Engine, Removing
Engine, Removing
• With lock carrier installed, engine is removed downward together with the transmission and the subframe.
• Collect escaping coolant in a clean container for disposal or reuse.
• During installation, cable ties must be installed at the same location.
Special tools, testers and auxiliary items required
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Oil Collecting and Extracting Device (V.A.G 1782)
• Step Ladder (VAS 5085)
• Engine Bung Set (VAS 6122)
• Scissor-Type Assembly Platform (VAS 6131 A) with Support Set (VAS 6131/10) as well as Supplementary Set, Audi A8 (VAS 6131/11) , Supplementary Set, Audi Q7 (VAS 6131/13) and qty. 3 Tapered Mounting Pin (VAS 6131/10-2)
• Drip Tray For VAS 6100 (VAS 6208)
• Hose Clip Pliers (VAS 6340)
• Hose Clip Pliers (VAS 6362)
• Puller for Gear Shaft Linkage (T40160)
Procedure
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 the high pressure area of the fuel injection system.
- Reduce the fuel pressure in high pressure area.
• Release the electrical parking brake before disconnecting the battery so the driveshaft can be rotated to remove it.
- Position the front wheels so they are straight.
Risk of destroying electrical components.
• Observe measures for disconnecting battery.
- Turn off the ignition and remove the key.
- Disconnect the Ground (GND) cable - 2 - from the battery post.
- Empty the coolant circuit.
- Extract the power steering oil from the reservoir with the (V.A.G 1782).
- Remove the engine cover - arrows -.
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.
- Remove the left and right front wheels.
- Remove left and right front wheel housing liners.
- Remove the noise insulation - 1 and 2 -.
- Place the (VAS 6208) under the engine.
- Remove the drain plug - arrow - on the front coolant hose and drain the coolant.
- Remove the drain plug - arrow - on the map controlled engine cooling thermostat (F265) and drain the coolant.
- Disconnect the coolant hose from the radiator, to do this, lift the retaining clip - 2 -.
• Ignore - 1, 3 and 4 -.
- Disconnect the vacuum hose - 1 - and free up the hydraulic hose - arrow - on the bracket.
- Remove the nuts - 2 - and vacuum reservoir.
- Place the (V.A.G 1782) under the disconnection point.
- Disconnect the power steering hydraulic oil feed line - 2 - and return line - 1 -.
- Seal any open lines and connections with a clean plug from the (VAS 6122).
Risk of damaging refrigerant lines and hoses.
• Do not stretch, kink or bend refrigerant lines and hoses.
- Remove the bolts - 1 and 2 -.
- Disconnect the refrigerant lines from the compressor.
- Seal any open lines and connections with a clean plug from the (VAS 6122).
- Remove the nut - arrow - on the right longitudinal member and free up the Ground (GND) wires.
- Disconnect the connector - 2 -.
- Place (VAS 6208) under the engine.
- Remove the coolant hoses from the after-run coolant pump (V51) - arrows -.
• Ignore - 1 -.
- Disconnect the connector - 3 - on the Secondary Air Injection (IAT) pump motor (Via).
- Remove the secondary air injection hose - 1 - and free it up.
• Ignore - 2 -.
- Disconnect the radiator fan electrical connectors - 1 and 2 -, to do this, push the clamp to the rear - arrow - and push the release down.
- Free up the wiring harness.
- Remove the left and right bolts - 1 - and nuts - 3 - and the lock carrier braces - 2 -.
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening the fuel system and carefully loosen.
Follow the guidelines for cleanliness when working on the fuel supply system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Disconnect the fuel line - arrow -.
- Free up the fuel line and the line to the EVAP canister on the air guide pipe.
- Disconnect the electrical connector - 2 - on the Evaporative Emission (EVAP) canister purge regulator valve 1 (N80) and disconnect the vacuum hose - 1 -.
- Remove the EVAP canister purge regulator valve 1 from the bracket and lay aside with hose and fuel line connected.
- Disconnect the vacuum hose leading to the leak detection pump (V144) - arrow -.
- Remove the air duct - arrows -.
- Disconnect the connector - 1 - from the Mass Airflow (MAF) sensor (G70).
- Disconnect the vacuum line - 3 - from the air guide pipe.
Risk of violating emissions legislation.
• Do not open hose connection - 2 -!
- Lay aside air guide pipe with connected crankcase ventilation hose - 2 - by loosening hose clamp - 4 - and opening clips - arrows -.
- Disconnect the vacuum line - 1 -.
- Remove the air filter housing and disconnect the electrical connector - 2 - on the rear side at the intake air switch-over valve (N335).
- Remove hose - 3 - from the secondary air system.
- Disconnect the coolant hose by lifting the retaining clamps - 2 - and loosening the hose clamp - 1 - on the coolant tube.
- Disconnect electrical connector - 1 - for the brake system vacuum pump (V192) and free up electrical wiring.
- Disconnect the vacuum hose - 2 -.
- Remove the coolant hoses - 1 and 3 - from the coolant overflow reservoir.
• Ignore - 2 and arrows -.
- Remove the seal - arrow -.
- Remove the plenum chamber cover.
- Release the retainer - arrow A - and open the cover - arrow B -.
- Remove the nuts - 1 and 2 - for the electrical wires.
- Disconnect the connectors - 3 and 4 -.
- Remove the bolt - 5 - and the terminal 30 wire junction 2 (TV22) from the tower brace - arrow -.
- Release the retainers from the wheel housing side using a 5.5 mm open end wrench - 1 - and remove the wiring bushing - 2 - upward.
- Free up the wiring harness - 3 - to the generator and starter using the (80 - 200).
- Free up the wiring duct by releasing the retainer - arrow B - and pulling the duct forward - arrow A -.
- Remove the nut - 1 - and tilt the washer fluid filler neck upward - arrow A -.
- Remove the filler neck - 2 - with the filler tube from the washer fluid reservoir and the opening in the body - arrow B -.
- Remove the bolts - 1 - and nuts - 2 - and the tower brace - 3 -. The procedure for doing this depends on the version.
- Remove the bolts - arrows - and the engine compartment E-box cover.
- Remove the nut - 1 - and free up the wire.
- Release the retainers - A arrows - and remove the engine control module - arrow B -.
- Disconnect the connector - 2 - if applicable.
- Disconnect the electrical connectors - 4 - and remove the nut - 3 - for the electrical wire.
- Release the retainers - arrow - and remove the relay carrier with the fuse holder - 1 -.
- Disengage the engine wiring harness at the engine compartment E-box and free it up.
- Open the retainers - arrows A - and remove the harness opening - 2 - - arrow B -.
- Remove the ground pin - 1 - and free up the ground wire.
- Lay the wiring harness on the engine and secure the Engine Control Module (ECM) so that it cannot fall.
- Mark and remove the coolant hoses - 1 and 2 - for re-installing.
- Press the coolant hoses with hose guide in the engine compartment.
- Disconnect the electrical connectors - arrow - at the left and right on the front speed sensors.
- Disconnect the connector - 1 - headlamp range control sensor 1 (G233) electrical sensor - arrow - and free up electrical wiring.
- Free up the electrical connector - 2 - on the bracket by pulling the retainer back - arrow A - and turning the connector approximately 90° in the direction of - arrow B -.
- Free up the electrical wiring - 3 - and brake line - 4 - on the bracket.
- Remove the bolts - 1 - and secure the brake caliper, with the brake line still connected, inside the wheel housing using wire.
Risk of damaging brake pistons.
• Do not operate brake pedal with brake caliper removed.
- Remove the nut - 2 - and the bolt - 1 -.
- Remove the upper control arm upward from the wheel bearing housing - arrows -.
- Repeat the procedure on the other side of the vehicle.
Vehicles through VIN 8T-8A-011200:
- Remove the left and right stabilizer bar bolt - 3 -.
- Remove the left and right nuts - 1 -.
• The bolts - 2 - will be removed later.
Vehicles from VIN 8T-8A-011201:
- Remove the left and right stabilizer bar bolt - 1 -.
- Remove the left and right nuts - 3 -.
• The bolts - 2 - will be removed later.
All Vehicles:
The suspension components could be damaged.
• Do not rest the vehicle on its wheels if the subframe mount, the steering gear or the subframe crossbrace are not installed correctly.
- Remove the subframe crossbrace.
- Remove the bolts - arrows - and the crossmember.
- Remove the left front muffler nuts - arrows -.
- Remove the right front muffler nuts - arrows -.
The decoupling elements in the front muffler could be damaged.
• Do not bend decoupling elements in front muffler more than 10°.
- Loosen the clamping sleeves - 1 and 2 -, slide them back and remove the left and right front mufflers.
- Remove the bolts - arrows - and the driveshaft heat shield - 1 -.
- Remove the driveshaft from the transmission.
- Slide the driveshaft toward the rear final drive; the CV joints can move axially.
- Secure the driveshaft to the side.
- Remove the steering intermediate shaft from the steering gear push them upward.
- Remove the bolt - 2 - and secure the clutch slave cylinder sideways in the engine compartment.
Risk of damaging clutch slave cylinder.
• Do not operate the clutch pedal anymore after slave cylinder has been removed.
- Remove the selector rod nut - 1 -.
- Position the (T40160) and remove the selector rod - 1 -.
Prepare Scissor Lift Platform:
- Equip the (VAS 6131 A) with the (VAS 6131/10) and (VAS 6131/13) as follows:
- Next secure mounting elements to scissor lift table by hand.
- Position the (VAS 6131 A) horizontally.
• Note bubble level (sight glass) on support platform.
- Move the (VAS 6131 A) under the engine/transmission subassembly.
The subframe could cause an accident if it is not secured.
• Do not loosen the subframe bolts - 2 and 3 -.
- Remove the left and right subframe bolts - 1 -.
- Attach the mounting elements from the (VAS 6131/10) and (VAS 6131/13) at the left and right front of the subframe as shown in the illustration.
- Ensure threaded spindles are completely installed.
- Attach the mounting elements from the (VAS 6131/10) at the left and right rear on the subframe crossbrace front connecting points as shown in the illustration.
- Attach mounting elements from the (VAS 6131/13) at the lower left and right of the wheel bearing housing as shown in the illustration.
- Remove the noise insulation retaining clips from the crossmember.
- Attach the mounting elements from the (VAS 6131/10) at the left and right rear of the crossmember as shown in the illustration.
- 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 (VAS 6131 A) and tighten to 20 Nm.
- Mark the location of the subframe and engine carrier to the longitudinal members using a felt-tip pen.
- Remove the left and right subframe bolts - 2 and 3 - in a diagonal sequence in stages.
• Ignore - 1 -.
- Remove the bolts - arrows - and remove the tunnel crossmember.
Vehicles through VIN 8T-8A-011200:
- Remove the left and right bolts - 2 -.
Vehicles from VIN 8T-8A-011201:
- Remove the left and right bolts - 2 -.
All Vehicles:
Risk of damaging hose and wiring connections as well as the engine compartment.
• Make sure all the hoses and lines between the engine, transmission, subframe and body have been disconnected.
• Carefully guide the engine-transmission assembly with subframe out of the engine compartment while lowering.
- Next lower engine/transmission subassembly with (VAS 6131 A) only by dimension - a -.
• Dimension - a - = 100 mm maximum.
- Remove the bolts - 1 and 3 - - 3 - for the selector rod and push rod.
• Ignore - 2 -.
- Lower the engine/transmission subassembly more.
- Remove the (VAS 6131 A) with the engine/transmission subassembly under the vehicle.