Engine, Removing
Engine, Removing
Special tools, testers and auxiliary items required
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Oil Collection and Extraction 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) Supplementary Set, Audi A8 (D3) (VAS 6131/11) , Supplementary Set, Audi Q7 (VAS 6131/13) and 3x Tapered Mounting Pin (VAS 6131/10-2)
• Drip Tray for VAS 6100 (VAS 6208)
• Hose Clip Pliers (VAS 6362)
• Locking Pin (T10060 A)
• Ball Joint Puller (T10187)
Procedure
• With lock carrier installed, the engine is removed downward with transmission and subframe.
• During installation, cable ties must be installed at the same location.
- On vehicles with air suspension, activate vehicle lift mode.
Risk of destroying electronic components when disconnecting the battery.
• Observe measures for disconnecting battery.
- Disconnect the Ground (GND) cable - 4 -.
- Extract the power steering fluid from the power steering reservoir using the (V.A.G 1782).
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 noise insulation - 1 and 2 -.
- Remove the left and right front wheel housing liners.
- Remove the rear driveshaft.
• Collect escaping coolant in a clean container for disposal or reuse.
- Place the (VAS 6208) under the engine.
- Remove the right lower coolant hose - arrow - from the radiator by lifting the clamp and let the coolant drain out.
- Free up the coolant hose.
- Open the clamps - 1 and 2 -, drain the coolant and then remove the coolant hoses from the coolant pipes.
- Open the clamps - arrows -, drain the coolant and remove the coolant hoses from the coolant pipes on the left longitudinal member.
- Open the clamp - 1 -, drain the coolant and remove the coolant hose from the coolant pipe on the lock carrier.
- Move the (V.A.G 1782) under the separating point.
- Open the clamp and remove the hydraulic hose - 2 -.
- Seal the open lines and connections with clean plugs from the (VAS 6122).
- Remove the coolant hose from the engine oil cooler by loosening the hose clamp - arrow - and letting the coolant drain out.
- Remove the engine covers - 1 and 2 - upward.
Danger of defects caused by dirt.
• Follow the guidelines for cleanliness when working on the fuel supply system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Free up the fuel supply line in the center of the plenum chamber bulkhead.
Risk of injury from fuel.
• To reduce fuel pressure, lay cloths around connecting point before opening the fuel system and carefully loosen.
- Roll up the protective boot to disconnect the fuel supply line - 1 -.
- Push the hose coupling - 2 - on the fuel line - arrow A - and then press the release buttons - arrows B -.
- Remove the hose coupling with the release buttons pressed.
- Unlock the brackets - 3 and 4 -, lay them on the engine and free up the fuel supply hose.
- Press the release buttons and disconnect the hose - 1 - from the Evaporative Emission (EVAP) canister.
- Disconnect the brake booster vacuum line - 2 -, free it up and lay it on the right side of the vehicle.
- Remove the vacuum hose - 1 - from the air guide pipe connection.
- Loosen the clamps - arrows - and remove the air guide pipe.
- Remove coolant hoses by loosening the hose clamps - 1 and 2 -.
- Remove the connectors - 1 through 4 - from the bracket on the right suspension strut tower, disconnect them and free up the wires.
- Open the clamps - 1 and 2 - and the clips - 3 - and then remove the coolant hoses.
Risk of destroying due to reversed running direction on a used ribbed belt.
• Before removing the ribbed belt, marking running direction with chalk or felt-tip pen for reinstallation later.
- To release the tension on the ribbed belt, swivel the tensioner clockwise - arrow - and then lock the tensioner using a (T10060 A).
- Remove the ribbed belt from the Air Conditioning (A/C) compressor.
• Place a cloth below to catch the draining hydraulic fluid.
- Remove the banjo bolt - 1 -.
- Loosen the hose clamp - 2 - and remove the power steering fluid hose.
- Open the tab - 4 - and open the cover - 5 - - arrow -.
- Remove the nut - 3 - and free up the battery positive wire on the plenum chamber bulkhead.
• Ignore - 1 and 2 -.
- Remove the windshield wiper arms - 1 and 3 -.
- Remove gasket - 5 -.
The plenum chamber cover could be damaged.
• To prevent the cowl grille - 2 - from tearing when removing, coat the transition between the windshield and cowl grille with soapy water and pull the grille up vertically out of the fastening strip starting at the edge of the window.
- Carefully remove plenum chamber cover - 2 - from the retainer on the windshield.
- Remove the bolts - arrows - and the engine compartment E-box plenum chamber.
- Disconnect electrical connectors - 1 through 3 - at E-box plenum chamber connector station.
- Free up the wiring harness.
- Remove the nut - 2 - and remove the GND wire.
- Remove Engine Control Module (ECM) - 1 -.
- Free up the wiring harness.
- Loosen upper control arm nut a few turns and pull joint off with (T10187).
- Completely remove upper control arm nut.
- Repeat procedure on opposite side of vehicle.
- Disconnect the electrical connectors - arrow - at the left and right on the front speed sensors.
- Remove wiring harness bolts - arrows -.
- Remove brake caliper bolts - 1 -.
• Do not change the shape of the brake lines.
- Secure the brake caliper with the brake line still attached inside the wheel housing with wire.
Risk of damaging brake pistons.
• Do not operate brake pedal with brake caliper removed.
- Repeat procedure on the opposite side of vehicle.
- Disconnect lower threaded connection - 2 - at left and right on stabilizer bar.
- Remove nuts from bolts - 1 - at left and right on strut.
• The bolts will be removed later.
- Remove the bolts - arrows - and the noise insulation bracket.
- Remove the nut - 2 - on the right longitudinal member and disconnect the GND wire.
- Press the release buttons and remove the hose - 1 - from the Secondary Air Injection (AIR) pump motor (V101).
- Remove the bolts - 1 - and - arrows - and remove the right bracket - 2 - for the catalytic converter.
• The bolt - 1 - is accessible from the top.
- Remove the selector lever cable ball head - 1 - from the transmission shift lever using the (80 - 200).
- Remove the bolt - 2 - and remove the cable mounting bracket from the transmission.
• Do not bend or kink the selector lever cable.
- Disconnect electrical connector - arrow - on the steering gear.
- Remove the 2 bolts and then remove the steering gear heat shield - A -.
The airbag spiral spring could be damaged.
• Separate the universal joint from steering gear only when front wheels are in straight ahead position.
• Do not change steering wheel position and steering gear position any more, secure steering wheel with adhesive tape.
- Remove the universal joint bolt - B -.
- Remove the universal joint from steering gear.
• Observe the rules of cleanliness for working on automatic transmissions.
- Remove the bolt - arrow - and disconnect the ATF lines from the ATF thermostat.
- Disconnect the connectors - 1, 2 and 3 - from the transmission.
Prepare Scissor Lift Platform
- Equip the (VAS 6131 A) with (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.
- Move the (VAS 6131 A) under the engine/transmission subassembly.
- Attach the mounting elements from the (VAS 6131/10) and (VAS 6131/11) at the left and right front of the subframe as shown in the illustration.
- Ensure threaded spindles are completely installed.
- Attach mounting elements from (VAS 6131/10) and (VAS 6131/13) as shown in illustration.
- Attach mounting elements from (VAS 6131/13) on struts as shown.
- Attach mounting elements from (VAS 6131/10) at rear of subframe as shown in illustration.
- Attach mounting elements from (VAS 6131/10) at left and right on transmission carrier as shown in illustration.
- Rotate the mounting element spindles upward until all the mounting pins come into contact with the mounting points.
- Attach the base plate to the (VAS 6131 A) and tighten to 20 Nm.
- Remove bolt - 1 - at left and right.
• The threaded connection - 2 - has already been disconnected.
- Mark position of the subframe, engine carrier and transmission carrier to longitudinal members with a felt-tip pen.
- Remove the bolts - 1 to 4 - in a diagonal sequence in steps.
Risk of damaging hose and wiring connections as well as 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 engine compartment while lowering.
• Carefully guide the suspension struts past the longitudinal members.
- Next lower engine/transmission subassembly using the (VAS 6131 A) only by dimension - a -.
• Dimension - a - = 180 mm maximum.
- Disconnect the connector - 1 - from the Air Conditioning (A/C) compressor regulator valve (N280).
Refrigerant can cause serious personal injury.
• Do not open the air conditioning.
- Remove A/C compressor bolts - arrows -.
Danger of damaging the refrigerant lines and hoses.
• Do not stretch, kink or bend refrigerant lines and hoses.
- Remove the A/C compressor from the bracket and with the refrigerant lines still connected to the left longitudinal member, tie it up.
- Lower the engine/transmission subassembly more.
- Remove the (VAS 6131 A) with the engine/transmission subassembly under vehicle.