With Multitronic Transmission
Engine, Removing
• With lock carrier installed, engine is removed downward with transmission and subframe.
• All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine.
• Drained coolant must be stored in a clean container for disposal or reuse.
Special tools, testers and auxiliary items required
• Pry Lever - Rmv Outside Mirror (80-200)
• Hose Clamps Up to 25 mm dia. (3094)
• Hose clamp pliers (V.A.G 1921)
• Step ladder (VAS 5085)
• Scissor lift table (VAS 6131 A) with support set (VAS 6131/10) and adapters (VAS 6131/10-12)
• Drip tray for workshop crane (VAS 6208)
• Lifting Eyebolt (3368)
• Old oil collecting and extracting device (V.A.G 1782 )
• Tension strap (T10038)
• If engine and transmission are to be separated after removal, the Supplementary Set Audi A6 (C6) (VAS 6131/12) will also be required.
Procedure
- Shift selector lever to position "N".
- Discharge refrigerant circuit.
CAUTION!
Observe safety precautions when disconnecting the battery.
- With ignition switched off, disconnect Battery Ground (GND) cable - arrow -.
- remove rear engine cover - arrows -.
- Remove front engine cover - arrows -.
CAUTION!
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 on noise insulation.
- Loosen quick-release fasteners - 1 through 3 - and remove front and rear noise insulation.
- Place drip tray for workshop crane (VAS 6208) under engine.
- Disconnect coolant hose - arrow - from oil cooler and drain coolant.
- Disconnect lower right coolant hose from radiator - arrow - and drain residual coolant.
- Remove bolts - arrows - at torque support stop.
- Remove bolts - arrows - for torque support.
• The torque support and torque support stop will later be removed.
• Observe rules of cleanliness for working on automatic transmissions.
- Place old oil collecting and extracting device ( V.A.G 1782) under engine.
- Loosen union nuts - 3 - and disconnect ATF lines.
• Ignore - 1 - and - 2 -.
- Remove Ground (GND) cable - arrow - from right longitudinal member.
- Disconnect brake booster vacuum hose from grommet - arrow - on bulkhead.
- Remove Ground (GND) cable - arrow - at bulkhead.
- Remove coolant hoses - 1 - and - 2 - at coolant expansion tank.
- Remove coolant expansion tank - arrow -.
- Disconnect electrical connection at Engine Coolant Level (ECL) Warning Switch (F66) at bottom of coolant expansion tank.
- Remove coolant hose - arrow - from front coolant line.
- Remove left front coolant hose in engine compartment - arrows -.
- Remove coolant hose - arrow - from front coolant line.
- Disconnect vacuum hose - arrow - to leak detection pump.
• Place a rag under hydraulic lines to catch escaping hydraulic fluid.
- Remove hydraulic pressure line - 2 - at power steering pump and set it aside on top of the longitudinal member.
- Clamp off hydraulic hose - 1 - for power steering pump with a Hose Clamps Up to 25 mm dia. (3094).
- Remove hydraulic hose from power steering pump.
• To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
- Remove bolts - arrows -.
• The refrigerant lines will be removed from air conditioning compressor at a later point in time.
- Remove bolts - arrows -.
- Remove air duct - 1 - and - 2 -.
- Disconnect vacuum hose - 1 - at vacuum pump.
- Remove bolts - arrows - and remove vacuum pump.
CAUTION!
Note rules of cleanliness for working on the fuel injection system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
CAUTION!
Fuel system is under pressure! Before opening the low pressure section of the fuel injection system, wrap a clean rag around the connection and relieve residual pressure by carefully loosening the connection.
- Separate fuel line - arrow - and lay aside.
- Disconnect check valve - 1 - from connection at air duct hose.
- Remove air duct hose, thereby loosening hose clamp - 2 - and opening clips - arrows -.
- Remove pin from spreader clips - arrow -.
- Remove air filter housing.
- Remove vacuum hose - arrow - to EVAP canister at Evaporative Emission (EVAP) Canister Purge Regulator Valve ( N80).
- Remove coolant hose - arrow - to heater core on rear of engine.
- Remove nuts and remove left bracket for harness connectors - 1 - and - 2 - from bulkhead.
- Remove nuts and remove right bracket for harness connectors - 1 - and - 2 - from bulkhead.
- Remove rubber seal - 2 - for plenum chamber cover.
- Remove plenum chamber cover - 1 -.
- Remove nut - 1 - and remove fuse strip on plus wire terminal clamp.
- Disconnect plus wire - 2 - on battery positive terminal.
- Pull plus wire through bulkhead toward front.
- Free up wiring harness lay it aside on engine.
• Ignore - 3 -.
- Pry off both covers - 3 - using a screwdriver.
- Loosen hex-nuts - 4 - by several turns.
- Loosen wiper arm - 2 - from wiper axle by lightly tilting.
- Remove nuts completely and remove wiper arms.
CAUTION!
To prevent the cowl grille - 5 - 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.
- Disconnect securing clips - 1 - and remove cowl grille - 5 -.
- Remove cover for E-Box in plenum chamber - arrows -.
- Using a screwdriver, carefully pry off mounting bracket - arrow - and remove Engine Control Module (ECM) from E-Box.
• Engine Control Module (ECM) remains connected at wiring harness.
- Release retaining hooks - arrows - toward outside and remove retaining bracket.
- Disconnect all electrical connectors on connector station - 2 -.
- Remove electrical wire connection - 1 -.
- Disengage locking mechanisms - arrows - and remove secondary relay carrier in E-Box toward top.
- Disengage engine wiring harness at E-Box and bulkhead.
- Set wiring harness on engine and secure Engine Control Module (ECM) against falling down.
- Have a second technician press brake pedal.
CAUTION!
To loosen collar bolt for drive axle, the wheel bearing must not be under load (vehicle must not be standing on its wheels).
- Remove collar bolt - 2 - at left and right drive axles - 1 -.
- Remove heat shield - 1 - for left and right drive axles.
- Remove left and right drive axles from flange shafts of transmission.
• The drive axles will be removed at a later point in time.
• To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
- Remove bracket for refrigerant lines at right on oil pan - arrow -.
- Remove refrigerant lines at A/C compressor.
- Tie up refrigerant line, that runs to catch reservoir at right of vehicle, to body.
- Seal open connections on A/C compressor using clean plugs.
- Remove bolts and nuts - arrows - uniformly at left and right.
- Remove stabilizer.
- If equipped, disconnect electrical harness connector at Left Front Level Control System Sensor (G78).
- Unclip actuator rod for Left Front Level Control System Sensor (G78) at bottom on control arm - arrow -.
- Remove outer suspension strut bolt from left and right of engine compartment.
- Rotate Lifting Eyebolt (3368) at left and right in suspension strut mount hole from below.
CAUTION!
Only install the Lifting Eyebolt (3368) until it is flush with the upper edge of the suspension strut mount so that hood is not damaged when it is closed.
- Tie up wheel bearing housing at left and right with Tensioning Strap (T10038) as shown in illustration.
CAUTION!
To prevent the upper control arm joints from being damaged, support the wheel bearing housing before loosening the lower suspension strut bolts.
- Remove suspension strut from control arm - arrow -.
- Remove nuts - 1 - and - 2 - for fastening control arm and guide control arm.
• The bolts will be removed from the subframe at a later point in time.
- Repeat procedure on opposite side of the vehicle.
- Loosen clamping sleeves - arrows -.
Prepare scissor lift platform:
- Equip scissor lift platform (VAS 6131 A) with support set for Audi (VAS 6131/10) as follows:
- Install attachments on scissor lift table by hand first.
- Place scissor lift platform (VAS 6131 A) in horizontal position.
• Note bubble level (sight glass) on support platform.
- Drive scissor lift table (VAS 6131 A) under engine/transmission subassembly.
- Position support elements from (VAS 6131/10) at front on engine as shown in illustration.
- Make sure that the threaded spindles are completely screwed in.
- Position support elements from (VAS 6131/10) at left and right on subframe as shown in illustration.
- Position support elements from (VAS 6131/10) at left and right on tunnel cross member as shown in illustration.
- Twist all spindles of support elements upward far enough until all support pins make contact at support points.
- Tighten base plates for support elements to 20 Nm on scissor lift platform (VAS 6131 A).
- Remove nuts - A - at bottom on left and right engine mounts.
- Cut through cable ties - arrows -, open starter harness retainer and take electrical harness out.
- Remove bolts - 1 -.
- Mark installation position of subframe and of both engine mount consoles to longmembers using a felt-tip marker.
- Remove bolts - 2 -, - 3 - and - 4 - in diagonal sequence and in stages.
- Remove left and right engine mount console.
• Verify that all hoses and lines between engine, transmission, subframe and body have been disconnected.
• While lowering, carefully guide engine/transmission subassembly with subframe out of engine compartment in order to prevent damage.
- First lower engine/transmission assembly using scissor lift platform (VAS 6131 A) only approximately by dimension - a -.
• Dimension - a - = 80 mm.
- Mark selector lever cable bracket installation location.
- Remove selector lever cable bracket bolt - 1 -.
- Press ball socket - 2 - of selector lever cable from selector shaft lever.
• Do not bend or kink selector lever cable.
- Remove bolts at guide control arm - 1 - and at control arm - 2 - from subframe.
- Swing guide control arm - 1 - and control arm - 2 - outward.
CAUTION!
Guide control arm and control arm must not hang free. Tie up both control arms on wheel bearing housing - arrows - as shown in illustration.
- Swing wheel bearing housing outward and remove drive shaft.
- Repeat work procedure on opposite side of the vehicle.
- Push scissor lift platform (VAS 6131 A) approximately 20 mm back and remove torque support and torque support stop.
- Push scissor lift platform (VAS 6131 A) back into the removal position and lower the scissor lift platform (VAS 6131 A) completely.
- Push scissor lift platform (VAS 6131 A) with engine/transmission subassembly under vehicle.