Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Oil collecting and Extracting Device (V.A.G 1782)
• Hose Clip Pliers (V.A.G 1921)
• Step Ladder (VAS 5085)
• Scissor-Type Assembly Platform (VAS 6131 A) with Support Set (VAS 6131/10) and Supplementary Set, Audi A8 (VAS 6131/11) and Supplementary Set, Audi Q7 (VAS 6131/13)
• Drip Tray (VAS 6208)
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Engine Bung Set (VAS 6122)
• Counterhold Tool Touareg V10 (T10172) with Adapter (T10172/5)
• With the lock carrier installed, the 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.
Procedure
Risk of vehicle tipping over with the 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.
Risk of destroying electrical components.
• Observe measures for disconnecting battery.
- Position the front wheels so they are straight.
• Release the electrical parking brake before disconnecting the battery so the drive axle can be rotated to remove it.
- Turn off the ignition and remove the ignition key.
- Remove the luggage compartment cargo floor - 3 -.
- Remove the bass box - 2 -.
- Fold back the carpet - 1 - over the flap.
- Press the release tabs - arrows - and open the flap - 1 -.
- Open the cover - 1 - over the battery Ground (GND) terminal post.
- Disconnect the GND wire - arrow - from the battery terminal.
- Empty coolant circuit.
- Extract the power steering oil from the reservoir with the (V.A.G 1782).
- Remove the engine covers - 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.
- Open the coolant reservoir cap.
- 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 - 1 - and drain the coolant.
- Remove the coolant hose - 2 - from the radiator by raising the retaining clip.
- Remove the coolant hose from the engine oil cooler by loosening the hose clamp - arrow - and letting the remaining coolant drain out.
- Place the (V.A.G 1782) under the disconnection point.
- Disconnect the power steering hydraulic oil supply line - 2 - and return line - 1 - in the left front wheel housing and free them up.
- Seal any open lines and connections with a clean plug from the (VAS 6122).
- Place the (V.A.G 1782) under the disconnection point.
- Mark the locations of the ATF lines - 1 and 2 - so they can be installed later and then disconnect them.
• Ignore - arrow -.
- Seal any open lines and connections with a clean plug from the (VAS 6122).
Vehicles with a Coolant Recirculation Pump (V50).
- Disconnect the connector - 1 -.
- Place the (VAS 6208) under the engine.
- Remove the coolant hose from the coolant recirculation pump - right arrow -.
• Ignore - 2 - and - left arrow -.
All Vehicles
- Disconnect the coolant fan electrical connector - 1 - by sliding the retainer back - arrow - and pressing the release down.
- Free up electrical wiring harness.
- Disconnect electrical connector - 3 - at Secondary Air Injection (AIR) pump motor (V101) and free up the electrical wiring.
• Ignore - 1 and 2 -.
- Remove the left and right bolt - 1 - and nut - 3 - and the lock carrier brace - 2 -.
- Remove the nut - arrow - on the right longitudinal member and free up the Ground (GND) wire.
- Remove the bolts - 1 - and nuts - 2 - and - arrow - and remove the strut tower brace.
- Remove gasket - 3 -.
- Open the clips - 1 - and remove the plenum chamber cover - 2 -.
- Disconnect the vacuum hose - arrow - to the leak detection pump (V144).
- Remove the vacuum connection - 2 - from the bulkhead by pulling the vacuum hose - 1 - on the rear side.
- Free up the fuel line and wire to the EVAP canister at the air guide pipe.
• Ignore - 3 and 4 -.
- Remove the air duct - arrows -.
- Remove the vacuum hose - 3 - from the connection on the air guide pipe.
- Remove the air guide pipe by loosening the hose clamp - 4 - and opening the clips - arrows -.
- Free up the fuel hose - 1 - on the air duct pipe.
• Ignore - 2 -.
- Press the release buttons, remove the air filter housing and remove the secondary air hose - arrow -.
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.
Risk of contamination to the fuel system.
• Note the rules of cleanliness for working on the fuel injection system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Remove the fuel supply line from the high pressure pump - arrow - and lay it aside.
- Disconnect the vacuum hose - 1 - and free it up.
- Remove the coolant hose - 2 - from the upper coolant pipe by lifting the retaining clamp.
- Remove the front secondary air hose - arrow - from its bracket and disconnect it; to do this press the release buttons.
- Vehicles without the coolant recirculation pump (V50) : Open the clamp and remove the right front coolant hose - arrow - from the front coolant pipe.
- Remove the coolant hose from the front coolant pipe by lifting the retaining clamp - arrow -.
- Loosen the clamp - arrow - and remove the coolant hose.
- Disconnect the coolant hose - 2 - from the coolant overflow reservoir.
- Remove the bolts - arrows -, disconnect the connector - 1 - on the engine coolant level warning switch (F66) and move the coolant reservoir to the side with the coolant hose still connected.
- Disconnect the electrical connector - arrow - on the power steering pump, if applicable.
- Press the hydraulic hose down slightly.
Risk of damaging refrigerant lines and hoses.
• Do not stretch, kink or bend refrigerant lines and hoses.
- Remove the bolts - arrows - and the refrigerant lines from the A/C compressor.
- Seal any open lines and connections with a clean plug from the (VAS 6122).
- Release the retainer - arrow A - and open the cover - arrow B -.
- Remove the nuts - 1 and 2 - for the electrical wires.
- Remove the electrical connector - 3 - from the bracket and disconnect it.
- Remove the bolt - 4 - and the terminal 30 wire junction 2 (TV22) from the tower brace - arrow -.
- Remove the foam piece - 1 -.
• Ignore - 2 -.
- 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).
- Open the catch - arrow -, free up the wiring harness and open the wiring duct - 1 -.
- Remove the nut - 3 - and the bolt - 2 -.
- Remove the filler neck - 1 - with the filler tube from the washer fluid reservoir and the opening in the body - arrow -.
- Remove the bolts - 1, 2 and 4 - and remove the E-box cover - 3 - in the engine compartment.
- Remove the nut - 5 - and free up the GND wire.
- Release the retainers - A arrows - and remove the engine control module - arrow B -.
- Disconnect the electrical connector - 2 - if applicable.
- Disconnect the connectors - 4 - and the wire - 3 -.
- Open the retaining tabs - arrow - and remove fuse holder B (SB) - 1 -.
- Disengage the engine wiring harness on the E-box and free it up.
- Release the retainers - A arrows - and remove the wiring bushing - 2 - upward - arrow B -.
- Remove the GND pin - 1 - and free up the electrical wire.
- Lay the wiring harness on the engine and secure the engine control module so that it cannot fall.
- Disconnect the electrical connectors - arrow - at the left and right on the front speed sensors.
- Disconnect the electrical connector - 1 - on the left front level control system sensor (G78) and right front level control system sensor (G289) and free up the electrical wiring - arrow -.
- 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 nut - 2 - and bolt - 1 -.
- Remove the upper control arm upward from the wheel bearing housing - arrows -.
- Repeat the procedure on the other side of the vehicle.
- Remove the left and right stabilizer bar bolt - 1 -.
- Remove the left and right nuts - 3 -.
• The bolt - 2 - will be removed later.
- Remove the nut - 1 - for the power steering hydraulic fluid line bracket.
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.
• Do not support the vehicle on the subframe or the subframe crossbrace (for example by a floor jack or similar device).
- Remove the bolts - arrows - and the subframe crossbrace.
The airbag spiral spring could be damaged.
• Separate universal joint from steering gear only when front wheels are in the straight ahead position.
• Do not change the position of the steering wheel or the steering gear.
- Remove universal joint bolt - arrow -.
- Press the CV joint off the steering gear and slide it all the way up.
- Remove the left front muffler nuts - arrows -.
- Remove the right front muffler nuts - arrows -.
Risk of damaging the flex joints in the front muffler.
• Do not bend the flex joints 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 -, if applicable.
- Remove the bolts connecting the driveshaft to the transmission while holding using a (T10172) with the (T10172/5).
- Slide the driveshaft toward the rear final drive; the CV joints can move axially.
- Secure the driveshaft to the side.
- Remove the ball socket - 1 - on the selector lever cable from the selector shaft lever using the (80 - 200).
- Press the securing clips - 2 - off and remove the selector lever cable from the transmission.
• Do not bend or kink the selector lever cable.
Prepare Scissor Lift Platform
- Equip the (VAS 6131 A) with the (VAS 6131/10) , (VAS 6131/11) and (VAS 6131/13) as follows:
- Next secure mounting elements to scissor lift table by hand.
- Position the scissor lift table horizontally.
• Note bubble level (sight glass) on support platform.
- Guide scissor lift table 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 bolt - 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.
- Attach the mounting elements from the (VAS 6131/10) and (VAS 6131/11) at the left and right rear of the tunnel 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.
• Bolt - 1 - is already removed.
- Remove the bolts - arrows - on the tunnel crossmember.
- Remove the left and right bolts - 2 -.
• The nut - 1 - and bolt - 3 - have already been removed.
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 engine-transmission assembly with subframe out of engine compartment while lowering.
- Lower the engine/transmission subassembly using the (VAS 6131 A).
- Remove scissor lift table with engine/transmission assembly from under vehicle.