Audi Workshop Service and Repair Manuals

Removing engine

Special tools and workshop equipment required

t	Removal lever -80 - 200-

t	Used oil collection and extraction unit -V.A.G 1782-

t	Stepladder -VAS 5085-

t	Engine bung set -VAS 6122-

t	Scissor-type assembly platform -VAS 6131 A- with support set for Audi -VAS 6131/10- and supplementary set -VAS 6131/13-

t	Drip tray for workshop hoist -VAS 6208-

t  Hose clamps for hoses up to 25 mm -3094-

t  Hose clip pliers -VAS 6362-

t  Counterhold tool -T10172- with -T10172/5-

t  Release tool -T40149- Procedure   WARNING Make sure the vehicle cannot tip over when the engine is removed. Secure the vehicle, to do so, the luggage compartment must be empty. –  Set front wheels to straight-ahead position.   Note The electromechanical parking brake must be released before disconnecting the battery, so that the propshaft can be turned during removal.

Caution Electronic components are susceptible to damage. Observe notes on procedure for disconnecting the battery. –  Switch off ignition and take out ignition key. –  Disconnect earth wire -2- from battery terminal → Electrical system; Rep. gr.27. –  Discharge refrigerant system → Air conditioner with refrigerant R134a. –  Extract hydraulic fluid for power steering from reservoir using used oil collection and extraction unit -V.A.G 1782-.

–  Remove engine cover panel -arrows-.   WARNING Hot steam/hot coolant can escape - risk of scalding. t  The cooling system is under pressure when the engine is hot. t  To allow pressure to dissipate, cover filler cap on coolant expansion tank with cloth and open carefully. –  Open filler cap on coolant expansion tank.

–  Remove both front wheels. –  Remove front left and front right wheel housing liners → Rep. gr.66. –  Remove noise insulation panels -1- and -2- → Rep. gr.66.

–  Place drip tray for workshop hoist -VAS 6208- beneath engine. –  Remove drain plug -arrow- at connection and drain off coolant. –  Then detach connection from radiator (lift retaining clip).

–  Release hose clip -arrow-, disconnect coolant hose from coolant pipe (left-side) and drain off coolant.

–  Vehicles with plug-in connector at coolant pipe (bottom right): Lift retaining clip -arrow-, disconnect coolant hose and drain off coolant.

–  Vehicles with plug-in connector at longitudinal member: Lift retaining clip -arrow-, disconnect coolant hose and drain off coolant.

–  Position used oil collection and extraction unit -V.A.G 1782- below connection point. –  Disconnect hydraulic fluid return line -arrow- for power steering. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Unplug electrical connector -1- at charge pressure sender -G31- and move electrical wiring clear.   Note Disregard -item 2-.

–  Unscrew nut -arrow- on longitudinal member (right-side) and move earth cables clear.

–  Unplug electrical connectors -1- and, if fitted, -2- for radiator fan (push retainer to the rear -arrow- and press down release catch). –  Move electrical wiring clear.

–  Release hose clip -arrow-, disconnect air hose from air pipe and move to one side.

–  On vehicles with auxiliary heater: remove nut -1-, loosen clamp -3- and detach exhaust pipe -2- for auxiliary heater

–  Remove bolt -1- and nut -3- on both sides and detach strut -2- for lock carrier.   Note

Observe rules for cleanliness when working on gearbox → Rep. gr.00. –  Position used oil collection and extraction unit -V.A.G 1782- below connection points. –  Disconnect ATF lines -arrows- at connections on right side of engine. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.

–  Remove air duct -arrow-.

–  Unplug electrical connector -1- from air mass meter -G70-. –  Unscrew bolt -3- and move clear exhaust gas pressure sensor 1 -G450--item 4- at air pipe. –  Unplug electrical connector -2- and move air pipe clear. –  Remove air hose and air mass meter -G70-. To do so, release hose clip -5- and clamps -arrows-.

–  Disconnect vacuum line -1-. –  Detach air cleaner housing, unplug electrical connector -2- at air filter bypass flap valve -N275- on reverse side of air cleaner and move electrical wiring clear.

Caution Take care to keep components clean. Observe rules for cleanliness when working on the fuel supply system → Chapter. –  Disconnect fuel supply hose -1- and fuel return hose -2-.

–  Release hose clip -3- and detach air hose. –  Unplug electrical connector -4-. –  Remove bolts -2- and detach throttle valve module -J338--item 5-.   Note Disregard -item 1-.

–  Disconnect coolant hose -3- from coolant expansion tank.   Note Disregard items marked -1, 2- and -arrows-.   Note

Lay a cloth under the separating point to catch escaping hydraulic fluid. –  Cut open cable tie -4-. –  Clamp off hydraulic hose -1- using hose clamp -3094-, release hose clip -2- and disconnect hose from power steering pump. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.   Note Disregard -items 3, 5-.

–  If fitted, unplug electrical connector -2-.   Note Disregard -item 1-.

Caution Danger of damage to refrigerant lines and hoses. Do NOT stretch, kink or bend refrigerant lines and hoses. –  Remove bolt -2-, disconnect refrigerant line from air conditioner compressor and move to one side. –  Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122-.   Note Disregard -items 1, 3-.

–  Remove seal. –  Remove plenum chamber cover → Rep. gr.50.

–  Release retainer -arrow A- and open cover -arrow B-.

–  Remove nuts -1 ... 3- for electrical wiring. –  Detach electrical connector -4- from bracket and unplug. –  Remove bolt -5- and detach terminal 30 wiring junction 2 -TV22- from body brace -arrow-.

–  Working from wheel housing, release catches using a 5.5 mm ring spanner -item 1- and remove wiring protector -2- from above. –  Release wiring harness -3- leading to alternator and starter using removal lever -80 - 200- and move clear.

–  Wiring duct (version 1): release catch -arrow B- and move wiring duct clear by pulling it towards front -arrow A-.

–  Wiring duct (version 2): release catch -arrow- to open wiring duct -1- and move wiring harness clear.

–  Press refrigerant lines -A- and -C- by hand as far as stop into connection piece -B- for refrigerant line with internal heat exchanger. –  Spray area around refrigerant lines with silicone-free lubricant. –  Fit release tool for air conditioner line -T40149/1- onto refrigerant line -A- and release tool for air conditioner line -T40149/2- onto refrigerant line -C- so that both tools engage audibly. This releases the retaining lugs. –  Using release tools for air conditioner line, pull refrigerant lines -A- and -C- out of connection piece -B- for refrigerant line with internal heat exchanger.   Note

t  If it is not possible to pull out the refrigerant lines, do NOT attempt to turn the refrigerant lines in connection piece -C-. t  In this case you will have to cut open the connectors -B- and take out the retaining rings -A-. t  When cutting open the connectors, take care not to damage the connection piece -C- for the refrigerant line with internal heat exchanger.

–  Remove nut -1- and swivel filler neck for washer fluid reservoir slightly upwards -arrow A-. –  Pull filler neck -2- with filler pipe out of washer fluid reservoir and through opening in body -arrow B-.

–  On vehicles with auxiliary heater: remove bolts -2- and move pump unit -1- clear to one side.

–  Remove bolts -1- and nuts -2- and detach body brace -3-.

–  Remove bolts -arrows- and detach cover for electronics box in engine compartment. –  Remove nut -1- and move electrical wiring clear.

–  Release catches -arrows A- and take out engine control unit -arrow B-.

–  If fitted, unplug electrical connector -2-. –  Unplug electrical connectors -4- and unscrew nut -3- for wiring. –  Release catches -arrow- and detach relay carrier with fuse holder -1-. –  Disengage engine wiring harness at electronics box in engine compartment and move clear.

–  Release catches -arrows A- and lift off wiring protector -1--arrow B-. –  Unscrew earth stud -2- and move wiring harness clear. –  Place wiring harness on engine and secure engine control unit to prevent it from dropping.

–  Release hose clip -1- and detach coolant hose. –  Disconnect vacuum hose -3- on rear side of plenum chamber partition panel in direction of -arrow- and detach vacuum connection -2- from plenum chamber partition panel.

–  Unplug electrical connectors -arrow- at front wheel speed sensors on both sides.

–  If fitted, unplug electrical connector -1- from front left vehicle level sender -G78- and front right vehicle level sender -G289- and move wiring clear -arrow-.

–  Release electrical connector -2- at bracket by pulling retainer catch to the rear -arrow A- and turning connector approx. 90° clockwise -arrow B-. –  Move clear electrical wire -3- and brake hose -4- at bracket. –  Remove bolts -1- and tie up brake caliper with attached brake hose in wheel housing.   Caution Avoid damage to brake pistons. Do not operate brake pedal with brake caliper removed.

–  Remove nut -2- and pull out bolt -1-. –  Pull upper suspension links upwards out of wheel bearing housing -arrows-. –  Perform the same work steps on the other side of the vehicle.

–  Remove bolt -1- for anti-roll bar on both sides. –  Remove nut -3- on both sides.   Note The bolts -2- are removed at a later stage.   Caution Risk of damage to running gear components. The vehicle must NOT be lowered onto its wheels if the engine/gearbox mountings, steering box or subframe cross brace are not properly installed.

A4 (all), A5 Coupé: –  Remove nut -1- for power steering hydraulic line. –  Remove bolts -arrows- and detach subframe cross brace.   Note Illustration shows the installation position on a vehicle with dynamic steering.

A5 Cabriolet: –  Remove bolts -1- and -2- on both sides and detach strut.

–  Remove bolt -2- for power steering hydraulic line. –  Remove bolts -1- and -arrows- and detach subframe cross brace.

All vehicles (continued): –  If fitted, remove bolts -arrows- on both sides and detach heat shield -1-.

Caution Risk of damage to coil connector for airbag. t  Make sure that front wheels are in straight-ahead position before removing universal joint from steering box. t  Do not alter the position of the steering wheel or the steering gear from this point onwards. –  Remove bolt -arrow- for universal joint → Rep. gr.48. –  Separate universal joint from steering box and move clear to the top as far as possible.

–  Remove bolts -arrows- and detach heat shield for propshaft.

–  Remove bolts connecting propshaft to gearbox (use counterhold tool -T10172- with -T10172/5-). –  Slide propshaft towards rear final drive; the constant velocity joints can be moved axially. –  Tie up propshaft on one side.

Set up the scissor-type assembly platform as follows: –  Set up scissor-type assembly platform -VAS 6131 A- with support set for Audi -VAS 6131/10-, support set -VAS 6131/11- and supplementary set -VAS 6131/13- as follows:

Platform coordinates	Parts of support set for Audi -VAS 6131/10-, support set -VAS 6131/11- and supplementary set -VAS 6131/13-
B4	/13-4	/10-4	/10-5	/13-1
G4	/13-4	/10-4	/10-5	/13-1
B6	/10-1	/10-2	/10-5	/10-11
G6	/10-1	/10-2	/10-5	/10-11
A8+C8	/13-6	–	–	/13-2
F8+H8	/13-6	–	–	/13-2
C13	/10-1	/10-4	/10-5	/10-7
F13	/10-1	/10-4	/10-5	/11-1
F17	/10-1	/10-4	/10-5	/13-2

–  Bolt the support elements onto the scissor-type assembly platform hand-tight to start with. –  Position scissor-type assembly platform -VAS 6131 A- horizontally. l  Take note of spirit level (bubble gauge). –  Position scissor-type assembly platform -VAS 6131 A- below engine/gearbox assembly.

WARNING Accident risk if subframe mountings are detached. Subframe bolts -2- and -3- must not be loosened. –  Remove subframe bolts -1- on both sides.

–  Position support elements from -VAS 6131/10- and -VAS 6131/13- at front left and right of subframe as shown. –  Make sure that threaded spindles are screwed in completely.

–  Position support elements from -VAS 6131/10- (rear left and right) at front attachment points of subframe cross brace as shown.

–  Position support elements from -VAS 6131/13- under left and right wheel bearing housings as shown.

–  Position support elements from -VAS 6131/10- at rear of cross member on both sides, as shown in illustration. –  Turn all spindles for support elements upwards until all locating lugs make contact with mounting points.

–  Position support elements from -VAS 6131/10- and -VAS 6131/13- underneath front exhaust pipe, as shown in illustration. –  Tighten base plates for support elements to 20 Nm on scissor-type assembly platform -VAS 6131 A-.

Caution Risk of damage to flexible joint in front exhaust pipe. Do NOT bend flexible joint in front exhaust pipe more than 10°. –  Loosen bolted connections -arrows- and push clamp towards rear.

–  Mark installation position of subframe on longitudinal members with felt-tip pen. –  Unscrew subframe bolts -2- and -3- on both sides in several stages and in diagonal sequence.   Note Disregard -item 1-.

–  Remove bolts -arrows- for tunnel cross member.

–  Remove bolt -2- on both sides.   Caution Danger of damage to hoses, pipes and wiring connections and to engine compartment. t  Check that all hoses and wiring connections between engine, gearbox, subframe and body have been detached. t  Carefully guide out engine/gearbox assembly with subframe from engine compartment when lowering.

–  Lower engine/gearbox assembly using scissor-type assembly platform -VAS 6131 A- initially only as far as distance -a-. l  Dimension -a- = 100 mm (maximum).

–  Pry ball socket -2- of selector lever cable off selector shaft lever using removal lever -80 - 200-. –  Press off securing clip -1- and remove selector lever cable from gearbox.   Note Take care not to bend or kink selector lever cable. –  Lower engine/gearbox assembly further. –  Pull out scissor-type assembly platform -VAS 6131 A- with engine/gearbox assembly from underneath vehicle.