Engine, Removing, 2.9L Engine

Special tools and workshop equipment required 

• Engine Bung Set:VAS6122 
• Scissor Lift Table:VAS6131B 
• Scissor Lift Table - Audi Set:VAS6131/10 
• Scissor Lift Table - A8 Set - Adapter:VAS6131/11-1  from Scissor Lift Table - A8 Set:VAS6131/11  , not illustrated
• Universal Supports:VAS6131/13-2  from Scissor Lift Table - Q7 Set:VAS6131/13 
• Coolant Collecting System:VAS5014  or Shop Crane - Drip Tray:VAS6208 
• Hose Clip Pliers:VAS6340 
• Hose Clip Pliers:VAS6362 
• Engine and Gearbox Jack:VAS6931 
• Ball Joint Splitter (Kukko 129-3):VAS251805 
• Ball Joint Splitter: VAS251809  with : VAS251809/1  , not illustrated
• Tensioning Strap:T10038 
• Commercially available Step Ladder

Procedure 

• With the lock carrier installed, the engine is removed downward with the transmission and subframe.
• Install cable ties at the same locations when installing.
• Pay attention to the guidelines for clean working conditions. Refer to GUIDELINES FOR CLEAN WORKING CONDITIONS .
• All chassis component bolts with bonded rubber bushings must be tightened in the control position.
• Bonded rubber bushings have a limited range of rotation. Before axle components with bonded rubber bushings are tightened, they have to be brought to a position which matches the position when the vehicle is being operated (control position). Otherwise, the bonded rubber bushing will be under stress, which will reduce the service life.

-- Before starting the procedure, determine the control position. Refer to WHEEL BEARING AT STANDARD VEHICLE HEIGHT, LIFTING VEHICLES WITH AIR SUSPENSION .

-- Position the front wheels so they are straight.

-- Switch off the ignition.

• The electro-mechanical parking brake must be released before disconnecting battery so the driveshaft can be rotated to remove it.

-- De-energize the 48 Volt system and disconnect the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the cover -1- toward the rear in direction of -arrows- and remove.

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-- Open the coolant expansion tank cap -1- by releasing the catch -arrow-.

-- Remove the lock carrier cover. Refer to OVERVIEW - BUMPER COVER .

-- Remove the front wheels. Refer to WHEELS AND TIRES .

-- Remove the left and right wheel spoiler and the front wheel housing liner. Refer to OVERVIEW - FRONT WHEEL HOUSING LINER .

-- Remove the noise insulation. Refer to OVERVIEW - NOISE INSULATION .

-- Remove the driveshaft. Refer to the appropriate service information .

-- Place the container of the Coolant Collection System :VAS5014  or the Shop Crane - Drip Tray:VAS6208  underneath.

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-- Lift the clamp -2-, remove the coolant hose from the radiator and allow the coolant to drain.

-- Loosen the hose clamps -1 and 3- and remove the coolant hoses.

-- Open the hose clamp -arrow-.

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-- Remove the coolant hose from the right coolant pipe, hold it downward, and allow the coolant to drain.

-- Carefully pull the engine cover off the retaining pins one after the other in direction of -arrows-. Do not remove the engine cover on one side or in a jerking manner.

-- If the engine and transmission must be separate, remove the ball pins and bolts -arrows- and remove the heat shield -1-.

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-- Remove the bolts -arrows- and air duct -1-.

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-- Loosen the hose clamp -2- and remove the air duct pipe.

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-- Pull the air filter housing -1- upward and remove it.

-- Disconnect the fuel hose -1-. Refer to CONNECTOR COUPLINGS, DISCONNECTING .

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-- Loosen the hose clamp -2- and disconnect the hose for the EVAP system.

-- Always seal off any open lines and connections with plugs that are thoroughly cleaned from the :VAS6122  .

-- Release the catch through the opening -8- using a small screwdriver and open the cover -1- in direction of -arrow-.

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-- Remove the nuts -3, 5 and 7- and free up the wires.

-- Remove the bolts -2 and 4- and move the Terminal 40 Wire Junction -TV66- to the side.

-- Release the catch in direction of -arrow A- and open the E-box -1- in direction of -arrow B-.

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-- Remove the nut -2- and free up the B+ wire.

-- Lift the clamp -arrow- and remove the coolant hose.

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-- Lift the clamp -2- and disconnect the coolant ventilation line.

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-- Loosen the hose clamps -1 and 3- and remove the air duct hose.

-- Lift the clip -1- and remove the upper left coolant hose from the radiator.

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

-- Disconnect the vacuum hose -2- at the same time to not damage it.

-- Equipment versions with vacuum brake booster: release the catch in direction of -arrow-, remove the vacuum hose -1- and do not damage it.

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-- Disconnect the electrical connectors -2- and free them up.

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-- Release the catches -arrows- and move the Engine Control Module -J623- -3- to the side.

-- Remove the connectors -1 and 2- from the bracket and disconnect them, and then free up the wires:

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-- Loosen the hose clamp -arrow- and disconnect the coolant hose.

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-- Remove the bolt/expanding rivet -1- and disconnect the connector -2-.

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-- Remove the connectors -2 and 3- from the bracket and disconnect.

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-- Remove the nuts -1 and 4- and free up the ground wires.

-- Disconnect the connector -arrow- on the starter generator.

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-- Remove the bolts -arrows- and press the coolant pipe -1- to the rear on the lock carrier.

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-- Loosen the hose clamp -1-, lift the clamp -2- and remove the coolant hose.

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-- Loosen the hose clamps -arrows- and remove the coolant hoses.

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-- Loosen the screw-type clamps -1- and remove the air duct hoses.

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-- Engage the left and right Engine Support Bridge - Special Hook (2 pc.):10-222A/20  to the body, and tie up the wheel bearing housing as shown using the Tensioning Strap:T10038 

-- To protect the threads, remove the nut -arrow- on the left and right side from the tie rod end joint pin until it is flush with the joint pin threads.

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• To prevent damage to the ball joint puller, both pry arms on the pull must be parallel to each other when the most force is applied.

-- Remove the left and right tie rod end with the Ball Joint Splitter:VAS251805  from the wheel bearing housing.

-- Remove the nut by counterholding at the ball joint with a 6 mm inner hex socket if necessary.

-- To protect the threads, remove the nut -arrow- on the left and right from the guide link joint pin just until it is flush with the joint pin threads. If necessary counterhold the joint pin.

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• To prevent damage to the ball joint puller, both pry arms on the pull must be parallel to each other when the most force is applied.

-- Remove the left and right guide link joint pin from the conical seat using the Ball Joint Splitter:VAS251809  with Ball Joint Splitter :VAS251809/1  . Do not damage the CV boot while doing this.

-- Remove the nut and free up the guide link on the wheel bearing housing. If necessary, counterhold the joint pin with a TX 40 socket to do this.

-- Loosen the subframe shield and push it slightly to the side. Refer to SUBFRAME SHIELD, REMOVING AND INSTALLING .

-- Equipped on some models: disconnect the left and right connector -3- for the level control system sensor and free up the wire.

-- Remove the nut -2- and free up the coupling rod.

-- Clean the steering gear and the subframe near the boot.

-- Open the spring clamp -3- using the Hose Clip Pliers:VAS6362  .

-- Remove the clamp -1- and remove the boot -2- outward from the steering gear.

-- Disconnect the threaded connections -1 and 3- for the control arm.

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-- Pivot the control arm toward the front.

• To remove the bolt -1-, push the steering all the way to the left or right.

-- Repeat the procedure on the other side of the vehicle.

-- Remove the left and right nut -3- and the bolt -1- for the coupling rod -2-.

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-- Remove the left and right drive axles from the transmission. Refer to DRIVE AXLE, REMOVING AND INSTALLING .

-- Remove the steering intermediate shaft from the steering gear and push together. Refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

-- Remove the ribbed belt from the A/C compressor belt pulley. Refer to RIBBED BELT, REMOVING AND INSTALLING .

-- Remove the A/C compressor from the bracket and tie it up on the left side. Refer to A/C COMPRESSOR, REMOVING AND INSTALLING FROM BRACKET .

-- Disconnect the connector -2- for the Transmission Fluid Auxiliary Hydraulic Pump 1 -V475- on the right side of the transmission and free up the wire.

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-- Disconnect the connector -2- for the Transmission Fluid Cooling Valve -N509-.

If the engine and transmission should then be separated:

-- Place a cloth under the separating point to soak up any escaping coolant.

-- Loosen the hose clamps -1- and remove the coolant hoses.

-- Remove the bolts -arrows- and then remove the transmission fluid cooling valve.

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-- Turn the twist lock counter-clockwise -arrow- and disconnect the connector -1- from the transmission.

-- Free up the wiring harness.

-- Remove the bolts -arrows- and free up the parking lock emergency release cable -1-.

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-- Secure the front muffler as shown with the Tensioning Strap:T10038  .

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-- Loosen the front area of the left and right center underbody trim panel. Refer to OVERVIEW - UNDERBODY TRIM PANELS .

Scissor Lift Table, Preparing:

-- Set up the Scissor Lift Table: VAS6131B  as follows:

Table Coordinates	Parts from the Scissor Lift Table - Audi Set:VAS6131/10  , Scissor Lift Table - A8 Set Adapter 1:VAS6131/11-1  and Scissor Lift Table - Audi Set Universal Supports:VAS6131/13-2
C4	/10-1	/10-4	/10-5	/10-11
E4	/10-1	/10-4	/10-5	/10-11
C14	/10-1	/10-3	/10-5	/10-6
E14	/10-1	/10-3	/10-5	/10-6

-- Secure the mounting elements to the scissor lift table by hand.

-- Position the :VAS6131B  so it is level.

• Note the bubble level (sight glass) on support platform.

-- Guide the :VAS6131B  under the engine/transmission assembly.

-- Position the mounting element from the :VAS6131/10  on the left and right on the engine.

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-- Make sure the threaded spindles are completely screwed in.

-- Install the mounting elements from the :VAS6131/10  on the tunnel crossmember.

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

-- Fasten the mounting element base plates to 20 Nm on the :VAS6131B  .

-- Secure the subframe. Refer to SUBFRAME, LOWERING .

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

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-- Lower the Scissor Lift Table:VAS6131B  with the engine/transmission assembly and remove from under the vehicle.

-- Tie up the drive axles.