Audi Workshop Service and Repair Manuals

Removing engine - vehicles with manual gearbox

Special tools and workshop equipment required

t	Removal lever -80 - 200-

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 clip pliers -VAS 6362-

t  Hose clip pliers -VAS 6340-

t  Locking pin -T10060 A-

t  Puller -T40160- Procedure   Note t  The engine is removed from underneath together with the gearbox and subframe (with lock carrier installed). t  Fit cable ties in the original positions when installing.   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. The fuel system operates at extremely high pressure. This can cause injury. The fuel pressure in the high-pressure section of the injection system must be reduced to a residual pressure prior to opening the system. –  Set front wheels to straight-ahead position.

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.

–  Remove engine cover panel -arrows-. –  Discharge refrigerant system → Air conditioner with refrigerant R134a.

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 → Wheels and tyres; Rep. gr.44. –  Remove front left and front right wheel housing liner → Rep. gr.66. –  Remove noise insulation panels -1- and -2- → Rep. gr.66.

–  Vehicles with four-wheel drive: Remove propshaft → Rear final drive 0BC; Rep. gr.39 or → Rear final drive 0BF and 0BE - sport differential; Rep. gr.39.   Note

Collect drained coolant in a clean container for re-use or disposal. –  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 (bottom left) and drain off coolant.

–  Unplug electrical connector -1- on charge pressure sender -G31-/intake air temperature sender -G42- and move clear electrical wiring.   Note Disregard -item 2-.

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

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

–  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.

–  Remove air duct -arrow-.

–  Unplug electrical connector -1- from air mass meter -G70-. –  Remove air hose and air mass meter -G70-. To do so, release hose clip -2- 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. –  Release hose clips and detach fuel hoses: 1 -  Fuel hose (blue) 2 -  Fuel hose (blue) 3 -  Fuel hose (white)

–  Release hose clip -arrow- and disconnect coolant hose from coolant pipe (front).

–  Release hose clip -arrow- and detach air hose.

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-.

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

–  Pull seal off plenum chamber partition panel. –  Remove plenum chamber cover → Rep. gr.50.

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

–  Remove nuts -1 ... 4- for electrical wiring. –  Detach electrical connector -5- from bracket and unplug. –  Remove bolt -6- 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.

–  Release catch -arrow- to open wiring duct -1- and move wiring harness clear.

–  Detach refrigerant lines -A- and -C- from inner heat exchanger → Rep. gr.87.

–  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.

–  Remove subframe cross brace → Rep. gr.40.   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.

–  Audi A5 Cabriolet/Sportback: Remove diagonal struts → Rep. gr.40.

–  Remove bolts -arrows- on both sides and detach heat shield -1-.

–  Unplug electrical connector -2- at power steering control unit -J500- (release retainer -arrow- and press down release catch). –  Unplug electrical connector -1- at power steering control unit -J500-. –  Move clear electrical wiring harness.

–  Detach intermediate steering shaft from steering box and slide splines together → Rep. gr.48.

–  Remove bolt -2- and tie up clutch slave cylinder at side of engine compartment.   Caution Avoid damage to clutch slave cylinder. Do not press clutch pedal after removing slave cylinder. –  Remove nut -1- for selector rod.

–  Apply puller -T40160- and pull off selector rod -1-.

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- and supplementary set -VAS 6131/13- as follows:

Platform coordinates	Parts of support set for Audi -VAS 6131/10- 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
C14	/10-1	/10-3	/10-5	/10-13
F14	/10-1	/10-3	/10-5	/10-10
F17	/10-1	/10-4	/10-5	/13-2

–  Initially hand-tighten the support elements on the scissor-type assembly platform. –  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.

–  Detach retaining clips for noise insulation from tunnel cross member. –  Position support elements from -VAS 6131/10- (rear left and right) at tunnel cross member as shown.

–  Position support elements from -VAS 6131/10- and -VAS 6131/13- underneath front exhaust pipe, as shown in illustration. –  Turn all spindles for support elements upwards until all locating lugs make contact with mounting points. –  Tighten base plates for support elements to 20 Nm on scissor-type assembly platform -VAS 6131 A-.

–  Vehicles with front-wheel drive: Loosen bolted connections -arrows- and push clamp towards rear.

–  Mark installation position of subframe and tunnel cross member on longitudinal members with felt-tip pen. –  Unscrew subframe bolts -2- and -3- on both sides in several stages and in diagonal sequence.

–  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. t  Carefully guide suspension struts past longitudinal members.

–  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).

–  Remove bolts -1- and -3- for selector rod and push rod.   Note Disregard -item 2-. –  Lower engine/gearbox assembly further. –  Pull out scissor-type assembly platform -VAS 6131 A- with engine/gearbox assembly from underneath vehicle.