Engine, Removing Audi A6 С6

Engine, Removing

Special tools, testers and auxiliary items required

1. Pry Lever - Rmv Outside Mirror 80-200
2. Hose Clamps Up to 25 mm dia. 3094
3. Hose clamp pliers V.A.G 1921
4. Step ladder VAS 5085

1. Scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10
2. Drip tray for workshop crane VAS 6208

Special tools, testers and auxiliary items required

1. Old oil collecting and extracting device V.A.G 1782

1. Tension strap T10038

Procedure

Note. With lock carrier installed, engine is removed downward with transmission and subframe. All cable ties which are opened or cut open when removing engine, must be replaced in the same position when installing engine. Drained coolant must be stored in a clean container for disposal or reuse.

Note. So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted. On vehicles with all-wheel drive, the electrical parking brake must be released before disconnecting the battery, so that the driveshaft can be rotated for removal.

1. Remove luggage compartment floor trim.
2. Release retaining clips - arrows - with a screwdriver - 2 - and remove cover - 1 -.

1. Disconnect Ground (GND) cable - arrow - at battery.

1. Remove front engine cover - arrows -.

1. Remove rear engine cover - arrows -.

1. Open cap of coolant expansion tank.

Note. Before removing ribbed belt, mark the turning direction on it with chalk or a felt tip pen. A reversed direction of rotation can cause damage to the belt under operating conditions.

1. Pivot tensioning device in direction of - arrow - to relieve tension on ribbed belt.
2. Remove ribbed belt and release tensioning device.
3. Remove both front wheels.

Note. Secure brake discs using a wheel bolt.

1. Remove noise insulation and mountings - 1, 2 - - arrow - where present.

1. Place drip tray for workshop crane VAS 6208 under engine.
2. Open drain plug - 1 - and allow coolant to drain.
3. Then disconnect coolant hose - 2 - from radiator.

1. Disconnect coolant hose - arrow - from oil cooler and drain remaining coolant.
2. Then remove coolant hose.

1. Separate connector - 1 - for wiring to air conditioning compressor clutch solenoid.

1. Remove air conditioning compressor from bracket - arrows -.

Note. To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

1. Hang up the air conditioning compressor with attached lines on left side of vehicle.

Note. Place a rag under hydraulic lines to catch escaping hydraulic fluid.

1. Clamp off hydraulic hose - 1 - for power steering pump with a Hose Clamps Up to 25 mm dia. 3094.
2. Remove hydraulic hose from power steering pump.
3. Remove hydraulic pressure line - 2 - at power steering pump and set it aside on top of the longitudinal member.

Vehicles with auxiliary heater

1. Remove right front wheel housing liner in front area --> «66 - EXTERIOR EQUIPMENT»(/audi/a6/6-2004-2008/remont/door-locks-anti-theft-systems/#body-exterior) .

1. Remove bolt - arrow - for corrugated exhaust pipe.

1. Loosen nut - A - on clamp for corrugated exhaust pipe.
2. Remove bolt - B - and remove muffler with corrugated exhaust pipe.

All

1. Remove bolts - arrows - and remove torque support from engine.

Note. Observe the rules of cleanliness for working on automatic transmissions --> 00 TECHNICAL DATA .

1. Place old oil collecting and extracting device V.A.G 1782 under engine.
2. Loosen union nuts - 2 - and - 3 - and disconnect ATF lines.

Note. Ignore - 1 -.

1. Remove Ground (GND) cable - arrow - from right longitudinal member.

1. Disconnect brake booster vacuum hose from grommet - arrow - on bulkhead.

1. Remove coolant hose - arrow - to heater core on rear of engine.

1. Remove coolant hoses - 1 - and - 2 - at coolant expansion tank.
2. Remove coolant expansion tank - arrow -.
3. Disconnect electrical connection at Engine Coolant Level (ECL) Warning Switch F66 at bottom of coolant expansion tank.

1. Remove coolant hose - arrow - from front coolant line.

1. Remove left front coolant hose in engine compartment - arrows -.

1. Remove coolant hose - arrow - from front coolant line.

1. Disconnect vacuum hose - arrow - to leak detection pump.

1. Separate fuel line - arrow - and lay aside.

1. Remove bolts - arrows -.
2. Remove air duct - 1 - and - 2 -.

1. Disconnect check valve - 1 - from connection at air duct hose.
2. Remove air duct hose, thereby loosening hose clamp - 2 - and opening the clips - arrows -.

1. Open clips - arrows - and remove upper part of air filter housing.

1. Disconnect vacuum line - 1 -.
2. Remove pin from spreader clips - 3 -.
3. Remove lower part of air filter housing and, on the backside, disconnect electrical connection - 2 - at the intake air switch-over valve N335.

1. Disconnect vacuum hose - arrow - to EVAP canister.

1. Remove nuts - 2 - and - 3 - and remove right bracket for harness connectors from bulkhead.
2. Remove Ground (GND) wire - 1 - on right strut tower.

1. Remove Ground (GND) wire - arrow - on left strut tower.

1. Remove left bracket for harness connectors - 1 - and - 2 - from bulkhead.

1. Remove rubber seal - 1 - for plenum chamber cover.
2. Remove plenum chamber cover - 2 -.

1. Pry off caps on the wiper arms using a screwdriver.
2. Loosen nuts - arrows - by several turns.
3. Loosen wiper arms by gently rocking the wiper arm. Remove nuts and wiper arms.

1. Remove bolts - arrows - for cowl grill - 1 -.

1. Pull cowl grill off from windshield.

1. If equipped, remove bolts - 1 - and - 3 - and remove strut tower brace - 2 -.

1. Remove bolts - arrows - and remove cover form E-box at left in engine compartment.

1. Release retaining tabs and pull fuse holder - 1 - and 3-socket relay carrier - 4 - upward and off.
2. Remove electrical wire connection - 3 -.
3. Disconnect all electrical connections - 2 - at rear on the connector strip.
4. Disengage and free up engine wiring harness at E-Box.

1. Remove bolts - arrows - and remove cover for E-box at right in engine compartment.

1. Where present, open cover - 1 - using a screwdriver - arrow - and remove.

1. Carefully pry off retaining clip - 3 - with a screwdriver - arrows 1 and 2 - and remove ECM from the E-box.

Note. Engine Control Module (ECM) remains connected at wiring harness.

1. Unclip suppression capacitor - 5 - from bracket in E-box.
2. Disconnect electrical connection - 4 - at rear on the connector strip.
3. Remove electrical wiring connections - 1 - and - 2 -.

1. Free electrical wiring up to generator using Pry Lever - Rmv Outside Mirror 80-200.
2. Set both wiring harnesses on engine and secure Engine Control Module (ECM) against falling down.

1. Have a second technician press brake pedal.

1. Remove collar bolt - 2 - at left and right drive axles - 1 -.

1. Evenly remove left and right nuts - 1 -.
2. Remove left and right bolts - 2 - and remove stabilizer bar.

1. Disconnect electrical harness connector - 2 - at Level Control System Sensor.
2. Disconnect connecting link - 1 - at control arm.

1. Tie up wheel bearing housing with Tension Strap T10038 as shown in illustration.

1. Remove suspension strut from control arm - arrow -.

1. Remove guide control arm - 1 - and control arm - 2 - on subframe.

1. Swing guide control arm - 1 - and control arm - 2 - outward.

1. Repeat work procedure on opposite side of the vehicle.
2. Remove drive axle from transmission flanged shaft.

1. Swing wheel bearing housing outward and remove drive axle.
2. Repeat work procedure on opposite side of the vehicle.

1. Remove subframe transverse beam - arrows -.

Scheme 89

Note. Mark the installation position of bracket for selector lever cable using a felt-tip marker.

1. Press ball socket - 1 - of selector lever cable from selector shaft lever.
2. Remove bracket on transmission - arrows -.
3. Move selector lever cable clear.

1. Loosen clamping sleeves - 1 - and - 2 -.

1. Remove front transverse beam - arrows -.

Scheme 90

1. Remove heat shield - A - for driveshaft - arrows -.
2. Remove bolts at transmission/driveshaft flange.
3. Push driveshaft together with rear final drive. The constant velocity (CV) joints can move axially.

Scheme 91

1. Tie driveshaft up and to the side against heat shield - arrow -.

Prepare scissor lift platform

1. Equip scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10 , VAS 6131/11 and VAS 6131/12 as follows

1. Install support elements first tightly by hand on scissor lift platform.
2. Place scissor lift platform VAS 6131 A in horizontal position.

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

1. Drive scissor lift platform VAS 6131 A under engine/transmission subassembly.

1. Position support elements from VAS 6131/10 at front on engine as shown in illustration.

1. Position support elements from VAS 6131/10 at left and right on subframe as shown in illustration.

Scheme 92

1. Position support elements from VAS 6131/10 and VAS 6131/12 at left on transmission and tunnel cross member as shown in illustration.

Scheme 93

1. Position support elements from VAS 6131/10 and VAS 6131/11 at right on transmission as shown in illustration.
2. Twist all spindles of support elements upward far enough until all support pins make contact at support points.
3. Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131 A.

1. Remove bolts - arrows - on tunnel cross member.

1. Remove bolts - 1 -.
2. Mark installation position of subframe and of both engine mount consoles to longmembers using a felt-tip marker.
3. Remove bolts - 2 - , - 3 - and - 4 - in diagonal sequence and in stages.

Note. Verify that all hoses and lines between engine, transmission, subframe and body have been disconnected. While lowering, carefully guide engine/transmission subassembly with subframe out of engine compartment in order to prevent damage.

1. Slowly lower engine/transmission subassembly downward.
2. Remove scissor lift table VAS 6131 A under vehicle.