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Engine, Removing Audi S6 C5

Mechanical 15 illustrations ~998 words

See Caution before beginning repairs on the electrical system . See ENGINE, REMOVING AND INSTALLING

Note. Remove engine together with transmission from the front. Replace all cable ties detached or cut when removing the engine in the same position when installing. The battery is located behind a cover on the right side of the luggage compartment.

  1. With ignition switched off, disconnect battery ground strap.
  2. Unscrew grille on left side -arrow-, unclip on right side.

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6
  1. Remove noise insulation.
  2. Remove both front wheels.
  3. Remove both front wheel housings.
  4. Remove front bumper behind wheel housings.
  5. Unbolt bumper on left and right sides. Vehicles with headlight washers
  6. Clamp off washer hose for headlight washers with clamp 3094.
  7. Disconnect hose to jets at bumper in right air intake grille.
  8. Disconnect hoses for headlight washers (in right grille).
WARNINGThe cooling system is under pressure when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection. Cover the cap with a rag and open carefully to relieve pressure slowly.
  1. Open cap of coolant expansion tank.
  2. Place drip tray VAG 1306 under engine.
  3. Drain coolant from radiator (bottom left) -arrow-. Install drain hose if necessary.
  4. Open drain plugs -arrows- and drain coolant.
CAUTIONDispose of used coolant properly.

Scheme 7

Scheme 7
Scheme 7
  1. Disconnect coolant hose connection -arrow-.
  2. Remove radiator shroud at left and right sides -arrows
  3. Remove engine cover -arrows
  4. Remove air intake duct for air cleaner -arrows-.
  5. Remove bracket for hydraulic oil lines -arrow-.
  6. Disconnect temperature sensor -1-. (Scheme 14)
  7. Remove long loop for hydraulic oil -arrows- and move aside.
  8. Disconnect connector -1- for pressure switch.
CAUTIONThe A/C refrigerant circuit must only be opened by specially trained technicians using proper tools and equipment.
  1. DO NOT open air conditioning refrigerant circuit.
  2. Disconnect A/C refrigerant line brackets and support points only.
  3. Set A/C compressor carefully aside. Avoid damage from bending lines or kinking hoses. Refrigerant lines kink easily.
  1. Remove condenser and hang up with wire.
  2. Disconnect left and right headlights
  3. Disconnect connectors for left and right indicator lights.

Automatic transmission only

  1. Disconnect ATF lines for automatic transmission -arrows-.

Scheme 8

Scheme 8
Scheme 8

All vehicles

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10
  1. Remove coolant hose at upper right radiator -arrow-.
  2. Disconnect thermal switch -arrow-.
  3. Disconnect connectors at horns.
  4. Remove cover -1- in front of ABS unit.
  5. Disconnect connectors in front of ABS unit -arrows-.
  6. Remove bolt -arrow- on left and right sides.
  7. Remove left and right impact absorbers -arrows-.
  8. Disengage hood release cable.
  9. Remove air shroud bolts -arrows- on left and right sides.
  10. Remove air shroud with radiator.
  11. Remove hose -1-.
  12. Remove hose -2- to throttle body.
  13. Remove hose -1- from air cleaner by turning it in direction of arrow. see scheme 25
  14. Remove bracket for frequency valve -2- from air cleaner housing.. see scheme 25
  15. Disconnect connector from mass air flow sensor -3-.
  16. Remove bolt -arrow- and remove air cleaner housing together with mass air flow sensor and air intake duct.
  17. Disconnect connector -1- from oil level sensor and move wiring aside.
  18. Counter-hold pulley for viscous fan with pin wrench 3212 and remove fan with wrench 3312 (FAN HAS LEFT HAND THREAD).
CAUTIONMark the running direction of the belt with crayon or marker before removing. Reinstalling a used belt in reversed running direction could damage the belt When installing a used ribbed belt be sure the belt runs in the right direction and is seated correctly on the belt pulleys.

Scheme 11

Scheme 11
Scheme 11
  1. To loosen ribbed belt, turn belt tensioner with 19mm wrench in direction of arrow until both holes are aligned. Insert 3204 to hold tensioner in position.
  2. Remove ribbed belt.
  3. Remove pulley of hydraulic pump using pin wrench 3212 to counter-hold. NOTE: Be aware of washers behind belt pulley. Install washers again when pulley is reinstalled.
  4. Remove hydraulic pump from bracket and move it aside.
  5. Remove clamp for refrigerant line -arrow-.
CAUTIONThe A/C refrigerant circuit must only be opened by specially trained technicians using proper tools and equipment.
  1. DO NOT open air conditioning refrigerant circuit.
  2. Disconnect A/C refrigerant line brackets and support points only.
  3. Set A/C compressor carefully aside. Avoid damage from bending lines or kinking hoses. Refrigerant lines kink easily.

Scheme 12

Scheme 12
Scheme 12
  1. Remove A/C compressor and hang up with wire. Watch out for centering dowels to locate A/C compressor on bracket.

Scheme 13

Scheme 13
Scheme 13

Automatic transmission only

  1. Remove bolts -arrow- for bracket for ATF lines at engine.

Scheme 14

Scheme 14
Scheme 14

All vehicles

  1. Remove torque support -arrows-.
  2. Disconnect connector -1- for oxygen sensor after Three Way Catalytic Converter (TWC) and free wiring to oxygen sensor.
  3. Disconnect connector -2- for oxygen sensor after Three Way Catalytic Converter (TWC) and free wiring to oxygen sensor.
  4. Disconnect connector -3- for right oxygen sensor and free wiring.
WARNINGFuel lines are under pressure. Keep anything away that could ignite fuel or fumes. Before disconnecting fuel lines, clean connections. Cover connections with rag to protect against fuel spray.

Scheme 15

Scheme 15
Scheme 15
  1. Disconnect fuel supply and return lines.
  2. Remove hose -2- and move it aside.
  3. Remove hoses -arrows- from coolant expansion tank
  4. Remove coolant expansion tank.
  5. Disconnect connector from coolant level sensor at expansion tank.
  6. Disconnect connector for left oxygen sensor -arrow- and set wiring aside.
  7. Remove coolant hose -1-. see scheme 38
  8. Disconnect connector -2-.
  9. Disconnect ground wire -3-at cylinder head.
  10. Disconnect connector -4-.
  11. Disconnect connector -5-.
  12. Disconnect connector -1- from Camshaft Position (CMP) sensor.
  13. Disconnect connector -2-.
  14. Disconnect connector -3-.
  15. Disconnect connector -3-.
  16. Disconnect connector -4- from ignition coils.
  17. Disconnect connector -6-.
  18. Disconnect connector -1- for knock sensor at cylinder bank 5-8.
  19. Disconnect connectors -arrows- from fuel injectors of cylinder bank 5-8 and set wiring harness aside.
  20. Disconnect connectors for knock sensor at cylinder bank 1-4.
  21. Disconnect connectors from fuel injectors of cylinder bank 1-4
  22. Remove clamp -arrow-from coolant line and set wiring harness aside.
CAUTIONDO NOT bend swivel joint of exhaust pipe by more than 10° to prevent damage.
  1. Remove upper exhaust pipe bolts, left and right.
  2. Remove exhaust pipe bolts -arrows-at left from below.
  3. Remove exhaust pipe from retainer -arrow-.
  4. Loosen double clamp-1-and push it forward.
  5. Carefully remove exhaust pipe.
CAUTIONDO NOT bend swivel joint of exhaust pipe by more than 10° to prevent damage.

Scheme 16

Scheme 16
Scheme 16
  1. From below, remove bolts -arrow- between exhaust pipe and exhaust manifold.
  2. Remove exhaust pipe from retainer -arrow-.
  3. Loosen double clamp -2- and push forward.
  4. Carefully remove exhaust pipe with Three Way Catalytic (TWC) converter.
CAUTIONDO NOT bend swivel joint of exhaust pipe by more than 10° to prevent damage.

Scheme 17

Scheme 17
Scheme 17
  1. Disconnect cable -1- from generator.
  2. Disconnect cable -2- from generator.
  3. Remove bracket -3-.
  4. Remove bracket for protective cover.
  5. Remove oil filter.
  6. Disconnect ground cable -arrow-.
  7. Remove bracket for starter motor.
  8. Disconnect electrical wiring from starter motor.
  9. Remove starter motor.

Note. Before unbolting torque converter, mark alignment with drive plate.

  1. Remove bolts of torque converter -arrow-(three bolts). Tightening torque: 85 Nm (63 ft lb)

If engine or transmission are replaced separately

Scheme 18

Scheme 18
Scheme 18
  1. With engine separated, turn crankshaft to TDC and align markings on torque converter and bell housing.
  2. Remove left and right engine mounts.
  3. Attach engine sling VAG 3033 at two engine lifting points shown.
  4. Position workshop crane VAG 202A and hook up sling VAG 3033.
WARNINGTo properly balance the engine assembly, install the hooks in the correct notches of the sling, exactly as shown in the illustration. Assure that hooks are firmly connected with the lifting eyes.
  1. Carefully lift engine and transmission and remove toward front.

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