Engine, Removing

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Pry Lever 80-200
Used Oil Collecting and Extracting Device VAG1782
Step Ladder VAS5085
Engine Bung Set VAS6122
Scissor Lift Table VAS6131A with Scissor Lift Table - Audi Set VAS6131/10 and Scissor Lift Table - A8 Set VAS6131/11
Shop Crane - Drip Tray VAS6208
Hose Clamps - Up To 25mm 3094
Hose Clip Pliers VAS6362
Tensioning Strap T10038

Procedure

NOTE:

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

During installation, cable ties must be 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.

Reduce the fuel pressure down to residual pressure before opening high pressure area of the fuel injection system.

-- Reduce fuel pressure in high pressure area. Refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

CAUTION:

Danger of causing damage to electrical components when disconnecting the battery.

Complete the steps for disconnecting the battery.
Turn off the ignition and disconnect the battery.

NOTE:

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

On vehicles with all-wheel drive, the electro-mechanical parking brake must be released before disconnecting the battery, so that the driveshaft can be rotated for removal.

-- Disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

Fig 1: Disconnecting Ground (GND) Cable At Battery

Courtesy of AUDI OF AMERICA, LLC

-- Remove the engine covers -1 and 2- upward.

Fig 2: Engine Covers -1- And -2-

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Risk of scalding due to hot steam and hot coolant.

The coolant system is under pressure when the engine is warm.
Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system.

-- Open the coolant reservoir cap.

-- Remove both front wheels. Refer to RUN-FLAT TIRES .

Fig 3: View Of Front Noise Insulation And Mounting Fasteners

Courtesy of AUDI OF AMERICA, LLC

-- Remove the noise insulation, to do this loosen the mounting parts -1, 2, arrow-.

-- Place the Shop Crane - Drip Tray VAS6208 under engine.

Fig 4: Identifying Drain Plug & Coolant Hose

Courtesy of AUDI OF AMERICA, LLC

-- 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 5: Disconnecting Coolant Hose From Oil Cooler

Courtesy of AUDI OF AMERICA, LLC

-- Remove the coolant hoses from the left front coolant pipes; loosen the hose clamps -arrows- and letting the remaining coolant drain out.

Fig 6: Locating Lower Coolant Pipe Bolt

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore -1-.

The installation location is shown with the lock carrier removed.

-- Disconnect the connector -1- on the Charge Air Cooling Pump -V188- and free it up.

Fig 7: Disconnect Charge Air Cooling Pump -V188- Electrical Harness Connector -1

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore items -2, 3- and -arrows-.

The installation location is shown with the bumper cover removed.

-- Disconnect the electrical connector -1- on the Left Electrohydraulic Engine Mount Solenoid Valve -N144-.

Fig 8: Removing Bolts And Left/Right Engine Support

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore -arrows-.

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

Fig 9: Releasing Belt Tension

Courtesy of AUDI OF AMERICA, LLC

-- Remove the ribbed belt from the A/C compressor ribbed belt pulley and release the tension on the tensioning device.

-- Disconnect the connector -1- for the wiring leading to the air conditioning compressor clutch solenoid.

Fig 10: Connector For Wiring To Air Conditioning Compressor Clutch Solenoid & Compressor Mounting Bolts

Courtesy of AUDI OF AMERICA, LLC

WARNING:

Refrigerant can cause serious personal injury.

Do not open the air conditioning refrigerant circuit.

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

CAUTION:

Danger of damaging the refrigerant lines and hoses.

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

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

NOTE:

To collect escaping hydraulic oil, lay a cloth under the hydraulic lines.

-- Clamp the hydrualic hose for the power steering pump using the Hose Clamps - Up To 25mm 3094.

Fig 11: Identifying Hydraulic Hose, Hydraulic Pressure Line & Hose Clamps 3094

Courtesy of AUDI OF AMERICA, LLC

-- Loosen the hose clamp -1- and remove the power steering fluid hose.

-- Remove the banjo bolt -2- on the power steering pump and lay the upper hydraulic oil line on the longitudinal member.

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

Fig 12: Removing Bolts And Torque Support From Engine

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Observe the rules of cleanliness for working on automatic transmissions. CLEAN WORKING CONDITIONS .

Fig 13: Loosening Union Nuts And Disconnecting ATF Lines

Courtesy of AUDI OF AMERICA, LLC

-- Place the Used Oil Collecting and Extracting Device VAG1782 under the disconnection 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 14: Removing Ground (GND) Strap From Right Longitudinal Member

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect electrical connector -2- at Secondary Air Injection Pump Motor -V101- and free up electrical wiring.

Fig 15: Disconnecting Electrical Connector On Secondary Air Injection (AIR) Pump Motor V101 & Removing Air Guide Hose

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore -1-.

-- Remove bolt -arrow-.

Fig 16: Identifying Coolant Hoses At Coolant Expansion Tank

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the electrical connector to the Engine Coolant Level 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.

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

Fig 17: Removing Nut And Left Electrical Connectors Bracket From Bulkhead & Ground (GND) Wire From Left Strut Tower

Courtesy of AUDI OF AMERICA, LLC

-- Remove the nut -arrow- for the GND cable on the left strut tower.

-- Remove the coolant hose and free it up, to do so, loosen the hose clamp -arrow-.

Fig 18: Engine Coolant Temperature (ECT) Sensor -G62- location

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Ignore items -1 and 2-.

-- Remove the left front coolant hose in the engine compartment; to do so, lift the clips -arrows-.

Fig 19: Disconnecting Top Coolant Hose From Radiator

Courtesy of AUDI OF AMERICA, LLC

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

Fig 20: Removing Coolant Hose From Front Coolant Line

Courtesy of AUDI OF AMERICA, LLC

-- Disconnect the vacuum hose leading to the Leak Detection Pump -V144-.

Fig 21: Locating Vacuum Hose Leading To The Leak Detection Pump -V144-

Courtesy of AUDI OF AMERICA, LLC

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

Fig 22: Locating Air Guides -1- And -2-

Courtesy of AUDI OF AMERICA, LLC

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

Fig 23: Locating Front Secondary Air Hose

Courtesy of AUDI OF AMERICA, LLC

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 24: Locating Fuel Supply Hose At High Pressure Pump -Arrow-

Courtesy of AUDI OF AMERICA, LLC

-- Free up the fuel line -4- and hose connection -1- from the EVAP canister on the air filter housing and on the air guide tube.

Fig 25: Free Up Fuel Line

Courtesy of AUDI OF AMERICA, LLC

-- 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 electrical connector -1- on EVAP Canister Purge Regulator Valve 1 -N80- and disconnect the vacuum hose -2- by pressing the release buttons.

Fig 26: Identifying Electrical Connector -1- To Evaporative Emission (EVAP) Canister Purge Regulator Valve & Vacuum Hose -2-

Courtesy of AUDI OF AMERICA, LLC

-- Remove the EVAP Canister Purge Regulator Valve 1 -N80- from the bracket and lay it aside with the hose connected.

-- Disconnect the brake booster vacuum hose -arrow-.

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

Fig 27: Opening Clips And Removing Upper Part Of Air Filter Housing

Courtesy of AUDI OF AMERICA, LLC

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

Fig 28: View Of Air Filter Housing And Secondary Air Injection Pump Hose

Courtesy of AUDI OF AMERICA, LLC

-- Remove the air filter housing lower section and disconnect the secondary air pump hose -1-.

-- Lift the clamp -arrow- and remove the coolant hose leading to the back of the heater core on the engine.

Fig 29: Locating Coolant Hose Leading To Back Of Heater Core On Engine

Courtesy of AUDI OF AMERICA, LLC

NOTE:

To provide a better illustration, component location is shown from behind with engine removed.

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

Fig 30: Identifying Ground Pins & Nuts

Courtesy of AUDI OF AMERICA, LLC

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

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

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

Fig 31: Removing Rubber Seal And Plenum Chamber Cover

Courtesy of AUDI OF AMERICA, LLC

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

Fig 32: Identifying Windshield Wiper Arm And Puller T10369/1

Courtesy of AUDI OF AMERICA, LLC

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 the grille up vertically out of fastening strip beginning at edge of window.

Fig 33: Bolts (Arrows) And Cowl Panel (1)

Courtesy of AUDI OF AMERICA, LLC

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

-- Remove the bolts -1 and 3- and the tower brace -2-.

Fig 34: Removing Bolts And Strut Tower Brace

Courtesy of AUDI OF AMERICA, LLC

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

Fig 35: Disconnecting Vacuum Line To Brake Booster At Bulkhead

Courtesy of AUDI OF AMERICA, LLC

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

Fig 36: Removing Bolts And Cover Form E-Box At Left In Engine Compartment

Courtesy of AUDI OF AMERICA, LLC

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

Fig 37: Identifying Fuse Holder, 3-Socket Relay Carrier, Electrical Wire Connection & Electrical Connections

Courtesy of AUDI OF AMERICA, LLC

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

Courtesy of AUDI OF AMERICA, LLC

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

Fig 39: Opening Cover Using Screwdriver

Courtesy of AUDI OF AMERICA, LLC

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 from the E-box.

Fig 40: Direction (Arrows 1 And 2) To Lever Retaining Clip (3)

Courtesy of AUDI OF AMERICA, LLC

NOTE:

Engine Control Module (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 Pry Lever 80-200.

Fig 41: Free Electrical Wiring Up To Generator Using 80-200

Courtesy of AUDI OF AMERICA, LLC

-- Lay both wiring harnesses on the engine and secure the engine control module 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 the brake pedal.

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

Fig 42: Identifying Collar Bolt For Left/Right Drive Axle

Courtesy of AUDI OF AMERICA, LLC

-- Remove the let and right drive axles from the transmission flange shaft.

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

Fig 43: Removing Left/Right Nuts, Bolts & Stabilizer Bar

Courtesy of AUDI OF AMERICA, LLC

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

-- Disconnect the electrical connector -2- on the Left Front Level Control System Sensor -G78-.

Fig 44: Disconnecting Electrical Harness Connector At Level Control System Sensor & Connecting Link From Control Arm

Courtesy of AUDI OF AMERICA, LLC

-- 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 the Tensioning Strap T10038 as shown in illustration.

Fig 45: Disconnecting Connecting Link At Control Arm

Courtesy of AUDI OF AMERICA, LLC

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

Fig 46: Air Spring Damper At Control Arm Bolt

Courtesy of AUDI OF AMERICA, LLC

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

Fig 47: Guide Control Arm & Control Arm

Courtesy of AUDI OF AMERICA, LLC

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

Fig 48: Identifying Guide Control Arms And Track Control Arms

Courtesy of AUDI OF AMERICA, LLC

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.

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.

NOTE:

Mark the installed position of the cable mounting bracket with a marker.

-- Remove the selector lever cable ball socket -1- from the transmission shift lever.

Fig 49: Pressing Ball Socket Of Selector Lever Cable From Selector Shaft Lever & Removing Bracket On Transmission

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -arrows- and remove the cable mounting bracket from the transmission.

-- Free up the selector lever cable.

-- Loosen the clamping sleeve -1 and 2- and slide it toward the rear.

Fig 50: Loosening Left/Right Clamping Sleeve

Courtesy of AUDI OF AMERICA, LLC

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

Fig 51: Front Cross Member

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts -arrows- and the driveshaft heat shield -A-.

Fig 52: Heat Shield For Driveshaft

Courtesy of AUDI OF AMERICA, LLC

-- Remove the bolts for the driveshaft to transmission connection.

-- Push driveshaft together with rear final drive. The Constant Velocity (CV) joints can move axially.

-- Tie driveshaft up and to the side against heat shield -arrow-.

Fig 53: Drive Shaft Tied To Side, Onto Heat Shield

Courtesy of AUDI OF AMERICA, LLC

Prepare Scissor Lift Platform:

Fig 54: Identifying Scissor Lift Platform VAS 6131

Courtesy of AUDI OF AMERICA, LLC

-- Equip the Scissor Lift Table VAS6131A with the Scissor Lift Table - Audi Set VAS6131/10 and the Scissor Lift Table - A8 Set VAS6131/11 as follows:

Platform Coordinates	Parts from Scissor Lift Table - Audi SetVAS6131/10 and Scissor Lift Table - A8 SetVAS6131/11
B4	/10-1	/10-4	/10-5	/10-13
F4	/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
C15	/10-1	/10-3	/10-5	/11-2
F15	/10-1	/10-3	/10-5	/11-2

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

-- Position the Scissor Lift Table VAS6131A horizontally.

Note the bubble level (sight glass) on support platform.

-- Move the Scissor Lift Table VAS6131A under the engine/transmission subassembly.

-- Attach mounting elements from the Scissor Lift Table - Audi Set VAS6131/10 at the front of the engine as shown in the illustration.

Fig 55: Attaching Mounting Elements At Front Of Engine

Courtesy of AUDI OF AMERICA, LLC

-- Attach mounting elements from Scissor Lift Table - Audi Set VAS6131/10 at left and right on subframe as illustrated.

Fig 56: Positioning Support Elements From Support Set VAS 6131/10 At Left/Right On Subframe

Courtesy of AUDI OF AMERICA, LLC

-- Attach mounting elements from the Scissor Lift Table - Audi Set VAS6131/10 and Scissor Lift Table - A8 Set VAS6131/11 at the back of the engine as illustrated.

Fig 57: Attaching Mounting Elements At Back Of Engine

Courtesy of AUDI OF AMERICA, LLC

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

-- Attach mounting element base plates to the Scissor Lift Table VAS6131A and tighten to 20 Nm.

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

Fig 58: Removing Bolts At Tunnel Cross Member

Courtesy of AUDI OF AMERICA, LLC

NOTE:

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

-- Remove the bolts -1-.

Fig 59: Identifying Subframe Bolts 1 Through 4

Courtesy of AUDI OF AMERICA, LLC

-- Mark location of the 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.

-- Slowly lower the engine/transmission subassembly.

-- Remove the Scissor Lift Table VAS6131A with the engine/transmission subassembly under vehicle.