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Contents Section: 3.2 v6 4v Engine Mechanical, Engine Code(s): Bkh All sections

Engine, with Multitronic Transmission, Removing and Installing Audi A6 C6 рестайлинг

3.2 v6 4v Engine Mechanical, Engine Code(s): Bkh 61 illustrations ~1759 words

Engine, with Multitronic Transmission, Removing and Installing

Scheme 10

Scheme 10: Engine, Removing
Scheme 10: 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

Scheme 11

Scheme 11
Scheme 11
  1. Old oil collecting and extracting device V.A.G 1782

Scheme 12

Scheme 12
Scheme 12
  1. Tension strap T10038

Note. If engine and transmission are to be separated after removal, the Supplementary Set Audi A6 (C6) VAS 6131/12 will also be required.

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.

CAUTIONBefore removing engine, secure vehicle against tipping over. For this the luggage compartment must be empty.
CAUTIONObserve safety precautions when disconnecting the battery --> 27 - STARTER, GENERATOR, CRUISE CONTROL .

Note. So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted.

  1. Remove luggage compartment floor trim.

Scheme 13

Scheme 13
Scheme 13
  1. Release retaining clips - arrows - with a screwdriver - 2 - and remove cover - 1 -.

Scheme 14

Scheme 14
Scheme 14
  1. Disconnect Ground (GND) cable - arrow - at battery.

Scheme 15

Scheme 15
Scheme 15
  1. Remove rear engine cover - arrows -.
  1. Remove front engine cover - arrows -.
CAUTIONCover cap of expansion tank with rag and open carefully, as hot steam i.e. hot coolant may escape when opening.
  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.

Scheme 16

Scheme 16
Scheme 16
  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 bolts.

Scheme 17

Scheme 17
Scheme 17
  1. Remove noise insulation and mountings - 1, 2 - - arrow - where present.

Scheme 18

Scheme 18
Scheme 18
  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.

Scheme 19

Scheme 19
Scheme 19
  1. Disconnect coolant hose - arrow - from oil cooler and drain remaining coolant.
  2. Then remove coolant hose.

Scheme 20

Scheme 20
Scheme 20
  1. Disconnect connector - 1 - for wiring to air conditioning compressor clutch solenoid.
CAUTIONThe air conditioning refrigerant circuit must not be opened.
  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 air conditioning compressor with attached lines on left side of vehicle.

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

Scheme 21

Scheme 21
Scheme 21
  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

Scheme 22

Scheme 22
Scheme 22
  1. Remove right front wheel housing liner in front area --> «66 - EXTERIOR EQUIPMENT»(ref-281388-S35527536922008031100000) .
  2. Remove bolt - arrow - for corrugated exhaust pipe.

Scheme 23

Scheme 23
Scheme 23
  1. Loosen nut - A - on clamp for corrugated exhaust pipe.
  2. Remove bolt - B - and remove muffler with corrugated exhaust pipe.

All

Scheme 24

Scheme 24
Scheme 24
  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.

Scheme 25

Scheme 25
Scheme 25
  1. Loosen union nuts - 2 - and - 3 - and disconnect ATF lines.

Note. Ignore - 1 -.

Scheme 26

Scheme 26
Scheme 26
  1. Remove Ground (GND) cable - arrow - from right longitudinal member.

Scheme 27

Scheme 27
Scheme 27
  1. Remove vacuum hose - arrow - for brake booster at bulkhead.

Scheme 28

Scheme 28
Scheme 28
  1. Remove coolant hose - arrow - to heater core on rear of engine.

Scheme 29

Scheme 29
Scheme 29
  1. Remove coolant hoses - 1 - and - 2 - at coolant expansion tank.
  2. Remove coolant expansion tank - arrow -.
  3. Disconnect electrical connector on Engine Coolant Level (ECL) Warning Switch F66 at bottom of expansion tank.

Scheme 30

Scheme 30
Scheme 30
  1. Remove coolant hose - arrow - from front coolant line.

Scheme 31

Scheme 31
Scheme 31
  1. Remove left front coolant hose in engine compartment - arrows -.

Scheme 32

Scheme 32
Scheme 32
  1. Remove coolant hose - arrow - from front coolant line.

Scheme 33

Scheme 33
Scheme 33
  1. Disconnect vacuum hose - arrow - to leak detection pump.
CAUTIONNote rules of cleanliness for working on the fuel injection system --> Clean Working Conditions .
CAUTIONFuel system is under pressure! Before opening system, place rags around the connection area. Then release pressure by carefully loosening the connection.

Scheme 34

Scheme 34
Scheme 34
  1. Separate fuel line - arrow - and lay aside.

Scheme 35

Scheme 35
Scheme 35
  1. Remove bolts - arrows -.
  2. Remove air duct - 1 - and - 2 -.

Scheme 36

Scheme 36
Scheme 36
  1. Disconnect check valve - 1 - from air duct hose.
  2. Remove air duct hose, thereby loosening the hose clamp - 2 - and opening clips - arrows -.

Scheme 37

Scheme 37
Scheme 37
  1. Open clips - arrows - and remove upper part of air filter housing.

Scheme 38

Scheme 38
Scheme 38
  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.

Scheme 39

Scheme 39
Scheme 39
  1. Disconnect vacuum hose - arrow - to EVAP canister.

Scheme 40

Scheme 40
Scheme 40
  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.

Scheme 41

Scheme 41
Scheme 41
  1. Remove Ground (GND) wire - arrow - on left strut tower.

Scheme 42

Scheme 42
Scheme 42
  1. Remove left bracket for harness connectors - 1 - and - 2 - from bulkhead.

Scheme 43

Scheme 43
Scheme 43
  1. Remove rubber seal - 1 - for plenum chamber cover.
  2. Remove plenum chamber cover - 2 -.

Scheme 44

Scheme 44
Scheme 44
  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 the nuts and remove the wiper arms.

Scheme 45

Scheme 45
Scheme 45
  1. Remove bolts - arrows - for cowl grill - 1 -.
CAUTIONTo prevent the cowl grille - 1 - from tearing when removing, coat transition between windshield and cowl grille with a soapy solution and pull grille up vertically out of fastening strip beginning at edge of window.
  1. Pull cowl grill off from windshield.

Scheme 46

Scheme 46
Scheme 46
  1. If equipped, remove bolts - 1 - and - 3 - and remove strut tower brace - 2 -.

Scheme 47

Scheme 47
Scheme 47
  1. Remove bolts - arrows - and remove cover form E-box at left in engine compartment.

Scheme 48

Scheme 48
Scheme 48
  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.

Scheme 49

Scheme 49
Scheme 49
  1. Remove bolts - arrows - and remove cover for E-box at right in engine compartment.

Scheme 50

Scheme 50
Scheme 50
  1. Where present, open cover - 1 - using a screwdriver - arrow - and remove.
CAUTIONThe heater pump valve unit (left of E-box) becomes very hot during operation - Risk of burning!

Scheme 51

Scheme 51
Scheme 51
  1. Carefully pry off the retaining clip - 3 - with a screwdriver - arrows 1 and 2 - and remove the 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 connector strip.
  3. Remove electrical wiring connections - 1 - and - 2 -.

Scheme 52

Scheme 52
Scheme 52
  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.
  3. Have a second technician press brake pedal.
CAUTIONTo loosen collar bolt for drive axle, the wheel bearing must not be under load (vehicle must not be standing on its wheels).

Scheme 53

Scheme 53
Scheme 53
  1. Remove collar bolt - 2 - at left and right drive axles - 1 -.

Scheme 54

Scheme 54
Scheme 54
  1. Evenly remove left and right nuts - 1 -.
  2. Remove left and right bolts - 2 - and remove stabilizer bar.

Scheme 55

Scheme 55
Scheme 55
  1. Disconnect electrical harness connector - 2 - at Level Control System Sensor.

Scheme 56

Scheme 56
Scheme 56
  1. Disconnect connecting link - 1 - at control arm.
CAUTIONRisk of damaging axle joints on upper control arms. Support wheel bearing housing.
  1. Tie up wheel bearing housing with Tension Strap T10038 as shown in illustration.

Scheme 57

Scheme 57
Scheme 57
  1. Remove suspension strut from control arm - arrow -.

Scheme 58

Scheme 58
Scheme 58
  1. Remove guide control arm - 1 - and control arm - 2 - on subframe.

Scheme 59

Scheme 59
Scheme 59
  1. Swing guide control arm - 1 - and control arm - 2 - outward.
CAUTIONGuide control arm and control arm must not hang free. Tie up both control arms on wheel bearing housing - arrows - as shown in illustration.
  1. Repeat work procedure on opposite side of the vehicle.

Scheme 60

Scheme 60
Scheme 60
  1. Remove heat shield for drive axle - arrows -.
  2. Remove drive axle from transmission flanged shaft.
CAUTIONDo not damage brake hose!
  1. Swing wheel bearing housing outward and remove drive axle.
  2. Repeat work procedure on opposite side of the vehicle.

Scheme 61

Scheme 61
Scheme 61
  1. Loosen clamping sleeves - 1 - and - 2 -.

Scheme 62

Scheme 62
Scheme 62
  1. Remove front transverse beam - arrows -.

Scheme 63

Scheme 63
Scheme 63
  1. Remove subframe transverse beam - arrows -.

Scheme 64

Scheme 64
Scheme 64

Prepare scissor lift platform

  1. Equip scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10 as follows
Platform coordinatesParts of support set for Audi VAS 6131/10
B4/10-1/10-4/10-5/10-11
G4/10-1/10-4/10-5/10-12
B10/10-1/10-2/10-5/10-8
G/10-1/10-2/10-5/10-8
E13/10-1/10-3/10-5/10-6
D16/10-1/10-3/10-5/10-6
  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.

Scheme 65

Scheme 65
Scheme 65
  1. Position support elements from VAS 6131/10 at front on engine as shown in illustration.
  2. Make sure that the threaded spindles are completely screwed in.

Scheme 66

Scheme 66
Scheme 66
  1. Position support elements from VAS 6131/10 at left and right on subframe as shown in illustration.

Scheme 67

Scheme 67
Scheme 67
  1. Position support elements from VAS 6131/10 at rear on tunnel cross member, 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.

Scheme 68

Scheme 68
Scheme 68
  1. Remove bolts - arrows - on tunnel cross member.

Scheme 69

Scheme 69
Scheme 69
  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 (approximately 10 cm).
  2. Mark selector lever cable bracket installation location.

Scheme 70

Scheme 70
Scheme 70
  1. Remove selector lever cable bracket bolt - 1 -.
  2. Press ball socket - 2 - of selector lever cable from selector shaft lever.

Note. Do not bend or kink selector lever cable.

  1. Completely lower Scissor Lift Table VAS 6131 A and remove it with engine/transmission assembly under vehicle.