Scheme 100
- Bolt 20 Nm
- Retaining plate For engine mount
- Bolt 40 Nm
- Engine support
- Bolt 10 Nm
- Heat shield
- Bolt Replace 90 Nm + an additional 90° turn
- Engine mount Removing and installing: Left «LEFT ENGINE MOUNT»(/audi/a5/i-2007-2011/remont/mechanical/#32l-engine-assembly-engine-codes-cala-coupe-as-of-112007__left-engine-mount) , right «RIGHT ENGINE MOUNT»(/audi/a5/i-2007-2011/remont/mechanical/#32l-engine-assembly-engine-codes-cala-coupe-as-of-112007__right-engine-mount) .
- Subframe
- Bolt 55 Nm
FASTENER TIGHTENING SPECIFICATIONS
| Components | Bolt Size | Nm |
|---|---|---|
| Bolts and Nuts | ||
| M6 | 9 | |
| M7 | 15 | |
| M8 | 20 | |
| M10 | 40 | |
| M12 | 65 | |
| Ground Pin to Strut Tower | 9 | |
Scheme 101
| Item | Bolt | Nm |
|---|---|---|
| 1 | M10 x 50 1) | 65 |
| 2 to 6 | M12 x 100 2) | 30 + 105° turn |
| 7 | M12 x 125 2) | 30 + 105° turn |
| 8, 11 | M10 x 60 2) | 15 + 105° turn |
| 9, 10 | M10 x 95 2) | 15 + 105° turn |
| A | Alignment sleeves for centering | |
| 1) Bolt class 10.9. 2) Replace bolts. | ||
ENGINE, REMOVING - MANUAL TRANSMISSION
Note. Remove engine downward together with transmission and subframe while the lock carrier is installed. Collect escaping coolant in a clean container for disposal or reuse. During installation, cable ties must be reinstalled at the same location.
Note. If the engine and transmission will be separated after removal, the supplementary set VAS 6131/14 will also be needed.
Special tools and workshop equipment required
- Old oil collecting and extracting device V.A.G 1782
- Hose clamp pliers V.A.G 1921
- Step ladder VAS 5085
- Scissor lift table VAS 6131 A with support set VAS 6131/10 and supplementary set VAS 6131/13
- Drip tray for workshop crane VAS 6208
- Pry lever - rmv outside mirror 80 - 200
- Counterhold tool T10172 with T10172/5 for vehicles with AWD
- Puller T40160
- Assembly aid T40169
- Bracket T40170
Procedure
Proceed as follows
| 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. Before opening high pressure area of the fuel injection system, fuel pressure must be relieved to residual pressure. |
Reduce fuel pressure in high pressure area BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .
| CAUTION | Risk of destroying electrical components. Observe measures when disconnecting battery. |
Note. Release electrical parking brake before disconnecting battery so the driveshaft can be rotated to remove it.
Position front wheels so they are straight.
Switch off ignition and remove ignition key.
Raise luggage compartment liner and engage it on the body.
Remove nut -1- and vehicle tool kit cover -2-.
Scheme 102
Pull cover -1- over negative terminal up slightly -arrow-.
Scheme 103
Loosen nut a few turns and remove ground (GND) wire terminal clamp -2- from the battery pole.
Empty coolant circuit COOLING SYSTEM, DRAINING AND FILLING .
Extract power steering fluid from reservoir with used oil collection and extraction device V.A.G 1782.
Remove engine covers -arrows-.
Scheme 104
| WARNING | Risk of scalding due to hot steam and hot coolant. When the engine is warm the cooling system is under pressure. To reduce pressure, cover coolant reservoir cap with cloth and carefully open. |
Open coolant reservoir cap.
Remove left and right front wheels.
Remove left and right front wheel housing liners Description and Operation .
Remove noise insulation by loosening fasteners -1 through 4-.
Scheme 105
Note. Ignore -arrow-.
Place drip tray VAS 6208 under engine.
Remove drain plug -1- and drain coolant.
Scheme 106
Remove coolant hose -2- from radiator by raising retaining clip.
Remove coolant hose -arrows- from oil cooler and drain remaining coolant.
Scheme 107
Place used oil collecting and extracting device V.A.G 1782 under separating point.
Scheme 108
Disconnect power steering hydraulic oil supply line -2- and return line -1- in the left front wheel housing and free them up.
Note. To prevent dirt from entering, seal open lines and connections with clean plugs or protective caps.
With Coolant Pump -V50
Disconnect electrical connector -1-.
Scheme 109
Place drip tray VAS 6208 under engine.
Remove coolant hose from coolant pump -V50- -right arrow-.
Note. Ignore -2- and -left arrow-.
Continuation for All
Disconnect coolant fan electrical connector -1- by sliding retainer back -arrow- and pressing release down.
Scheme 110
Free up electrical wiring harness.
Remove left and right bolts -1- and nuts -3- and lock carrier braces -2-.
Scheme 111
Remove nut -arrow- on right longitudinal member and free up ground (GND) wire.
Scheme 112
Remove seal -arrow-.
Scheme 113
Unclip plenum chamber covers -1, 2 and 3- and remove it.
Remove vacuum connection -2- from bulkhead by pulling vacuum hose -1- on rear side.
Scheme 114
Free up fuel line and wire to EVAP canister at air guide pipe.
Disconnect vacuum hose -arrow- to leak detection pump -V144-.
Scheme 115
Remove air duct -arrows-.
Scheme 116
Remove vacuum hose -3- from connection on air guide pipe.
Scheme 117
Remove air guide pipe by loosening hose clamp -4- and opening clips -arrows-.
Note. Ignore -1 and 2-.
Disconnect vacuum line -1-.
Scheme 118
Remove air filter housing and, if applicable, disconnect electrical connector -2- on rear side at intake air switch-over valve -N335-.
| WARNING | Risk of injury from fuel. To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen. |
| CAUTION | Follow cleanliness precautions when working on the fuel supply system CLEAN WORKING CONDITIONS . |
Remove fuel supply line from high pressure pump -arrow- and lay it aside.
Scheme 119
Disconnect vacuum hose -1- and free it up.
Scheme 120
Remove coolant hose -2- from upper coolant pipe by lifting retaining clamp.
In vehicles without a coolant pump -V50-, remove right front coolant hose -arrow- from front coolant pipe by lifting retaining clamp.
Scheme 121
Remove coolant hose -arrow- from front coolant pipe by lifting retaining clamp.
Scheme 122
Remove coolant hose -3- from coolant reservoir and free it up.
Scheme 123
Remove bolts -arrows-, disconnect electrical connector on Engine Coolant Level (ECL) warning switch -F66- and lay coolant reservoir aside with coolant hoses -1- and -2- attached.
Disconnect electrical connector -arrow- on power steering pump, if applicable.
Scheme 124
Press hydraulic oil hose to the side.
| CAUTION | Risk of damaging coolant lines and hoses. Do not stretch, kink or bend coolant lines and hoses. |
Remove bolts -arrows- and refrigerant lines from A/C compressor.
Scheme 125
Note. To prevent dirt and moisture from entering, seal open lines and connections with clean plugs or protective caps.
Release retainer -arrow A- and open cover -arrow B-.
Scheme 126
Remove nuts -1- and -2- for electrical wires.
Scheme 127
Remove electrical connector -3- from bracket and disconnect it.
Remove bolt -4- and terminal 30 wire junction 2 -TV22- from tower brace -arrow-.
Release retainers from wheel housing side using a 5.5 mm open end wrench -1- -arrow- and remove wiring bushing -2- upward.
Scheme 128
Free up wiring harness -3- to generator and starter using pry lever - rmv outside mirror 80 - 200.
Free up wiring duct by releasing retainer -arrow B- and pulling duct forward -arrow A-.
Scheme 129
Remove nut -1- and tip washer fluid filler neck back -arrow A-.
Scheme 130
Remove filler neck -2- with filler tube from washer fluid reservoir and opening in body -arrow B-.
Remove bolts -1- and nuts -2- and tower brace -3-.
Scheme 131
Remove bolts -arrows- and engine compartment E-box cover.
Scheme 132
Remove nut -1- and free up electrical wire.
Release retainers -A arrows- and remove engine control module -arrow B-.
Scheme 133
Disconnect electrical connector -2- if applicable.
Scheme 134
Disconnect electrical connectors -4- and remove nut -3- for electrical wire.
Release retainers -arrow- and remove relay carrier with fuse holder -1-.
Disengage engine wiring harness at engine compartment E-box and free it up.
Release retainers -A arrows- and remove wiring bushing -2- upward -arrow B-.
Scheme 135
Remove ground pin -1- and free up electrical wire.
Lay wiring harness on engine and secure engine control module against falling down.
Disconnect electrical connectors -arrow- at left and right on front speed sensors.
Scheme 136
Disconnect electrical connector -1- on left front level control system sensor -G78- and right front level control system sensor -G289- and free up electrical wiring -arrow-.
Scheme 137
Free up electrical connector -2- on bracket by pulling retainer back -arrow A- and turning connector approximately 90° in direction of -arrow B-.
Scheme 138
Free up electrical wiring -3- and brake line -4- on bracket.
Remove bolts -1- and secure brake caliper in wheel housing using wire.
| CAUTION | Risk of damaging brake pistons. Do not operate brake pedal with brake caliper removed. |
Remove nut -2- and bolt -1-.
Scheme 139
Remove upper control arm upward from wheel bearing housing -arrows-.
Repeat procedure on the other side of the vehicle.
Remove left and right stabilizer bar bolts -3-.
Scheme 140
Remove left and right nuts -1-.
Note. The bolts -2- will be removed later.
Remove bolt -1- for power steering hydraulic fluid line bracket.
Scheme 141
| CAUTION | Suspension components could be damaged. Do not rest the vehicle on its wheels if the subframe mount, steering gear or subframe cross brace are not installed correctly. |
Remove bolts -arrows- and subframe cross brace.
Remove bolts -arrows- and front crossmember, if applicable.
Scheme 142
Remove left front muffler nuts -arrows-.
Scheme 143
Remove right front muffler nuts -arrows-.
Scheme 144
| CAUTION | The decoupling elements in the front muffler could be damaged. Do not bend decoupling elements in front muffler more than 10 degrees. |
Loosen clamping sleeves -1- and -2-, slide them back and remove left and right front mufflers.
Scheme 145
Remove bolts -arrows- and driveshaft heat shield -1-.
Scheme 146
Remove bolts connecting driveshaft to transmission while holding using a counter hold tool T10172 with T10172/5.
Scheme 147
Slide driveshaft toward rear final drive; the constant velocity joints can move axially.
Secure driveshaft to the side.
Scheme 148
| CAUTION | The airbag spiral spring could be damaged. Separate 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 universal joint bolt -arrow- Description and Operation .
Press constant velocity joint off steering gear and slide it all the way up.
Remove bolt -2- and secure clutch slave cylinder sideways in the engine compartment.
Scheme 149
| CAUTION | Risk of damaging clutch slave cylinder. Do not operate clutch pedal anymore after slave cylinder has been removed. |
Remove selector rod nut -1-.
Position puller T40160 and remove selector rod -1-.
Scheme 150
Prepare Scissor Lift Platform
Scheme 151
Equip scissor lift table VAS 6131 A with support set VAS 6131/10 and supplementary set VAS 6131/13 as follows
| Platform coordinates | Parts from support set VAS 6131/10 and supplementary set VAS 6131/13 | |||
|---|---|---|---|---|
| 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 | /13-6 | /13-2 | ||
| C14 | /10-1 | /10-3 | /10-5 | /10-13 |
| F14 | /10-1 | /10-3 | /10-5 | /10-10 |
Next secure mounting elements to scissor lift table by hand.
Position scissor lift table VAS 6131 A horizontally.
- Note bubble level (sight glass) on support platform.
Guide scissor lift table VAS 6131 A under engine/transmission assembly.
| WARNING | The subframe could cause an accident if it is not secured. Do not loosen subframe bolts -2- and -3-. |
Remove left and right subframe bolts -1-.
Scheme 152
Attach mounting elements from VAS 6131/10 and VAS 6131/13 at left and right front of subframe as shown in the illustration.
Scheme 153
Ensure threaded spindles are completely installed.
Attach mounting elements from VAS 6131/10 at left and right rear on subframe cross brace front connecting points as shown in the illustration.
Scheme 154
Attach mounting elements from VAS 6131/13 at lower left and right of wheel bearing housing as shown in the illustration.
Scheme 155
Remove noise insulation retaining clips from crossmember.
Attach mounting elements from VAS 6131/10 at left and right rear of crossmember as shown in the illustration.
Scheme 156
Rotate mounting element spindles upward until all mounting pins come into contact with mounting points.
Attach mounting element base plates to scissor lift table VAS 6131 A and tighten to 20 Nm.
Mark location of subframe and engine carrier to longitudinal members using a felt-tip pen.
Remove left and right subframe bolts -2- and -3- diagonally in stages.
Note. Ignore -1-.
Remove bolts -arrows- on tunnel crossmember.
Scheme 157
Remove left and right bolts -2-.
Note. The nuts -1- and bolts -3- have already been removed.
| 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 engine-transmission assembly with subframe out of engine compartment while lowering it. |
Next lower engine/transmission assembly with scissor lift table VAS 6131 A only by dimension -a-.
Scheme 158
- Dimension -a- = 100 mm maximum.
Remove bolts -1- and -3- for selector rod and push rod.
Scheme 159
Note. Ignore -2-.
Lower engine/transmission assembly more.
Remove scissor lift table VAS 6131 A with engine/transmission assembly under vehicle.
ENGINE AND TRANSMISSION, SEPARATING - MANUAL TRANSMISSION
Special tools and workshop equipment required
- Adapter T40058
- Support set VAS 6131/10, supplementary set VAS 6131/13 and transmission support VAS 6131/14
Procedure
Proceed as follows
- Engine/transmission assembly removed and placed on scissor lift table VAS 6131 A.
Remove electrical connector -1- for Oxygen Sensor (O2S) 2 behind Three Way Catalytic Converter (TWC) -G131- from bracket and disconnect it.
Scheme 160
Note. Ignore -2, 3 and 4- and -arrows-.
Remove nuts -arrows- and bolt -1- and left catalytic converter.
Scheme 161
Remove electrical connector -1- for Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC) -G130- from bracket and disconnect it.
Scheme 162
Note. Ignore -2, 3 and 4- and -arrows-.
Remove nuts -arrows- and bolt -1- and right catalytic converter.
Scheme 163
Disconnect electrical connector -2- on engine speed (RPM) sensor -G28- and free up electrical wiring.
Scheme 164
Note. Ignore -1-.
Disconnect electrical connector -2- on back-up light switch -F4-.
Note. Ignore -1 and 3-.
Remove left and right drive axles from transmission flange shafts.
Remove bottom cover -1- from transmission -arrow-.
Scheme 165
Insert adapter T40058 guide pins as follows
Scheme 166
- The large diameter -arrow 1- faces engine.
- Small diameter -arrow 2- points to adapter.
To loosen crankshaft, counter hold drive plate bolts using adapter T40058.
Scheme 167
Note. Only turn crankshaft in direction of engine rotation -arrow-.
Remove 6 clutch module bolts -arrow- by turning crankshaft 60 degrees in direction of engine rotation.
Scheme 168
Equip scissor lift table VAS 6131 A with support set VAS 6131/10, supplementary set VAS 6131/13 and transmission support VAS 6131/14 as follows
Note. The other attachments remain unchanged.
| Platform coordinates | Parts from support set VAS 6131/10, supplementary set VAS 6131/13 and transmission support VAS 6131/14 | |||
|---|---|---|---|---|
| F2 | /13-7 | |||
| B10 | /10-1 | /10-2 | /10-5 | /14 |
| G10 | /10-1 | /10-2 | /10-5 | |
Install joint support VAS 6131/13-7 at front right of engine in threaded hole as shown in the illustration.
Scheme 169
Install joint support VAS 6131/13-7 on scissor lift table and tighten it to 20 Nm.
Attach mounting elements from VAS 6131/10 and transmission support VAS 6131/14 at front of transmission as shown in the illustration.
Scheme 170
Rotate left and right spindles up until transmission support VAS 6131/14 rests firmly against the transmission.
Attach mounting element base plates to scissor lift table VAS 6131 A and tighten to 20 Nm.
Remove starter bolts -1- and -2-.
Scheme 171
Press starter off transmission and leave it in the installation position.
Remove remaining bolts -3 through 11- connecting engine to the transmission.
Note. Ignore -A-.
Loosen clamping bolts -1- on sides of scissor lift table VAS 6131 A and pull rear table plate with transmission toward rear -arrow-.
Scheme 172
ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER - MANUAL TRANSMISSION
Special tools and workshop equipment required
- Lifting tackle 2024 A
- Engine and transmission holder VAS 6095 with V6 FSI engine holder VAS 6095/1-5
- Shop crane VAS 6100
- Lift arm extension for workshop crane VAS 6101
Procedure
Proceed as follows
- The engine/transmission assembly is removed «ENGINE, REMOVING»(/audi/a5/i-2007-2011/remont/mechanical/#32l-engine-assembly-engine-codes-cala-coupe-as-of-112007__engine-removing-manual-transmission) ; the engine and transmission are separated «ENGINE AND TRANSMISSION, SEPARATING»(/audi/a5/i-2007-2011/remont/mechanical/#32l-engine-assembly-engine-codes-cala-coupe-as-of-112007__engine-and-transmission-separating-manual) .
- Engine secured with joint support VAS 6131/13-7.
Disconnect electrical connector -arrow- on steering gear.
Scheme 173
Note. To collect escaping hydraulic oil, lay a cloth under separating point.
Remove bolt -1- and disconnect power steering hydraulic oil line.
Scheme 174
Note. To prevent dirt from entering, seal open lines and connections with clean plugs or protective caps. Ignore -arrow-.
Remove nut -1- and remove bracket with wiring harness from subframe.
Scheme 175
Note. The illustration shows the installation position with the engine installed.
Engage lifting tackle 2024 A on engine lifting eyes and on shop crane as shown in the illustration.
Scheme 176
Note. To be aligned to the center of gravity of the engine assembly, the hole rails of the lifting hook must be inserted as shown in the illustration.
| WARNING | Risk of accident. Lifting hooks and alignment pins on lifting tackle must be secured with securing pins -arrows-. |
Tension engine slightly with shop crane, do not raise.
Remove left engine mount bolt -3-.
Scheme 177
Note. The illustration shows the installation position with the engine installed. Ignore -1, 2, 4-.
Remove right engine mount bolt -2-.
Scheme 178
Note. The illustration shows the installation position with the engine installed. Ignore -1, 3, 4-.
Remove joint support VAS 6131/13-7 from engine.
Raise engine from engine carrier.
Remove bolts -arrows- and left engine support.
Scheme 179
Remove nut -1- and free up ground (GND) wire at engine support.
Scheme 180
Remove bolts -arrows- and right engine support.
Secure starter on engine.
Secure engine to engine and transmission holder VAS 6095 using bracket VAS 6095/1-5 and tighten to 40 Nm, as shown in the illustration.
Scheme 181
ENGINE, INSTALLING - MANUAL TRANSMISSION
Tightening Specifications
Note. Tightening specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts. Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not. Do not use any parts that have had the lubrication removed. Tolerance for tightening specifications ±15%.
Tightening specifications ENGINE MOUNT ASSEMBLY OVERVIEW .
| Component | Nm | ||
|---|---|---|---|
| Bolts and nuts | M6 | 9 | |
| M7 | 15 | ||
| M8 | 20 | ||
| M10 | 40 | ||
| M12 | 65 | ||
| Exceptions | |||
| Ground pins to the strut tower | 9 | ||
Securing engine to transmission
| Item | Bolt | Nm |
|---|---|---|
| 1 | M10 x 50 1) | 65 |
| 2 to 6 | M12 x 100 2) | 30 + 105° turn |
| 7 | M12 x 125 2) | 30 + 105° turn |
| 8, 11 | M10 x 60 2) | 15 + 105° turn |
| 9, 10 | M10 x 95 2) | 15 + 105° turn |
| A | Alignment sleeves for centering | |
| 1) Bolt class 10.9. 2) Replace bolts. | ||
| (1) To avoid damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt in a 14 mm socket with a / 2 inch drive ratchet which is clamped into a vise, as shown in the illustration. | ||
| (1) | To avoid damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt in a 14 mm socket with a / 2 inch drive ratchet which is clamped into a vise, as shown in the illustration. |
- Aluminum bolts -2 through 11- may be used twice. After using the bolts once, mark them with an "X" made by a chisel -arrow-.
- Do not used bolts marked with an "X" again.
- There is no limit to the number of times the steel bolt -1- can be used.
Procedure
Proceed as follows
Note. Replace bolts which have been tightened to specifications. Replace self-locking nuts and bolts as well as sealing rings, seals and O-rings. There is a needle bearing in the drive plate. Check if the needle bearing is inserted before installing. Needle bearing, removing from and installing on drive plate DRIVE PLATE NEEDLE BEARING . Secure all hose connections with hose clamps appropriate for the model. During installation, all cable ties must be reinstalled at the same location.
Check if alignment sleeves for centering the engine and transmission are in the cylinder block and insert them if they are not.
Clean threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.
Install engine supports and engine mount ENGINE MOUNT ASSEMBLY OVERVIEW .
Complete the following steps before connecting the engine and transmission
Insert assembly aid T40169 into transmission housing and clutch module from below as shown in the illustration.
Scheme 182
- The assembly aid T40169 must engage in the semicircular opening -1- and in the inspection hole -2-.
Note. The inspection hole is only in one location on the circumference so rotate the clutch module as needed.
Insert transportation lock T40170 in the transmission housing from below and clamp it onto flange shaft -1-.
Scheme 183
Also align drive plate to clutch module so tabs -2- on drive plate can engage in large holes -1- on clutch module.
Scheme 184
Note. The tabs must not lie on any part of the clutch module that does not have a hole.
Position transmission on engine and tighten bolts -1 through 11-.
Note. Ignore -A-.
Tighten clutch module bolts -arrow- on drive plate in two stages while turning crankshaft 60 degrees Removal and Installation .
Install starter Removal and Installation .
Install power steering hydraulic oil lines Removal and Installation .
Install left and right drive axles on transmission flange shafts Removal and Installation .
Install catalytic converters: Left LEFT CATALYTIC CONVERTER , right RIGHT CATALYTIC CONVERTER .
Next, raise engine/transmission assembly high enough using scissor lift table VAS 6131 A until dimension -a- is reached between subframe and body.
- Dimension -a- = at least 100 mm.
Install shift rod and pivot rod Description and Operation .
Continue raising engine/transmission assembly using scissor lift table VAS 6131 A.
Align subframe and transmission carrier using marks made on longitudinal members during removal.
Tighten subframe bolts only to tightening specifications, do not tighten them further (tighten bolts only after axle alignment) Removal and Installation .
| WARNING | Risk of accident due to loose connections. If the bolts in the subframe are not tightened to final specifications, vehicle must not be driven. |
Tighten tunnel crossmember bolts -arrow- Description and Operation .
The rest of is in reverse order of removal, note the following
Install clutch slave cylinder Removal and Installation .
Install universal joint on steering gear Description and Operation .
Install driveshaft Removal and Installation .
Install front muffler FRONT MUFFLER .
Install exhaust system free of stress EXHAUST SYSTEM, INSTALLING .
Install subframe cross brace, upper control arm and stabilizer bar and tighten the suspension strut on control arm Description and Operation .
Install brake caliper Description and Operation
Install Engine Control Module (ECM) Removal and Installation .
Electrical connections and routing, refer to appropriate SYSTEM WIRING DIAGRAM.
Install electrical wires, terminal 30 wire junction 2 -TV22- and engine compartment E-box cover Wiring .
Install tower brace Description and Operation .
Install washer fluid reservoir filler tube Removal and Installation .
Install refrigerant lines Removal and Installation .
Follow measures after connecting battery Removal and Installation .
| CAUTION | Risk of destroying control modules with excess voltage. Do not use a battery charger for starting assistance! |
Install air filter housing Removal and Installation .
Install lock carrier braces Description and Operation .
Fill engine oil and check oil level ENGINE OIL, CHECKING LEVEL .
Before starting engine for the first time, check hydraulic oil in power steering reservoir Diagnosis and Testing .
Note. Power-steering pump must not run dry.
Connect coolant hose to connector on the radiator (Scheme 185)
Scheme 185
Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .
Note. Do not use drained coolant in the following situations: If cylinder head or cylinder block was replaced. If coolant is contaminated.
Fill refrigerant circuit DESCRIPTION AND OPERATION .
Align subframe Description and Operation .
Perform axle alignment Description and Operation .
| WARNING | Risk of accident due to loose connections. Tighten the subframe bolts to the specification after performing axle alignment. |
Install noise insulation and the wheel housing liners. Noise insulation Description and Operation Wheel housing liner Description and Operation .
ENGINE, REMOVING - AUTOMATIC TRANSMISSION
Note. Remove the engine downward together with transmission and subframe while the lock carrier is installed. Collect escaping coolant in a clean container for disposal or reuse. During installation, cable ties must be reinstalled at the same location.
Note. If the engine and transmission will be separated after removal, the supplementary set VAS 6131/14 will also be needed.
Special tools and workshop equipment required
- Old oil collecting and extracting device V.A.G 1782
- Hose clamp pliers V.A.G 1921
- Step ladder VAS 5085
- Scissor lift table VAS 6131 A with Support Set VAS 6131/10 and Supplementary Set VAS 6131/11 and VAS 6131/13
- Drip tray for workshop crane VAS 6208
- Pry lever - rmv outside mirror 80 - 200
- Counterhold tool T10172 with T10172/5
Procedure
Proceed as follows
| 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. Before opening high pressure area of the fuel injection system, fuel pressure must be relieved to residual pressure. |
Reduce fuel pressure in high pressure area BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .
| CAUTION | Risk of destroying electrical components. Observe measures when disconnecting battery. |
Note. Release electrical parking brake before disconnecting battery so the driveshaft can be rotated to remove it.
Position front wheels so they are straight.
Switch off ignition and remove ignition key.
Raise luggage compartment liner and engage it on the body.
Remove nut -1- and vehicle tool kit cover -2-.
Pull cover -1- over negative terminal up slightly -arrow-.
Loosen nut a few turns and remove ground (GND) wire terminal clamp -2- from battery pole.
Empty coolant circuit COOLING SYSTEM, DRAINING AND FILLING .
Extract power steering fluid from reservoir with used oil collection and extraction device V.A.G 1782.
Remove engine covers -arrows-.
| WARNING | Risk of scalding due to hot steam and hot coolant. When the engine is warm the cooling system is under pressure. To reduce pressure, cover coolant reservoir cap with cloth and carefully open. |
Open coolant reservoir cap.
Remove left and right front wheels.
Remove left and right front wheel housing liners Description and Operation .
Remove noise insulation by loosening fasteners -1 through 4-.
Note. Ignore -arrow-.
Place drip tray VAS 6208 under engine.
Remove drain plug -1- and drain coolant.
Remove coolant hose -2- from radiator by raising retaining clip.
Remove coolant hose -arrows- from oil cooler and drain remaining coolant.
Place used oil collecting and extracting device V.A.G 1782 under separating point.
Disconnect power steering hydraulic oil supply line -2- and return line -1- in left front wheel housing and free them up.
Note. To prevent dirt from entering, seal open lines and connections with clean plugs or protective caps.
Place used oil collecting and extracting device V.A.G 1782 under separating point.
Mark locations of ATF lines -1- and -2- so they can be installed later and then disconnect them.
Scheme 186
Note. To prevent dirt from entering, seal open lines and connections with clean plugs or protective caps. Ignore -arrow-.
With a Coolant Pump -V50
Disconnect electrical connector -1-.
Place drip tray VAS 6208 under engine.
Remove coolant hose from coolant pump -V50- -right arrow-.
Note. Ignore -2- and -left arrow-.
Continuation for All
Disconnect coolant fan electrical connector -1- by sliding retainer back -arrow- and pressing release down.
Free up electrical wiring harness.
Remove left and right bolt -1- and nut -3- and lock carrier brace -2-.
Remove nut -arrow- on right longitudinal member and free up ground (GND) wire.
Remove seal -arrow-.
Unclip plenum chamber covers -1, 2 and 3- and remove it.
Remove vacuum connection -2- from bulkhead by pulling vacuum hose -1- on rear side.
Free up fuel line and wire to EVAP canister at air guide pipe.
Disconnect electrical connector -3- on evaporative emission (EVAP) canister purge regulator valve -N80- and disconnect vacuum hose -4-.
Disengage evaporative emission (EVAP) canister purge regulator valve -N80- from bracket and lay it aside with hose connected.
Disconnect vacuum hose -arrow- to leak detection pump -V144-.
Remove air duct -arrows-.
Remove vacuum hose -3- from connection on air guide pipe.
Remove air guide pipe by loosening hose clamp -4- and opening clips -arrows-.
Note. Ignore -1 and 2-.
Disconnect vacuum line -1-.
Remove air filter housing and, if applicable, disconnect electrical connector -2- on rear side at intake air switch-over valve -N335-.
| WARNING | Risk of injury from fuel. To reduce fuel pressure, lay cloths around connecting point before opening fuel system and carefully loosen. |
| CAUTION | Follow cleanliness precautions when working on the fuel supply system CLEAN WORKING CONDITIONS . |
Remove fuel supply line from high pressure pump -arrow- and lay it aside.
Disconnect vacuum hose -1- and free it up.
Remove coolant hose -2- from upper coolant pipe by lifting retaining clamp.
In vehicles without a coolant pump -V50-, remove right front coolant hose -arrow- from front coolant pipe by lifting retaining clamp.
Remove coolant hose -arrow- from front coolant pipe by lifting retaining clamp.
Remove coolant hose -3- from coolant reservoir and free it up.
Remove bolts -arrows-, disconnect electrical connector on Engine Coolant Level (ECL) warning switch -F66- and lay coolant reservoir aside with coolant hoses -1- and -2- attached.
Disconnect electrical connector -arrow- on power steering pump, if applicable.
Press hydraulic hose down slightly.
| CAUTION | Risk of damaging coolant lines and hoses. Do not stretch, kink or bend coolant lines and hoses. |
Remove bolts -arrows- and refrigerant lines from A/C compressor.
Note. To prevent dirt and moisture from entering, seal open lines and connections with clean plugs or protective caps.
Release retainer -arrow A- and open cover -arrow B-.
Remove nuts -1- and -2- for electrical wires.
Remove electrical connector -3- from bracket and disconnect it.
Remove bolt -4- and terminal 30 wire junction 2 -TV22- from tower brace -arrow-.
Release retainers from wheel housing side using a 5.5 mm open end wrench -1- and remove wiring bushing -2- upward.
Free up wiring harness -3- to generator and starter using pry lever - rmv outside mirror 80 - 200.
Free up wiring duct by releasing retainer -arrow B- and pulling duct forward -arrow A-.
Remove nut -1- and tip washer fluid filler neck back -arrow A-.
Remove filler neck -2- with filler tube from washer fluid reservoir and opening in body -arrow B-.
Remove bolts -1- and nuts -2- and tower brace -3-.
Remove bolts -arrows- and engine compartment E-box cover.
Remove nut -1- and free up electrical wire.
Release retainers -A arrows- and remove engine control module -arrow B-.
Disconnect electrical connector -2- if applicable.
Disconnect electrical connectors -4- and remove nut -3- for electrical wire.
Release retainers -arrow- and remove relay carrier with fuse holder -1-.
Disengage engine wiring harness at engine compartment E-box and free it up.
Release retainers -A arrows- and remove wiring bushing -2- upward -arrow B-.
Remove ground pin -1- and free up electrical wire.
Lay wiring harness on engine and secure engine control module against falling down.
Disconnect electrical connectors -arrow- at left and right on front speed sensors.
Disconnect electrical connector -1- on left front level control system sensor -G78- and right front level control system sensor -G289- and free up electrical wiring -arrow-.
Free up electrical connector -2- on bracket by pulling retainer back -arrow A- and turning connector approximately 90° clockwise -arrow B-.
Free up electrical wiring -3- and brake line -4- on bracket.
Remove bolts -1- and secure brake caliper in wheel housing using wire.
| CAUTION | Risk of damaging brake pistons. Do not operate brake pedal with brake caliper removed. |
Remove nut -2- and bolt -1-.
Remove upper control arm upward from wheel bearing housing -arrows-.
Repeat procedure on other side of vehicle.
Remove left and right stabilizer bar bolts -3-.
Remove left and right nuts -1-.
Note. The bolts -2- will be removed later.
Remove bolt -1- for power steering hydraulic fluid line bracket.
| CAUTION | Suspension components could be damaged. Do not rest vehicle on its wheels if the subframe mount, steering gear or subframe cross brace are not installed correctly. |
Remove bolts -arrows- and subframe cross brace.
Remove bolts -arrows- and front crossmember, if applicable.
Remove left front muffler nuts -arrows-.
Remove right front muffler nuts -arrows-.
| CAUTION | The decoupling elements in the front muffler could be damaged. Do not bend decoupling elements in front muffler more than 10°. |
Loosen clamping sleeves -1- and -2-, slide them back and remove left and right front mufflers.
Remove bolts -arrows- and driveshaft heat shield -1-.
Remove bolts connecting driveshaft to transmission while holding using a counterhold tool T10172 with T10172/5.
Slide driveshaft toward rear final drive; the constant velocity joints can move axially.
Secure driveshaft to the side.
| CAUTION | The airbag spiral spring could be damaged. Separate 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 universal joint bolt -arrow- Description and Operation .
Press constant velocity joint off steering gear and slide it all the way up.
Remove selector lever cable ball socket -A- from selector shaft lever using pry lever - rmv outside mirror 80 - 200 -arrow-.
Scheme 187
Press securing clips -2- off and remove selector lever cable from transmission.
Scheme 188
Note. Do not bend or kink selector lever cable. Ignore -1
Prepare Scissor Lift Platform
Equip scissor lift table VAS 6131 A with support set VAS 6131/10 and supplementary set VAS 6131/13 as follows
| Platform coordinates | Parts from support set VAS 6131/10 and supplementary set VAS 6131/13 | |||
|---|---|---|---|---|
| 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 | /13-6 | /13-2 | ||
| C14 | /10-1 | /10-4 | /10-5 | /10-7 |
| F14 | /10-1 | /10-4 | /10-5 | /11-1 |
Next secure mounting elements to scissor lift table by hand.
Position scissor lift table VAS 6131 A horizontally.
- Note bubble level (sight glass) on support platform.
Guide scissor lift table VAS 6131 A under engine/transmission assembly.
| WARNING | The subframe could cause an accident if it is not secured. Do not loosen subframe bolts -2- and -3-. |
Remove left and right subframe bolts -1-.
Attach mounting elements from VAS 6131/10 and VAS 6131/13 at left and right front of subframe as shown in the illustration.
Ensure threaded spindles are completely installed.
Attach mounting elements from VAS 6131/10 at left and right rear on subframe cross brace front connecting points as shown in the illustration.
Attach mounting elements from VAS 6131/13 at lower left and right of wheel bearing housing as shown in the illustration.
Attach mounting elements from VAS 6131/10 and VAS 6131/11 at left and right rear of tunnel crossmember as shown in the illustration.
Scheme 189
Rotate mounting element spindles upward until all mounting pins come into contact with mounting points.
Attach mounting element base plates to scissor lift table VAS 6131 A and tighten to 20 Nm.
Mark location of subframe and engine carrier to longitudinal members using a felt-tip pen.
Remove left and right subframe bolts -2- and -3- diagonally in stages.
Note. Ignore -1-.
Remove bolts -arrows- on tunnel crossmember.
Scheme 190
Remove left and right bolts -2-.
Note. The nuts -1- and bolts -3- have already been removed.
| 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 engine-transmission assembly with subframe out of the engine compartment while lowering it. |
Lower engine/transmission assembly using scissor lift table VAS 6131 A.
Remove scissor lift table VAS 6131 A with engine/transmission assembly under vehicle.
ENGINE AND TRANSMISSION, SEPARATING - AUTOMATIC TRANSMISSION
Special tools and workshop equipment required
- Adapter T40058
- Support set VAS 6131/10, supplementary set VAS 6131/13 and transmission support VAS 6131/14
Procedure
Proceed as follows
- Engine/transmission assembly removed and placed on scissor lift table VAS 6131 A.
Remove electrical connector -arrow- for Oxygen Sensor (O2S) 2 behind Three Way Catalytic Converter (TWC) -G131- from bracket, disconnect it and lay it aside.
Note. Ignore -2, 3 and 4- and -arrows-.
Remove nuts -arrows- and bolt -1- and left catalytic converter.
Remove electrical connector -1- for Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC) -G130- from bracket and disconnect it.
Remove electrical connector -2- from bracket.
Remove bolts -arrow- and lay aside bracket with electrical connectors -3- and -4-.
Remove nuts -arrows- and bolt -1- and right catalytic converter.
Disconnect electrical connector -2- on engine speed (RPM) sensor -G28- and free up electrical wiring.
Note. Ignore -1-.
| CAUTION | Risk of destroying transmission control module (mechatronic) with static discharge. Do not touch contacts in transmission connector with hands. |
Touch transmission housing (when not wearing gloves) to discharge static electricity.
Disconnect electrical connector on transmission by rotating twist lock counterclockwise -arrow-.
Scheme 191
Free up electrical wiring harness on transmission.
Remove left and right drive axles from transmission flange shafts.
Remove bottom cover -1- from transmission -arrow-.
Insert adapter T40058 guide pins as follows
- The large diameter -arrow 1- faces engine.
- Small diameter -arrow 2- points to adapter.
To loosen crankshaft, counter hold drive plate bolts using adapter T40058.
Note. Only turn the crankshaft in the direction of engine rotation -arrow-.
Remove 6 torque converter bolts -arrow- by turning the crankshaft 60 degrees in direction of engine rotation.
Remove bolt -arrow- for ATF line bracket.
Note. Ignore -1 and 2-.
Note. Place a cloth under separating point to prevent ATF from leaking out.
Remove bolts -1- and -2- and remove ATF lines from transmission and secure them at the top.
Scheme 192
Note. To prevent dirt from entering, seal open lines and connections with clean plugs or protective caps.
Equip scissor lift table VAS 6131 A with support set VAS 6131/10, supplementary set VAS 6131/13 and transmission support VAS 6131/14 as follows
Note. The other attachments remain unchanged.
| Platform coordinates | Parts from the support set VAS 6131/10, supplementary set VAS 6131/13 and transmission support VAS 6131/14 | |||
|---|---|---|---|---|
| F2 | /13-7 | |||
| B10 | /10-1 | /10-2 | /10-5 | /14 |
| G10 | /10-1 | /10-2 | /10-5 | |
Install joint support VAS 6131/13-7 at right front of engine in threaded hole as shown in the illustration.
Install joint support VAS 6131/13-7 on scissor lift table and tighten to 20 Nm.
Attach mounting elements from VAS 6131/10 and transmission support VAS 6131/14 at front of transmission as shown in the illustration.
Scheme 193
Rotate left and right spindles up until transmission support VAS 6131/14 rests firmly against the transmission.
Attach mounting element base plates to Scissor Lift Table VAS 6131 A and tighten to 20 Nm.
Remove starter bolts -1- and -2-.
Press starter off transmission and leave it in the installation position.
Remove remaining bolts -3 through 11- connecting engine to transmission.
Note. Ignore -A-.
Loosen clamping bolts -1- on sides of scissor lift table VAS 6131 A and pull rear table plate with transmission toward rear -arrow-.
ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER - AUTOMATIC TRANSMISSION
Special tools and workshop equipment required
- Lifting tackle 2024 A
- Engine and transmission holder VAS 6095 with V6 FSI engine holder VAS 6095/1-5
- Shop crane VAS 6100
- Lift arm extension for workshop crane VAS 6101
Procedure
Proceed as follows
- The engine/transmission assembly is removed «ENGINE, REMOVING»(/audi/a5/i-2007-2011/remont/mechanical/#32l-engine-assembly-engine-codes-cala-coupe-as-of-112007__engine-removing-automatic-transmission) ; the engine and transmission are separated «ENGINE AND TRANSMISSION, SEPARATING»(/audi/a5/i-2007-2011/remont/mechanical/#32l-engine-assembly-engine-codes-cala-coupe-as-of-112007__engine-and-transmission-separating-automatic) .
- Engine secured with joint support VAS 6131/13-7.
Disconnect electrical connector -arrow- on steering gear.
Note. To collect escaping hydraulic oil, lay a cloth under separating point.
Remove bolt -1- and disconnect power steering hydraulic oil line.
Note. To prevent dirt from entering, seal open lines and connections with clean plugs or protective caps. Ignore -arrow-.
Remove nut -1- and remove bracket with wiring harness from subframe.
Note. The illustration shows the installation position with the engine installed.
Engage lifting tackle 2024 A on engine lifting eyes and on shop crane as shown in the illustration.
Note. To be aligned to the center of gravity of the engine assembly, the hole rails of the lifting hook must be inserted as shown in the illustration.
| WARNING | Risk of accident. Lifting hooks and alignment pins on lifting tackle must be secured with securing pins -arrows-. |
Tension engine slightly with shop crane, do not raise.
Remove left engine mount bolt -3-.
Note. The illustration shows the installation position with the engine installed. Ignore -1, 2, 4-.
Remove right engine mount bolt -2-.
Note. The illustration shows the installation position with the engine installed. Ignore -1, 3, 4-.
Remove joint support VAS 6131/13-7 from engine.
Raise engine from engine carrier.
Remove bolts -arrows- and left engine support.
Remove nut -1- and free up ground (GND) wire at engine support.
Remove bolts -arrows- and right engine support.
Secure starter on engine.
Secure engine to engine and transmission holder VAS 6095 using bracket VAS 6095/1-5 and tighten to 40 Nm, as shown in the illustration.
ENGINE, INSTALLING - AUTOMATIC TRANSMISSION
Tightening Specifications
Note. Tightening specifications only apply to lightly greased, oiled, phosphated or blackened nuts and bolts. Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not. Do not use any parts that have had the lubrication removed. Tolerance for tightening specifications ±15%.
Tightening specifications ENGINE MOUNT ASSEMBLY OVERVIEW .
| Component | Nm | ||
|---|---|---|---|
| Bolts and nuts | M6 | 9 | |
| M7 | 15 | ||
| M8 | 20 | ||
| M10 | 40 | ||
| M12 | 65 | ||
| Exceptions | |||
| Ground pins to strut tower | 9 | ||
Securing engine to transmission
| Item | Bolt | Nm |
|---|---|---|
| 1 | M10 x 50 1) | 65 |
| 2 to 6 | M12 x 100 2) | 30 + 105° |
| 7 | M12 x 125 2) | 30 + 105° |
| 8, 11 | M10 x 60 2) | 15 + 105° |
| 9, 10 | M10 x 95 2) | 15 + 105° |
| A | Alignment sleeves for centering | |
| 1) Bolt class 10.9. 2) Replace bolts. | ||
| (1) To avoid damaging the bolts when marking them, do not clamp them in a vise. Insert bolt in a 14 mm socket with a / 2 inch drive ratchet which is clamped into a vise, as shown in the illustration. | ||
| (1) | To avoid damaging the bolts when marking them, do not clamp them in a vise. Insert bolt in a 14 mm socket with a / 2 inch drive ratchet which is clamped into a vise, as shown in the illustration. |
- Aluminum bolts -2 through 11- may be used twice. After using the bolts once, mark them with an "X" made by a chisel -arrow-.
- Do not used bolts marked with an "X" again.
- There is no limit to the number of times the steel bolt -1- can be used.
Procedure
Proceed as follows
Note. Replace bolts which have been tightened to torque. Replace self-locking nuts and bolts as well as sealing rings, seals and O-rings. Secure all hose connections with hose clamps appropriate for the model. During installation, all cable ties must be reinstalled at the same location.
Check if alignment sleeves for centering the engine and transmission are in the cylinder block and insert them if they are not.
Clean threaded holes in the cylinder block for connecting engine and transmission using a thread tap before installing transmission.
When joining the engine and subframe, hold ATF lines in their installation position.
Install engine supports and engine mount ENGINE MOUNT ASSEMBLY OVERVIEW .
Position transmission on engine and tighten bolts -1 through 11-.
Note. Ignore -A-.
Tighten torque converter bolts -arrow- on drive plate in two stages while turning crankshaft 60 degrees Removal and Installation .
Install starter Removal and Installation .
Install power steering hydraulic oil lines Removal and Installation .
Install left and right drive axles on transmission flange shafts Removal and Installation .
Install catalytic converters: Left LEFT CATALYTIC CONVERTER , right RIGHT CATALYTIC CONVERTER .
Raise engine/transmission assembly using scissor lift table VAS 6131 A.
Align subframe and transmission carrier using marks made on longitudinal members during removal.
Tighten subframe bolts only to tightening specifications, do not tighten them further (tighten bolts only after axle alignment) Removal and Installation .
| WARNING | Risk of accident due to loose connections. If the bolts in the subframe are not tightened to final torque, vehicle must not be driven. |
Tighten tunnel crossmember bolts -arrow- DESCRIPTION AND OPERATION .
The rest of installation is in reverse order of removal, note the following
Install universal joint on steering gear Description and Operation .
Install drive shaft Removal and Installation .
Install front muffler FRONT MUFFLER .
Install exhaust system free of stress EXHAUST SYSTEM, INSTALLING .
Install subframe cross brace, upper control arm and stabilizer bar and tighten suspension strut on control arm Description and Operation .
Install brake caliper Description and Operation
Install Engine Control Module (ECM) Removal and Installation .
Electrical connections and routing, refer to appropriate SYSTEM WIRING DIAGRAM.
Install electrical wires, terminal 30 wire junction 2 -TV22- and engine compartment E-box cover Wiring .
Install tower brace Description and Operation .
Install washer fluid reservoir filler tube Removal and Installation .
Install refrigerant lines Removal and Installation .
Follow measures after connecting battery Removal and Installation .
| CAUTION | Risk of destroying control modules with excess voltage. Do not use a battery charger for starting assistance! |
Install air filter housing Description and Operation .
Install lock carrier braces Description and Operation .
Fill engine oil and check the oil level ENGINE OIL, CHECKING LEVEL .
Before starting engine for the first time, check hydraulic oil in power steering reservoir Diagnosis and Testing .
Note. Power-steering pump must not run dry.
Connect coolant hose to connector on radiator (Scheme 185)
Fill with coolant COOLING SYSTEM, DRAINING AND FILLING .
Note. Do not use drained coolant in the following situations: If cylinder head or cylinder block was replaced. If coolant is contaminated.
Fill refrigerant circuit DESCRIPTION AND OPERATION .
Align subframe Description and Operation .
Perform axle alignment Description and Operation .
| WARNING | Risk of accident due to loose connections. Tighten subframe bolts to specification after performing axle alignment. |
Install noise insulation and wheel housing liners Description and Operation .
LEFT ENGINE MOUNT
Special tools and workshop equipment required
- Engine support bridge 10 - 222 A
- Engine support supplement set T40093
REMOVING
Proceed as follows
Place used oil collecting and extracting device V.A.G 1782 under engine.
Remove bolts -arrows- and lay aside oil cooler with coolant hoses -1- and -2- connected.
Scheme 194
On vehicles with after-run coolant pump -V51-, remove it AFTER-RUN COOLANT PUMP , and oil cooler OIL COOLER .
Remove air conditioner compressor Removal and Installation .
Remove rear engine cover -top arrows-.
Position engine support bridge 10 - 222 A on left and right suspension strut tower with engine support basic set T40091/3 as shown in the illustration.
Scheme 195
Engage spindle 10 - 222 A /11 on right engine lifting eye.
Install additional engine support bridge 10 - 222 A components as shown in the illustration. Position supports T40093/3 on notches on longitudinal members.
Scheme 196
Engage spindle 10 - 222 A /11 on left engine lifting eye.
Lightly pretension engine with spindles.
Remove left subframe bolt -2-.
Note. The left subframe bolts -1- and -3- and all the right subframe bolts remain installed.
Remove left engine mount bolts -1-, -3- and -4-.
Lay aside left engine mount retaining plate -2-.
Remove left engine mount.
INSTALLING
- Tightening specifications «ENGINE MOUNT ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-engine-assembly-engine-codes-cala-coupe-as-of-112007) .
Installation is in reverse order of removal, note the following
Note. Replace bolts which have been tightened to specification.
Tighten subframe Description and Operation .
Install oil cooler OIL COOLER .
Install A/C compressor Removal and Installation .
Install after-run coolant pump -V51- AFTER-RUN COOLANT PUMP .
RIGHT ENGINE MOUNT
Special tools and workshop equipment required
- Engine support bridge 10 - 222 A
Proceed as follows
Remove rear engine cover -top arrows-.
Position engine support bridge 10 - 222 A on left and right suspension strut tower as shown in the illustration.
Scheme 197
Engage spindle 10 - 222 A /11 on right engine lifting eye and tension it slightly.
Remove right front wheel.
Remove right front wheel housing liner Description and Operation .
Remove noise insulation by loosening fasteners -1- and -2-.
Remove nut -1- and remove bracket with wiring harness from subframe.
Remove bolts -1, 2 and 4- and lay right engine mount retaining plate -3- aside.
In vehicles with automatic transmission, remove bolt -arrow- on the ATF line bracket.
Raise engine by dimension -a- using spindle 10 - 222 A /11.
Scheme 198
- Dimension -a- = approximately 20 mm.
Remove right engine mount.
- Tightening specifications «ENGINE MOUNT ASSEMBLY OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-engine-assembly-engine-codes-cala-coupe-as-of-112007) .
Installation is in reverse order of removal, note the following
Install noise insulation and the wheel housing liners. Description and Operation .
SPECIAL TOOLS
Special tools and workshop equipment required
Scheme 199
Scheme 200
Scheme 201
Scheme 202
Scheme 203
Scheme 204
- Assembly aid T40169
- Bracket T40170
- Support set VAS 6131/10, supplementary set VAS 6131/13 and transmission support VAS 6131/14
- Pry lever - rmv outside mirror 80 - 200
- Counterhold tool T10172 with T10172/5
- Puller T40160
- Adapter T40058
- Engine support bridge 10 - 222 A
- Engine support supplement set T40093
Scheme 205
Special tools and workshop equipment required
- Old oil collecting and extracting device V.A.G 1782
- Hose clamp pliers V.A.G 1921
- Step ladder VAS 5085
- Scissor lift table VAS 6131 A with support set VAS 6131/10 and supplementary set VAS 6131/13
- Drip tray for workshop crane VAS 6208
Scheme 206
Special tools and workshop equipment required
- Lifting tackle 2024 A
- Engine and transmission holder VAS 6095 with V6 FSI engine holder VAS 6095/1-5
- Shop crane VAS 6100
- Lift arm extension for workshop crane VAS 6101
See also:
• BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM
• COOLING SYSTEM, DRAINING AND FILLING
• Description and Operation
• CLEAN WORKING CONDITIONS
• Description and Operation
• DRIVE PLATE NEEDLE BEARING
• Removal and Installation
• Removal and Installation
• Removal and Installation
• LEFT CATALYTIC CONVERTER
• Description and Operation
• Removal and Installation
• EXHAUST SYSTEM, INSTALLING
• Description and Operation
• Removal and Installation
• Wiring
• Removal and Installation
• Removal and Installation
• Description and Operation
• ENGINE OIL, CHECKING LEVEL
• DESCRIPTION AND OPERATION
• Description and Operation
• Removal and Installation
• DESCRIPTION AND OPERATION
• AFTER-RUN COOLANT PUMP
• OIL COOLER
• LEFT ENGINE MOUNT
• RIGHT ENGINE MOUNT
• ENGINE, REMOVING
• ENGINE AND TRANSMISSION, SEPARATING
• ENGINE MOUNT ASSEMBLY OVERVIEW
• ENGINE, REMOVING
• ENGINE AND TRANSMISSION, SEPARATING