Engine, Removing

Special tools and workshop equipment required

Pry Lever80-200
Used Oil Collection and Extraction UnitSMN372500
Step ladder such as Step LadderVAS5085
Engine Bung SetVAS6122
Scissor Lift TableVAS6131A with Scissor Lift Table - Audi SetVAS6131/10, Scissor Lift Table - A8 SetVAS6131/11 and Scissor Lift Table - Q7 SetVAS6131/13
Shop Crane - Drip TrayVAS6208
Hose Clip PliersVAS6340
Hose Clip PliersVAS6362

Removing

NOTE:

With lock carrier installed, engine is removed downward together with the transmission and the subframe.

During installation, cable ties must be installed at the same location.

WARNING:

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 high pressure area of the fuel injection system. Refer to RELEASING PRESSURE IN HIGH PRESSURE AREA .
To reduce remaining residual pressure, place clean cloth around the connector and carefully loosen connector.

NOTE:

To be able to turn the drive axle to remove it, shift the transmission to "N" and release the electromechanical parking brake before disconnecting the battery.

-- Position the front wheels so they are straight.

CAUTION:

Danger of causing damage to electronic components.

Complete the steps for disconnecting the battery.

-- Turn off the ignition, if necessary remove the key.

Fig 1: Disconnecting Battery

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-- Disconnect the battery Ground (GND) cable -2-, refer to Battery, Starter, Generator, Cruise Control .

-- Empty the coolant circuit, refer to Refrigerant Circuit Components, Replacing .

-- Extract the power steering oil from the reservoir with the Used Oil Collection and Extraction UnitSMN372500.

-- Remove the engine cover -arrows-.

Fig 2: Identifying Engine Cover, Removal

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-- Remove the lock carrier cover -2-, refer to Front Bumper .

Fig 3: Identifying Bolts And Pull Air Guide Off Air Filter Housing

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Fig 4: Identifying MIN/MAX Markings -Arrow-

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WARNING:

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.

-- Open the coolant reservoir cap.

-- Remove the left and right front wheel housing liners completely, refer to Wheel Housing Liner .

Fig 5: Identifying Front Wheel Housing Liner

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-- Remove the noise insulations -1 and 2-, refer to Noise Insulation .

Fig 6: Removing Noise Insulation

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-- Remove the left and right underbody panel -2-, refer to Underbody Panel .

Fig 7: Identifying Left And Right Lower Longitudinal Member

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-- Remove the left and right lower longitudinal member, refer to Lock Carrier .

-- Remove the driveshaft, refer to Driveshaft, Bolts on Transmission Side Overview .

Fig 8: Counter Hold Using Counterhold Tool Touareg V10 T10172 And Adapters T10172/5

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NOTE:

Collect escaping coolant in a clean container for disposal.

-- Place the Shop Crane - Drip TrayVAS6208 under engine.

-- Remove the drain plug -arrow- on the front coolant hose and drain the coolant.

Fig 9: Identifying Drain Plug -Arrow- On Front Coolant Hose

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-- Remove the drain plug -arrow- on the Map Controlled Engine Cooling Thermostat -F265- and drain the coolant.

Fig 10: Identifying Drain Plug

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-- Loosen the clamp -1- and remove the coolant hose from the lower left coolant pipe.

Fig 11: Locating Clamp -1- And Remove Coolant Hose

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NOTE:

Ignore item -2-.

WARNING:

Risk of injury from fuel.

To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen.

CAUTION:

Danger of defects caused by dirt.

Follow the guidelines for cleanliness when working on the fuel supply system, refer to CLEAN WORKING CONDITIONS .

-- Fold down the boot -1- and disconnect the fuel line.

Fig 12: Identifying Fuel Line

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-- First push the hose coupling -2- downward -arrow A-, then press the release buttons -arrow B-.

-- Remove the hose coupling with the release buttons pressed.

-- Free up the fuel line and the line to the Evaporative Emission (EVAP) canister on the air guide pipe.

Fig 13: Identifying Connector And EVAP Canister Purge Regulator Valve

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-- Disconnect the connector -2- on EVAP Canister Purge Regulator Valve 1 -N80- and disconnect the vacuum hose -1-.

-- Remove EVAP Canister Purge Regulator Valve 1 -N80- from bracket and lay aside with hose and fuel line connected.

-- Open the clamps -1 and 3- and remove the air guide pipe.

Fig 14: Locating Clamps -1 & 3- To Remove Right Air Guide Pipe

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NOTE:

Ignore item -2-.

-- Remove the upper right longitudinal member -2-, refer to Lock Carrier .

Fig 15: Identifying Upper Right Longitudinal Member -2-

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-- Remove the plenum chamber cover -2-, refer to Bulkhead .

Fig 16: Removing Seal -1- Near Plenum Chamber Cover

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-- Release the cover -2- and swivel it to the side -arrow-.

Fig 17: Identifying Cover, Positive Cable And Nuts

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-- Remove the nut -4- and free up the positive cable.

-- Remove the nut -3- and remove the positive cable -1-.

-- Open the tabs -1 and 3- and swivel the positive terminal -2- out of the mount.

Fig 18: Identifying Positive Terminal Grip

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-- Remove the bolts -arrows- and the engine compartment E-box cover -1-.

Fig 19: Identifying Engine Compartment E-Box Cover Bolts

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-- Disconnect the connectors -1, 2 and 3- and free up the wires.

Fig 20: Identifying Engine Compartment E-Box Components

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-- Release the retainers -arrows- and remove the relay carrier with the fuse panel -4-.

-- Open the release -5- and remove the condenser -6-.

-- Disengage and free up the engine wiring harness on the engine compartment E-box and then lay it on the engine.

-- Open the clamps -1 and 2- and remove the coolant hoses.

Fig 21: Opening Clamps -1 And 2- And Remove Coolant Hoses

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-- Disconnect the right, upper coolant hose from the radiator, to do this, lift the retaining clip -1-.

Fig 22: Identifying Retaining Clip

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NOTE:

Ignore item -2-.

-- Open the clamp -2-, free up the coolant hose -arrow- and remove it from the coolant reservoir.

Fig 23: Locating Clamps -1 & 3- To Remove Left Air Guide Pipe

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-- Open the clamps -1 and 3- and remove the air guide pipe.

-- Disconnect the vacuum hose -1- and free it up -arrow-.

Fig 24: Identifying Vacuum Hose And Clamp

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-- Remove the tower brace, refer to Suspension Strut and Upper Control Arm .

Fig 25: Identifying Tower Brace

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-- Open the clamps -arrows-, remove the Engine Control Module -J623- -2- and lay it on the engine.

Fig 26: Component Location Engine Control Module -J623-

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NOTE:

Ignore items -1, 3 and 4-.

-- Remove the bolt -4- for the battery positive cable -3- and the bolt -2- for the Ground (GND) cable -1- and free up the cables.

Fig 27: Identifying Battery Positive And Ground Cables And Bolts

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-- Press the release buttons and remove the air guide hose -arrow-.

Fig 28: Identifying Air Guide Hose

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-- Loosen the clamp -3- and remove the coolant hose.

Fig 29: Identifying Coolant Hose And Spring Clip

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NOTE:

Ignore items -1, 2 and 4-.

-- Place the Used Oil Collection and Extraction UnitSMN372500 under the separating point.

Fig 30: Identifying Hydraulic Hose And Clamp

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-- Loosen the clamp -arrow- and remove the hydraulic hose.

-- Seal the open lines and connections with clean plugs from the Engine Bung SetVAS6122.

NOTE:

Place a cloth underneath to catch the draining hydraulic fluid.

-- Loosen the clamp -arrow- and remove the hydraulic hose.

Fig 31: Locating Clamp -Arrow- And Remove Hydraulic Hose

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-- Seal the open lines and connections with clean plugs from the Engine Bung SetVAS6122.

Fig 32: Identifying Bolts & Refrigerant Lines To A/C Compressor

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CAUTION:

Risk of damaging refrigerant lines and hoses.

Do not stretch, kink or bend refrigerant lines and hoses.

-- Remove the bolt -1 and 2- and remove the refrigerant lines from the Air Conditioning (A/C) compressor.

-- Seal the open lines and connections with clean plugs from the Engine Bung SetVAS6122.

-- Disconnect the left and right connector -arrow- from the Left Front Level Control System Sensor -G78- / Right Front Level Control Sensor -G289- and free up the wires.

Fig 33: Identifying Left And Right Connector

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-- Disconnect the electrical connectors -arrow- at the left and right on the front speed sensors.

Fig 34: Identifying Speed Sensor Connector

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-- Remove the brake caliper and with the brake hose still connected, inside the wheel housing using wire, refer to Front Brakes .

Fig 35: Freeing Up Electrical Connector

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CAUTION:

Risk of damaging brake pistons.

Do not operate brake pedal with brake caliper removed.

-- Remove the nut -2- and the bolt -1-.

Fig 36: Identifying Nut And Bolt

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-- 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-.

Fig 37: Identifying Left And Right Stabilizer Bar Bolt

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-- Remove the left and right nuts -3-.

NOTE:

The bolt -2- will be removed later.

-- Remove the left and right bolts -3-.

Fig 38: Identifying Left And Right Bolt And Transmission Mount Brace

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NOTE:

Ignore items -1 and 2-.

-- Remove the subframe crossbrace, refer to Subframe .

Fig 39: Identifying Subframe Crossbrace

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CAUTION:

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 were not installed correctly.

-- Remove the steering intermediate shaft from the steering gear push them upward, refer to Steering .

Fig 40: Locating Universal Joint Bolt

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-- Remove the nuts -1- and the bolts -2- and then remove the left front muffler.

Fig 41: Identifying Muffler Nuts And Bolts

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-- Remove the nuts -4- and the bolts -3- and then remove the left front muffler.

-- Squeeze the retainers -arrows A- and pull the sleeve -1- on the emergency release cable in direction of -arrow B-.

Fig 42: Identifying Emergency Release Cable

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-- Disengage the rear section of the emergency release cable from the front section of the emergency release cable -arrow C-.

-- Remove electrical connectors from bracket and disconnect:

Fig 43: Removing Connector From Bracket

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For Left Electrohydraulic Engine Mount Solenoid Valve -N144- / Right Electrohydraulic Engine Mount Solenoid Valve -N145-
For the Servotronic Solenoid Valve -N119-

-- Remove the bolt -arrow- from the auxiliary heater bracket, if equipped.

Fig 44: Identifying Bolt

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Prepare Scissor Lift Platform:

Fig 45: Identifying Scissor Lift Platform VAS 6131

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-- Equip the Scissor Lift TableVAS6131B with the Scissor Lift Table - Audi SetVAS6131/10 and Scissor Lift Table - A8 SetVAS6131/11, and Scissor Lift Table - Q7 SetVAS6131/13 as follows:

Platform Coordinates	Components from the Scissor Lift Table - Audi SetVAS6131/10, Scissor Lift Table - A8 SetVAS6131/11 and Scissor Lift Table - Q7 SetVAS6131/13
B4	/13-4	/10-4	/10-5	/13-1
G4	/13-4	/10-4	/10-5	/13-1
B6	/10-1	/10-2	/10-5	/10-11
G6	/10-1	/10-2	/10-5	/10-11
A8+C8	/13-6			/13-2
F8+H8	/13-5			/13-2
B14	/10-1	/10-4	/10-5	/10-7
G14	/10-1	/10-4	/10-5	/11-1

-- First manually secure the mounting elements to the scissor lift table.

-- Position the Scissor Lift TableVAS6131A horizontally.

Note bubble level (sight glass) on support platform.

-- Guide the Scissor Lift TableVAS6131A under the engine/transmission subassembly.

Fig 46: Identifying Subframe Bolts (Tighten To Specifications)

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WARNING:

The subframe could cause an accident if it is not secured.

Do not loosen the subframe bolts -2 and 3- yet.

-- Remove the left and right subframe bolt -1-.

-- Attach mounting elements from the Scissor Lift Table - Audi SetVAS6131/10 and Scissor Lift Table - Q7 SetVAS6131/13 at the left and right on the front of the subframe as shown in the illustration.

Fig 47: Attaching At Left And Right Front Of Subframe As Shown In Illustration

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-- Ensure threaded spindles are completely installed.

-- Attach the mounting elements from the Scissor Lift Table - Audi SetVAS6131/10 at the left and right rear on the subframe crossbrace front connecting points as shown in the illustration.

Fig 48: Attaching At Left And Right Front Of Subframe As Shown In Illustration

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-- Position mounting elements Scissor Lift Table - Q7 SetVAS6131/13 at the lower left and right on the wheel bearing housing as shown in the illustration.

Fig 49: Attaching At Lower Left And Right Of Wheel Bearing Housing As Shown In Illustration

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-- Attach mounting elements from the Scissor Lift Table - Audi SetVAS6131/10 and Scissor Lift Table - A8 SetVAS6131/11 at the left and right rear of the tunnel crossmember, as shown in the illustration.

Fig 50: Identifying Mounting Elements

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-- Rotate the mounting element spindles upward until all the mounting pins come into contact with the mounting points.

-- Attach mounting element base plates to Scissor Lift TableVAS6131B and tighten to 20 Nm.

-- Mark the location of the subframe and engine carrier to the longitudinal members using a felt-tip pen.

Fig 51: Identifying Subframe Bolts (Tighten To Specifications)

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-- Remove the left and right subframe bolts -2 and 3- in steps.

-- Remove the bolts from the tunnel crossmember -arrows-.

Fig 52: Identifying Crossmember & Bolts

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-- Remove the left and right bolts -2-.

Fig 53: Identifying Left And Right Stabilizer Bar Bolt

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CAUTION:

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 sub-assembly with subframe out of engine compartment while lowering.

-- Lower the engine/transmission assembly with the Scissor Lift Table VAS6131A.

-- Remove the Scissor Lift TableVAS6131B with engine/transmission assembly from under the vehicle.