Engine — removal and installation (Audi A6 C5)

Removal

1. Set the gear shift lever to neutral position.

2. Remove the seal from the fairing (see arrows in the illustration), and then remove the grille 1 of the fairing.

Attention! If the radio has an access code, then when the battery is disconnected, it is erased, so check and write down this code. Otherwise, the radio can only be turned on by asking a representative of the manufacturer.

3. Disconnect the ground (-) wire terminal from the negative battery terminal by unscrewing the nut (see arrow in illustration).

Attention! The manufacturer recommends draining the refrigerant from the air conditioner. However, you cannot open the refrigerant circulation system yourself - there is a risk of frostbite! You can try to disconnect the air conditioner compressor without opening the system and without disconnecting the hoses and pipes from it, and move it away from the work site.

4. Remove the cap from the coolant expansion tank.

Caution: Before removing the expansion tank cap, place a rag on it to avoid being burned by hot coolant or steam.

5. Remove the front wheels.

6. Cars with parking heater. Unscrew the bolts (see arrows in the illustration) fastening the heater pipe to the soundproofing shield.



7. Unscrew bolts/remove fasteners 1-3 and remove the engine splash guard (see illustration).





8. Unscrew the bolts (see arrows in the illustration) engine splash guard bracket and remove the bracket.



9. Remove the front bumper (see the relevant chapter).

10. Disconnect the plug (see arrow in illustration) sound signal.



11. Remove the left fairing (see arrow in illustration 8.11) and the right fairing (see arrow in illustration 8.11a) additional radiator.

8.11 Remove the left fairing (see arrow) additional radiator

8.11a. Remove the right fairing (see arrow) additional radiator

12. Place a suitable container under the engine to collect the coolant.

13. Unscrew the plug (see arrow in illustration) drain hole on the thermostat housing and drain the coolant.



14. Disconnect the lower hose from the radiator (see arrow in illustration) and drain the coolant from the radiator.



15. Place a suitable container to collect the transmission oil and disconnect the transmission oil circulation hose from the radiator frame (see arrow in illustration).





16. Disconnect the hose from the transmission oil cooling radiator (see arrow in illustration).

17. Remove the cap from the power steering expansion tank (see arrow in illustration).



18. Press the latches and remove the air filter cover 2 (see illustration).



19. Unscrew the bolts (see arrows in illustration 8.18) fastening the air intake 1 to the upper front cross member and remove the air intake.

20. Disconnect the headlight power connectors on both sides (see arrow in illustration).





21. Release plugs 1 and 2 from the holders and move the wiring harness away from the work area (see illustration).



22. Disconnect the plug (see arrow in illustration) radiator fan, release the wire harness from the holder.



23. Remove the hood release cable.

24. Disconnect the upper hose from the radiator (see arrow in illustration).





25. Unscrew the bolts (see arrows in the illustration), press the fasteners and remove the left and right radiator fairings.



26. Disconnect the outside air temperature sensor 1 and release the wire from the holder (see illustration).



27. Unscrew the bolts (see arrows in illustration 8.26) power steering line holders and move the line away from the work area without opening the system. Carefully tie up the line to avoid damaging it.

28. Unscrew the holder bolts (see arrows in the illustration) and disconnect the refrigerant circulation lines from the air conditioner compressor.

Attention! All work related to the air conditioner should be entrusted to a specialized workshop. Do not open the refrigerant circulation system yourself - there is a risk of frostbite.

29. Unscrew the bolts (see arrows in the illustration) on the right and left sides of the upper front cross member.



30. Unscrew the shock absorber mounting bolts (see arrows in the illustration) and carefully remove the radiator frame, working together with an assistant.



31. Remove the engine protective covers (see arrows in the illustration).



32. Disconnect the coolant hoses from expansion tank 2 by removing clamps 1 and 3 (see illustration).



33. Unscrew the mounting bolts (see arrows in illustration 8.32) and remove the coolant expansion tank 2.

34. Disconnect the low pressure hoses (see arrows in the illustration).



35. Disconnect the coolant hose by removing the clamp (see arrow in illustration).



36. Disconnect the low pressure hose from the intake manifold (see arrow in illustration).



37. Disconnect the coolant hose from the engine (see arrow in illustration).



38. Disconnect the plug (see arrow in illustration) from the brake booster and release the wire from the holder.



39. Pump out the fluid from the power steering reservoir using an oil pumping tool, part number VAG 1358A or VAG 1782A. Collect the leaking fluid with a rag.

40. Disconnect the hose from the power steering reservoir by removing clamp 1 (see illustration).



41. Disconnect the coolant hoses by removing the mounting clamps (see arrows in the illustration).



42. Disconnect the coolant hose (see arrow in illustration) from the oil radiator.



43. Disconnect the coolant hoses by removing the mounting clamps (see arrows in the illustration).



44. Vehicles with afterburning system. Disconnect plug 1 from the electric motor of the fresh air supply pump to the outlet valves and release the wire from the holder (see illustration).



45. Disconnect wire 2 "ground" (-) from the side member (see illustration 8.44).

46. Disconnect plugs 1 and 2 located in front of the air filter (see illustration).



47. Release plug 3 of the solenoid valve of the adsorber from the holder 2 (see illustration), then remove the valve.



48. Disconnect plug 4 of the mass air flow sensor (see illustration 8.47).

49. Disconnect hose 1 of the fresh air supply pump to the outlet valves (see illustration 8.47).

50. Remove clamp 5 and disconnect the supply air duct from the air filter housing (see illustration 8.47).

51. Unscrew the bolt (see arrow in illustration 8.47) fasteners and remove the air filter housing together with the mass air flow sensor.

52. Remove the clamp (see arrow in illustration) fasteners and disconnect the supply air duct from the throttle valve.



53. Disconnect the supply 1 and return 2 fuel lines (see illustration).

Caution! The fuel system is under pressure. Before disconnecting the fuel lines, cover the joint with a rag. Disconnect the fuel line slowly to relieve pressure in the system.

54. Cars with afterburning system. Remove the mounting clamp (see arrow in illustration) and disconnect the hose from the fresh air supply valve to the outlet valves.



55. Disconnect plugs 1-4 located on the engine compartment bulkhead (see illustration) and move the wiring harness away from the work area.



56. Disconnect the positive potential (+) cable terminal from the battery by unscrewing nuts 1 and 2 (see illustration).



57. Disconnect plug 3 of the brake booster sensor (see illustration 8.56) and release the sensor wire from the holder.

58. Unscrew the bolts (see arrows in the illustration) and remove the engine control unit cover.



59. Use a screwdriver to pry up the mounting bracket (see arrow in illustration) and remove the engine control unit without disconnecting the wiring harness from it.



60. Disconnect the plugs (see arrows in the illustration) engine control unit.



61. Use a screwdriver to pry up the retainer (see arrow in illustration) and remove the fuse and relay box.



62. Disconnect the wiring harness from the engine control unit.

63. Disconnect the ground (-) wire by unscrewing nut 2 (see illustration).



64. Release the wiring harness from the holder, then unscrew the bolts 1 and remove the holder (see illustration 8.63).

65. Unscrew bolts 1 and 2 of the holders and disconnect the exhaust pipes (see illustration).



66. Unscrew the bolts (see arrows in the illustration) and remove both heat shields.



67. Unscrew the bolts (see arrows in the illustration) and remove the heat shield A of the propeller shaft.



68. Loosen the mounting bolts and carefully move the propeller shaft toward the gearbox flange. Tie the shaft to the body with wire.

69. Unscrew the bolts (see arrows in the illustration) and remove the gearbox heat shield.



70. Unscrew the bolt (see arrow in illustration) fastenings of the left inlet pipe trim.



71. Unscrew bolts 1, 3 and 4 and remove the heat deflector shield together with the exhaust system bracket (see illustration).



72. Unscrew bolt 2 of the gear selection cable end holder (see illustration 8.71).

73. Disconnect the ball joint of the gear selection cable end (see arrow in illustration 8.71) from the gearshift lever on the gearbox.

74. Unscrew bolts 1 and 2 securing the left and right gearbox suspension supports (see illustration).



75. Turn the lock 1 and disconnect the gearbox wiring harness plug (see illustration).



76. Disconnect plug 2 of the multifunction switch of the gearbox, remove the holder 3 of the plug (see illustration 8.75).

77. Remove heat shields 1 from both drive shafts (see illustration).



78. Disconnect both drive shafts from the gearbox, then move and tie up the right drive shaft and remove the left drive shaft (see the relevant chapter).



79. Unscrew bolts 1 and 2 and disconnect the refrigerant circulation pipes from the air conditioning compressor (see illustration).

Attention! All work related to the air conditioner must be entrusted to a specialized workshop. Do not open the refrigerant circulation system yourself - risk of frostbite!

80. Remove the clamp (see arrow in illustration) fastenings of the refrigerant circulation pipeline.



81. Unscrew the bolt (see arrow in illustration) fasteners and remove the refrigerant circulation pipe.



82. Disconnect the power steering pressure hose by unscrewing the union nut (see arrow in illustration). Collect the leaking liquid with a rag.



83. Disconnect the pressure line from the power steering pump(see arrow in illustration).



84. Unscrew nuts 1-4 of the anti-roll bar mounting cushions (see illustration).



85. Cars with automatic transmission. Unscrew the bolt (see arrow in illustration) transmission oil circulation pipe holder and disconnect the pipes. Collect the leaking oil with a rag.



86. Cars with automatic transmission. Disconnect the pipe from the transmission oil cooling radiator (see arrow in illustration).



87. Cars with automatic transmission. Unscrew bolts 1 and 2 of the transmission oil circulation pipeline mounting bracket, remove the bracket, and then carefully remove the pipelines (see illustration).



88. Unscrew the lower nuts 1 of the right and left engine mounts (see illustration), loosen the upper nut securing the left engine mount support.



89. Unload the power unit supports by lifting the engine and gearbox using a lift or hoist. In specialized workshops, a VAS 6100 service crane and jack 1, which are installed under the gearbox, are used for this purpose (see illustration).

Caution: Do not place a support or jack under the oil pan.

90. First unscrew the lower and then the upper bolts securing the gearbox to the engine.

91. Cars with automatic transmission. Disconnect the torque converter from the drive disk, to which it is attached with three bolts. The bolts are unscrewed alternately through the mounting hole for the starter (see illustration), therefore, the starter must first be removed (see the relevant chapter). To ensure that the bolts enter the starter mounting hole, turn the engine to the right using a socket head on the bolt on the crankshaft.



92. Carefully separate the engine and gearbox, making sure not to let the torque converter fall out. Then remove the engine from the engine compartment.

Installation

The engine is installed in the reverse order of removal.

93. Tighten the gearbox to engine mounting bolts in the sequence shown in the illustration:

• 1 - bolt M10x80. Tightening torque - 65 Nm (if the bolt does not have a ribbed head), 85 Nm (if the bolt has a ribbed head);
• 2, 4, 5-bolt M12x105. Tightening torque-65 Nm;
• 3-bolt M12x110. Tightening torque-65 Nm;
• 6-bolt M12x120. Tightening torque-65 Nm;
• 7-bolt M12x170. Tightening torque-65 Nm;
• 8-10 - bolt M10x60. Tightening torque - 45 Nm.

A link to the original source is available on the website Audimanual.ru