Part 1
S-Tronic Transmission
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 Lift Table (VAS 6131 A) with Support Set (VAS 6131/10) and Supplementary Set (VAS 6131/11) and (VAS 6131/13)
• Drip Tray for VAS 6100 (VAS 6208)
• Hose Clip Pliers (VAS 6362)
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 fuel pressure in high pressure area.
- Position the front wheels so they are straight.
• Release the electro-mechanical parking brake before disconnecting the battery so the drive axle can be rotated to remove it.
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 coolant circuit.
Vehicles with Hydraulic Power Steering
- Extract the power steering fluid from the power steering reservoir using the (V.A.G 1782) - 3 -.
• Ignore - 1, 2 and 4 -.
All Vehicles
- Remove the engine covers - 1 and 2 - upward.
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 (VAS 6208) under engine.
- Remove the drain plug - 1 - and drain the coolant.
- Lift the clip - 2 - and disconnect the coolant hose from the radiator.
- Loosen the hose clamp - arrow -, remove the coolant hose from the oil cooler and drain the coolant.
• The engine is not shown in the following illustrations.
Vehicles with Left Front Coolant Pipes, Version 1
- Loosen the hose clamps - 1 and 3 -, remove the left front coolant hoses from the coolant pipes and drain any remaining coolant.
• Ignore - 2 -.
Vehicles with Left Front Coolant Pipes, Version 2
- Loosen the clamps - arrows -, drain any remaining coolant and then remove the coolant hoses from the left front coolant pipes.
• Ignore - 1 -.
All Vehicles
- Disconnect and free up the connector - 3 - on the charge air cooling pump (V188).
• Ignore - 1 and 2 -.
Vehicles with Hydraulic Power Steering
- 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).
All Vehicles
- 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.
- Seal any open lines and connections with a clean plug from the (VAS 6122).
• Ignore - arrow -.
Vehicles with Coolant Recirculation Pump (V50) , Version 1
- Disconnect the connector - 2 -.
- Place the (VAS 6208) under the engine.
- Loosen the hose clamp - 1 - and remove the coolant hose from the coolant recirculation pump.
• Ignore - 3 and 4 -.
All Vehicles
- 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.
Vehicles with Secondary Air Injection (AIR) Pump Motor (V101) , Version 1
- Disconnect the connector - 3 - on the AIR pump motor.
- Press the release buttons and remove the secondary air hose - 1 -.
• Ignore - 2 -.
Vehicles with Secondary Air Injection (AIR) Pump Motor (V101) , Version 2
- Disconnect the connector - 2 - on the AIR pump motor.
- Press the release buttons and remove the secondary air hose - 1 -.
• Ignore - 3 -.
All Vehicles
- 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) wires.
- Remove the seal from the plenum chamber bulkhead.
- Remove the plenum chamber cover.
- Remove the air duct - arrows -.
- Free up the fuel hose - 1 - and the EVAP canister hose - 2 - on the air duct pipe.
- Remove the vacuum hose - 3 - from the air guide pipe connection.
- Remove the air guide pipe by loosening the hose clamp - 4 - and opening the clips - arrows -.
- Remove the air filter housing and where equipped, disconnect the connector - arrow - on the intake air switch-over valve (N335).
- Disconnect the vacuum connection - 2 - from the plenum chamber bulkhead. Remove the vacuum hose - 1 - on the back.
- Disconnect the connector - 3 - on Evaporative Emission (EVAP) canister purge regulator valve 1 (N80) and disconnect the vacuum hose - 4 -.
- Disengage the EVAP canister purge regulator valve 1 from the bracket and lay it aside with the hoses connected.
- Disconnect the vacuum hose leading to the leak detection pump (V144) - arrow -.
All Vehicles
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening the fuel system and carefully loosen.
There is a risk of contamination.
• Follow the guidelines for cleanliness when working on the fuel supply system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Remove the fuel supply line from the high pressure pump - arrow - and lay it aside.
- Seal any open lines and connections with a clean plug from the (VAS 6122).
Vehicles with Version 1
- Lift the clamp - arrow - and remove the coolant hose leading to the back of the heater core on the engine.
• To provide a better illustration, component location is shown from behind with engine removed.
- Remove the vacuum hose - 1 - for the climatronic refrigerant shut-off valve (N422).
• Ignore - 2 and 3 -.
Vehicles with Version 2
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening the fuel system and carefully loosen.
There is a risk of contamination.
• Follow the guidelines for cleanliness when working on the fuel supply system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Press the release buttons and disconnect the fuel hose - 1 -.
- Seal any open lines and connections with a clean plug from the (VAS 6122).
• Ignore - arrows -.
- Lift the clamp - 2 - and remove the coolant hose leading to the heater core on the plenum chamber bulkhead.
• Ignore - 1 -.
All Vehicles
- Open the clamp and remove the right front coolant hose - arrow - from the front coolant pipe.
- Loosen the clamp - arrow - and remove the coolant hose.
• Ignore - 1 and 2 -.
- Lift the clamp - arrow - and remove the coolant hose from the front coolant pipe
Vehicles with Hydraulic Power Steering
- Remove the coolant hoses - 1 and 2 - from the coolant overflow reservoir.
- Remove the bolts - arrows -, disconnect the connector on the engine coolant level warning switch (F66) and remove the coolant reservoir.
- Disconnect the connector - arrow - from the power steering pump, if applicable.
- Press the hydraulic hose down slightly.
All Vehicles
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 Air Conditioning (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 - from the electric wires.
- Remove the electrical connector - 2 - from the bracket and disconnect it.
- Remove the bolt - 3 - 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 wrench - 1 - and remove the wiring bushing - 2 - upward.
- Free up the wiring harness - 3 - to the generator and starter using the (80 - 200).
- Wiring duct version 1: Free up the wiring harness by releasing the retainer - arrow B - and pulling the duct forward - arrow A -.
- Wiring duct version 2: Open the catch - arrow -, free up the wiring harness and open the wiring duct - 1 -.
- Remove the nut - 1 - and tilt - arrow A - the washer fluid reservoir filler neck - 2 - upward slightly.
- Remove the filler neck 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 remove the tower brace - 3 -.
- 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 (ECM) - arrow B -.
- Disconnect the connector - 2 - if applicable.
- Disconnect the 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.
- Release the retainers - A arrows - and remove the wiring bushing - 2 - upward - arrow B -.
- Remove the ground pin - 1 - and free up the wiring harness.
- Lay the wiring harness on the engine and secure the ECM so that it cannot fall.
- Disconnect the connectors - arrow - at the left and right on the front speed sensors.
- Disconnect the connector - 1 - from the left front level control system sensor (G78) and from the right front level control system sensor (G289) and free up the wires - arrow -.
- Free up the electrical connector - 2 - on the bracket by pulling the retainer back - arrow A - and turning the connector approximately 90° clockwise - 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 when the brake caliper is 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.
- Remove the left and right stabilizer bar bolt - 1 -.
- Remove the left and right nuts - 3 -.
• The bolts - 2 - will be removed later.
- Remove the subframe cross brace.
The suspension components could be damaged.
• Do not rest the vehicle on its wheels if the subframe mount, the steering gear or the subframe cross brace are not installed correctly.
Audi A5 Cabriolet
- Remove diagonal braces.
Vehicles with Electro-Mechanical Power Steering
- Release the safety catch - arrow -, push the retainer down and disconnect the connector from - 2 - from the power steering control module (J500).
- Free up the wiring harness.
• Ignore - 1 -.
All Vehicles
- Remove the left and right bolts - arrows -, if applicable, and the heat shield - 1 -.
- Remove the bolts - arrows - and the front crossmember, if applicable.
- 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 element in front muffler more than 10°.
- Loosen the clamping sleeves - 1 and 2 -, slide them back and remove the left and right front mufflers.