Installation (A6) Audi A6 C5

1. Before installing the bumper, ensure the expanding clips are pressed into the fender. see scheme 17 When installing the tabs, the bumper cover must latch into clip (4). see scheme 18
2. Latch bumper cover (1) into guide (2). see scheme 18 Tighten flange nuts (10) to 53 INCH lbs. (6 N.m).
3. Screw in socket-head bolts (7) and tighten to 17 ft. lbs. (23 N.m). see scheme 18

Note. Obtain radio code before disconnecting battery. Remove engine, without transmission, through front of engine compartment.

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-147486-S17694092262002091600000). Ensure ignition switch is in the OFF position. Disconnect battery cables. Remove clip for accelerator pedal cable on throttle body and remove cable from throttle body.
2. Turn ignition off. Disconnect negative battery cable. Remove engine cover. (Scheme 21)
3. Remove lower engine shield. see scheme 8 Open cap on engine coolant expansion tank. Drain coolant from radiator and at engine coolant drain screw on engine block using Hex Ball Socket (3247). (Scheme 22)- (Scheme 23).
4. Remove complete front bumper assembly. See «FRONT BUMPER»(ref-147486-S21797918242002091600000).
5. Disconnect power steering cooling coil, located at lower left of radiator. Let cooling coil hang free. (Scheme 24)
6. Remove left and right side air ducts (4). Remove condenser mounting bolts (1) and (2). Disconnect harness connector (3) for A/C pressure switch. (Scheme 25) Pull condenser up out of its bracket, rotate it to side and use wire to secure it on or near right front wheel.
7. Move lock carrier to service position. See «LOCK CARRIER»(ref-147486-S40535456302002091600000).
8. Using Spanner Wrench (3212), hold viscous fan pulley. (Scheme 26) Using Open End Wrench (3312), or equivalent, rotate viscous fan clockwise to remove. Using a wrench, rotate ribbed belt tensioner clockwise and install a drift to hold. Remove serpentine belt. (Scheme 27)
9. Remove air intake hose between Mass Airflow (MAF) sensor and intake air elbow. Remove secondary air injection duct by turning it 1/4 turn to the right. (Scheme 28)and (Scheme 29). Remove upper part of air cleaner assembly. Disconnect cruise control vacuum unit. Disconnect accelerator pedal cable. DO NOT remove locking clip on accelerator pedal cable bracket.
10. Disconnect fuel supply and return lines. Disconnect coolant, electrical and vacuum connections at engine. (Scheme 30) Remove 3 bolts at rear part of intake manifold. Remove engine coolant expansion tank and position to side.
11. Disconnect 5 harness connectors below cover of ABS hydraulic control unit. Remove retainer form ground wire and remove ground electrical connector. (Scheme 31)and (Scheme 32). Remove vacuum connections at engine.
12. Remove wiper arms and water deflector. Remove cover from ECM (E-Box). Disconnect wiring harness connectors from ECM. (Scheme 33)
13. Disconnect exhaust manifold connections. Disconnect 4 oxygen sensor harness connectors. Remove ground wire at engine/cross member. (Scheme 34) Remove front exhaust pipes with converters. Disconnect starter and generator electrical connections. Unbolt starter and remove between subframe and drive axle.
14. Clamp off two hoses at hydraulic fluid supply line using Hose Clamps(3094). Disconnect supply line (see arrow) below left cylinder head. (Scheme 35) Place rag(s) under connection to catch escaping fluid.
15. Disconnect hydraulic pressure line at rear coolant line. Disconnect hydraulic pressure line at right side cylinder head. (Scheme 36)
16. Detach A/C refrigerant line from oil pan at front of engine. (Scheme 37)
17. Remove upper engine-to-transmission bolts. Remove lower left and right engine mount nuts. If equipped with automatic transmission, remove 3 torque converter bolts. (Scheme 38) Lift engine and transmission slightly usingHoist Crane (VAG 1202 A) to allow lower engine/transmission connecting bolts to be removed. Remove lower engine/transmission connecting bolts. (Scheme 39)
18. Mark positions of left and right engine mount locating sleeves from bottom. see scheme 40 Position Support Bridge (10-222A) on bolted flanges of fenders. Engage Support Adaptor (3147) in bolt hole in bellhousing on transmission. see scheme 41
19. Attach Engine Sling (2024A) to engine. Using hoist, lift engine from vehicle. see scheme 41and see scheme 42.

Scheme 37

1. To install, reverse removal procedure. Always replace self-locking nuts. Ensure engine and transmission locating dowel pins and centering sleeves are properly installed in cylinder block and bell housing. For manual transmission, go to next step. For automatic transmission, go to step 7.
2. For manual transmission, clean and lubricate transmission input shaft splines with lubricant (G 000100). Make sure clutch disc and pressure plate are properly installed. Make sure pilot needle bearing is installed. If pilot needle bearing is worn, see «PILOT NEEDLE BEARING (MANUAL TRANSMISSION)»(ref-147486-S04109496632002091600000). For more information on transmission servicing, see appropriate article in CLUTCHES.
3. Align engine to transmission bell-housing. Install proper length bolts and torque to specifications. see scheme 43 See «TORQUE SPECIFICATIONS»(ref-147486-S18918128872002091600000).
4. Install engine mounts free of tension by aligning engine with shaking motions prior to tightening bolts. See «TORQUE SPECIFICATIONS»(ref-147486-S30794586192002091600000).
5. Align exhaust so components are free of stress. Adjust accelerator pedal. See «ACCELERATOR PEDAL»(ref-147486-S13820663132002091600000) under ADJUSTMENTS. Verify engine fluids are filled to proper levels.
6. Install vacuum lines. see scheme 44 Install serpentine drive belts. see scheme 46or see scheme 47.
7. If the torque converter is installed correctly, the distance between contact surfaces at the mounting holes on the torque converter and contact surface of the bell housing flange will be about 7/8". see scheme 45 If the torque converter was not completely installed, this distance will be about 7/16".
8. For automatic transmission, when mounting torque converter to drive plate, use only bolts specified for this use. Before installing engine, align torque converter and drive plate so that one hole in torque converter and one hole in drive plate are level with opening for starter. (Scheme 38)
9. Align engine to transmission bell-housing. Install proper length bolts and torque to specification. See «TORQUE SPECIFICATIONS»(ref-147486-S18918128872002091600000). For more information, see appropriate REMOVAL & INSTALLATION article TRANSMISSION/TRANSAXLE.
10. Install engine mounts free of tension by aligning engine with shaking motions prior to tightening engine mounts. See «TORQUE SPECIFICATIONS»(ref-147486-S30794586192002091600000).
11. Align exhaust so components are free of stress. Adjust accelerator pedal. See «ACCELERATOR PEDAL»(ref-147486-S13820663132002091600000) under ADJUSTMENTS. Verify engine fluids are filled to proper levels. Also check ATF fluid is filled to proper level.
12. Install vacuum lines. see scheme 44
13. Install serpentine drive belt. see scheme 46or see scheme 47.

Scheme 38

Scheme 39