3.0L - Engine Assembly - Engine Code(s): Ccba (Cabriolet): Other

ENGINE, SECURING TO ENGINE AND TRANSMISSION HOLDER

Special tools and workshop equipment required

Engine Sling 2024 A
Engine and Transmission Holder VAS 6095 with Universal Mounting VAS 6095/1 and Bracket for V6 FSI Engine, Audi A6 VAS 6095/1-5
Shop Crane -Load Cap=700-1200 Kg VAS 6100
Lift Arm Ext./Workshop Hoist VAS 6101
Joint Support VAS 6131/13-7
Engine Bung Set VAS 6122

Procedure

WARNING

Risk of an accident! The engine may be transported only in the manner described and without the transmission.

The engine/transmission subassembly is removed and the engine and transmission are separated.
Engine secured with VAS 6131/13-7.

Vehicles with Hydraulic Power Steering

Scheme 409

Disconnect electrical connector -arrow- on steering gear.

Note. Place a cloth underneath to soak up any escaping power steering fluid.

Remove the threaded connection -3-.

Seal any open lines and connections with a clean plug from the VAS 6122.

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

All Vehicles

Scheme 410

Remove and disconnect the connector -2- on the right electrohydraulic engine mount solenoid valve -N145-.

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

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 411

Note. To be aligned to the center of gravity of the engine assembly, the hole rails of the lifting hook must be inserted as shown in the illustration.

WARNING

There is the risk of an accident. Lifting hooks and alignment pins on lifting tackle must be secured with securing pins -arrows-.

Tension engine slightly with the shop crane, do not raise.

Disconnect the connector -3- on the left electrohydraulic engine mount solenoid valve -N144-.

Scheme 412

Remove the left engine mount bolt -4-.

Note. Ignore -1, 2 and 5-.

Remove the right engine mount bolt -2-.

Scheme 413

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

Remove the VAS 6131/13-7 from engine.

Scheme 414

Raise engine from engine carrier.

Remove the bolts -arrows- and the left engine support.

Scheme 415

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

Scheme 416

Remove the bolts -arrows- and the right engine support.

Secure the starter on the engine.

Secure the engine to the VAS 6095/1 and VAS 6095/1-5 on the VAS 6095 to 40 Nm, as illustrated.

Scheme 417

LEFT ENGINE MOUNT

Note. To avoid repeat repairs, do the following if the engine mount is faulty: Replace the faulty engine mount and its retaining plate. Likewise replace the engine mount on the opposite side, check the retaining plate and replace it if necessary.

Special tools and workshop equipment required

Engine Support Bridge 10 - 222 A
Spindles 10 - 222 A /11
Oil Collecting and Extracting Device V.A.G 1782
Engine Support Supplement Set T40093
Adapter T40093/6

Scheme 418

Scheme 418: REMOVING

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

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

Scheme 419

Remove the bolts -arrows- and move oil cooler to the side with the coolant hoses -1 and 2- still connected.

Vehicles with an After-Run Coolant Pump -V51

Remove the after-run coolant pump. Refer to After-Run Coolant Pump -V51 and the oil cooler ENGINE OIL COOLER .

All Vehicles

Scheme 420

Remove Air Conditioning (A/C) compressor. Refer to Removal and Installation .

Install the 10 - 222 A with T40093/6 on the left and right strut towers, as shown in the illustration.

Scheme 421

Attach the 10 - 222 A /11 to the left and right engine lifting eyes.

Lightly pretension engine with spindles.

Vehicles with Hydraulic Power Steering

Remove the nut -2- and free up the bracket -1-.

All Vehicles

Scheme 422

Remove the left subframe bolt -2-.

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

Disconnect the connector -3- on the left electrohydraulic engine mount solenoid valve -N144-.

Remove the left engine mount bolts -1, 4 and 5-.

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

Remove the left engine mount.

INSTALLING

Install in reverse order of removal. Note the following

Tightening specifications

«SUBFRAME MOUNT OVERVIEW»(ref-522408-S33328460732013011400000)
see scheme 2

Note. Replace bolts that are tightened to the specification.

Tighten the subframe. Refer to Removal and Installation .

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

Install the oil cooler. Refer to ENGINE OIL COOLER .

Install the noise insulation. Refer to Description and Operation .

ENGINE, REMOVING

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 installed at the same location.

Special tools and workshop equipment required

Pry Lever - Rmv Outside Mirror 80 - 200
Oil Collecting and Extracting Device V.A.G 1782
Step Ladder VAS 5085
Engine Bung Set VAS 6122
Scissor-Type Assembly Platform VAS 6131 A with support set VAS 6131/10 and Supplementary set, Audi Q7 VAS 6131/13
Drip Tray for VAS 6100 VAS 6208
Hose Clip Pliers VAS 6362
Puller for Gear Shaft Linkage T40160

Procedure

WARNING

Risk of vehicle tipping over with the engine removed. Secure vehicle. Luggage compartment must be empty for this. There is a risk of injury because the fuel is under very high pressure. Reduce the fuel pressure down to residual pressure before opening high pressure area of the fuel injection system.

Reduce fuel pressure in high pressure area. Refer to General Information .

Position the front wheels so they are straight.

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

Scheme 423

CAUTION

Risk of destroying electrical components. Observe measures for disconnecting battery.

Turn off the ignition and remove the key.

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

Empty coolant circuit. Refer to Description and Operation .

Vehicles with Hydraulic Power Steering

Scheme 424

Extract the power steering fluid from the power steering reservoir using the V.A.G 1782 -3-.

Note. Ignore -1, 2 and 4-.

All Vehicles

Scheme 425

Remove the engine covers -1 and 2- upward.

Scheme 426

WARNING

Risk of scalding due to hot steam and hot coolant. The coolant system is under pressure when the engine is warm. Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system.

Open the coolant reservoir cap.

Remove the left and right front wheels. Refer to Removal and Installation .

Remove left and right front wheel housing liners. Refer to Removal and Installation .

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

Place VAS 6208 under the engine.

Scheme 427

Remove the drain plug -1- and drain the coolant.

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

Remove the coolant hose from the engine oil cooler by loosening the hose clamp -arrow- and letting the coolant drain out.

Scheme 428

Note. The engine is not shown in the following illustrations.

Vehicles with Left Front Coolant Pipes, Version

Scheme 429

Loosen the hose clamps -1 and 3-, remove the left front coolant hoses from the coolant pipes and drain any remaining coolant.

Note. Ignore -2-.

Vehicles with Left Front Coolant Pipes, Version 2

Scheme 430

Loosen the clamps -arrows-, drain any remaining coolant and then remove the coolant hoses from the left front coolant pipes.

Note. Ignore -1-.

All Vehicles

Scheme 431

Disconnect and free up the connector -3- on the charge air cooling pump -V188-.

Note. Ignore -1 and 2-.

Vehicles with Hydraulic Power Steering

Scheme 432

Place the 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 any open lines and connections with a clean plug from the VAS 6122.

Vehicles with Coolant Recirculation Pump -V50-, Version 1

Scheme 433

Disconnect the connector -2-.

Place VAS 6208 under engine.

Loosen the hose clamp -1- and remove the coolant hose from the coolant recirculation pump.

Note. Ignore -3 and 4-.

All Vehicles

Scheme 434

Disconnect the radiator fan electrical connectors -1 and 2-, to do this, push the clamp to the rear -arrow- and push the release down.

Free up the wiring harness.

Vehicles with Secondary Air Injection (AIR) Pump Motor -V101-, Version 1

Scheme 435

Disconnect the connector -3- on the AIR pump motor.

Press the release buttons and remove the secondary air hose -1-.

Note. Ignore -2-.

Vehicles with Secondary Air Injection (AIR) Pump Motor -V101-, Version 2

Scheme 436

Disconnect the connector -2- on the AIR pump motor.

Press the release buttons and remove the secondary air hose -1-.

Note. Ignore -3-.

All Vehicles

Scheme 437

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

Remove the nut -arrow- on the right longitudinal member and free up the ground wires.

Remove the seal from the plenum chamber bulkhead.

Scheme 438

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

Remove the air duct -arrows-.

Scheme 439

Free up the fuel hose -1- and the EVAP canister hose -2- on the air duct pipe.

Scheme 440

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

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

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

Scheme 441

Disconnect the vacuum connection -2- from the plenum chamber bulkhead. Remove the vacuum hose -1- on the back.

Scheme 442

Disconnect the connector -3- on the 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.

Disconnect the vacuum hose leading to the leak detection pump -V144- -arrow-.

Scheme 443

Vehicles with Version 1

Scheme 444

WARNING

Risk of injury from fuel. To reduce the fuel pressure, lay cloths around the connecting point before opening fuel system and carefully loosen.

CAUTION

There is a risk of contamination. Follow the guidelines for cleanliness when working on the fuel supply system. Refer to CLEAN WORKING CONDITIONS .

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

Seal any open lines and connections with a clean plug from the VAS 6122.

Lift the clamp -arrow- and remove the coolant hose leading to the back of the heater core on the engine.

Scheme 445

Note. To provide a better illustration, component location is shown from behind with the engine removed.

Disconnect the vacuum hose -1- and free it up.

Scheme 446

Note. Ignore -2 and 3-.

Vehicles with Version 2

Scheme 447

WARNING

Risk of injury from fuel. To reduce fuel pressure, lay cloths around the connecting point before opening the fuel system and carefully loosen.

CAUTION

There is a risk of contamination. Follow the guidelines for cleanliness when working on the fuel supply system. Refer to CLEAN WORKING CONDITIONS .

Press the release buttons and disconnect the fuel hose -1-.

Seal any open lines and connections with a clean plug from the VAS 6122.

Note. Ignore -arrows-.

Lift the clamp -2- and remove the coolant hose leading to the heater core on the plenum chamber bulkhead.

Scheme 448

Note. Ignore -1-.

All Vehicles

Scheme 449

Open the clamp and remove the right front coolant hose -arrow- from the front coolant pipe.

Loosen the clamp -arrow- and remove the coolant hose.

Scheme 450

Note. Ignore -1 and 2-.

Lift the clamp -arrow- and remove the coolant hose from the front coolant pipe

Scheme 451

Vehicles with Hydraulic Power Steering

Scheme 452

Remove the coolant hoses -1 and 2- from the coolant overflow reservoir.

Remove the bolts -arrows-, disconnect the connector on the engine coolant level warning switch -F66- and remove the coolant reservoir.

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

Scheme 453

Press the hydraulic hose down slightly.

All Vehicles

Scheme 454

CAUTION

Risk of damaging refrigerant lines and hoses. Do not stretch, kink or bend refrigerant lines and hoses.

Remove the bolts -arrows- and the refrigerant lines from the Air Conditioning (A/C) compressor.

Seal any open lines and connections with a clean plug from the VAS 6122.

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

Scheme 455

Remove the nut -1- from the electric wires.

Scheme 456

Remove the electrical connector -2- from the bracket and disconnect it.

Remove the bolt -3- 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 wrench -1- and remove the wiring bushing -2- upward.

Scheme 457

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

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

Scheme 458

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

Scheme 459

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

Scheme 460

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 461

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

Scheme 462

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

Release the retainers -A arrows- and remove the Engine Control Module (ECM) -arrow B-.

Scheme 463

Disconnect the connector -2- if applicable.

Scheme 464

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

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

Remove the ground pin -1- and free up the wiring harness.

Lay the wiring harness on the engine and secure the ECM so that it cannot fall.

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

Scheme 465

Disconnect the connector -1- from the left front level control system sensor -G78- and from the right front level control sensor -G289- and free up the wires -arrow-.

Scheme 466

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 467

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

Remove the bolts -1- and secure the brake caliper, with the brake line still connected, inside the wheel housing using wire.

CAUTION

Risk of damaging brake pistons. Do not operate the brake pedal when the brake caliper is removed.

Remove the nut -2- and the bolt -1-.

Scheme 468

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

Repeat the procedure on the other side of the vehicle.

Remove the left and right stabilizer bar bolt -1-.

Scheme 469

Remove the left and right nuts -3-.

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

Remove the subframe cross brace. Refer to Removal and Installation .

Scheme 470

CAUTION

The suspension components could be damaged. Do not rest the vehicle on its wheels if the subframe mount, the steering gear or the subframe cross brace are not installed correctly.

Audi A5 Cabriolet

Scheme 471

Remove diagonal braces. Refer to Removal and Installation .

Vehicles with Electro-Mechanical Power Steering

Scheme 472

Release the safety catch -arrow-, push the retainer down and disconnect the connector from -2- from the power steering control module -J500-.

Free up the wiring harness.

Note. Ignore -1-.

All Vehicles

Scheme 473

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

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

Scheme 474

Remove the left front muffler nuts -arrows-.

Scheme 475

Remove the right front muffler nuts -arrows-.

Scheme 476

Scheme 477

CAUTION

The decoupling elements in the front muffler could be damaged. Do not bend decoupling element in front muffler more than 10°.

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

Vehicles with a Bolted Driveshaft

Scheme 478

Remove the driveshaft from the transmission. Refer to Removal and Installation or Removal and Installation .

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

Secure the driveshaft to the side.

Vehicles with an Attached Driveshaft

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

All Vehicles

Scheme 479

Remove the steering intermediate shaft from the steering gear push them upward. Refer to Removal and Installation .

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

Scheme 480

CAUTION

Risk of damaging clutch slave cylinder. Do not operate the clutch pedal anymore after slave cylinder has been removed.

Remove the selector rod nut -1-.

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

Scheme 481

Prepare Scissor Lift Platform

Scheme 482

Equip the VAS 6131 A with the VAS 6131/10 and VAS 6131/13 as follows

Table Coordinates	Parts from VAS 6131/10 and VAS 6131/13
B4	/13-4	/10-4	/10-5	/13-1
G4	/13-4	/10-4	/10-5	/13-1
B6	/10-1	/10-2	/10-5	/10-11
G6	/10-1	/10-2	/10-5	/10-11
A8+C8	/13-6			/13-2
F8+H8	/13-6			/13-2
C14	/10-1	/10-3	/10-5	/10-13
F14	/10-1	/10-3	/10-5	/10-10

Next secure mounting elements to scissor lift table by hand.

Position the VAS 6131 A horizontally.

Note bubble level (sight glass) on support platform.

Move the VAS 6131 A under the engine/transmission subassembly.

WARNING

The subframe could cause an accident if it is not secured. Do not loosen the subframe bolts -2 and 3-.

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.

Scheme 483

Ensure threaded spindles are completely installed.

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

Scheme 484

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 485

Remove the noise insulation retaining clips from the crossmember.

Scheme 486

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 the 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- in a diagonal sequence in stages.

Remove the bolts -arrows- on the tunnel crossmember.

Scheme 487

Remove the left and right bolts -2-.

CAUTION

Risk of damaging hose and wiring connections as well as the engine compartment. Make sure all the hoses and lines between the engine, transmission, subframe and body have been disconnected. Carefully guide engine-transmission assembly with subframe out of the engine compartment while lowering.

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

Scheme 488

Dimension -a- = 100 mm maximum.

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

Scheme 489

Note. Ignore -2-.

Lower the engine/transmission subassembly more.

Remove the VAS 6131 A with the engine/transmission subassembly under vehicle.

ENGINE AND MANUAL TRANSMISSION, SEPARATING

Special tools and workshop equipment required

Scissor-Type Assembly Platform VAS 6131 A
Support Set VAS 6131/10, Supplementary Set VAS 6131/13-7 and Gearbox Support VAS 6131/14
Socket T40058

Procedure

Scheme 490

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

Remove the electrical connector -3- for the Oxygen Sensor (O2S) 2 after catalytic converter -G131- from the bracket and disconnect it.

Note. Ignore -1 and 2-.

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

Scheme 491

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

Scheme 492

Note. Ignore -2 and 3-.

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

Scheme 493

Disconnect the connector -2- from the Engine Speed (RPM) sensor -G28-.

Scheme 494

Note. Ignore -1-.

Vehicles with Electro-Mechanical Power Steering

Disconnect the connector -1- from the power steering control module -J500-.

Free up the wiring harness.

Note. Ignore -2-.

Remove the bolt -arrow- and move the coolant recirculation pump -V50- to the side.

Scheme 495

All Vehicles

Disconnect the connector -2- from the gear recognition sensor -G604-.

Note. Ignore -1 and 3-.

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

Scheme 496

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

Scheme 497

Insert the T40058 guide pins as follows

Scheme 498

The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

Counter hold the crankshaft and loosen the drive plate bolts using a T40058 and a ring wrench.

Scheme 499

Note. The crankshaft may be turned only in the direction of engine rotation -arrow-.

Remove the 6 bolts -arrow- on the clutch module. Turn the crankshaft an additional 60° in the direction of engine rotation.

Scheme 500

Equip the VAS 6131 A with the VAS 6131/10, VAS 6131/13-7 and VAS 6131/14 as follows

Note. The other attachments remain unchanged.

Table Coordinates	Parts from the VAS 6131/10, VAS 6131/13-7 and VAS 6131/14
F2	/13-7
B10	/10-1	/10-2	/10-5	/14
G10	/10-1	/10-2	/10-5	/14

Install the 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 VAS 6131/10 and VAS 6131/14 at the front of the transmission as shown in the illustration.

Scheme 501

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

Attach mounting element base plates to the 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 the remaining bolts -3 through 11- that attach the engine to the transmission.

Note. Ignore -A-.

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

Scheme 502

ENGINE, INSTALLING

Special tools and workshop equipment required

Ring Spanner Insert AF 16 V.A.G 1332/14
Assembly Aid T40169
Transportation Lock T40170
Scissor-Type Assembly Platform VAS 6131 A

Tightening Specifications

Note. The tightening specifications apply only 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. Tightening specification tolerance +/- 15%.

Component		Nm
Bolts and nuts	M6	9
	M7	15
	M8	20
	M10	40
	M12	65

Subframe mount, refer to SUBFRAME MOUNT OVERVIEW .

Tighten the ground bolt -1- to 9 Nm.

Tighten the nut -arrow- to 9 Nm.

Engine to Manual Transmission

Item	Bolt	Nm
1	M10 x 50 1)	65
2 through 6	M12 x 100 2)	30 + 90°
7	M12 x 125 2)	30 + 90°
8, 11	M10 x 60 2)	15 + 90°
9, 10	M10 x 95 2)	15 + 90°
A	Alignment sleeves for centering
1) Bolt class 10.9, the steel bolt may be used again unlimited number of times. 2) The aluminum bolts can be used 2 times ENGINE, INSTALLING .
(1) To prevent damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt using a 14 mm socket with a / 2 drive, which is inserted in to the vise, as illustrated.

(1)	To prevent damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt using a 14 mm socket with a / 2 drive, which is inserted in to the vise, as illustrated.

Scheme 503

The aluminum bolts -2 through 11- may be used two times. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have been used the first time -arrow-.
Bolts marked with an "X" may not be used again.

Procedure

Note. Replace the bolts which are being tightened with an additional turn. Replace self-locking nuts and bolts and seals, gaskets 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. Needle bearing, removing from and installing on drive plate. Refer to NEEDLE BEARING ON DRIVE PLATE . The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing. Secure all hose connections with hose clamps of the same type as those equipped by the factory. To mount the air guide hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing. When installing, bring all cable ties back to the same positions.

Install the 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.

The following preparations must be made before connecting the engine and transmission

Scheme 504

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

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

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

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

Insert the T40170 in the transmission housing from below and secure it on the flange shaft -1-.

Scheme 505

Check if the alignment sleeves -A- for centering the engine/transmission are in the cylinder block and insert them if they are not.

Inspect the aluminum bolts used to connect the engine to the transmission to see if they 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 the T40058 guide pins as follows

The large diameter -arrow 1- faces the engine.
The small diameter -arrow 2- faces the adapter.

Turn the crankshaft further one complete turn (360°) in direction of engine rotation -arrow- using the T40058 and ring wrench.

Scheme 506

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- and tighten by hand (2 Nm).

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

Tighten the bolts that are accessible in this position to the tightening specification. Refer to SPECIFICATIONS .

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

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: for the left one, refer to LEFT CATALYTIC CONVERTER and for the right one, refer to RIGHT CATALYTIC CONVERTER .

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

a- = minimum 100 mm

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

Continue raising the engine/transmission subassembly 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 Specifications .

WARNING

Risk of accident due to loose connections. If the bolts in the subframe are not tightened to final torque, vehicle must not be driven.

Tighten the tunnel crossmember bolts -arrow-. Refer to Specifications .

Install in reverse order of removal paying attention to the following

Install the clutch slave cylinder. Refer to Removal and Installation .

Attach the steering intermediate shaft to the steering gear. Refer to Removal and Installation .

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

Install the front muffler. Refer to FRONT MUFFLER .

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

Install the front crossmember. Refer to Description and Operation .

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

Install diagonal braces. Refer to Removal and Installation .

Install brake caliper. Refer to Removal and Installation .

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

Electrical connectors and wiring 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 116, see scheme 117 and Removal and Installation.

Install the tower brace. Refer to Removal and Installation .

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

Install refrigerant lines. Refer to Removal and Installation .

Be sure to follow the procedure for connecting the battery and afterwards. Refer to Removal and Installation .

CAUTION

There is a risk of destroying control modules with excess voltage. Do not use a charger as a starting aid.

Install the fuel supply hose and air filter housing. Refer to Removal and Installation .

Install the lock carrier braces. Refer to Description and Operation .

Fill the engine oil and check the level.

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

Note. The power steering pump must not run dry.

Connect the coolant hose to the coupling. see scheme 130

Scheme 507

Fill the coolant. Refer to COOLANT, 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 Description and Operation .

Install the wheel housing liners. Refer to Removal and Installation .

Install the front wheels. Refer to Removal and Installation .

Perform axle alignment. Refer to General Information .

WARNING

Risk of accident due to loose connections. Tighten the subframe bolts to the specification after performing axle alignment.

Install the noise insulation. Refer to Description and Operation .

RIGHT ENGINE MOUNT

Special tools and workshop equipment required

Engine Support Bridge 10 - 222 A
Spindles 10 - 222 A /11
Engine Support Supplement Set T40093
Adapter T40093/6

REMOVING

Install the 10 - 222 A with one on the left and right strut towers, as shown in the illustration.

Attach the 10 - 222 A /11 to the left and right engine lifting eyes.

Lightly tension the engine with spindles.

Remove the right front wheel. Refer to Removal and Installation .

Remove the right front wheel housing liner. Refer to Removal and Installation .

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

Remove and disconnect the connector -2- on the right electrohydraulic engine mount solenoid valve -N145-.

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

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

Vehicles with S-Tronic transmission 0B5

Scheme 508

Remove bolt -arrow- on ATF line bracket.

Note. Ignore -1 and 2-.

All Vehicles

Scheme 509

Lift the engine by the right 10 - 222 A /11 -1- by dimension -a-.

Dimension -a- = approximately 20 mm.

Remove the right engine mount.

Install in reverse order of removal. Note the following

Tightening specifications, refer to «SUBFRAME MOUNT OVERVIEW»(ref-522408-S33328460732013011400000) .

Note. Replace bolts that are tightened to the specification.

Vehicles with S-Tronic Transmission 0B5

Install ATF lines. Refer to Removal and Installation .

All Vehicles

Install the front wheel housing liner and noise insulation. Refer to Removal and Installation .

Install the front wheel. Refer to Removal and Installation .

Special tools and workshop equipment required

Pry Lever - Rmv Outside Mirror 80 - 200
Oil Collecting and Extracting Device V.A.G 1782
Step Ladder VAS 5085
Engine Bung Set VAS 6122
Scissor Lift Table VAS 6131 A with Support Set VAS 6131/10 and Supplementary Set VAS 6131/11 and VAS 6131/13
Drip Tray for VAS 6100 VAS 6208
Hose Clip Pliers VAS 6362

Procedure

WARNING

Risk of vehicle tipping over with engine removed. Secure vehicle. Luggage compartment must be empty for this. There is a risk of injury because the fuel is under very high pressure. Reduce the fuel pressure down to residual pressure before opening the high pressure area of the fuel injection system.

Reduce fuel pressure in high pressure area. Refer to General Information .

Position the front wheels so they are straight.

Note. Release the electro-mechanical parking brake before disconnecting the battery so the drive axle can be rotated to remove it.

CAUTION

Risk of destroying electrical components. Observe measures for disconnecting battery.

Turn off the ignition and remove the key.

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

Empty coolant circuit. Refer to Description and Operation .

Vehicles with Hydraulic Power Steering

Extract the power steering fluid from the power steering reservoir using the V.A.G 1782 -3-.

Note. Ignore -1, 2 and 4-.

All Vehicles

Remove the engine covers -1 and 2- upward.

WARNING

Open the coolant reservoir cap.

Remove the left and right front wheels. Refer to Removal and Installation .

Remove left and right front wheel housing liners. Refer to Removal and Installation .

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

Place VAS 6208 under engine.

Remove the drain plug -1- and drain the coolant.

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

Loosen the hose clamp -arrow-, remove the coolant hose from the oil cooler and drain the coolant.

Note. The engine is not shown in the following illustrations.

Vehicles with Left Front Coolant Pipes, Version 1

Loosen the hose clamps -1 and 3-, remove the left front coolant hoses from the coolant pipes and drain any remaining coolant.

Note. Ignore -2-.

Vehicles with Left Front Coolant Pipes, Version 2

Loosen the clamps -arrows-, drain any remaining coolant and then remove the coolant hoses from the left front coolant pipes.

Note. Ignore -1-.

All Vehicles

Disconnect and free up the connector -3- on the charge air cooling pump -V188-.

Note. Ignore -1 and 2-.

Vehicles with Hydraulic Power Steering

Place the 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 any open lines and connections with a clean plug from the VAS 6122.

All Vehicles

Place the 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 any open lines and connections with a clean plug from the VAS 6122.

Note. Ignore -arrow-.

Vehicles with Coolant Recirculation Pump -V50-, Version 1

Disconnect the connector -2-.

Place the VAS 6208 under the engine.

Loosen the hose clamp -1- and remove the coolant hose from the coolant recirculation pump.

Note. Ignore -3 and 4-.

All Vehicles

Disconnect the radiator fan electrical connectors -1 and 2-, to do this, push the clamp to the rear -arrow- and push the release down.

Free up the wiring harness.

Vehicles with Secondary Air Injection (AIR) Pump Motor -V101-, Version 1

Disconnect the connector -3- on the AIR pump motor.

Press the release buttons and remove the secondary air hose -1-.

Note. Ignore -2-.

Vehicles with Secondary Air Injection (AIR) Pump Motor -V101-, Version 2

Disconnect the connector -2- on the AIR pump motor.

Press the release buttons and remove the secondary air hose -1-.

Note. Ignore -3-.

All Vehicles

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

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

Remove the seal from the plenum chamber bulkhead.

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

Remove the air duct -arrows-.

Free up the fuel hose -1- and the EVAP canister hose -2- on the air duct pipe.

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

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

Remove the air filter housing and where equipped, disconnect the connector -arrow- on the intake air switch-over valve -N335-.

Disconnect the vacuum connection -2- from the plenum chamber bulkhead. Remove the vacuum hose -1- on the back.

Disconnect the 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.

Disconnect the vacuum hose leading to the leak detection pump -V144- -arrow-.

All Vehicles

WARNING

Risk of injury from fuel. To reduce fuel pressure, lay cloths around connecting point before opening the fuel system and carefully loosen.

CAUTION

There is a risk of contamination. Follow the guidelines for cleanliness when working on the fuel supply system. Refer to CLEAN WORKING CONDITIONS .

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

Seal any open lines and connections with a clean plug from the VAS 6122.

Vehicles with Version 1

Lift the clamp -arrow- and remove the coolant hose leading to the back of the heater core on the engine.

Note. To provide a better illustration, component location is shown from behind with engine removed.

Remove the vacuum hose -1- for the climatronic refrigerant shut-off valve -N422-.

Note. Ignore -2 and 3-.

Vehicles with Version 2

WARNING

Risk of injury from fuel. To reduce fuel pressure, lay cloths around connecting point before opening the fuel system and carefully loosen.

CAUTION

There is a risk of contamination. Follow the guidelines for cleanliness when working on the fuel supply system. Refer to CLEAN WORKING CONDITIONS .

Press the release buttons and disconnect the fuel hose -1-.

Seal any open lines and connections with a clean plug from the VAS 6122.

Note. Ignore -arrows-.

Lift the clamp -2- and remove the coolant hose leading to the heater core on the plenum chamber bulkhead.

Note. Ignore -1-.

All Vehicles

Open the clamp and remove the right front coolant hose -arrow- from the front coolant pipe.

Loosen the clamp -arrow- and remove the coolant hose.

Note. Ignore -1 and 2-.

Lift the clamp -arrow- and remove the coolant hose from the front coolant pipe

Vehicles with Hydraulic Power Steering

Remove the coolant hoses -1 and 2- from the coolant overflow reservoir.

Remove the bolts -arrows-, disconnect the connector on the engine coolant level warning switch -F66- and remove the coolant reservoir.

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

Press the hydraulic hose down slightly.

All Vehicles

CAUTION

Risk of damaging refrigerant lines and hoses. Do not stretch, kink or bend refrigerant lines and hoses.

Remove the bolts -arrows- and the refrigerant lines from the Air Conditioning (A/C) compressor.

Seal any open lines and connections with a clean plug from the VAS 6122.

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

Remove the nuts -1- from the electric wires.