Part 1
Engine (vehicles with automatic transmission), removing
Note:
- With lock carrier removed,
engine is removed downward with transmission and subframe.
Special tools, testers and auxiliary items required
- 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
- 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
Note:
- If engine and transmission are to be separated after removal, Supplementary Set, Audi A8 > 2002 VAS 6131/11 and Supplementary Set, Audi A6 > 2005 VAS 6131/12 will also be required.
Special tools, testers and auxiliary items required
- Lifting Eyebolt 3368
- Tension strap T10038
Work procedure
Note:
- All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.
- Drained coolant must be stored in a clean container for disposal or reuse.
- Remove plenum chamber cover rubber seal.
- Remove plenum chamber cover - 1 - toward front - arrows - .
CAUTION! Observe safety precautions when disconnecting battery.
- With ignition switched off, disconnect Battery Ground (GND) strap - arrow - .
- Discharge refrigerant circuit.
- Extract hydraulic oil for power-steering from reservoir using old oil collecting and extracting device V.A.G 1782.
CAUTION! Cover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.
- Open cap of coolant expansion tank.
- Remove both front wheels.
- Remove quick-release fasteners - 1 - , remove screws - 2 - and remove noise insulation.
- Remove bracket for noise insulation - arrows - .
- Remove left and right front wheel housing liners.
- Remove front bumper.
- Remove left air guide - arrow - in front of auxiliary cooler.
- Remove right air guide - arrow - in front of auxiliary cooler.
- Place drip tray for workshop crane VAS 6208 under engine.
- Remove drain plug - arrow - on coolant thermostat housing and drain coolant from engine.
- Disconnect lower coolant hose from radiator - arrow - and drain residual coolant.
- Place old oil collecting and extracting device V.A.G 1782 under engine.
- Disconnect hydraulic lines to cooling coil at left rear of bumper - arrows - .
Note:
- Observe the rules of cleanliness for working on automatic transmissions.
- Place old oil collecting and extracting device V.A.G 1782 under engine.
- Loosen union nuts - arrows - and disconnect ATF lines.
- Remove cover - 1 - in engine compartment (left side).
- Remove cover - 1 - in engine compartment (right side).
- Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 - from air guide.
- Remove bolts - arrows -.
- Remove air duct - 2 -.
- Disconnect top coolant hose - arrow - from radiator.
- Remove electrical harness connectors - 1 - and - 2 - from bracket and disconnect them.
- Free up wires to lock carrier.
- Disconnect electrical harness connector - arrow - for headlights at both sides of vehicle.
- Free up electrical wiring.
- Disconnect electrical harness connector - arrow - for left and right airbag sensors on lock carrier.
- Free up cables.
- Remove hood cable at lock carrier.
- Disconnect electrical harness connector - arrow - for right fan.
Note:
- To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
- Remove refrigerant line - arrow - leading to A/C compressor.
- Remove refrigerant line - arrow - leading to A/C evaporator.
- Remove bolts - arrows - at left and right side of bumper.
- Pull off hood seal from lock carrier and fender edges.
- Remove bolts at impact absorbers - arrows - at left and right.
Note:
- A second technician is required to remove the lock carrier.
- Remove lock carrier and set aside so it cannot topple.
- Remove rear engine cover -arrows - .
- Remove front engine cover - arrows 1 and 2 - .
- Remove coolant hoses - 1 - and - 2 - .
- Remove coolant expansion tank - arrow - .
- Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch F66 at bottom of expansion tank.
- Disconnect vacuum line - arrow - to brake booster at bulkhead.
- Unclip coolant hose - arrow - from bracket on bulkhead.
- If installed, disconnect vacuum line - arrow - to vacuum reservoir.
- Disconnect vacuum hose - arrow - from intake manifold.
- Disconnect coolant hose - arrow - to heater core at rear coolant pipe on engine.
- If installed, disconnect vacuum line at area designated with -arrow - .
- If installed, disconnect electrical harness connector - arrow - for After-Run Coolant Pump V51 (behind auxiliary cooler at left) and free up electrical wire.
Note:
- Place a rag under separating point to catch escaping hydraulic fluid.
- Disconnect hose - arrow - from power steering fluid reservoir.
Note:
- Ignore - 2 - .
- Disconnect coolant hoses at positions indicated by - arrows - .
- Disconnect coolant hoses at positions indicated by - arrows - .
- Disconnect coolant hose to oil cooler - arrow - .
- Disconnect coolant hoses at positions indicated by - arrows - .
- Remove bolts - 1 - and - 2 - .
- Remove right auxiliary cooler together with coolant hoses.
Note:
- The hose - arrow - can remain connected at auxiliary cooler.