4.2L - Engine Assembly - Engine Code(s): Caua (Coupe): Other

ENGINE TO MANUAL TRANSMISSION

Item	Bolt	Nm
1 1)	M10 x 50 2)	65
2 3) to 6	M12x100 4)5)	30 + 90°
7	M12x125 4)5)	30 + 90°
8, 11	M10x60 4)5)	15 + 90°
9, 10	M10x95 4)5)	15 + 90°
A	Alignment sleeves for centering
1) Also secures the starter 2) Bolt strength rating 10.9. There is no limit to the number of times steel bolts may be used. 3) Also secures the starter. 4) Through VIN 8T-9A-007999: replace the aluminum bolts. 5) From VIN 8T-9A-008000: the aluminum bolts may be used twice ENGINE, INSTALLING From VIN 8T-9A-008000: the aluminum bolts -2 through 11- may be used twice. .

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 as well as Supplementary Set, Audi A8 VAS 6131/11, Supplementary Set, Audi Q7 VAS 6131/13 and qty. 3 Tapered Mounting Pin VAS 6131/10-2
Drip Tray For VAS 6100 VAS 6208
Hose Clip Pliers VAS 6340
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 high pressure area of the fuel injection system.

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

Note. Release the electrical parking brake before disconnecting battery so the driveshaft can be rotated to remove it. Place the selector lever in the "N" position and release the electromechanical parking brake before disconnecting the battery so that the driveshaft can still move freely.

Position the front wheels so they are straight.

Scheme 49

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 pole. Refer to Removal and Installation .

Empty coolant circuit. Refer to Description and Operation .

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

Remove the engine cover -arrows-.

Scheme 50

Scheme 51

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.

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 .

Scheme 52

Place VAS 6208 under engine.

Remove the drain plug -arrow- on the front coolant hose and drain the coolant.

Scheme 53

Remove the drain plug -arrow- on the map controlled engine cooling thermostat -F265- and drain the coolant.

Scheme 54

Disconnect the coolant hose from the radiator, to do this, lift the retaining clip -2-.

Scheme 55

Note. Ignore -1, 3 and 4-.

Disconnect the vacuum hose -1- and free up the hydraulic hose -arrow- on the bracket.

Scheme 56

Remove the nuts -2- and vacuum reservoir.

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

Scheme 57

Disconnect the power steering hydraulic oil feed line -2- and return line -1-.

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

Note. Observe the rules of cleanliness for working on automatic transmissions. Refer to General Information .

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

Disconnect the ATF line -2-.

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

Note. Ignore -1-.

CAUTION

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

Remove the bolts -1 and 2-.

Scheme 58

Disconnect the refrigerant lines from the compressor.

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

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

Scheme 59

Disconnect the connector -2-.

Scheme 60

Place VAS 6208 under engine.

Remove the coolant hoses from the after-run coolant pump -V51- -arrows-.

Note. Ignore -1-.

Disconnect the connector -3- on the secondary air injection (AIR) pump motor -Via-.

Scheme 61

Remove the AIR hose -1- and free it up.

Note. Ignore -2-.

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

Scheme 62

Free up the wiring harness.

Remove the left and right bolts -1- and nuts -3- and the lock carrier braces -2-.

Scheme 63

WARNING

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

CAUTION

Follow the guidelines for cleanliness when working on the fuel supply system. Refer to CLEAN WORKING CONDITIONS .

Disconnect the fuel line -arrow-.

Scheme 64

Free up the fuel line and the line to the Evaporative Emission (EVAP) canister on the air guide pipe.

Scheme 65

Disconnect the electrical connector -2- on EVAP canister purge regulator valve 1 -N80- and disconnect the vacuum hose -1-.

Remove the EVAP canister purge regulator valve 1 from the bracket and lay aside with hose and fuel line connected.

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

Scheme 66

Remove the air duct -arrows-.

Scheme 67

Disconnect the connector -1- from the Mass Airflow (MAF) sensor -G70-.

Scheme 68

Disconnect the vacuum line -3- from the air guide pipe.

CAUTION

Risk of violating emissions legislation. Do not open the hose connection -2- !

Lay aside air guide pipe with connected crankcase ventilation hose -2- by loosening hose clamp -4- and opening clips -arrows-.

Disconnect the vacuum line -1-.

Scheme 69

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

Remove hose -3- from the secondary air system.

Disconnect the coolant hose by lifting the retaining clamps -2- and loosening the hose clamp -1- on the coolant tube.

Scheme 70

Disconnect electrical connector -1- for the brake system vacuum pump -V192- and free up the electrical wiring.

Scheme 71

Disconnect the vacuum hose -2-.

Remove the coolant hoses -1 and 3- from the coolant overflow reservoir.

Scheme 72

Note. Ignore -2 and arrows-.

Note. Catch any leaking ATF with a cloth.

Disconnect the ATF line -arrow-.

Scheme 73

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

Remove the seal -arrow-.

Scheme 74

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

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

Scheme 75

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

Scheme 76

Disconnect the connectors -3 and 4-.

Remove the bolt -5- 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 77

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

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

Scheme 78

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

Scheme 79

Remove the filler neck -2- 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-. The procedure for doing this depends on the version.

Scheme 80

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

Scheme 81

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

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

Scheme 82

Disconnect the connector -2- if applicable.

Scheme 83

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

Open the retainers -arrows A- and remove the harness opening -2- -arrow B-.

Scheme 84

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

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

Mark and remove the coolant hoses -1 and 2- for re-installing.

Scheme 85

Press the coolant hoses with hose guide in the engine compartment.

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

Scheme 86

Disconnect the connector -1- headlamp beam control sensor 1 -G233- electrical sensor -arrow- and free up electrical wiring.

Scheme 87

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

Scheme 88

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 with brake caliper removed.

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

Scheme 89

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 90

Remove the left and right nuts -3-.

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

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 crossbrace are not installed correctly. Do not support the vehicle on the subframe or the subframe crossbrace (for example by a floor jack or similar device).

Remove the subframe crossbrace. Refer to Removal and Installation .

Scheme 91

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

Scheme 92

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

Scheme 93

Remove the left front muffler nuts -arrows-.

Scheme 94

Remove the right front muffler nuts -arrows-.

Scheme 95

CAUTION

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

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

Scheme 96

Remove the bolts -arrows- and the driveshaft heat shield -1-.

Scheme 97

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

Scheme 98

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

Secure the driveshaft to the side.

Remove the ball socket -1- on the selector lever cable from the selector shaft lever using the 80 - 200.

Scheme 99

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

Note. Do not bend or kink the selector lever cable.

Prepare Scissor Lift Platform

Scheme 100

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

Platform 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	/10-4	/10-5	/10-7
F14	/10-1	/10-4	/10-5	/11-1

Next secure mounting elements to scissor lift table by hand.

Position the VAS 6131 A horizontally.

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

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

Scheme 101

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 102

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 103

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 104

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 105

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 the left and right subframe bolts -2 and 3- in a diagonal sequence in stages.

Note. Ignore -1-.

Remove the bolts -arrows- on the tunnel crossmember.

Scheme 106

Remove the left and right bolts -2-.

Note. Ignore -1 and 3-.

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 the engine-transmission assembly with subframe out of the engine compartment while lowering.

Lower the engine/transmission subassembly using the VAS 6131 A.

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

ENGINE AND AUTOMATIC 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 Transmission Support VAS 6131/14
Engine Bung Set VAS 6122
Socket T40058
Adapter T40257
Wrench T40263
M10 x 65 bolt

Procedure

Scheme 107

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

Remove electrical connectors from the bracket and disconnect

2 - For Heated Oxygen Sensor (HO2S) 2 -G108

3 - For Oxygen Sensor (O2S) 2 after catalytic converter -G131

Note. Ignore -1 and 4-.

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

Scheme 108

Note. Catch any leaking ATF with a cloth.

Remove the bolts -1, 2, 4, 5 and 6- and the nut -3-.

Scheme 109

Remove the ATF line.

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

Remove electrical connectors from bracket and disconnect

Scheme 110

2 - For Oxygen Sensor (O2S) after Three Way Catalytic Converter (TWC) -G130

3 - For Heated Oxygen Sensor (HO2S) -G39

Note. Ignore -1 and 4-.

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

Scheme 111

Disconnect the electrical connectors -1- leading to the steering gear -2- on the Engine Speed (RPM) sensor -G28- and free up the electrical wires.

Scheme 112

CAUTION

There is a risk of destroying the transmission control module (Mechatronic) with static discharge. Do not touch contacts in the transmission connector with hands.

To discharge static electricity, touch the transmission housing (without wearing gloves).

Disconnect the connector on the transmission by rotating screw connections counter-clockwise -arrow-.

Scheme 113

Free up the wiring harness on the transmission.

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

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

Scheme 114

Insert the T40058 guide pins as follows

Scheme 115

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

Attach the T40257 to the T40263.

Scheme 116

Attach the adapter to the bolts on the vibration damper.

The notch -arrow A- on the T40257 must face the color dash -arrow B- on the vibration damper.

Note. Ignore the semi-round countersink on the T40257. When mounting, turn the crankshaft only in the direction of engine rotation -arrow-.

Remove the six torque converter bolts -arrow- while turning the crankshaft 60° further in the direction of engine rotation.

Scheme 117

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.

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

Connect the right front VAS 6131/13-7 to the engine using the MD bolt in threaded hole as shown in the illustration.

Scheme 118

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 119

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 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 rear table plate with transmission toward the rear -arrow-.

Scheme 120

ENGINE, INSTALLING

Special tools and workshop equipment required

Scissor-Type Assembly Platform VAS 6131 A
Ring Spanner Insert AF 16 V.A.G 1332/14
Transportation Lock T40170
Adapter T40257
Wrench T40263

Tightening specifications

Note. The tightening specifications apply only to lightly greased, oiled, phosphated or blackened nuts and bolts. Additional lubricant such as engine or transmission oil may be used, but do not use graphite lubricant. 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
Exceptions
Ground pins to the strut tower		9

Subframe mount, refer to SUBFRAME MOUNT OVERVIEW .

Engine to Automatic Transmission 0B6

Item	Bolt	Nm
1	M10 x 50 1)	65
2 ••• 6	M12x100 2)3)	30 + 90°
7	M12x175 2)3)	30 + 90°
8, 11	M10x60 2)3)	15 + 90°
9	M10x75 2)3)	15 + 90°
10	M10x95 2)3)	15 + 90°
A	Alignment sleeves for centering
1) Bolt class 10.9, the steel bolt may be used again unlimited number of times. 2) Through VIN 8T-9A-007999: replace the aluminum bolts. 3) From VIN 8T-9A-008000: the aluminum bolts may be used twice ENGINE, INSTALLING => From VIN 8T-9A-008000: the aluminum bolts -2 through 11- may be used twice. .
(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 121

From VIN 8T-9A-008000: the aluminum bolts -2 through 11- may be used twice. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have be 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. The hose connections and charge air system 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. 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. When installing, bring all cable ties back to same positions.

Install Secondary Air Injection (AIR) pipe. Refer to SECONDARY AIR INJECTION SYSTEM WITHOUT VACUUM CONTROL OVERVIEW .

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

Before installing a replacement engine, make sure the semi-circular ring -arrow- is inserted in the power steering pump driveshaft.

Scheme 122

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

Scheme 123

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

Note. There is only 1 notch on the circumference; rotate the torque converter as needed.

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

Scheme 124

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

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

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. Be careful of the starter.

Tighten bolts -1 to 11-.

Remove the T40170.

Note. The following step is necessary to make sure the torque converter rests on the drive plate evenly and is not tilted.

Press the torque converter -2- against the drive plate -3- slightly in the direction of the -arrow- using an assembly lever -1-.

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

Attach the T40257 to the T40263.

Attach the adapter to the bolts on the vibration damper.

Turn the crankshaft 180° in the 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 Specifications .

Install the power steering hydraulic lines. Refer to Removal and Installation .

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

Installing the lower left coolant pipe. Refer to LOWER LEFT COOLANT PIPE .

Install selector lever cable. Refer to Removal and Installation .

Install the ATF lines. Refer to Removal and Installation .

Install the catalytic converter. Refer to MUFFLER OVERVIEW .

Raise the engine/transmission assembly using the VAS 6131 A.

Align the subframe and the tunnel crossmember 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 .

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 Description and Operation .

Install in reverse order of removal paying attention to the following

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

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

Install the brake caliper. Refer to Removal and Installation .

Install the engine control module. Refer to Removal and Installation .

Electrical connectors and wiring routing. Refer to appropriate SYSTEM WIRING DIAGRAM.

Install the electrical wires, terminal 30 wire junction 2 -TV22- and the engine compartment E-box cover. Refer to 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 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 and adjust the windshield wiper arms. Refer to Removal and Installation .

Install the air filter housing. Refer to Removal and Installation .

Install the lock carrier braces. Refer to Removal and Installation .

Fill engine oil and check oil level.

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

Note. The power steering pump must not run dry.

Fill the coolant system 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 General Information .

Align the subframe. Refer to Removal and Installation .

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.

Fill transmission with ATF. Refer to General Information .

Install the noise insulation. Refer to Description and Operation .

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 6131/10as well as Supplementary Set, Audi A8 VAS 6131/11, Supplementary Set, Audi Q7 VAS 6131/13 and qty. 3 Tapered Mounting Pin VAS 6131/10-2
Drip Tray For VAS 6100 VAS 6208
Hose Clip Pliers VAS 6340
Hose Clip Pliers VAS 6362
Puller for Gear Shaft Linkage T40160

Procedure

WARNING

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

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

Position the front wheels so they are straight.

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 the coolant circuit. Refer to Description and Operation .

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

Remove the engine cover -arrows-.

WARNING

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 the VAS 6208 under the engine.

Remove the drain plug -arrow- on the front coolant hose and drain the coolant.

Remove the drain plug -arrow- on the map controlled engine cooling thermostat -F265- and drain the coolant.

Disconnect the coolant hose from the radiator, to do this, lift the retaining clip -2-.

Note. Ignore -1, 3 and 4-.

Disconnect the vacuum hose -1- and free up the hydraulic hose -arrow- on the bracket.

Remove the nuts -2- and vacuum reservoir.

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

Disconnect the power steering hydraulic oil feed line -2- and return line -1-.

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

CAUTION

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

Remove the bolts -1 and 2-.

Disconnect the refrigerant lines from the compressor.

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

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

Disconnect the connector -2-.

Place VAS 6208 under the engine.

Remove the coolant hoses from the after-run coolant pump -V51- -arrows-.

Note. Ignore -1-.

Disconnect the connector -3- on the Secondary Air Injection (IAT) pump motor -Via-.

Remove the secondary air injection hose -1- and free it up.

Note. Ignore -2-.

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.

Remove the left and right bolts -1- and nuts -3- and the lock carrier braces -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

Follow the guidelines for cleanliness when working on the fuel supply system. Refer to CLEAN WORKING CONDITIONS .

Disconnect the fuel line -arrow-.

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

Disconnect the electrical connector -2- on the Evaporative Emission (EVAP) canister purge regulator valve 1 -N80- and disconnect the vacuum hose -1-.

Remove the EVAP canister purge regulator valve 1 from the bracket and lay aside with hose and fuel line connected.

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

Remove the air duct -arrows-.

Disconnect the connector -1- from the Mass Airflow (MAF) sensor -G70-.

Disconnect the vacuum line -3- from the air guide pipe.

CAUTION

Risk of violating emissions legislation. Do not open hose connection -2- !

Lay aside air guide pipe with connected crankcase ventilation hose -2- by loosening hose clamp -4- and opening clips -arrows-.

Disconnect the vacuum line -1-.

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

Remove hose -3- from the secondary air system.

Disconnect the coolant hose by lifting the retaining clamps -2- and loosening the hose clamp -1- on the coolant tube.

Disconnect electrical connector -1- for the brake system vacuum pump -V192- and free up electrical wiring.