3.2l - Engine Assembly - Engine Code(s): Cala (coupe) (as of 12.2008) Audi A5 I

ENGINE, WITH MANUAL TRANSMISSION

Note. With lock carrier installed, engine is removed downward together with the transmission and the subframe. Collect escaping coolant in a clean container for disposal or reuse. During installation, cable ties must be re-installed at the same location.

ENGINE, WITH MULTITRONIC TRANSMISSION

Note. With lock carrier installed, engine is removed downward together with the transmission and the subframe. Collect escaping coolant in a clean container for disposal or reuse. During installation, cable ties must be re-installed at the same location.

ENGINE, WITH AUTOMATIC TRANSMISSION

Note. With lock carrier installed, engine is removed downward together with the transmission and the subframe. Collect escaping coolant in a clean container for disposal or reuse. During installation, cable ties must be re-installed at the same location.

Scheme 207

1. Bolt 20 Nm
2. Mounting Plate For engine mount Replace when replacing the engine mount
3. Bolt 40 Nm
4. Engine Support
5. Bolt 10 Nm
6. Heat Shield
7. Bolt Replace 90 Nm plus an additional 90° turn
8. 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-122008__left-engine-mount) , right «RIGHT ENGINE MOUNT»(/audi/a5/i-2007-2011/remont/mechanical/#32l-engine-assembly-engine-codes-cala-coupe-as-of-122008__right-engine-mount) Replace in pairs on the left and right
9. Subframe
10. Bolt 55 Nm

FASTENER TIGHTENING SPECIFICATIONS

Scheme 208

Tighten ground bolt -1- to 9 Nm.

Scheme 209

Tighten the nut -arrow- to 9 Nm.

Scheme 210

GROUND BOLT TO STRUT TOWER - TIGHTENING SPECIFICATION

Tighten the ground bolt -1- to 9 Nm.

TIGHTENING SPECIFICATION FOR GROUND WIRES TO THE LONGITUDINAL MEMBER

Tighten the nut -arrow- to 9 Nm.

ENGINE TO MULTITRONIC TRANSMISSION 0AW

Tighten the ground bolt -1- to 9 Nm.

Tighten the nut -arrow- to 9 Nm.

ENGINE TO AUTOMATIC TRANSMISSION 0B6

ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER

Special tools and workshop equipment required

1. Lifting Tackle 2024 A
2. Engine and Transmission Holder VAS 6095 with V6 FSI Engine Holder VAS 6095/1-5
3. Shop Crane VAS 6100
4. Lift Arm Extension for Workshop Crane VAS 6101
5. Engine Bung Set VAS 6122

Procedure

1. The engine/transmission assembly must be removed and the engine and transmission must be separated.
2. Engine secured with joint support VAS 6131/13-7.

Disconnect electrical connector -arrow- on steering gear.

Scheme 211

Note. To collect escaping power steering fluid, lay a cloth under the separating point.

Remove threaded connection -3-.

Scheme 212

Seal the open lines and connections with clean plugs from the VAS 6122.

Note. The illustration shows the installation location on a vehicle with dynamic steering. Ignore -1 and 2- and -arrows-.

Remove the nut -1- and remove the bracket with the wiring harness from the subframe.

Scheme 213

Note. The illustration shows the installation position with the engine installed.

Engage the 2024 A on the engine lifting eyes and on the shop crane as shown in the illustration.

Scheme 214

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.

Tension engine slightly with shop crane, do not raise.

Remove the left engine mount bolt -3-.

Scheme 215

Note. The illustration shows the installation position with the engine installed. Ignore -1, 2 and 4-.

Remove the right engine mount bolt -2-.

Scheme 216

Note. The illustration shows the installation position with the engine installed. Ignore -1, 3 and 4-.

Remove joint support VAS 6131/13-7 from engine.

Scheme 217

Raise engine from engine carrier.

Remove bolts -arrows- and the left engine support.

Scheme 218

Remove nut -1- and free up the Ground (GND) cable at the engine support.

Scheme 219

Remove bolts -arrows- and the right engine support.

Secure the starter on the engine.

Secure the engine to the VAS 6095 using the VAS 6095/1-5 and tighten to 40 Nm, as shown in the illustration.

Scheme 220

LEFT ENGINE MOUNT

Note. Only replace engine mounts in pairs of left and right. The retaining plates for them must also be replaced.

Special tools and workshop equipment required

1. Engine Support Bridge 10 - 222 A
2. Used Oil Collecting and Extracting Device V.A.G 1782
3. Engine Support Basic Set T40091
4. Engine Support Supplement Set T40093

REMOVING

Place the V.A.G 1782 under the engine.

Remove the bolts -arrows- and lay aside the oil cooler with the coolant hoses -1- and -2- connected.

Scheme 221

On vehicles with the after-run coolant pump -V51-, remove it (refer to After-Run Coolant Pump -V51 ) and the oil cooler (refer to OIL COOLER ).

Remove air conditioner compressor. Refer to Removal and Installation .

Scheme 222

Remove the rear engine cover -top arrows-.

Scheme 223

Position the 10 - 222 A on the left and right suspension strut tower with the T40091/3 as shown in the illustration.

Scheme 224

Engage the 10 - 222 A /11 on the right engine lifting eye.

Install additional 10 - 222 A components as shown in the illustration. Position the supports T40093/3 on the notches on the longitudinal members.

Scheme 225

Engage the spindle 10 - 222 A /11 on the left engine lifting eye.

Lightly pretension engine with spindles.

Remove the left subframe bolt -2-.

Scheme 226

Note. The left subframe bolts -1- and -3- and all the right subframe bolts remain installed.

Remove the left engine mount bolts -1, 3 and 4-.

Move the left engine mount retaining plate -2- to the side.

Remove left engine mount.

INSTALLING

1. Tightening specifications. Refer to «SUBFRAME MOUNT OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-engine-assembly-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

Note. Replace bolts which have been tightened to torque.

Tighten subframe. Refer to Removal and Installation .

Install oil cooler. Refer to OIL COOLER .

Install A/C compressor. Refer to Removal and Installation .

Install After-Run Coolant Pump -V51-. Refer to After-Run Coolant Pump -V51 .

RIGHT ENGINE MOUNT

Note. Only replace engine mounts in pairs of left and right. The retaining plates for them must also be replaced.

Special tools and workshop equipment required

1. Engine Support Bridge 10 - 222 A

Remove rear engine cover -top arrows-.

Position 10 - 222 A on the left and right suspension strut tower as shown in the illustration.

Scheme 227

Engage the 10 - 222 A /11 on the right engine lifting eye and tension it slightly.

Remove right front wheel.

Remove right front wheel housing liner. Refer to Description and Operation .

Remove front noise insulation -1-. Refer to Description and Operation .

Scheme 228

Remove nut -1- and remove the bracket with the wiring harness from the subframe.

Remove bolts -1, 2 and 4- and move the right engine mount retaining plate -3- to the side.

Vehicles with the multitronic transmission 0AW or automatic transmission 0B6: remove the bolt -arrow- on the ATF line bracket.

Scheme 229

Raise the engine by dimension -a- using the 10 - 222 A /11.

Scheme 230

1. Dimension -a- = Approximately 20 mm.

Remove right engine mount.

1. Tightening specifications. Refer to «SUBFRAME MOUNT OVERVIEW»(/audi/a5/i-2007-2011/remont/mechanical/#32l-engine-assembly-engine-codes-cala-coupe-as-of-122008) .

Installation is in reverse order of removal, note the following

Install the wheel housing liner and noise insulation. Refer to Description and Operation .

Mount front wheel. Refer to General Information .

ENGINE, REMOVING - MANUAL TRANSMISSION 0B2 AND 0B4

Special tools and workshop equipment required

1. Used Oil Collecting and Extracting Device V.A.G 1782
2. Hose Clamp Pliers V.A.G 1921
3. Step Ladder VAS 5085
4. Scissor Lift Table VAS 6131 A with Support Set VAS 6131/10 and Supplementary Set VAS 6131/13
5. Drip Tray for Workshop Crane VAS 6208
6. Pry Lever - Rmv Outside Mirror 80 - 200
7. Engine Bung Set VAS 6122
8. Counterhold Tool T10172 with T10172/5 for vehicles with AWD
9. Puller T40160

Procedure

Reduce fuel pressure in high pressure area. Refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

Position the front wheels so they are straight.

Note. Release the electrical parking brake before disconnecting battery so the driveshaft can be rotated to remove it.

Switch off ignition and remove ignition key.

Disconnect the Ground (GND) cable -2- from the battery terminal. Refer to Removal and Installation .

Scheme 231

Empty coolant circuit. Refer to General Information .

Extract power steering oil from the reservoir with the V.A.G 1782.

Remove engine covers -arrows-.

Open coolant reservoir cap.

Remove the left and right front wheels.

Remove left and right front wheel housing liners. Refer to Description and Operation .

Remove noise insulation -1- and -2-. Refer to Description and Operation .

Place VAS 6208 under engine.

Scheme 232

Remove drain plug -1- and drain the coolant.

Lift the clip -2- and disconnect the coolant hose from the radiator.

Remove the coolant hose -arrows- from the oil cooler and drain the remaining coolant.

Scheme 233

Place the V.A.G 1782 under the disconnection point.

Scheme 234

Disconnect the power steering hydraulic oil supply line -2- and return line -1- in the left front wheel housing and free them up.

Seal the open lines and connections with clean plugs from the VAS 6122.

Vehicles with a Coolant Pump -V50

Disconnect electrical connector -1-.

Scheme 235

Place VAS 6208 under engine.

Remove coolant hose from the coolant pump -V50- -right arrow-.

Note. Ignore -2- and -left arrow-.

All Vehicles

Push the retainer back -arrow-, press the release down and disconnect the radiator fan connectors -1 and 2-, if applicable.

Scheme 236

Free up electrical wiring harness.

Disconnect the connector -3- on the Secondary Air Injection (AIR) pump motor -V101-, if applicable, and free up the wire.

Scheme 237

Note. Ignore -1 and 2-.

Remove the left and right bolt -1- and nut -3- and the lock carrier brace -2-.

Scheme 238

Remove nut -arrow- on the right longitudinal member and free up the Ground (GND) cable.

Remove seal -arrow-.

Scheme 239

Remove plenum chamber cover. Refer to Removal and Installation .

Remove vacuum connection -2- from the bulkhead by pulling the vacuum hose -1- on the rear side.

Scheme 240

Free up the fuel line and wire to the EVAP canister at the air guide pipe.

Disconnect the electrical connector -3- on Evaporative Emission (EVAP) canister purge regulator valve 1 -N80- and disconnect the vacuum hose -4-.

Disengage EVAP canister purge regulator valve 1 -- from the bracket and lay it aside with the hoses connected.

Remove air duct -arrow-.

Scheme 241

Free up the fuel hose -1- on the air duct pipe.

Scheme 242

Remove the vacuum hose -3- from the connection on the air guide pipe.

Remove the air guide pipe by loosening the hose clamp -4- and opening the clips -arrows-.

Note. Ignore -2-.

Disconnect vacuum line -1-.

Scheme 243

Remove the air filter housing and, if applicable, disconnect the electrical connector -2- on the rear side at the intake air switch-over valve -N335-.

Remove the fuel supply line from the high pressure pump -arrow- and lay it aside.

Scheme 244

Seal the open lines and connections with clean plugs from the VAS 6122.

Disconnect the vacuum hose -1- and free it up, if applicable.

Scheme 245

Remove coolant hose -2- from the upper coolant pipe by lifting the retaining clamp.

In vehicles without a coolant pump --, lift the clamp -arrow- and remove the right front coolant hose from the front coolant pipe.

Scheme 246

Remove the coolant hose -arrow- from the front coolant pipe by lifting the retaining clamp.

Scheme 247

Remove coolant hose -3- from the coolant reservoir and free it up.

Scheme 248

Remove bolts -arrows-, disconnect the electrical connector on the Engine Coolant Level (ECL) warning switch -F66- and lay the coolant reservoir aside with the coolant hoses -1- and -2- attached.

Disconnect the electrical connector -arrow- on the power steering pump, if applicable.

Scheme 249

Press hydraulic oil hose to the side.

Remove bolts -arrows- and the refrigerant lines from the A/C compressor.

Scheme 250

Seal the open lines and connections with clean plugs from the VAS 6122.

Release the retainer -arrow A- and open the cover -arrow B-.

Scheme 251

Remove nuts -1 and 2- for the electrical wires.

Scheme 252

Remove the electrical connector -3- from the bracket and disconnect it.

Remove the bolt -4- and the Terminal 30 Wire Junction 2 -TV22- from the tower brace -arrow-.

Release the retainers from the wheel housing side using a 5.5 mm open end wrench -1- and remove the wiring bushing -2- upward.

Scheme 253

Free up the wiring harness -3- to the generator and starter using the 80 - 200.

Wiring duct version 1: Free up the wiring duct by releasing the retainer -arrow B- and pulling the duct forward -arrow A-.

Scheme 254

Wiring duct version 2: Open the catch -arrow-, free up the wiring harness and open the wiring duct -1-.

Scheme 255

Remove the nut -1- and tilt -arrow A- the washer fluid reservoir filler neck -2- upward slightly.

Scheme 256

Remove the filler neck with the filler tube from the washer fluid reservoir and the opening in the body -arrow B-.

Remove the bolts -1- and nuts -2- and the tower brace -3-.

Scheme 257

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

Scheme 258

Remove the nut -1- and free up the electrical wire.

Release the retainers -A arrows- and remove the engine control module -arrow B-.

Scheme 259

Disconnect the electrical connector -2- if applicable.

Scheme 260

Disconnect the electrical connectors -4- and remove the nut -3- for the electrical wire.

Release the retainers -arrow- and remove the relay carrier with the fuse holder -1-.

Disengage engine wiring harness at the engine compartment E-box and free it up.

Release retainers -A arrows- and remove the wiring bushing -2- upward -arrow B-.

Remove the ground pin -1- and free up the electrical wire.

Lay the wiring harness on the engine and secure the engine control module against falling down.

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

Scheme 261

Disconnect the electrical connector -1- on the left front level control system sensor -G78- and right front level control system sensor -G289- and free up the electrical wiring -arrow-.

Scheme 262

Free up the electrical connector -2- on the bracket by pulling the retainer back -arrow A- and turning the connector approximately 90° clockwise -arrow B-.

Scheme 263

Free up the electrical wiring -3- and brake line -4- on the bracket.

Remove the bolts -1- and secure the brake caliper in the wheel housing using wire.

Remove nut -2- and bolt -1-.

Scheme 264

Remove the upper control arm upward from the wheel bearing housing -arrows-.

Repeat the procedure on the other side of the vehicle.

A5 through VIN 8T-8-011200

Remove left and right stabilizer bar bolt -3-.

Scheme 265

Remove left and right nuts -1-.

Note. The bolts -2- will be removed later.

All A4, A5 from VIN: 8T-8-011201

Remove left and right stabilizer bar bolt -1-.

Scheme 266

Remove left and right nuts -3-.

Note. The bolts -2- will be removed later.

All Vehicles

All A4, A5 Coupe

Remove nut -1- for the power steering hydraulic fluid line bracket.

Scheme 267

Remove bolts -arrows- and the subframe crossbrace.

Note. The illustration shows the installation location on a vehicle with dynamic steering.

A5 Cabriolet

Remove left and right bolts -1 and 2- and the brace.

Scheme 268

Remove bolt -2- for the power steering hydraulic fluid line bracket.

Scheme 269

Remove bolts -1- and -arrows- and the subframe crossbrace.

All Vehicles

Remove left and right bolts -arrows-, if applicable, and the heat shield -1-.

Scheme 270

Remove bolts -arrows- and the front crossmember, if applicable.

Scheme 271

Remove left front muffler nuts -arrows-.

Scheme 272

Remove right front muffler nuts -arrows-.

Scheme 273

Loosen the clamping sleeves -1 and 2-, slide them back and remove the left and right front mufflers.

Scheme 274

Remove bolts -arrows- and the driveshaft heat shield -1-, if applicable.

Scheme 275

Remove the bolts connecting the driveshaft to the transmission while holding using a T10172 with T10172/5.

Scheme 276

Slide the driveshaft toward the rear final drive; the CV joints can move axially.

Secure the driveshaft to the side.

Remove universal joint bolt -arrow- Description and Operation .

Scheme 277

Press the CV joint off the steering gear and slide it all the way up.

Remove the bolt -2- and secure the clutch slave cylinder sideways in the engine compartment.

Scheme 278

Remove selector rod nut -1-.

Position the T40160 and remove the selector rod -1-.

Scheme 279

Prepare scissor lift platform

Scheme 280

Equip the Scissor Lift Table VAS 6131 A with the Support Set VAS 6131/10 and Supplementary Set VAS 6131/13 as follows

Next secure mounting elements to scissor lift table by hand.

Position the VAS 6131 A horizontally.

1. Note bubble level (sight glass) on support platform.

Guide the VAS 6131 A under the engine/transmission assembly.

Remove left and right subframe bolts -1-.

Attach the mounting elements from the VAS 6131/10 and VAS 6131/13 at the left and right front of the subframe as shown in the illustration.

Scheme 281

Ensure threaded spindles are completely installed.

Attach the mounting elements from the VAS 6131/10 at the left and right rear on the subframe crossbrace front connecting points as shown in the illustration.

Scheme 282

Attach mounting elements from the VAS 6131/13 at the lower left and right of the wheel bearing housing as shown in the illustration.

Scheme 283

Remove noise insulation retaining clips from the crossmember.

Scheme 284

Attach the mounting elements from the VAS 6131/10 at the left and right rear of the crossmember as shown in the illustration.

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

Attach mounting element base plates to VAS 6131 A and tighten to 20 Nm.

Mark the location of the subframe and engine carrier to the 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 the tunnel crossmember.

Scheme 285

A5 through VIN 8T-8-011200

Remove left and right bolts -2-.

All A4, A5 from VIN: 8T-8-011201

Remove left and right bolts -2-.

All Vehicles

Next lower engine/transmission assembly with VAS 6131 A only by dimension -a-.

Scheme 286

1. Dimension -a- = 100 mm maximum.

Remove the bolts -1- and -3- for the selector rod and push rod.

Scheme 287

Note. Ignore -2-.

Lower engine/transmission assembly more.

Remove VAS 6131 A with engine/transmission assembly under vehicle.

ENGINE AND MANUAL TRANSMISSION, SEPARATING - MANUAL TRANSMISSION 0B2 AND 0B4

Special tools and workshop equipment required

1. Scissor Lift Table VAS 6131 A
2. Support Set VAS 6131/10, Supplementary Set VAS 6131/13 and Transmission Support VAS 6131/14
3. Adapter T40058

Procedure

1. Engine/transmission assembly removed and placed on VAS 6131 A.

Remove the electrical connector -1- for the Oxygen Sensor (O2S) 2 after catalytic converter -G131- from the bracket and disconnect it.

Scheme 288

Note. Ignore items -2, 3 and 4- and the -arrows-.

Remove the nuts -arrows- and the bolt -1- and the left catalytic converter.

Scheme 289

Remove electrical connector -1- for the O2S) after Catalytic Converter -- from the bracket and disconnect it.

Scheme 290

Note. Ignore items -2, 3 and 4- and the -arrows-.

Remove nuts -arrows- and bolt -1- and the right catalytic converter.

Scheme 291

Disconnect electrical connector -2- on the Engine Speed (RPM) sensor -G28- and free up the electrical wiring.

Scheme 292

Note. Ignore -1-.

Disconnect electrical connector -2- on back-up lamp switch -F4-.

Note. Ignore -1 and 3-.

Remove left and right drive axles from the transmission flange shafts.

Scheme 293

Remove bottom cover -1- from the transmission -arrow-.

Scheme 294

Insert T40058 guide pins as follows

Scheme 295

1. The large diameter -arrow 1- faces the engine.
2. Small diameter -arrow 2- points to adapter.

To loosen the crankshaft, counter hold the drive plate bolts using the T40058.

Scheme 296

Note. Only turn the crankshaft in the direction of engine rotation -arrow-.

Remove the 6 clutch module bolts -arrow- by turning the crankshaft 60° in the direction of engine rotation.

Scheme 297

Equip the scissor lift table VAS 6131 A with the support set VAS 6131/10, supplementary set VAS 6131/13 and transmission support VAS 6131/14 as follows

Note. The other attachments remain unchanged.

Install the joint support VAS 6131/13-7 at the front right of the engine in the threaded hole as shown in the illustration.

Install the VAS 6131/13-7 on the scissor lift table and tighten it to 20 Nm.

Attach the mounting elements from the VAS 6131/10 and transmission support VAS 6131/14 at the front of the transmission as shown in the illustration.

Scheme 298

Rotate left and right spindles up until the VAS 6131/14 rests firmly against the transmission.

Attach mounting element base plates to VAS 6131 A and tighten to 20 Nm.

Remove the starter bolts -1- and -2-.

Press the starter off the transmission and leave it in the installation position.

Remove remaining bolts -3 through 11- connecting the engine to the transmission.

Note. Ignore -A-.

Loosen clamping bolts -1- on sides of VAS 6131 A and pull rear table plate with transmission toward rear -arrow-.

Scheme 299

ENGINE, INSTALLING - MANUAL TRANSMISSION 0B2 AND 0B4

Special tools and workshop equipment required

1. Assembly Aid T40169
2. Transportation Lock T40170
3. Scissor Lift Table VAS 6131 A
4. Socket T40058
5. Ring Spanner Insert AF 16 V.A.G 1332/14

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%.

Subframe mount. Refer to SUBFRAME MOUNT OVERVIEW .

Tighten the ground bolt -1- to 9 Nm.

Tighten nut -arrow- to 9 Nm.

Engine to Manual Transmission

Scheme 300

1. Audi A4 from VIN 8K-9-066500, Audi A5 from VIN 8T-9-008000: The aluminum bolts -2 through 11- may be used two times. After using the bolts once, mark them with an "X" made by a chisel -arrow-.
2. Do not used bolts marked with an "X" again.

Procedure

Note. Replace bolts which have been tightened to torque. Replace self-locking nuts and bolts as well as sealing rings, seals and O-rings. In vehicles with manual transmissions, there is a needle bearing in the drive plate. Check if the needle bearing is inserted before installing. Refer to NEEDLE BEARING ON DRIVE PLATE . Secure all hose connections with hose clamps appropriate for the model. In order to be able to securely mount the air guide hoses on their connectors, spray the bolts on the previously used clamps with a rust remover. During installation, all cable ties must be re-installed at the same location.

Install engine supports and engine mount. Refer to SUBFRAME MOUNT OVERVIEW .

Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.

Complete the following steps before connecting the engine and transmission

Insert the T40169 into the transmission housing and clutch module from underneath as illustrated.

Scheme 301

1. The assembly aid must engage in the semi-circular 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.

Install the assembly aid bolt into the hole on the transmission housing.

Install the T40170 into the transmission housing from underneath and secure it to the flange shaft -1-.

Scheme 302

Make sure the alignment sleeves -A- for centering the engine and transmission in the cylinder block are present. Insert the alignment sleeves if they are missing.

Determine if the engine/transmission aluminum bolts can be used again and mark them if necessary ENGINE, INSTALLING .

Position the transmission on the engine and tighten the bolts -1 through 11-.

Remove the T40170 and T40169.

Note. The following procedure is necessary to assure that the clutch module contacts the drive plate evenly and does not get bent.

Insert T40058 guide pins as follows

1. The large diameter -arrow 1- faces the engine.
2. Small diameter -arrow 2- points to adapter.

Rotate the crankshaft one complete rotation (360°) in engine rotation direction -arrow- with the T40058.

Scheme 303

1. The inspection hole -arrow- must be visible through the opening in the transmission housing.

Secure the clutch module to the drive plate as follows

Note. Tighten the bolt with the V.A.G 1332/14.

Install the first bolt -arrow- by hand (2 Nm).

Rotate the crankshaft with the T40058 180° in direction of engine rotation -arrow-.

Tighten the bolts that are accessible in this position to the tightening specification. Refer to Removal and Installation .

Turn the crankshaft 60° further and tighten the remaining 5 bolts to the tightening specification. Refer to Removal and Installation .

Install the power steering hydraulic oil lines. Refer to Description and Operation .

Install the catalytic converters. Refer to: Left LEFT CATALYTIC CONVERTER, MANUAL TRANSMISSION , right RIGHT CATALYTIC CONVERTER, MANUAL OR MULTITRONIC TRANSMISSION .

Install the left and right drive axles on the transmission flange shafts. Refer to Removal and Installation .

Next, raise engine/transmission assembly high enough using VAS 6131 A until dimension -a- is reached between subframe and body.

1. Dimension -a- = at least 100 mm.

Install shift rod and pivot rod. Refer to Description and Operation .

Continue raising the engine/transmission assembly using the VAS 6131 A.

Align the subframe and transmission carrier using the marks made on the longitudinal members during removal.

Tighten the subframe bolts only to the tightening specifications, do not tighten them further (tighten the bolts only after axle alignment). Refer to Removal and Installation .

Tighten the tunnel crossmember bolts -arrow-. Refer to Removal and Installation .

The rest is in reverse order of removal, note the following

Install clutch slave cylinder. Refer to Removal and Installation .

Install universal joint on the steering gear. Refer to Description and Operation .

Install driveshaft. Refer to Removal and Installation or Removal and Installation .

Install front muffler. Refer to FRONT MUFFLER .

Install exhaust system free of stress. Refer to EXHAUST SYSTEM, INSTALLING .

Install front crossmember. Refer to Removal and Installation .

Install subframe crossbrace, upper control arm and stabilizer bar and tighten the suspension strut on the control arm. Refer to Removal and Installation .

Install brake caliper. Refer to Removal and Installation .

Install Engine Control Module (ECM). Refer to Removal and Installation .

Electrical connections and routing. Refer to appropriate SYSTEM WIRING DIAGRAM.

Install wires, terminal 30 wire junction 2 -TV22- and the engine compartment E-box cover. see scheme 117, see scheme 118 Refer to Removal and Installation.

Install tower brace. Refer to Removal and Installation .

Install washer fluid reservoir filler tube. Refer to Removal and Installation .

Install refrigerant lines. Refer to Removal and Installation .

Follow measures after connecting battery. Refer to Removal and Installation .

Install air filter housing. Refer to Description and Operation .

Install lock carrier braces. Refer to Description and Operation .

Fill the engine oil and check the oil level. Refer to Maintenance, Diagnosis ..

Before starting engine for the first time, check the fluid level in power steering reservoir. Refer to General Information .

Note. Power-steering pump must not run dry.

Connect coolant hose with the connector coupling. (Scheme 304)

Scheme 304

Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Note. Do not use drained coolant in the following situations: If the cylinder head or cylinder block was replaced. If the coolant is contaminated.

Fill refrigerant circuit. Refer to General Information .

Install wheel housing liners. Refer to Description and Operation .

Install front wheels and perform an alignment. Refer to General Information .

Install noise insulation. Refer to Description and Operation .

ENGINE, REMOVING - MULTITRONIC TRANSMISSION 0AW

Special tools and workshop equipment required

1. Used Oil Collecting and Extracting Device V.A.G 1782
2. Hose Clamp Pliers V.A.G 1921
3. Step Ladder VAS 5085
4. Scissor Lift Table VAS 6131 A with Support Set VAS 6131/10 and Supplementary Set VAS 6131/11 and VAS 6131/13
5. Drip Tray for Workshop Crane VAS 6208
6. Pry Lever - Rmv Outside Mirror 80 - 200
7. Engine Bung Set VAS 6122

Procedure

Reduce fuel pressure in high pressure area. Refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

Position the front wheels so they are straight.

Switch off ignition and remove ignition key.

Disconnect the Ground (GND) cable -2- from the battery terminal. Refer to Removal and Installation .

Empty coolant circuit. Refer to General Information .

Extract the power steering oil from the reservoir with the V.A.G 1782.

Remove engine covers -arrows-.

Open coolant reservoir cap.

Remove the left and right front wheels.

Remove left and right front wheel housing liners. Refer to Description and Operation .

Remove noise insulation -1- and -2-. Refer to Description and Operation .

Place VAS 6208 under engine.

Remove drain plug -1- and drain the coolant.

Lift the clip -2- and disconnect the coolant hose from the radiator.

Remove the coolant hose -arrows- from the oil cooler and drain the remaining coolant.

Place V.A.G 1782 under the disconnection point.

Disconnect power steering hydraulic oil supply line -2- and return line -1- in the left front wheel housing and free them up.

Seal the open lines and connections with clean plugs from the VAS 6122.

Place V.A.G 1782 under the disconnection point.

Mark the locations of the ATF lines -1- and -2- so they can be installed later and then disconnect them.

Seal the open lines and connections with clean plugs from the VAS 6122.

Note. Disregard -arrow-.

Vehicles with a Coolant Pump -V50

Disconnect electrical connector -1-.

Place VAS 6208 under engine.

Remove coolant hose from the coolant pump -V50- -right arrow-.

Note. Ignore -2- and -left arrow-.

All Vehicles

Push the retainer back -arrow-, press the release down and disconnect the radiator fan connectors -1 and 2-, if applicable.

Free up electrical wiring harness.

Disconnect the connector -3- on the Secondary Air Injection (AIR) pump motor -V101-, if applicable, and free up the wire.

Note. Ignore -1 and 2-.

Remove left and right bolt -1- and nut -3- and the lock carrier brace -2-.

Remove nut -arrow- on the right longitudinal member and free up the Ground (GND) cable.

Remove seal -arrow-.

Remove plenum chamber cover. Refer to Removal and Installation .

Remove vacuum connection -2- from the bulkhead by pulling the vacuum hose -1- on the rear side.

Free up the fuel line and wire to the EVAP canister at the air guide pipe.

Disconnect the electrical connector -3- on Evaporative Emission (EVAP) Canister Purge Regulator Valve 1 -N80- and disconnect the vacuum hose -4-.

Disengage the EVAP canister purge regulator valve 1 -- from the bracket and lay it aside with the hoses connected.

Remove air duct -arrows-.

Free up fuel hose -1- on the air duct pipe.

Remove vacuum hose -3- from the connection on the air guide pipe.

Remove air guide pipe by loosening the hose clamp -4- and opening the clips -arrows-.

Note. Ignore -2-.

Disconnect vacuum line -1-.

Remove the air filter housing and, if applicable, disconnect the electrical connector -2- on the rear side at the intake air switch-over valve -N335-.

Remove the fuel supply line from the high pressure pump -arrow- and lay it aside.

Seal the open lines and connections with clean plugs from the VAS 6122.

Disconnect the vacuum hose -1- and free it up, if applicable.

Remove coolant hose -2- from the upper coolant pipe by lifting the retaining clamp.

In vehicles without a coolant pump -- and with an auxiliary heater, lift the clamp and remove the right front coolant hose -arrow- from the front coolant pipe.

Remove coolant hose -arrow- from the front coolant pipe by lifting the retaining clamp.

Remove coolant hose -3- from the coolant reservoir and free it up.

Remove bolts -arrows-, disconnect the electrical connector on the Engine Coolant Level (ECL) warning switch -F66- and lay the coolant reservoir aside with the coolant hoses -1 and 2- attached.

Disconnect electrical connector -arrow- on the power steering pump, if applicable.

Press hydraulic hose down slightly.

Remove bolts -arrows- and the refrigerant lines from the A/C compressor.

Seal the open lines and connections with clean plugs from the VAS 6122.

Release retainer -arrow A- and open the cover -arrow B-.

Remove nuts -1 and 2- for the electrical wires.

Remove electrical connector -3- from the bracket and disconnect it.

Remove bolt -4- and terminal 30 wire junction 2 -TV22- from the tower brace -arrow-.

Release retainers from the wheel housing side using a 5.5 mm open end wrench -1- and remove the wiring bushing -2- upward.

Free up the wiring harness -3- to the generator and starter using the 80 - 200.

Wiring duct version 1: Free up the wiring duct by releasing the retainer -arrow B- and pulling the duct forward -arrow A-.

Wiring duct version 2: Open the catch -arrow-, free up the wiring harness and open the wiring duct -1-.

Remove the nut -1- and tilt -arrow A- the washer fluid reservoir filler neck -2- upward slightly.

Remove the filler neck with the filler tube from the washer fluid reservoir and the opening in the body -arrow B-.

Remove the bolts -1- and nuts -2- and the tower brace -3-.

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

Remove nut -1- and free up the electrical wire.

Release retainers -A arrows- and remove the 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 the relay carrier with the fuse holder -1-.

Disengage the engine wiring harness at the engine compartment E-box and free it up.

Release retainers -A arrows- and remove the wiring bushing -2- upward -arrow B-.

Remove Ground (GND) pin -1- and free up the electrical wire.

Lay the wiring harness on the engine and secure the engine control module against falling down.

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

Disconnect the electrical connector -1- on the left front level control system sensor -G78- and right front level control system sensor -G289- and free up the electrical wiring -arrow-.

Free up the electrical connector -2- on the bracket by pulling the retainer back -arrow A- and turning the connector approximately 90° clockwise -arrow B-.

Free up the electrical wiring -3- and brake line -4- on the bracket.

Remove bolts -1- and secure the brake caliper in the wheel housing using wire.

Remove nut -2- and bolt -1-.

Remove upper control arm upward from the wheel bearing housing -arrows-.

Repeat procedure on the other side of the vehicle.

A5 through VIN 8T-8-011200

Remove left and right stabilizer bar bolt -3-.

Remove left and right nuts -1-.

Note. The bolts -2- will be removed later.

All A4, A5 from VIN: 8T-8-011201

Remove left and right stabilizer bar bolt -1-.

Remove left and right nuts -3-.

Note. The bolts -2- will be removed later.

All Vehicles

All A4, A5 Coupe

Remove nut -1- for the power steering hydraulic fluid line bracket.

Remove bolts -arrows- and subframe crossbrace.

Note. The illustration shows the installation location on a vehicle with dynamic steering.

A5 Cabriolet

Remove left and right bolts -1 and 2- and the brace.

Remove bolt -2- for the power steering hydraulic fluid line bracket.

Remove bolts -1- and -arrows- and the subframe crossbrace.

All Vehicles

Remove the left and right bolts -arrows-, if applicable, and the heat shield -1-.

Remove bolts -arrows- and front crossmember, if applicable.

Remove left front muffler nuts -arrows-.

Remove right front muffler nuts -arrows-.

Loosen clamping sleeves -1 and 2-, slide them back and remove the left and right front mufflers.

Remove universal joint bolt -arrow-. Refer to Description and Operation .

Press the CV joint off the steering gear and slide it all the way up.

Remove the selector lever cable ball socket -A- from the selector shaft lever using the 80 - 200 -arrow-.

Scheme 305

Remove bracket bolts -2-.

Scheme 306

Note. Do not bend or kink the selector lever cable. Ignore -1- and -arrow-.

Prepare Scissor Lift Platform

Equip the Scissor Lift Table VAS 6131 A with the Support Set VAS 6131/10 and Supplementary Set VAS 6131/13 as follows

Next secure mounting elements to scissor lift table by hand.

Position the VAS 6131 A horizontally.

1. Note bubble level (sight glass) on support platform.

Guide the VAS 6131 A under the engine/transmission assembly.

Remove left and right subframe bolts -1-.

Attach the mounting elements from the VAS 6131/10 and VAS 6131/13 at the left and right front of the subframe as shown in the illustration.

Ensure threaded spindles are completely installed.

Attach mounting elements from the VAS 6131/10 at the left and right rear on the subframe crossbrace front connecting points as shown in the illustration.

Attach mounting elements from the VAS 6131/13 at the lower left and right of the wheel bearing housing as shown in the illustration.

Remove noise insulation retaining clips from the crossmember.

Attach mounting elements from the VAS 6131/10 at the left and right rear of the crossmember as shown in the illustration.

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

Attach mounting element base plates to VAS 6131 A and tighten to 20 Nm.

Mark the location of the subframe and engine carrier to the 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 the tunnel crossmember.

A5 through VIN 8T-8-011200

Remove left and right bolts -2-.

All A4, A5 from VIN: 8T-8-011201

Remove left and right bolts -2-.

All Vehicles

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 MULTITRONIC TRANSMISSION, SEPARATING - MULTITRONIC TRANSMISSION 0AW

Special tools and workshop equipment required

1. Scissor Lift Table VAS 6131 A
2. Support Set VAS 6131/10, Supplementary Set VAS 6131/13 and Transmission Support VAS 6131/14
3. Socket T40058
4. Ring Spanner Insert AF 16 V.A.G 1332/14

Procedure

1. Engine/transmission assembly removed and placed on VAS 6131 A.

Remove the electrical connector -arrow- for the Oxygen Sensor (O2S) 2 after catalytic converter -G131- from the bracket, disconnect it and lay it aside.

Note. Ignore items -2, 3 and 4- and the -arrows-.

Remove nuts -arrows- and bolt -1- and the left catalytic converter.

Remove electrical connector -1- for the Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130- from the bracket and disconnect it.

Note. Ignore items -2, 3 and 4- and the -arrows-.

Remove nuts -arrows- and the bolt -1- and the right catalytic converter.

Disconnect electrical connector -2- on the Engine Speed (RPM) sensor -G28- and free up the electrical wiring.

Note. Ignore -1-.

Disconnect electrical connector on transmission by rotating twist lock counter-clockwise -arrow-.

Free up the electrical wire.

Note. Ignore -1 and 2-.

Remove left and right drive axles from the transmission flange shafts.

Remove bottom cover -1- from the transmission -arrow-.

Insert T40058 guide pins as follows

1. The large diameter -arrow 1- faces the engine.
2. Small diameter -arrow 2- points to adapter.

To loosen the crankshaft, counter hold the drive plate bolts using the T40058.

Note. Only turn the crankshaft in the direction of engine rotation -arrow-.

Remove the six drive plate bolts -arrow- by turning the crankshaft 60° in direction of engine rotation.

Remove bolt -arrow- for the ATF line bracket.

Scheme 307

Note. To collect escaping ATF, lay a cloth under the separating point.

Remove bolts -1- and -2- and remove the ATF lines from the transmission and secure them at the top.

Scheme 308

Seal the open lines and connections with clean plugs from the VAS 6122.

Equip the VAS 6131 A with the support set VAS 6131/10, adapter set VAS 6131/13 and transmission mount VAS 6131/14 as follows

Note. The other attachments remain unchanged.

Install the joint support VAS 6131/13-7 at the right front of the engine in the threaded hole as shown in the illustration.

Install the VAS 6131/13-7 on the scissor lift table and tighten it to 20 Nm.

Attach the mounting elements from the support set for Audi VAS 6131/10 and transmission support VAS 6131/14 at the front of the transmission as shown in the illustration.

Rotate the left and right spindles up until the VAS 6131/14 rests firmly against the transmission.

Attach mounting element base plates to VAS 6131 A and tighten to 20 Nm.

Remove starter bolts -1 and 2-.

Press starter off the transmission and leave it in the installation position.

Remove remaining bolts -3 through 11- connecting the engine to the transmission.

Note. Ignore -A-.

Loosen clamping bolts -1- on sides of VAS 6131 A and pull rear table plate with transmission toward rear -arrow-.

ENGINE, INSTALLING - MULTITRONIC TRANSMISSION 0AW

Special tools and workshop equipment required

1. Ring Spanner Insert AF 16 V.A.G 1332/14
2. Assembly Aid T40169
3. Transportation Lock T40170
4. Socket T40058

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%.

Subframe mount SUBFRAME MOUNT OVERVIEW .

Tighten the ground bolt -1- to 9 Nm.

Tighten the nut -arrow- to 9 Nm.

Engine to Multitronic Transmission 0AW

1. Audi A4 from VIN 8K-9-066500, Audi A5 from VIN 8T-9-008000: The aluminum bolts -2 through 11- may be used two times. After using the bolts once, mark them with an "X" made by a chisel -arrow-.
2. Do not used bolts marked with an "X" again.

Procedure

Note. Replace bolts which have been tightened to torque. Replace self-locking nuts and bolts as well as sealing rings, seals and O-rings. In vehicles with the multitronic transmission 0AW, there is a needle bearing in the drive plate. Check if the needle bearing is inserted before installing. Refer to NEEDLE BEARING ON DRIVE PLATE . Secure all hose connections with hose clamps appropriate for the model. In order to be able to securely mount the air guide hoses on their connectors, spray the screws on the previously used clamps with a rust remover. During installation, all cable ties must be re-installed at the same location.

Install the engine supports and engine mount. Refer to SUBFRAME MOUNT OVERVIEW .

When jointing the engine and subframe, hold the ATF lines in their installation position.

Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.

Complete the following steps before connecting the engine and transmission

Insert the T40169 into the transmission housing and flywheel from below as illustrated.

1. The assembly aid must engage in the semi-circular opening -1- and in the inspection hole -2-.

Note. The inspection hole is only in one location on the circumference so rotate the flywheel as needed.

Install the assembly aid bolt into the hole on the transmission housing.

Install T40170 into the transmission housing from underneath and secure it to the flange shaft -1-.

Make sure the alignment sleeves -A- for centering the engine and transmission in the cylinder block are present. Insert the alignment sleeves if they are missing.

Determine if the engine/transmission aluminum bolts can be used again and mark them if necessary ENGINE, INSTALLING .

Position the transmission on the engine and tighten the bolts -1 through 11-.

Remove the T40170 and T40169.

Note. The following procedure is necessary to make sure the clutch module contacts the drive plate evenly and is not bent.

Press the dual mass flywheel -2- against the drive plate -3- lightly in direction of -arrow- using a pry bar -1-.

Scheme 309

Secure dual mass flywheel to the drive plate as follows

Note. Tighten the bolt with the V.A.G 1332/14.

Install the first bolt -arrow- by hand (2 Nm).

Insert the Adapter T40058 guide pins as follows

1. The large diameter -arrow 1- faces the engine.
2. Small diameter -arrow 2- points to adapter.

Rotate the crankshaft with the Socket T40058 180° in direction of engine rotation -arrow-.

Tighten the bolts that are accessible in this position to the tightening specifications. .

Turn the crankshaft 60° further and tighten the remaining 5 bolts to the tightening specification. .

Install the power steering hydraulic oil lines. Refer to Description and Operation .

Install the left and right drive axles on the transmission flange shafts. Refer to Removal and Installation .

Install the catalytic converters. Refer to: Left LEFT CATALYTIC CONVERTER, MULTITRONIC OR AUTOMATIC TRANSMISSION , right RIGHT CATALYTIC CONVERTER, MANUAL OR MULTITRONIC TRANSMISSION .

Raise the engine/transmission assembly using the Scissor Lift Table VAS 6131 A.

Align the subframe and transmission carrier using the marks made on the longitudinal members during removal.

Tighten the subframe bolts only to the tightening specifications, do not tighten them further (tighten the bolts only after axle alignment) Removal and Installation .

Tighten the tunnel crossmember bolts. .

The rest of the installation is in reverse order of removal, note the following

Install the universal joint on the steering gear. Refer to Description and Operation .

Install front muffler. Refer to FRONT MUFFLER .

Install exhaust system free of stress. Refer to EXHAUST SYSTEM, INSTALLING .

Install front crossmember. Refer to Removal and Installation .

Install subframe crossbrace, upper control arm and stabilizer bar and tighten the suspension strut on the control arm. Refer to Removal and Installation .

Install brake caliper. Refer to Removal and Installation .

Install Engine Control Module (ECM). Refer to Removal and Installation .

Electrical connections and routing. Refer to appropriate SYSTEM WIRING DIAGRAM.

Install the wires, Terminal 30 Wire Junction 2 -TV22- and the engine compartment E-box cover. see scheme 213, see scheme 214 and Removal and Installation.

Install tower brace. Refer to Removal and Installation .

Install washer fluid reservoir filler tube. Refer to Removal and Installation .

Install refrigerant lines. Refer to Removal and Installation .

Follow measures after connecting battery. Refer to Removal and Installation .

Install air filter housing. Refer to Description and Operation .

Install lock carrier braces. Refer to Description and Operation .

Fill the engine oil and check the oil level.

Before starting engine for the first time, check the fluid level in power steering reservoir. Refer to General Information .

Note. Power steering pump must not run dry.

Connect the coolant hose with the connector coupling (Scheme 304)

Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING => Filling .

Note. Do not use drained coolant in the following situations: If the cylinder head or cylinder block was replaced. If the coolant is contaminated.

Fill the refrigerant circuit. Refer to General Information .

Align the subframe. Refer to Removal and Installation .

Install the wheel housing liners. Refer to Description and Operation .

Install the front wheels and perform an alignment. Refer to General Information .

Fill ATF. .

Install noise insulation. Refer to Description and Operation .

ENGINE, REMOVING - AUTOMATIC TRANSMISSION 0B6

Special tools and workshop equipment required

1. Used Oil Collecting and Extracting Device V.A.G 1782
2. Hose Clamp Pliers V.A.G 1921
3. Step Ladder VAS 5085
4. Scissor Lift Table VAS 6131 A with Support Set for Audi VAS 6131/10 and Supplementary Set VAS 6131/13
5. Drip Tray for Workshop Crane VAS 6208
6. Pry Lever - Rmv Outside Mirror 80 - 200
7. Engine Bung Set VAS 6122
8. Counterhold Tool T10172 with T10172/5

Procedure

Reduce fuel pressure in high pressure area. Refer to BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM .

Position the front wheels so they are straight.

Note. Release the electrical parking brake before disconnecting battery so the driveshaft can be rotated to remove it.

Switch off ignition and remove ignition key.

Disconnect Ground (GND) cable -2- from the battery terminal. Refer to Removal and Installation .

Empty coolant circuit. Refer to General Information .

Extract the power steering oil from the reservoir with the Used Oil Collection and Extraction Device V.A.G 1782.

Remove engine covers -arrows-.

Open coolant reservoir cap.

Remove left and right front wheels.

Remove left and right front wheel housing liners. Refer to Description and Operation .

Remove noise insulation -1- and -2-. Refer to Description and Operation .

Place Drip Tray for Workshop Crane under engine.

Remove drain plug -1- and drain the coolant.

Lift the clip -2- and disconnect the coolant hose from the radiator.

Remove coolant hose -arrows- from the oil cooler and drain the remaining coolant.

Place the Used Oil Collection and Extraction Device V.A.G 1782 under the disconnection point.

Disconnect the power steering hydraulic oil supply line -2- and return line -1- in the left front wheel housing and free them up.

Seal the open lines and connections with clean plugs from the Engine Bung Set VAS 6122.

Place the Used Oil Collection and Extraction Device V.A.G 1782 under the disconnection point.

Mark the locations of the ATF lines -1- and -2- so they can be installed later and then disconnect them.

Seal the open lines and connections with clean plugs from the Engine Bung Set VAS 6122.

Note. Disregard -arrow-.

Vehicles with a Coolant Pump -V50

Disconnect electrical connector -1-.

Place Drip Tray for Workshop Crane under engine.

Remove the coolant hose from the Coolant Pump -V50- -right arrow-.

Note. Ignore -2- and -left arrow-.

All Vehicles

Push the retainer back -arrow-, press the release down and disconnect the radiator fan connectors -1- and -2-, if applicable.

Free up electrical wiring harness.

Disconnect the connector -3- on the Secondary Air Injection Pump Motor -V101-, if applicable, and free up the wire.

Note. Ignore -1 and 2-.

Remove the left and right bolt -1- and nut -3- and the lock carrier brace -2-.

Remove nut -arrow- on the right longitudinal member and free up the Ground (GND) cable.

Remove seal -arrow-.

Remove the plenum chamber cover. Refer to Removal and Installation .

Remove vacuum connection -2- from the bulkhead by pulling the vacuum hose -1- on the rear side.

Free up the fuel line and wire to the EVAP canister at the air guide pipe.

Disconnect the vacuum hose -arrow- to the Leak Detection Pump -V144-.

Scheme 310

Remove air duct -arrows-.

Free up the fuel hose -1- on the air duct pipe.

Remove the vacuum hose -3- from the connection on the air guide pipe.

Remove the air guide pipe by loosening the hose clamp -4- and opening the clips -arrows-.

Note. Ignore -2-.

Disconnect vacuum line -1-.

Remove air filter housing and, if applicable, disconnect the electrical connector -2- on the rear side at the Intake Air Switch-Over Valve -N335-.

Remove fuel supply line from the high pressure pump -arrow- and lay it aside.

Seal the open lines and connections with clean plugs from the Engine Bung Set VAS 6122.

Disconnect the vacuum hose -1- and free it up, if applicable.

Remove coolant hose -2- from the upper coolant pipe by lifting the retaining clamp.

In vehicles without a Coolant Pump -V50-, lift the clamp -arrow- and remove the right front coolant hose from the front coolant pipe.

Remove coolant hose -arrow- from the front coolant pipe by lifting the retaining clamp.

Remove coolant hose -3- from the coolant reservoir and free it up.

Remove bolts -arrows-, disconnect the electrical connector on the Engine Coolant Level (ECL) Warning Switch -F66- and lay the coolant reservoir aside with the coolant hoses -1- and -2- attached.

Disconnect electrical connector -arrow- on the power steering pump, if applicable.

Press hydraulic hose down slightly.

Remove bolts -arrows- and the refrigerant lines from the A/C compressor.

Seal the open lines and connections with clean plugs from the Engine Bung Set VAS 6122.

Release the retainer -arrow A- and open the cover -arrow B-.

Remove nuts -1- and -2- for the electrical wires.

Remove electrical connector -3- from the bracket and disconnect it.

Remove bolt -4- and the Terminal 30 Wire Junction 2 -TV22- from the tower brace -arrow-.

Release the retainers from the wheel housing side using a 5.5 mm open end wrench -1- and remove the wiring bushing -2- upward.

Free up the wiring harness -3- to the generator and starter using the Pry Lever - Rmv Outside Mirror 80 - 200.

Wiring duct version 1: Free up the wiring duct by releasing the retainer -arrow B- and pulling the duct forward -arrow A-.

Wiring duct version 2: Open the catch -arrow-, free up the wiring harness and open the wiring duct -1-.

Remove nut -1- and tilt -arrow A- the washer fluid reservoir filler neck -2- upward slightly.

Remove filler neck with the filler tube from the washer fluid reservoir and the opening in the body -arrow B-.

Remove the bolts -1- and nuts -2- and the tower brace -3-.

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

Remove nut -1- and free up the electrical wire.

Release retainers -A arrows- and remove the engine control module -arrow B-.

Disconnect electrical connector -2- if applicable.

Disconnect electrical connectors -4- and remove nut -3- for the electrical wire.

Release retainers -arrow- and remove the relay carrier with the fuse holder -1-.

Disengage engine wiring harness at the engine compartment E-box and free it up.

Release retainers -A arrows- and remove the wiring bushing -2- upward -arrow B-.

Remove Ground (GND) pin -1- and free up the electrical wire.

Lay the wiring harness on the engine and secure the engine control module against falling down.

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

Disconnect electrical connector -1- on the Left Front Level Control System Sensor -G78- and Right Front Level Control System Sensor -G289- and free up the electrical wiring -arrow-.

Free up the electrical connector -2- on the bracket by pulling the retainer back -arrow A- and turning the connector approximately 90° clockwise -arrow B-.

Free up the electrical wiring -3- and brake line -4- on the bracket.

Remove the bolts -1- and secure the brake caliper in the wheel housing using wire.

Remove nut -2- and bolt -1-.

Remove upper control arm upward from the wheel bearing housing -arrows-.

Repeat the procedure on the other side of the vehicle.

A5 through VIN 8T-8-011200

Remove left and right stabilizer bar bolt -3-.

Remove left and right nuts -1-.

Note. The bolts -2- will be removed later.

All A4, A5 from VIN: 8T-8-011201

Remove left and right stabilizer bar bolt -1-.

Remove left and right nuts -3-.

Note. The bolts -2- will be removed later.

All Vehicles

All A4, A5 Coupe

Remove nut -1- for the power steering hydraulic fluid line bracket.

Remove bolts -arrows- and the subframe crossbrace.

Note. The illustration shows the installation location on a vehicle with dynamic steering.

A5 Cabriolet

Remove the left and right bolts -1- and -2- and the brace.

Remove bolt -2- for the power steering hydraulic fluid line bracket.

Remove bolts -1- and -arrows- and the subframe crossbrace.

All Vehicles

Remove left and right bolts -arrows-, if applicable, and the heat shield -1-.

Remove bolts -arrows- and the front crossmember, if applicable.

Remove left front muffler nuts -arrows-.

Remove right front muffler nuts -arrows-.

Loosen clamping sleeves -1- and -2-, slide them back and remove the left and right front mufflers.

Remove bolts -arrows- and the driveshaft heat shield -1-, if applicable.

Remove bolts connecting the driveshaft to the transmission while holding using a Counterhold Tool T10172 with T10172/5.

Slide the driveshaft toward the rear final drive; the CV joints can move axially.

Secure the driveshaft to the side.

Remove universal joint bolt -arrow-. Refer to Description and Operation .

Press the CV joint off the steering gear and slide it all the way up.

Remove the selector lever cable ball socket -A- from the selector shaft lever using the Pry Lever - Rmv Outside Mirror 80 - 200 -arrow-.

Press securing clips -2- off and remove the selector lever cable from the transmission.

Scheme 311

Note. Do not bend or kink the selector lever cable. Ignore -1-.

Prepare scissor lift platform

Equip the Scissor Lift Platform VAS 6131 A with the Support Set for Audi VAS 6131/10, Adapter Set VAS 6131/11 and VAS 6131/13 as follows

Next secure mounting elements to scissor lift table by hand.

Position the Scissor Lift Table VAS 6131 A horizontally.

1. Note bubble level (sight glass) on support platform.

Guide the Scissor Lift Table VAS 6131 A under the engine/transmission assembly.

Remove the left and right subframe bolts -1-.

Attach the mounting elements from the VAS 6131/10 and VAS 6131/13 at the left and right front of the subframe as shown in the illustration.

Ensure threaded spindles are completely installed.

Attach the mounting elements from the VAS 6131/10 at the left and right rear on the subframe crossbrace front connecting points as shown in the illustration.

Attach mounting elements from the VAS 6131/13 at the lower left and right of the wheel bearing housing as shown in the illustration.

Attach the mounting elements from the VAS 6131/10 and VAS 6131/11 at the left and right rear of the tunnel crossmember as shown in the illustration.

Scheme 312

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 Table VAS 6131 A and tighten to 20 Nm.

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

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

Note. Ignore -1-.

Remove bolts -arrows- on the tunnel crossmember.

Scheme 313

A5 through VIN 8T-8-011200

Remove left and right bolts -2-.

All A4, A5 from VIN: 8T-8-011201

Remove left and right bolts -2-.

All Vehicles

Lower engine/transmission assembly using the Scissor Lift Table VAS 6131 A.

Remove Scissor Lift Table VAS 6131 A with engine/transmission assembly under vehicle.

ENGINE AND AUTOMATIC TRANSMISSION, SEPARATING - AUTOMATIC TRANSMISSION 0B6

Special tools and workshop equipment required

1. Support set VAS 6131/10, Supplementary Set VAS 6131/13 and Transmission Support VAS 6131/14
2. Adapter T40058

Procedure

1. Engine/transmission assembly removed and placed on Scissor Lift Table VAS 6131 A.

Remove electrical connector -arrow- for the Oxygen Sensor (O2S) 2 behind Three Way Catalytic Converter (TWC) -G131- from the bracket, disconnect it and lay it aside.

Note. Ignore items -2, 3 and 4- and the -arrows-.

Remove nuts -arrows- and bolt -1- and the left catalytic converter.

Remove the electrical connector -1- for the Oxygen Sensor (O2S) behind Three Way Catalytic Converter (TWC) -G130- from the bracket and disconnect it.

Remove electrical connector -2- from the bracket.

Remove bolts -arrow- and lay aside the bracket with electrical connectors -3- and -4-.

Remove nuts -arrows- and bolt -1- and the right catalytic converter.

Disconnect electrical connector -2- on Engine Speed (RPM) Sensor -G28- and free up the electrical wiring.

Note. Ignore -1-.

Touch the transmission housing (when not wearing gloves) to discharge the static electricity.

Disconnect electrical connector on transmission by rotating twist lock counter-clockwise -arrow-.

Scheme 314

Free up the electrical wiring harness on the transmission.

Remove the left and right drive axles from the transmission flange shafts.

Remove bottom cover -1- from the transmission -arrow-.

Insert the Adapter T40058 guide pins as follows

1. The large diameter -arrow 1- faces the engine.
2. Small diameter -arrow 2- points to adapter.

To loosen the crankshaft, counterhold the drive plate bolts using the Adapter T40058.

Note. Only turn the crankshaft in the direction of engine rotation -arrow-.

Remove the 6 torque converter bolts -arrow- by turning the crankshaft 60° in the direction of engine rotation.

Remove the bolt -arrow- for the ATF line bracket.

Note. Ignore -1 and 2-.

Note. To collect escaping ATF, lay a cloth under the separating point.

Remove bolts -1- and -2- and remove the ATF lines from the transmission and secure them at the top.

Scheme 315

Seal the open lines and connections with clean plugs from the Engine Bung Set VAS 6122.

Equip the Scissor Lift Platform VAS 6131 A with the Support Set for Audi VAS 6131/10, Adapter Set VAS 6131/13 and Transmission Mount VAS 6131/14 as follows

Note. The other attachments remain unchanged.

Install the Joint Support VAS 6131/13-7 at the front right of the engine in the threaded hole as shown in the illustration.

Install the Joint Support VAS 6131/13-7 on the scissor lift table and tighten it to 20 Nm.

Attach the mounting elements from the VAS 6131/10 and Transmission Support VAS 6131/14 at the front of the transmission as shown in the illustration.

Scheme 316

Rotate the left and right spindles up until the 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 the transmission and leave it in the installation position.

Remove the remaining bolts -3 through 11- connecting the 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 the rear -arrow-.

ENGINE, INSTALLING - AUTOMATIC TRANSMISSION 0B6

Special tools and workshop equipment required

1. Ring Spanner Insert AF 16 V.A.G 1332/14
2. Transportation Lock T40170
3. Socket T40058

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%.

Subframe mount. Refer to SUBFRAME MOUNT OVERVIEW .

Tighten the ground bolt -1- to 9 Nm.

Tighten the nut -arrow- to 9 Nm.

Engine to automatic transmission 0B6

1. Audi A4 from VIN 8K-9-066500, Audi A5 from VIN 8T-9-008000: The aluminum bolts -2 through 11- may be used two times. After using the bolts once, mark them with an "X" made by a chisel -arrow-.
2. Do not used bolts marked with an "X" again.

Procedure

Note. Replace bolts which have been tightened to torque. Replace self-locking nuts and bolts as well as sealing rings, seals and O-rings. The drive plate in the vehicles with the automatic transmission 0B6 must not have any needle bearings. Check if a needle bearing is inserted before installing. Remove the needle bearing in the drive plate. Refer to NEEDLE BEARING ON DRIVE PLATE . Secure all hose connections with hose clamps appropriate for the model. In order to be able to securely mount the air guide hoses on their connectors, spray the bolts on the previously used clamps with a rust remover. During installation, all cable ties must be re-installed at the same location.

Install the engine supports and engine mount. Refer to SUBFRAME MOUNT OVERVIEW .

When jointing the engine and subframe, hold the ATF lines in their installation position.

Clean the threaded holes in the cylinder block for connecting the engine and transmission using a thread tap before installing the transmission.

Complete the following steps before connecting the engine and transmission

Turn the torque converter so that the hole next to the notch -arrow- is visible in the transmission housing in the lower cut-out, as illustrated.

Scheme 317

Note. The notch is only in one location on the circumference, so rotate the torque converter as needed.

Install the Transport Lock T40170 into the transmission housing from underneath and secure it to the flange shaft -1-.

Make sure the alignment sleeves -A- for centering the engine and transmission in the cylinder block are present. Insert the alignment sleeves if they are missing.

Determine if the engine/transmission aluminum bolts can be used again and mark them if necessary ENGINE, INSTALLING .

Position the transmission on the engine and tighten bolts -1 and 6 through 11-.

Remove Transport Lock T40170.

Note. The following procedure is necessary to assure that the torque converter contacts the drive plate evenly and does not get bent.

Press the torque converter -2- slightly against the drive plate -3- using a pry bar -1- in direction of -arrow-.

Secure the torque converter to the drive plate as follows

Note. Tighten the bolt with the V.A.G 1332/14.

Install the first bolt -arrow- by hand (2 Nm).

Insert Adapter T40058 guide pins as follows

1. The large diameter -arrow 1- faces the engine.
2. Small diameter -arrow 2- points to adapter.

Rotate the crankshaft with the Socket T40058 180° in direction of engine rotation -arrow-.

Tighten the bolts that are accessible in this position to the tightening specifications. Refer to Removal and Installation .

Turn the crankshaft 60° further and tighten the remaining 5 bolts to the tightening specification. Refer to Removal and Installation .

Install the power steering hydraulic oil lines. Refer to Description and Operation .

Install the left and right drive axles on the transmission flange shafts. Refer to Removal and Installation .

Install the catalytic converters. Refer to: Left LEFT CATALYTIC CONVERTER, MULTITRONIC OR AUTOMATIC TRANSMISSION , right RIGHT CATALYTIC CONVERTER, AUTOMATIC TRANSMISSION .

Raise the engine/transmission assembly using the Scissor Lift Table VAS 6131 A.

Align the subframe and transmission carrier using the marks made on the longitudinal members during removal.

Tighten the subframe bolts only to the tightening specifications, do not tighten them further (tighten the bolts only after axle alignment). Refer to Removal and Installation .

Tighten the tunnel crossmember bolts -arrow-. Refer to Removal and Installation .

The rest of installation is in reverse order of removal, note the following

Install universal joint on the steering gear. Refer to Description and Operation .

Install the driveshaft. Refer to Removal and Installation or Removal and Installation .

Install front muffler. Refer to FRONT MUFFLER .

Install exhaust system free of stress. Refer to EXHAUST SYSTEM, INSTALLING .

Install front crossmember. Refer to Removal and Installation .

Install the subframe crossbrace, upper control arm and stabilizer bar and tighten the suspension strut on the control arm. Refer to Removal and Installation .

Install brake caliper. Refer to Removal and Installation .

Install Engine Control Module (ECM). Refer to Removal and Installation .

Electrical connections and routing. Refer to appropriate SYSTEM WIRING DIAGRAM.

Install wires, terminal 30 wire junction 2 -TV22- and the engine compartment E-box cover. see scheme 311, see scheme 312 and Removal and Installation.

Install the tower brace. Refer to Removal and Installation .

Install the washer fluid reservoir filler tube. Refer to Removal and Installation .

Install refrigerant lines. Refer to Removal and Installation .

Follow measures after connecting battery. Refer to Removal and Installation .

Install air filter housing. Refer to Description and Operation .

Install lock carrier braces. Refer to Description and Operation .

Fill the engine oil and check the oil level.

Before starting engine for the first time, check the fluid level in power steering reservoir. Refer to General Information .

Note. Power-steering pump must not run dry.

Connect the coolant hose with the connector coupling. (Scheme 304)

Fill with coolant. Refer to COOLING SYSTEM, DRAINING AND FILLING .

Note. Do not use drained coolant in the following situations: If the cylinder head or cylinder block was replaced. If the coolant is contaminated.

Fill the refrigerant circuit. Refer to General Information .

Align the subframe. Refer to Removal and Installation .

Install wheel housing liners. Refer to Description and Operation .

Install front wheels and perform an alignment. Refer to General Information .

Fill the ATF. Refer to General Information .

Install noise insulation. Refer to Description and Operation .

Scheme 318

Special tools and workshop equipment required

1. Used Oil Collecting and Extracting Device V.A.G 1782
2. Hose Clamp Pliers V.A.G 1921
3. Step Ladder VAS 5085
4. VAS 6131 A with VAS 6131/10 and Supplementary Set VAS 6131/13
5. Drip Tray for Workshop Crane VAS 6208

Scheme 319

Special tools and workshop equipment required

1. Lifting Tackle 2024 A
2. Engine and Transmission Holder VAS 6095 with V6 FSI Engine Holder VAS 6095/1-5
3. Shop Crane VAS 6100
4. Lift Arm Extension for Workshop Crane VAS 6101

Special tools and workshop equipment required

Scheme 320

Scheme 321

Scheme 322

Scheme 323

Scheme 324

Scheme 325

Scheme 326

Scheme 327

Scheme 328

Scheme 329

Scheme 330

Scheme 331

1. Engine Support Bridge 10 - 222 A
2. Used Oil Collecting and Extracting Device V.A.G 1782
3. Engine Support Basic Set T40091
4. Engine Support Supplement Set T40093
5. Pry Lever - Rmv Outside Mirror 80 - 200
6. Engine Bung Set VAS 6122
7. Counterhold Tool T10172 with T10172/5 for vehicles with AWD
8. Puller T40160
9. Adapter T40058
10. Socket AF 16 mm V.A.G 1332/14
11. Assembly Aid T40169
12. Transportation Lock T40170

See also:
• After-Run Coolant Pump -V51
• OIL COOLER
• Removal and Installation
• Removal and Installation
• Description and Operation
• General Information
• BEFORE OPENING HIGH PRESSURE FUEL INJECTION SYSTEM
• Removal and Installation
• General Information
• Removal and Installation
• CLEAN WORKING CONDITIONS
• Description and Operation
• NEEDLE BEARING ON DRIVE PLATE
• Removal and Installation
• LEFT CATALYTIC CONVERTER, MANUAL TRANSMISSION
• Description and Operation
• Removal and Installation
• Removal and Installation
• EXHAUST SYSTEM, INSTALLING
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Removal and Installation
• Maintenance, Diagnosis
• COOLING SYSTEM, DRAINING AND FILLING
• General Information
• Removal and Installation
• LEFT ENGINE MOUNT
• RIGHT ENGINE MOUNT
• ENGINE, INSTALLING
• ENGINE, INSTALLING
• ENGINE, INSTALLING
• SUBFRAME MOUNT OVERVIEW