Engine, Removing, AUDI S6/S7: Notes

WARNING: This page is about a different car, the 2018 Audi S6, 2017 Audi S6, and 2016 Audi S6. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required

Pry Lever :80-200
Engine Bung Set :VAS6122
Scissor Lift Table :VAS6131B with Scissor Lift Table - Audi Set :VAS6131/10 , Scissor Lift Table - A8 Set :VAS6131/11 and Scissor Lift Table - Q7 Set Articulated Joint Support :VAS6131/13-7
Shop Crane - Drip Tray :VAS6208
Hose Clip Pliers :VAS6362
Commercially available Step Ladder
Protective Eyewear
Safety Gloves

NOTE:

The engine is removed downward with transmission and subframe.

When installing, bring all cable ties back to same positions.

All bolts on suspension components must be equipped with bonded rubber bushings and tightening in curb weight position (no load).

Bonded rubber bushings have a limited range of motion. Axle components with bonded rubber bushings must be brought into the position they will be in during driving before tightening (curb weight position). Otherwise, the bonded rubber bushing will have tension, which will reduce the service life.

Measure dimension -a- from the center of the wheel to the lower edge of the wheel housing before beginning work, for example, using a tape measure.

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The measurement must be taken with the vehicle in curb weight position (no load).

Note the measurement. This number will be needed when tightening the bolts/nuts.

NOTE:

To be able to turn the drive axle to remove it, shift the transmission to "N" and release the electromechanical parking brake before disconnecting the battery.

-- Position the front wheels so they are straight.

CAUTION:

Risk of damaging the electronic components.

Follow the steps for disconnecting the battery.

-- Disconnect the ground cable from the battery terminal. Refer to BATTERY .

-- Empty the coolant circuit. Refer to A/C System with Refrigerant R134a.

-- Remove the lock carrier cover. Refer to ATTACHMENTS, REMOVING AND INSTALLING .

-- Remove the driveshaft. Refer to REMOVAL AND INSTALLATION .

-- Remove the engine cover. Refer to ENGINE COVER, REMOVING AND INSTALLING .

WARNING:

Fire hazards and risk of damage for a faulty engine cover.

The engine cover must be always be installed before the hood is closed.
The engine may neither be started nor driven without an engine cover.

WARNING:

The cooling system is under pressure when the engine is warm. Risk of scalding due to hot steam and hot coolant.

Scalding the skin and other parts of the body is possible.

Wear safety gloves.
Wear protective eyewear.
Reduce the pressure by covering the coolant expansion tank cap with a cloth and carefully opening it.

-- Remove the cap -arrow- from the coolant reservoir.

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-- Remove the front left and right wheel housing liners. Refer to WHEEL HOUSING LINER .

-- Remove the left and right front wheel spoiler. Refer to WHEEL HOUSING LINER .

-- Remove the noise insulations. Refer to NOISE INSULATION .

-- Remove the front bumper cover end plate. Refer to Front Bumper .

-- Place the :VAS6208 under engine.

-- Remove the drain plug -2- and drain the coolant.

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-- Loosen the clamp -1-, remove the coolant hose from the left lower coolant pipe and let the coolant drain out.

-- Remove the plenum chamber cover. Refer to BULKHEAD .

-- Remove the bolts -arrows- and air guide -1-.

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-- Remove the bolts -arrows- and the air guide -2-.

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NOTE:

Ignore -item 1-.

-- Loosen the hose clamps -arrows- and remove the air guide hoses.

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-- Remove the air filter housing -1- upward.

-- Loosen the clamp -2- and remove the vacuum connection from the plenum chamber bulkhead.

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-- Open the clamp -1- and remove the coolant hose.

WARNING:

The fuel system is under pressure.

Risk of injury from fuel spraying out.

Wear protective eyewear.
Wear safety gloves.
Reduce the pressure: place clean cloths around the connection point and carefully open the connection point.

-- Place a clean cloth around the connection location and loosen the union nuts -arrows- and reduce the fuel pressure at the same time counterhold on the hex fitting of the corresponding connection.

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NOTE:

Do not change the shape of the high pressure pipe.

-- Press the release ring and disconnect the fuel line -2-.

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-- Loosen the clamp -1- and disconnect the hose from the EVAP canister.

-- Seal the open lines and connections with clean plugs from the :VAS6122 .

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

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-- Loosen the hose clamps to remove the coolant hoses from the charge air cooling circuit radiator -1-.

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-- Free up the coolant hoses -arrow-.

-- Open the clamp -2- to remove the coolant hose line.

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-- Free up the coolant hose line.

-- Remove the bolts -1- and free up the refrigerant lines.

-- Disconnect the connector -3-.

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-- Disconnect the vacuum hose -1-.

-- Disconnect the secondary air hose -2- by pressing the release buttons.

-- Remove the left and right fasteners -arrows- and remove the cover -1-.

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-- Remove the tower brace. Refer to SUSPENSION STRUT AND UPPER CONTROL ARM .

-- Release the retainer in direction of -arrow A- and open the cover in direction of -arrow B-.

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-- Remove the nuts -2 and 3- and free up the wires.

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-- Disconnect the connector -1- from the bracket.

-- Remove the nuts -arrows- and then remove Terminal 30 Wire Junction -TV2- from the plenum chamber bulkhead.

-- Move the foam wedge -1- to the side.

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-- Remove the bolts -arrows-.

-- Remove the nut -2- on the right longitudinal member and free up the ground wires.

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-- Unlock the retainer in direction of -arrow- and free up the wiring harness to open the wiring duct -1-.

-- Remove the bolts -arrows-. Pull the filler tube -1- out of the windshield washer fluid reservoir and out of the opening in the body and move it to the right.

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-- Remove the cap nut -2- and free up the ground cable.

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-- Open the retainer in direction of -arrow- and remove the Engine Control Module -J623- -1- from the bracket and move it to the side.

-- Remove the bolts -arrows- and the engine compartment E-box cover -1-.

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-- Disconnect the connectors -1- and remove the nut -2- for the wire.

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-- Release the retainers in direction of -arrows- and remove the relay carrier with the fuse panel -3-.

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

-- Release the retainers in direction of -arrows A- and remove the wiring bushing -1- upward in direction of -arrow B-.

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-- Lay the wiring harness on the engine and secure the Engine Control Module -J623- so that it cannot fall.

-- Remove the bolt -1- and guide the refrigerant line -2- through the left air guide -3-.

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-- Disconnect the connectors -1 and 2- and free them up.

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-- Remove the air filter -2- from the mount in direction of -arrow-.

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-- Loosen the clamp -1- and remove the coolant hose.

-- Open the clamp -arrow- to remove the coolant hose.

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-- Remove the coolant fan electrical connectors -1 and 2- from the bracket and disconnect them by sliding the retainer back in direction of -arrow-, while pressing the release downward.

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-- Free up the wiring harness.

-- Disconnect the connector -arrow-.

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NOTE:

If the engine must be removed from the scissor lift table for future procedures, remove the connector from the mount and guide it through the subframe.

-- Disconnect the electrical connectors -arrow- at the left and right on the front speed sensors -G45- / -G47-.

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-- Disconnect the left and right connector -1- from the front vehicle level sensor -G78- / -G289- and free up the wire -arrow-.

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-- Remove the brake caliper and secure the brake caliper with the brake hoses still attached inside the wheel housing with wire. .

CAUTION:

Risk of damaging brake pistons.

Do not operate brake pedal when the brake caliper is removed.

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

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

-- Repeat the procedure on the other side of the vehicle.

NOTE:

The bolts -2- will be removed later.

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

-- Remove the left and right nuts -3-.

-- Free up the clip -arrow-.

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-- Disconnect the connector -1- and free up the wire.

-- Remove the subframe crossbrace. Refer to SUBFRAME CROSSBRACE, REMOVING AND INSTALLING .

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.

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

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-- Remove the nuts -arrows- and the left front muffler.

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-- Remove the nuts -arrows- and the right front muffler.

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-- Remove the steering intermediate shaft from the steering gear and the push the splines together. Refer to STEERING INTERMEDIATE SHAFT, REMOVING AND INSTALLING .

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-- Release the safety catch in direction of -arrow-, push the retainer down and disconnect the connector from -2- from the Power Steering Control Module -J500-.

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-- Disconnect the connector -1- from the Power Steering Control Module -J500-.

-- Free up the wiring harness.