Engine, Removing

NOTE:

With lock carrier installed, engine is removed downward with transmission and subframe.
Drained coolant must be stored in a clean container for disposal or reuse.
During installation, reinstall all heat insulation sleeves and heat shields at the same locations.
All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

Special tools, testers and auxiliary items required

Fig 1: Identifying Special Tools - Engine, Removing (1 Of 2)

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Pry Lever - Rmv Outside Mirror 80 - 200
Ring screw 3368
Old oil collecting and extracting device V.A.G 1782
Hose clamp pliers V.A.G 1921

Spark plug connector pliers V.A.G 1922
Hose clip pliers VAS 6340 (formerly: VAS 5024 A)

Special tools, testers and auxiliary items required

Fig 2: Identifying Special Tools - Engine, Removing (2 Of 2)

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Step ladder VAS 5085
Scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10
Drip tray for workshop crane VAS 6208
Tensioning Strap T10038 qty. 2

Ignition Coil Puller T40039

NOTE:

If engine should be separated from transmission after removal, two additional adapter sets VAS 6131/10-12 are needed.

Procedure

CAUTION: Observe safety precautions when disconnecting the battery → 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL .

NOTE:

So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted.
In order for the driveshaft to be able to rotate for removal, the electronic parking brake must be released before disconnecting battery.

Fig 3: Right Luggage Compartment Side Trim

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Remove cover of right luggage compartment side trim - arrows -.

Fig 4: Removing Cover Above Battery

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Remove cover - 1 - above battery.

NOTE:

Ignore - 2 -.

Fig 5: Ground (GND) Battery Lead

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With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
Discharge refrigerant circuit → 87 - AIR CONDITIONING .

Fig 6: Removing Front Engine Cover And Rear

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Remove front engine cover - 1 - and rear - 2 - - arrows -.

Fig 7: Cover Above Coolant Reservoir

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Remove cover above coolant reservoir - arrows -.

CAUTION: Cover cap of coolant expansion tank with rag and open carefully, as hot steam or hot coolant may escape when opening.

Open cap of coolant expansion tank.
Remove both front wheels.

Fig 8: Identifying Exhaust Pipe Fasteners

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For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

Fig 9: Noise Insulation Quick-Release Fasteners

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Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
Remove front and rear part of left and right front wheel housing liner → 66 - EXTERIOR EQUIPMENT .

Fig 10: Removing/Installing Drain Plug At Coolant Thermostat Housing

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Place drip tray for workshop crane VAS 6208 under engine.
Remove drain plug - arrow - at coolant thermostat housing and drain coolant.

Fig 11: Front Coolant Pipe Drain Plug

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Remove drain plug - arrow - at front coolant pipe and drain coolant.

Fig 12: Coolant Hoses

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Remove coolant hoses - 1 to 3 - and drain coolant.

Fig 13: Left Driveshaft Coolant Hose

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Disconnect coolant hose next to left driveshaft from coolant pipe - arrow - and drain coolant.

Fig 14: Screws, Front Lower Coolant Pipe & Hoses

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Remove screws - 2 - and - 3 -.
Remove front lower coolant pipe from hoses - 1 - and - 4 -.

Fig 15: Secondary Air Injection Connecting Pipes Hoses

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Remove hoses - 1 - and - 2 - from secondary air injection connecting pipes.

Fig 16: Right Auxiliary Cooler Coolant Hoses

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Remove coolant hoses - 1 - and - 2 - from right auxiliary cooler and drain remaining coolant.

Fig 17: Right Auxiliary Cooler Coolant Hose & Nut

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Remove nut - 1 - and remove coolant hose - 2 - from right auxiliary cooler.

Fig 18: Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 Electrical Harness Connector

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Disconnect electrical connector - 1 - on Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 and remove vacuum hose - 2 -.
Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 from bracket and lay aside with hose connected.

Fig 19: Coolant Reservoir Coolant Hose

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Remove coolant hose - arrow - from coolant pipe to coolant reservoir.

Fig 20: Mass Air Flow (MAF) Sensor 2 G246 Electrical Connector, Intake Manifold Air Duct Hose & Air Filter Housing Bolts

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Disconnect electrical connector - 2 - for Mass Air Flow (MAF) Sensor 2 G246.
Disconnect air duct hose - 1 - from intake manifold.
Remove bolts - arrows - and remove left upper part of air filter housing.

Fig 21: Air Duct, Bolts, Air Filter Housing & Air Flap Vacuum Hose

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Remove air duct - 1 -.
Remove bolts - arrows -.
Tilt lower part of air filter housing and remove air flap vacuum hose.
Remove lower part of left air filter housing.

Fig 22: Extracting Hydraulic Oil From Power Steering Reservoir Using Used Oil Collecting And Extracting Device V.A.G 1782

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Extract hydraulic oil from power steering reservoir using Used Oil Collecting and Extracting Device V.A.G 1782.

NOTE:

Place a rag under separating point to catch escaping hydraulic fluid.

Disconnect power steering hydraulic pressure line - arrow - at front left on engine.
Remove hood seal from lock carrier and from fender edges.

Fig 23: Vacuum Hoses

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Disconnect vacuum hoses - 1 - and - 2 - and free them up.

Fig 24: Mass Air Flow (MAF) Sensor G70 Electrical Connector, Air Guide Hose Vacuum Hose, Air Guide Hose & Hose Clamps

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Separate electrical connector - 1 - for mass air flow (MAF) sensor G70.
Disconnect vacuum hose - 2 - from air guide hose.
Loosen hose clamps and lay aside air guide hose - 4 -.

CAUTION: Hose connectors - 3 - must not be opened.

Remove bolts - arrows - and remove right upper part of air filter housing.

Fig 25: Lower Air Guide Hose

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Remove lower air guide hose - arrow - from right upper part of air filter housing.

Fig 26: Vacuum Hoses, Air Duct, Bolts & Intake Air Switch-Over Valve N335 Electrical Connector

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Disconnect both vacuum hoses - 1 -.
Remove air duct - 2 -.
Remove bolts - arrows -.
Tilt lower part of air filter housing and disconnect electrical connector - 3 - on Intake Air Switch-Over valve N335.

Remove lower part of right air filter housing.

Fig 27: Coolant Hose & Clamp

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Disconnect coolant hose - arrow - at right on engine.

Fig 28: Torque Support Mount Bolt

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Remove bolt - arrow - at torque support mount.

Fig 29: Oxygen Sensor Electrical Connectors

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Remove oxygen sensor electrical connectors - 1 - and - 2 - from right bracket in engine compartment.

Fig 30: Vacuum Hoses

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Disconnect vacuum hoses - 1 - and - 2 - and free them up.

CAUTION: Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening the connection.

Fig 31: Fuel Supply Line

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Disconnect fuel supply line - arrow - on distribution piece.

Fig 32: Identifying Crankcase Ventilation Hose, Electrical Harness Connectors & Bolts

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Disconnect crankcase ventilation hose - 2 -.
Disconnect electrical connectors - 1 - and - 5 -.
Remove bolts - 3 - and - 4 -.
Disconnect electrical connectors to ignition coils in cylinder bank 1 (right) and free up electrical wiring harness.

Fig 33: Removing Ignition Coils Using Ignition Coil Puller T40039

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Remove ignition coils using Ignition Coil Puller T40039.

Fig 34: Right Cylinder Head Cover Bolts Removal Sequence

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Loosen bolts in sequence - 16 to 1 - and remove them.
Remove right cylinder head cover.
Cover open valvetrain with a clean cloth.

Fig 35: Identifying Rubber Seal & Plenum Chamber Covers

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Remove rubber seal - 1 - and remove plenum chamber covers - 2 - and - 3 -.

Fig 36: Identifying Wiper Arm Nuts

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Pry out cover caps on windshield wiper arms with a screwdriver and loosen nuts - arrows - a few turns.
Loosen wiper arms by tilting slightly from windshield wiper axle.
Remove nuts completely and remove wiper arms.

Fig 37: Cowl Grille & Bolts

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Remove dust and pollen filter by opening 4 quick-release fasteners.

NOTE:

Cover the air duct at air conditioning housing with a clean rag so that nothing can fall in.

Remove bolts - arrows - at left and right for cowl grill - 1 -.
Carefully pull the cowl grill off from the retainers at the windshield.

Fig 38: Strut Tower Brace

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Remove suspension strut crossmember - arrow -.

Fig 39: Retaining Bracket Bolts & Engine Control Modules (ECM) Retaining Tabs

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Remove bolts - 1 - and - 2 - and remove retaining bracket.
Release retaining tabs - arrows - and remove both engine control modules (ECM).

NOTE:

Electrical harnesses remains connected.

Fig 40: Removing Air Quality Sensor G238 & Retaining Clips

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Remove Air Quality Sensor G238 by rotating approximately 90 counter-clockwise - arrow - and removing from bracket.
Release retaining clips - 1 to 4 -.
Fold cover for the E-box in plenum chamber open slightly and pull off toward the front.

Fig 41: Multi-Pin Harness Connectors

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Disconnect multi-pin harness connectors - arrows - using spark plug connector pliers V.A.G 1922.
Disengage engine wiring harness at E-Box and bulkhead.
Lay wiring harness aside on the engine with engine control modules (ECM) connected.

NOTE:

Protect the engine control modules from falling off.

Fig 42: Identifying Terminal 30 Wire To Starter Cap & Nut

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Remove right A-pillar trim → 70 - INTERIOR TRIM .
Fold floor covering back.
Remove protective cover above main fuse holder.
Fold cap - 2 - aside.

Remove nut - 4 -.
Remove terminal 30 wire to starter.

NOTE:

Ignore - 1 - and - 3 -.

Fig 43: Pulling Wiring Harness Out From Interior

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Unfasten harness clamp - 1 - in right front wheel housing.
Pull wiring harness out from interior - arrow -.

Fig 44: Electrical Connector, Ground (GND) Wire & Wiring Harness Bracket From Longmember

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Disconnect electrical connector - 2 -.
Remove Ground (GND) wire - 1 - on longmember.
Remove wiring harness bracket on longmember - arrows -.
Free up wiring harness.

Fig 45: Identifying Left Level Control System Sensor Electrical Harness Connector & Left/Right Control Arms Coupling Rod

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Disconnect electrical harness connector - 2 - at Level Control System Sensor.
Disconnect connecting link - 1 - from control arm.
Repeat procedure on opposite side of the vehicle.

Fig 46: Removing Bolts & Right Refrigerant Line From A/C Compressor

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NOTE:

To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

Remove bolts - 1 - and - 2 -.
Disconnect refrigerant lines from A/C compressor.

NOTE:

Seal open lines and connections at A/C compressor with suitable sealing caps (to prevent dirt and moisture from entering).

Fig 47: Climate Control System Reservoir Bracket Bolts

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Remove bolts - arrows - on climate control system reservoir bracket.

NOTE:

Climate control system reservoir remains in installation location.

Fig 48: Power Steering Fluid Reservoir Hydraulic Hose

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NOTE:

Place a rag under separating point to catch escaping hydraulic fluid.

Remove hydraulic hose - arrow - from power steering fluid reservoir.

Fig 49: Identifying Collar Bolt For Right Drive Axle

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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 -.

Fig 50: Stabilizer & Bolts

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Remove bolts - arrows - uniformly at left and right.
Remove stabilizer.

Fig 51: Securing Lifting Eyebolt 3368 With Nut With Washer Over Several Threads & Tie Up Wheel Bearing Housing At Left/Right With Tensioning Strap T10038

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Insert left and right Lifting Eyebolt 3368 from below into hole in strut tower.
Secure Lifting Eyebolt 3368 with a nut - 2 - with washer - 1 - over several threads (do not install nut all the way down on threads).
Tie up wheel bearing housing at left and right with Tensioning Strap T10038 as shown in illustration.

CAUTION: To prevent upper control arm joints from being damaged, wheel bearing housing must be supported before loosening lower suspension strut bolts.

Fig 52: Air Spring Damper At Control Arm Bolt

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Remove air spring damper from control arm - arrow -.

Fig 53: Removing Guide Control Arm And Control Arm On Subframe

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Remove guide control arm - 1 - and control arm - 2 - from subframe.

Fig 54: Swinging Guide Control Arm And Control Arm Outward

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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.

Repeat work procedure on opposite side of the vehicle.
Remove drive axle from transmission flanged shaft.

CAUTION: Do not damage brake hose!

Swing wheel bearing housing outward and remove drive shaft.
Repeat work procedure on opposite side of the vehicle.

Fig 55: Front Transverse Beam

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Remove front transverse beam - arrows -.

Fig 56: Clamping Sleeves

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NOTE:

Do not bend the flex joint in front of the exhaust pipe more than 10 or it could be damaged.

Loosen clamping sleeves - 1 - and - 2 -.

Fig 57: Removing/Installing Heat Shield For Driveshaft

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Remove heat shield - A - for drive shaft - arrows -.
Remove bolts on transmission/driveshaft connection.
Slide driveshaft back to rear final drive; constant velocity joints can move axially.

Fig 58: Drive Shaft Tied To Side, Onto Heat Shield

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Tie driveshaft up and to the side against heat shield - arrow -.

Prepare scissor lift platform:

Fig 59: Identifying Scissor Lift Platform VAS 6131

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Equip scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10 as follows:

Platform coordinates	Parts from Support Set VAS 6131/10
B3	/10-1	/10-4	/10-5	/10-11
G3	/10-1	/10-4	/10-5	/10-11
B6	/10-1	/10-3	/10-5	/10-7
G6	/10-1	/10-3	/10-5	/10-7
B10	/10-1	/10-2	/10-5	/10-8
G10	/10-1	/10-2	/10-5	/10-8
D16	/10-1	/10-2	/10-5	/10-12

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.

Fig 60: Positioning Support Elements From VAS 6131/10 At Front On Engine

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Position support elements from VAS 6131/10 at front on engine as shown in illustration.

Fig 61: Positioning Support Elements From VAS 6131/10 At Left/Right On Engine Carrier And Subframe

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Position support elements from VAS 6131/10 at left and right on engine carrier and subframe as shown in illustration.

Fig 62: Oxygen Sensor Electrical Connectors & Tunnel Cross Member Bolts

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Remove bracket for oxygen sensor electrical connectors - 1 - and - 2 - from tunnel crossmember - arrows -.

NOTE:

Electrical connectors remain connected.

Fig 63: Position Support Elements From VAS 6131/10 At Rear On Transmission

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Position support elements from VAS 6131/10 at rear on transmission as shown in illustration.
Twist all spindles of support elements upward far enough until all support pins make contact at support points.
When all attachments are positioned, lift scissor lift table far enough until engine and transmission mount are free of tension.
Tighten base plates for attachments to 20 Nm on the scissor lift table VAS 6131 A.

Fig 64: Removing/Installing Bolts At Tunnel Cross Member

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Remove bolts - arrows - on tunnel cross member.

Fig 65: Removing/Installing Long Member Subframe

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Mark installation position of subframe on longmember using a felt tip pen.
Remove bolts - 1 - and - 4 -.
Remove bolts - 2 - and - 3 - in diagonal sequence and in stages.

NOTE:

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.

Fig 66: Lowering/Lifting Engine/Transmission Assembly Using Scissor Lift Platform VAS 6131 Only Approx. By Dimension

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First lower engine/transmission assembly using scissor lift platform VAS 6131 A only approximately by dimension - a -.

Dimension - a - = approximately 300 mm.

Fig 67: Pressing Ball Socket Of Selector Lever Cable From Selector Shaft Lever Using Pry Lever - Rmv Outside Mirror 80 - 200 And Unclipping Locking Plate From Selector Lever Cable Bracket

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Press ball socket - 2 - of selector lever cable from selector shaft lever using Pry Lever - Rmv Outside Mirror 80 - 200.
Unclip locking plate - 1 - from selector lever cable bracket.
Remove selector lever cable.
Lower engine/transmission subassembly downward.

Push scissor lift platform VAS 6131 A with engine/transmission subassembly under vehicle.