Engine, Removing Audi S8 D3 facelift

Engine, Removing

Note. With lock carrier installed, engine is removed downward with transmission and subframe. Drained coolant must be stored in a clean container for disposal or reuse. During installation, reinstall all heat insulation sleeves and heat shields at the same locations. All cable ties opened or cut during engine removal must be reinstalled at the same locations during installation.

Special tools, testers and auxiliary items required

Scheme 43

1. Pry Lever - Rmv Outside Mirror 80 - 200
2. Ring screw 3368
3. Old oil collecting and extracting device V.A.G 1782
4. Hose clamp pliers V.A.G 1921

1. Spark plug connector pliers V.A.G 1922
2. Hose clip pliers VAS 6340 (formerly: VAS 5024 A)

Special tools, testers and auxiliary items required

Scheme 44

1. Step ladder VAS 5085
2. Scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10
3. Drip tray for workshop crane VAS 6208
4. Tensioning Strap T10038 qty. 2

1. Ignition Coil Puller T40039

Note. If engine should be separated from transmission after removal, two additional adapter sets VAS 6131/10-12 are needed.

Procedure

Note. So that the front wheels can still be turned with the battery disconnected, the battery must only be disconnected with ignition key inserted. In order for the driveshaft to be able to rotate for removal, the electronic parking brake must be released before disconnecting battery.

Scheme 45

1. Remove cover of right luggage compartment side trim - arrows -.

Scheme 46

1. Remove cover - 1 - above battery.

Note. Ignore - 2 -.

Scheme 47

1. With ignition switched off, disconnect Battery Ground (GND) strap - arrow -.
2. Discharge refrigerant circuit --> «87 - AIR CONDITIONING»(ref-289226-S15694198272008062700000) .

1. Remove front engine cover - 1 - and rear - 2 - - arrows -.

Scheme 48

1. Remove cover above coolant reservoir - arrows -.

1. Open cap of coolant expansion tank.
2. Remove both front wheels.

Scheme 49

1. For vehicles with auxiliary heater, remove bolts - arrows - for exhaust pipe of parking heater/auxiliary heater on noise insulation.

Scheme 50

1. Loosen quick-release fasteners - 1 - and - 2 - and remove noise insulation.
2. Remove front and rear part of left and right front wheel housing liner --> «66 - EXTERIOR EQUIPMENT»(ref-289221-S23584739002008062700000) .

Scheme 51

1. Place drip tray for workshop crane VAS 6208 under engine.
2. Remove drain plug - arrow - at coolant thermostat housing and drain coolant.

Scheme 52

1. Remove drain plug - arrow - at front coolant pipe and drain coolant.

Scheme 53

1. Remove coolant hoses - 1 to 3 - and drain coolant.

Scheme 54

1. Disconnect coolant hose next to left driveshaft from coolant pipe - arrow - and drain coolant.

Scheme 55

1. Remove screws - 2 - and - 3 -.
2. Remove front lower coolant pipe from hoses - 1 - and - 4 -.

Scheme 56

1. Remove hoses - 1 - and - 2 - from secondary air injection connecting pipes.

Scheme 57

1. Remove coolant hoses - 1 - and - 2 - from right auxiliary cooler and drain remaining coolant.

Scheme 58

1. Remove nut - 1 - and remove coolant hose - 2 - from right auxiliary cooler.

Scheme 59

1. Disconnect electrical connector - 1 - on Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 and remove vacuum hose - 2 -.
2. Remove Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 from bracket and lay aside with hose connected.

Scheme 60

1. Remove coolant hose - arrow - from coolant pipe to coolant reservoir.

Scheme 61

1. Disconnect electrical connector - 2 - for Mass Air Flow (MAF) Sensor 2 G246.
2. Disconnect air duct hose - 1 - from intake manifold.
3. Remove bolts - arrows - and remove left upper part of air filter housing.

Scheme 62

1. Remove air duct - 1 -.
2. Remove bolts - arrows -.
3. Tilt lower part of air filter housing and remove air flap vacuum hose.
4. Remove lower part of left air filter housing.

Scheme 63

1. Extract hydraulic oil from power steering reservoir using Used Oil Collecting and Extracting Device V.A.G 1782.

Note. Place a rag under separating point to catch escaping hydraulic fluid.

1. Disconnect power steering hydraulic pressure line - arrow - at front left on engine.
2. Remove hood seal from lock carrier and from fender edges.

Scheme 64

1. Disconnect vacuum hoses - 1 - and - 2 - and free them up.

Scheme 65

1. Separate electrical connector - 1 - for mass air flow (MAF) sensor G70.
2. Disconnect vacuum hose - 2 - from air guide hose.
3. Loosen hose clamps and lay aside air guide hose - 4 -.

1. Remove bolts - arrows - and remove right upper part of air filter housing.

Scheme 66

1. Remove lower air guide hose - arrow - from right upper part of air filter housing.

Scheme 67

1. Disconnect both vacuum hoses - 1 -.
2. Remove air duct - 2 -.
3. Remove bolts - arrows -.
4. Tilt lower part of air filter housing and disconnect electrical connector - 3 - on Intake Air Switch-Over valve N335.

1. Remove lower part of right air filter housing.

Scheme 68

1. Disconnect coolant hose - arrow - at right on engine.

Scheme 69

1. Remove bolt - arrow - at torque support mount.

Scheme 70

1. Remove oxygen sensor electrical connectors - 1 - and - 2 - from right bracket in engine compartment.

Scheme 71

1. Disconnect vacuum hoses - 1 - and - 2 - and free them up.

Scheme 72

1. Disconnect fuel supply line - arrow - on distribution piece.

Scheme 73

1. Disconnect crankcase ventilation hose - 2 -.
2. Disconnect electrical connectors - 1 - and - 5 -.
3. Remove bolts - 3 - and - 4 -.
4. Disconnect electrical connectors to ignition coils in cylinder bank 1 (right) and free up electrical wiring harness.

Scheme 74

1. Remove ignition coils using Ignition Coil Puller T40039.

Scheme 75

1. Loosen bolts in sequence - 16 to 1 - and remove them.
2. Remove right cylinder head cover.
3. Cover open valvetrain with a clean cloth.

Scheme 76

1. Remove rubber seal - 1 - and remove plenum chamber covers - 2 - and - 3 -.

Scheme 77

1. Pry out cover caps on windshield wiper arms with a screwdriver and loosen nuts - arrows - a few turns.
2. Loosen wiper arms by tilting slightly from windshield wiper axle.
3. Remove nuts completely and remove wiper arms.

Scheme 78

1. Remove dust and pollen filter by opening 4 quick-release fasteners.

Note. Cover the air duct at air conditioning housing with a clean rag so that nothing can fall in.

1. Remove bolts - arrows - at left and right for cowl grill - 1 -.
2. Carefully pull the cowl grill off from the retainers at the windshield.

Scheme 79

1. Remove suspension strut crossmember - arrow -.

Scheme 80

1. Remove bolts - 1 - and - 2 - and remove retaining bracket.
2. Release retaining tabs - arrows - and remove both engine control modules (ECM).

Note. Electrical harnesses remains connected.

Scheme 81

1. Remove Air Quality Sensor G238 by rotating approximately 90 counter-clockwise - arrow - and removing from bracket.
2. Release retaining clips - 1 to 4 -.
3. Fold cover for the E-box in plenum chamber open slightly and pull off toward the front.

Scheme 82

1. Disconnect multi-pin harness connectors - arrows - using spark plug connector pliers V.A.G 1922.
2. Disengage engine wiring harness at E-Box and bulkhead.
3. Lay wiring harness aside on the engine with engine control modules (ECM) connected.

Note. Protect the engine control modules from falling off.

Scheme 83

1. Remove right A-pillar trim --> «70 - INTERIOR TRIM»(ref-289222-S30170627502008062700000) .
2. Fold floor covering back.
3. Remove protective cover above main fuse holder.
4. Fold cap - 2 - aside.

1. Remove nut - 4 -.
2. Remove terminal 30 wire to starter.

Note. Ignore - 1 - and - 3 -.

Scheme 84

1. Unfasten harness clamp - 1 - in right front wheel housing.
2. Pull wiring harness out from interior - arrow -.

Scheme 85

1. Disconnect electrical connector - 2 -.
2. Remove Ground (GND) wire - 1 - on longmember.
3. Remove wiring harness bracket on longmember - arrows -.
4. Free up wiring harness.

Scheme 86

1. Disconnect electrical harness connector - 2 - at Level Control System Sensor.
2. Disconnect connecting link - 1 - from control arm.
3. Repeat procedure on opposite side of the vehicle.

Scheme 87

Note. To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.

1. Remove bolts - 1 - and - 2 -.
2. Disconnect refrigerant lines from A/C compressor.

Note. Seal open lines and connections at A/C compressor with suitable sealing caps (to prevent dirt and moisture from entering).

Scheme 88

1. Remove bolts - arrows - on climate control system reservoir bracket.

Note. Climate control system reservoir remains in installation location.

Scheme 89

Note. Place a rag under separating point to catch escaping hydraulic fluid.

1. Remove hydraulic hose - arrow - from power steering fluid reservoir.

Scheme 90

1. Have a second technician press brake pedal.

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

Scheme 91

1. Remove bolts - arrows - uniformly at left and right.
2. Remove stabilizer.

Scheme 92

1. Insert left and right Lifting Eyebolt 3368 from below into hole in strut tower.
2. Secure Lifting Eyebolt 3368 with a nut - 2 - with washer - 1 - over several threads (do not install nut all the way down on threads).
3. Tie up wheel bearing housing at left and right with Tensioning Strap T10038 as shown in illustration.

Scheme 93

1. Remove air spring damper from control arm - arrow -.

Scheme 94

1. Remove guide control arm - 1 - and control arm - 2 - from subframe.

Scheme 95

1. Swing guide control arm - 1 - and control arm - 2 - outward.

1. Repeat work procedure on opposite side of the vehicle.
2. Remove drive axle from transmission flanged shaft.

1. Swing wheel bearing housing outward and remove drive shaft.
2. Repeat work procedure on opposite side of the vehicle.

Scheme 96

1. Remove front transverse beam - arrows -.

Scheme 97

Note. Do not bend the flex joint in front of the exhaust pipe more than 10 or it could be damaged.

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

Scheme 98

1. Remove heat shield - A - for drive shaft - arrows -.
2. Remove bolts on transmission/driveshaft connection.
3. Slide driveshaft back to rear final drive; constant velocity joints can move axially.

Scheme 99

1. Tie driveshaft up and to the side against heat shield - arrow -.

Prepare scissor lift platform

Scheme 100

1. Equip scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10 as follows

1. Install attachments on scissor lift table by hand first.
2. Place scissor lift platform VAS 6131 A in horizontal position.

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

1. Drive scissor lift table VAS 6131 A under engine/transmission subassembly.

Scheme 101

1. Position support elements from VAS 6131/10 at front on engine as shown in illustration.

Scheme 102

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

Scheme 103

1. Remove bracket for oxygen sensor electrical connectors - 1 - and - 2 - from tunnel crossmember - arrows -.

Note. Electrical connectors remain connected.

Scheme 104

1. Position support elements from VAS 6131/10 at rear on transmission as shown in illustration.
2. Twist all spindles of support elements upward far enough until all support pins make contact at support points.
3. When all attachments are positioned, lift scissor lift table far enough until engine and transmission mount are free of tension.
4. Tighten base plates for attachments to 20 Nm on the scissor lift table VAS 6131 A.

Scheme 105

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

Scheme 106

1. Mark installation position of subframe on longmember using a felt tip pen.
2. Remove bolts - 1 - and - 4 -.
3. Remove bolts - 2 - and - 3 - 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.

Scheme 107

1. First lower engine/transmission assembly using scissor lift platform VAS 6131 A only approximately by dimension - a -.

1. Dimension - a - = approximately 300 mm.

Scheme 108

1. Press ball socket - 2 - of selector lever cable from selector shaft lever using Pry Lever - Rmv Outside Mirror 80 - 200.
2. Unclip locking plate - 1 - from selector lever cable bracket.
3. Remove selector lever cable.
4. Lower engine/transmission subassembly downward.

1. Push scissor lift platform VAS 6131 A with engine/transmission subassembly under vehicle.