rear Of Engine

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-- Remove bolt -arrow-.

Fig 14: Identifying Coolant Hoses At Coolant Expansion Tank

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-- Disconnect the electrical connector to the Engine Coolant Level (ECL) warning switch -F66- on the bottom of the coolant reservoir and lay the reservoir aside with the coolant hoses -1 and 2- attached.

-- Free up the electrical wire.

-- Loosen the clamp -arrow- and remove the coolant hose from the coolant pipe.

Fig 15: Removing Coolant Hose From Front Coolant Line

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-- Open the clips -arrows- and remove the left front coolant hose.

Fig 16: Disconnecting Top Coolant Hose From Radiator

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-- Remove the coolant hose -arrow- from the front coolant pipe by lifting the retaining clamp.

Fig 17: Removing Coolant Hose From Front Coolant Line

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-- Press the release button -1- and free up the vacuum hose -arrow- on the leak detection pump -V144-.

Fig 18: Locating Leak Detection Pump -V144- Vacuum Hose -Arrow-

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-- Remove the bolts -arrows-, remove the air guides -1 and 2-.

Fig 19: Identifying Air Guide Components

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CAUTION:

There is a risk of contamination.

Note rules of cleanliness for working on the fuel injection system. Refer to CLEAN WORKING CONDITIONS .

WARNING:

Risk of injury from fuel.

To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.

-- Remove the fuel supply hose from the high pressure pump -arrow- and free it up.

Fig 20: Identifying Fuel Supply Hose

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-- Free up the fuel line -4- and the line -1- to the Evaporative Emission (EVAP) canister on the air filter housing and on the air guide pipe.

Fig 21: Identifying Air Guide Hose Components

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-- Remove the vacuum hose -2- from the air guide hose connection.

-- Remove the air guide pipe by loosening the hose clamp -3- and opening the clips -arrows-.

-- Disconnect the connector -1- on evaporative EVAP purge regulator valve 1 -N80- and then disconnect the vacuum hose -2-.

Fig 22: Disconnecting Electrical Connectors

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-- Remove the EVAP canister purge regulator valve 1 -N80- from the bracket and lay it aside with the hose connected.

-- Remove the brake booster check valve -arrow- from the plenum chamber bulkhead.

-- Open the clips -arrows- and remove the air filter housing upper section.

Fig 23: Opening Clips And Removing Upper Part Of Air Filter Housing

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-- Remove the pin from spreader clips -2-.

Fig 24: View Of Air Filter Housing And Secondary Air Injection Pump Hose

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-- Remove the air filter housing lower section. Then press the release button and disconnect the hose -1- from the Secondary Air Injection (AIR) pump.

Vehicles with intake air switch-over valve -N335-

-- Disconnect the vacuum line -1-.

Fig 25: Identifying Vacuum Line, Spreader Clips & Electrical Connection

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-- Disconnect the -2- intake air switch-over valve -- connector on the back of the air filter housing lower section.

NOTE:

Ignore -3-.

All Vehicles

-- Remove the front secondary air hose -arrow- from its bracket and disconnect it; to do this, press the release buttons.

Fig 26: Identifying Front Air Hose -Arrow

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-- Remove the nuts -3- and then remove the right bracket from the plenum chamber bulkhead.

Fig 27: Identifying Ground Pins & Nuts

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-- Remove the nut -1- on the positive terminal pick-off.

-- Remove the Ground (GND) bolt -2-.

-- Remove the nuts -1- and then remove the left bracket from the plenum chamber bulkhead.

Fig 28: Removing/Installing Nut And Left Electrical Connectors Bracket From Bulkhead & Ground (GND) Wire From Left Strut Tower

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-- Remove the nut -arrow- on the left suspension strut tower and free up the GND wire.

-- Remove the windshield wiper arms -arrows-. Refer to WIPER ARM .

Fig 29: Identifying Hex Head Nuts

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-- Remove the seal -1- and remove the plenum chamber cover -2-.

Fig 30: Removing Rubber Seal And Plenum Chamber Cover

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Fig 31: Bolts (Arrows) And Cowl Panel (1)

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CAUTION:

Danger of causing damage to the wind cowl.

To prevent the cowl grille -1- from tearing when removing, coat transition between windshield and cowl grille with a soapy solution and pull grille up vertically out of fastening strip beginning at edge of window.

-- Remove the screws -arrows- and remove the cowl panel trim from the windshield.

-- Remove the bolts -1 and 3- and then remove the tower brace -2-, if equipped.

Fig 32: Removing Bolts And Strut Tower Brace

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-- Remove the brake booster vacuum line -arrow- on the plenum chamber bulkhead.

Fig 33: Disconnecting Vacuum Line To Brake Booster At Bulkhead

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-- Remove the bolts -arrows- and the left engine compartment E-box cover.

Fig 34: Removing Bolts And Cover Form E-Box At Left In Engine Compartment

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-- Release the retainers, pull the fuse holder -1- and then the 3-socket relay carrier -4- upward.

Fig 35: Identifying Fuse Holder, 3-Socket Relay Carrier, Electrical Wire Connection & Electrical Connections

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-- Disconnect the electrical connectors -3-.

-- Disconnect the three front connectors -2- at the rear on the connector strip.

-- Disengage the engine wiring harness on the E-box and free it up.

-- Remove the bolts -arrows- and the right engine compartment E-box cover.

Fig 36: Removing Bolts And Cover For E-Box At Right In Engine Compartment

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-- Open the cover -1- with a screwdriver -arrow- and remove it.

Fig 37: Opening Cover Using Screwdriver

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WARNING:

Risk of burning on heater pump valve unit (at left in front of E-box).

Wear protective gloves when working near heater pump valve unit.

-- Using a screwdriver, carefully pry off the mounting clamp -3- -arrows, 1 and 2- and remove the Engine Control Module (ECM) from the E-box.

Fig 38: Direction (Arrows 1 And 2) To Lever Retaining Clip (3)

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NOTE:

ECM remains connected at wiring harness.

-- Unclip the suppression capacitor -5- from the bracket in the E-box.

-- Disconnect the electrical connector -4- at the back on the connector strip.

-- Disconnect the electrical wire connections -1 and 2-.

-- Free up the electrical line up to the generator using the 80 - 200.

Fig 39: Free Electrical Wiring Up To Generator Using 80-200

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-- Lay both wiring harnesses on the engine and secure the ECM against falling down.

CAUTION:

Danger of personal injury and of damage to the brake discs and wheel bearing.

To loosen drive axle collar bolt, vehicle must not be resting on wheels.
The brake discs must be secured from turning by 2 wheel bolts.

-- Have a 2nd technician apply to the brake pedal.

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

Fig 40: Identifying Collar Bolt For Left/Right Drive Axle

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-- Remove the left and right nuts -1-.

Fig 41: Removing Left/Right Nuts, Bolts & Stabilizer Bar

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-- Remove the left and right bolt -2- and remove the stabilizer bar.

-- Disconnect the connector -2- on the left front level control system sensor -G78-.

Fig 42: Disconnecting Electrical Harness Connector At Level Control System Sensor & Connecting Link From Control Arm

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-- Remove the nut -1- and remove the coupling rod from the control arm.

CAUTION:

Risk of damaging axle joints on upper control arms.

Support wheel bearing housing.

-- Tie up wheel bearing housing using T10038 as shown in illustration.

Fig 43: Disconnecting Connecting Link At Control Arm

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-- Remove the bolt -arrow- and remove the suspension strut from the control arm.

Fig 44: Air Spring Damper At Control Arm Bolt

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-- Remove the guide control arm nut -1- and the control arm nut -2- on the subframe; then remove the bolts.

Fig 45: Guide Control Arm & Control Arm

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-- Swivel the guide control arm -1- and the control arm -2- toward the outside.

Fig 46: Identifying Guide Control Arms And Track Control Arms

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CAUTION:

The control arm and the guide control arm could be damaged if they are allowed to hang free.

Tie the guide control arm and the control arm to the wheel bearing housing -arrows- as illustrated.

-- Remove the bolts -arrows- and remove the left drive axle heat shield.

Fig 47: Driveshaft Heat Shaft

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-- Remove the drive axle from the transmission flange shaft.

CAUTION:

Risk of damaging brake line.

Carefully remove the drive axle.

-- Swivel the wheel bearing housing toward the outside and remove the drive axle.

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

-- Remove the bolts -arrows- and remove the crossbrace from the subframe.

Fig 48: Removing Subframe Transverse Beam

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-- Separate the exhaust system at the clamping sleeves -1- and -2-.

Fig 49: Loosening Left/Right Clamping Sleeve

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-- Remove the bolts -arrows- and remove the front transverse beam.

Fig 50: Front Cross Member

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Prepare Scissor Lift Platform

Fig 51: Identifying Scissor Lift Platform VAS 6131

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-- Set up the VAS 6131 A and VAS 6131/10 as follows:

Platform Coordinates	Parts from Support Set VAS 6131/10
B4	/10-1	/10-4	/10-5	/10-13
G4	/10-1	/10-4	/10-5	/10-12
B10	/10-1	/10-2	/10-5	/10-8
G10	/10-1	/10-2	/10-5	/10-8
E13	/10-1	/10-3	/10-5	/10-6
D16	/10-1	/10-3	/10-5	/10-6

-- Next secure mounting elements to scissor lift table by hand.

-- Position the VAS 6131 A horizontally.

Note bubble level (sight glass) on support platform.

-- Move the VAS 6131 A under the engine/transmission subassembly.

-- Attach mounting elements from the VAS 6131/10 at the front of the engine as shown in the illustration.

Fig 52: Attaching Mounting Elements At Front Of Engine

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-- Ensure threaded spindles are completely installed.

-- Attach mounting elements from VAS 6131/10 at left and right on subframe as illustrated.

Fig 53: Positioning Support Elements From Support Set VAS 6131/10 At Left/Right On Subframe

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-- Attach support elements from the VAS 6131/10 to the back of the tunnel crossmember as illustrated.

Fig 54: Positioning Support Elements From VAS 6131/10 At Rear On Tunnel Cross Member

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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 VAS 6131 A and tighten to 20 Nm.

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

Fig 55: Removing/Installing Bolts At Tunnel Cross Member

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NOTE:

The installation location is shown with the front exhaust pipes removed.

-- Remove bolts -1-.

Fig 56: Locating Subframe And Engine Mount Brackets Bolts 1 Through 4

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-- Mark location of subframe and both engine mount brackets to the longitudinal members with a felt-tip pen.

-- Remove the bolts -2, 3 and 4- in diagonal sequence in steps.

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 engine-transmission assembly with subframe out of engine compartment while lowering.

-- Lower the engine/transmission subassembly on the VAS 6131 A 100 mm at first.

NOTE:

Mark selector lever cable bracket installation location.

-- Remove the bolt -1- on the cable mounting bracket.

Fig 57: Removing Support Bracket For Selector Lever Cable

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-- Remove the selector lever cable ball socket -2- from the transmission shift lever using the 80 - 200.

CAUTION:

Danger of causing damage to the selector lever cable.

Do not bend or kink selector lever cable.

-- Lower the engine/transmission subassembly using the VAS 6131 A.

-- Remove the VAS 6131 A with the engine/transmission subassembly under vehicle.