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Home >> Audi >> 2002 >> A6 Sedan (4B2) V6-3.0L (AVK) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Engine, Removing >> Part 1 of 2

Part 1 of 2


Engine, removing

CAUTION:

Before beginning repairs on the electrical system:

- Obtain the anti-theft radio security code.
- Switch the ignition off.
- Disconnect the battery Ground (GND) strap.

- On vehicles equipped with Audi Telematics by OnStar ©, switch-off the emergency (backup) battery for the Telematic/Telephone Control Module prior to disconnecting vehicle battery.

- After reconnecting vehicle battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Repair Manual and/or Owner's Manual.

- After reconnecting vehicle battery on vehicles equipped with Audi Telematics by OnStar ©, switch-on the emergency (backup) battery for the Telematic/Telephone Control Module.





Special Tools and Equipment
^ 10-222A Engine support bridge
^ 2024A Engine Sling
^ 3147 engine support adapter
^ 3299 ribbed belt installation tool with
^ 3299/1 claw for tensioner
^ VAG1306 drip tray for
^ VAG1202A/ VAG1383A engine/gearbox jack





^ VAG1202A workshop crane
or
^ VAS6100





^ T10062 support
^ Oil receptacle

Removing

Notes:
^ Engine is removed toward the front without transmission and with the lock carrier removed.
^ All cable ties opened or cut during engine removal must be reinstalled at the same locations.
^ Heat boots, which are removed during engine removal must be reinstalled at the same locations when re-installing engine.
^ Drained coolant must be stored in a clean container for disposal or reuse.

Vehicles with automatic transmission
- Shift selector lever into position "N".





All:
- Pull off rubber seal of plenum chamber cover in direction of arrow.
- Remove plenum chamber cover -1- toward front.

WARNING: For vehicles with telematic, activate service -mode of telematic- of the control module before disconnecting the battery.

- Note radio code and determine if necessary (for vehicles with coded anti-theft radio / radio-navigation system -RNS-).





- Switch ignition off and disconnect battery Ground (GND) strap (arrow).

WARNING: Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.

- Open cap of coolant expansion tank.
- Remove both front wheels.





- For vehicles with auxiliary heater, remove bolts (arrows) for exhaust pipe of parking heater/auxiliary heater at noise insulation.





- Loosen mounting parts -1 to 4- and remove noise insulation.





- Remove bracket for noise insulation (arrows).
- Remove front bumper:
- Place VAG1306 Drip Tray beneath engine.





- Turn radiator drain plug -2 counter clockwise, if needed attach accessory hose to connection flange and drain coolant.
- Pull off retaining clip -1- for lower coolant hose and Disconnect coolant hose from radiator.





- Disconnect left coolant hose from radiator (arrow).





- In addition, disconnect coolant hose at oil cooler (arrow) and drain remaining coolant.
- Place oil pan underneath.





- Disconnect hydraulic lines to cooling coil at rear of bumper (arrows).

Vehicles with automatic transmission

Note: Observe the rules of cleanliness for working on automatic transmissions:

- Place oil pan underneath.





- Remove union nuts -3- and disconnect ATF lines.
- Remove bracket for ATF lines, to do so remove nuts -1- and -2-.





All:
- Remove cover-1- in engine compartment (right side).





- Remove bolts (arrows).
- Remove air guide -1-.





- Remove cover -1- in engine compartment (left side).





- Disconnect top coolant hose from radiator (arrow).





- Remove electrical harness connectors -1- and -2- from bracket and disconnect them.
- move cable clear.





- Disconnect electrical harness connector (arrow) for headlights at both sides of the vehicle.





- Remove air guides from left and right of radiator (arrows).





- Unclip temperature sensor -2- for outside temperature display from bracket.
- Unscrew bolts -1- and -2- and remove power steering cooling coil.
- Disconnect harness connector -3- at High Pressure Sensor -G65-.

WARNING: Do not open refrigerant circuit for A/C system.

- Remove condenser mounting bolts (arrows).





Note: To prevent damage to the condenser as well as to the coolant lines/hoses, make sure the lines and hoses are not over stretched, kinked or bent.

- Carefully swing condenser downward and move aside.
- Unscrew bolts (arrows) at left and right.
- Unhook hood cable from lock and move cable free.





- Unscrew bolts (arrows) at impact absorbers at left and right.

Note: A second technician is required to remove the lock carrier.

- Remove lock carrier and set aside so it cannot topple.





- Remove rear engine cover (arrows).





- Remove bolts for holding plate -3- for solenoid valves (arrows).
- Disconnect intake air hose -1- at Mass Air Flow (MAF)sensor.
- Disconnect hose -4- from air guide -2-.





- Remove bolt (arrow) and disconnect air guide -2- at throttle valve control module.
- Disconnect hose -1- from air guide if installed.

Note: Illustration depicts air guide with the removed engine from rear.





- Remove coolant hoses -1- and -2-.

Note: Coolant hose -3- remains connected.

- Unbolt coolant reservoir (arrow).
- Disconnect electrical wiring to Engine Coolant Level (CELL) Warning Switch -F66- at bottom of expansion tank.





- Disconnect Ground (GND) connection -3-.
- Disconnect vacuum hoses -1- and -2-.





- Disconnect vacuum line (arrow) to leak detection pump at throttle valve control module,





Vehicles with automatic transmission
- Disconnect electrical harness connector (arrow) and lay cable free.
- Place oil pan underneath.





- Disconnect hose -1- from power steering fluid reservoir.
- Disconnect vacuum hose -2- to vacuum reservoir.





- Disconnect electrical harness connector-1 at Secondary Air Injection (AIR) Pump Motor -V101- and move cable free.
- Disconnect hose at tube to combination valve for Secondary Air Injection (AIR) -2-.





- Disconnect electrical harness connectors -2- and -3- at Evaporative Emission (EVAP) canister purger regulator valve -N80- item 1 and at Mass Air Flow (MAP)sensor.
- Disconnect vacuum hose -6- at Evaporative Emission (EVAP) canister purge regulator valve and unhook solenoid valve at air filter housing.

WARNING: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.

- Disconnect Fuel supply line At- and fuel return line -5- and move free.
- Disconnect hose connections, move wires free and remove air filter housing (arrows).

Note: Place a rag under the hydraulic pressure lines, to catch escaping hydraulic fluid.





- Unbolt hydraulic pressure line for power steering at rear coolant pipe -1 and disconnect the line at the height of right cylinder head -2-.





Vehicles with automatic transmission
- Disconnect electrical harness connector (arrow) at Brake Booster Pressure Sensor G294-.
- move cable clear.

All:





- Remove E-box cover in plenum chamber arrows-.





- Using a screwdriver, carefully pry off retaining bracket (arrow).





- Disengage connector catch (arrows) and disconnect harness connectors -1 and -2- from Engine Control Module (ECM).





- Disconnect connectors at rear of connector strip.





- Detach release catch (arrow) and remove secondary relay carrier in Ebox upward.
- Unhook engine wiring harness at Ebox and at bulkhead and move it free.

- Remove heat shield for harness connectors at left of bulkhead.





- Remove harness connectors -1 to 4- from bracket at left of bulkhead.
- Disconnect electrical harness connectors -1 and -4-.
- Expose oxygen sensor wires.
- Remove bracket for harness connectors.
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