Removal and installation the engine (Audi A8 D2)

Recommendations for engine removal

Please read this entire section before removing the engine.

If the engine is removed for repair, it is necessary first of all to select a place for the work, provide space for maintenance and storage of spare parts. It is recommended to repair the engine at a service station or in a garage with a level horizontal floor with a clean hard surface.

Before removing the engine, flush the engine and engine compartment. To remove the engine, use a lifting mechanism that allows you to safely lift the power unit.

If you are removing the engine for the first time, you should invite an experienced specialist. Some work should be done with an assistant.

Warning: Any clamps or straps that are damaged or cut during engine removal must be replaced with new ones when the engine is reassembled.

The engine is removed forward without the gearbox.

The drained coolant must be collected and disposed of.

Before disconnecting the battery, find out if you have a radio activation code.

Removal

Turn off the ignition and disconnect the ground wire from the battery.

Remove the front cross member.

Loosen the screws and remove the protective cover located behind the air filter.







Loosen the clamps and remove the air duct connecting the air filter and the air pipe (Fig. 3.4–1).

Loosen the air filter housing mounting screws.





Loosen the screws and remove the air pipe (Fig. 3.4–2).





Loosen the clamps (Fig. 3.4–3) and disconnect the cooling system hoses going to the heater.

Disconnect the vacuum hose and gray electrical connector located near the heater fittings on the engine compartment bulkhead and set them aside.

Loosen the clamp and disconnect the coolant hose from the fitting behind the fuel pump.

Loosen the clamps and remove the hoses from the distribution line.



Loosen the clamps, remove the crankcase ventilation hoses and move them to the side.

Remove the bolt and the pressure line from the power steering pump.





Loosen the tension of the poly V-belt by turning the tensioning mechanism clockwise with a key (Fig. 3.4–4).

Remove the poly V-belt.

Loosen the clamps and disconnect the cooling system hoses from the engine.

Loosen the clamps and disconnect the fuel supply line from the T-piece.

Remove the screws and the engine control unit cover. Release the spring clips and remove the bulkhead seal at the rear of the engine compartment.

Remove the protective covers at the rear of the engine compartment.

Lift up the left cover covering the control unit and remove the rear right screw.

Remove the remaining mounting screws.

Remove the control unit cover.

Disconnect the electrical connectors from the engine control module and transmission control module, as well as all electrical connectors on the engine compartment bulkhead.

Remove the screws and remove the engine control unit base.







Remove screws 1 and remove the relay block (Fig. 3.4–5).

Disconnect electrical connector 2 and remove fuse housings 3 and 4.

Unscrew the clamp securing the wires to the engine compartment bulkhead and move the wires to the side.





Loosen the clamp and disconnect the air pipe from the generator (Fig. 3.4–6).

Disconnect the green electrical connector from the electromagnetic clutch, release the retainer and move the wires to the side.





Unscrew the bolts securing the air conditioner compressor to the bracket, then, without disconnecting the pipes from the compressor, move it to the side and secure it to the body (Fig. 3.4–7).



Disconnect the electrical connectors and unscrew the vehicle height sensor bracket under the left front wheel arch.

Unscrew the bolts and remove the drive shaft protective covers.

On the right side of the engine compartment, disconnect the electrical connectors, release the wire holders, unscrew the nut securing the ground wire end and move the wires to the side.





Unscrew the mounting bolts and remove the heat shields of the right and left drive shafts (Fig. 3.4–8).

Unscrew the drive shafts from the gearbox flanges.





Unscrew the flanged nut securing the lower arm ball joint pin of the front suspension. Using a ball joint puller, remove the lower arm ball joint pin from the steering knuckle (Fig. 3.4–9).







Unscrew the nuts and bolts securing the lower arm of the front suspension and remove it from the bracket (Fig. 3.4–10).

Move the steering knuckles away from the car and use soft wire to secure the drive shafts to the car body.

Unscrew the bolt securing the exhaust pipe hanger to the bracket.

Unscrew the connecting bolts securing the left exhaust pipe.

Unscrew the exhaust pipe connecting clamp nuts and remove the left and right catalytic converters.

Unscrew the bolts and remove the cardan shaft heat shield.

Unscrew the bolts securing the propeller shaft flange, move the propeller shaft toward the final drive and position it on the cross beam.

Unscrew the heat shield of the automatic transmission control lever cable.

Disconnect the automatic transmission control cable by first setting the selector lever to the "P" position and turning the cable coupling clockwise.

Remove the bolts and remove the front engine compartment lower splash guard bracket.







Unscrew the bolts and remove the rear bracket of the lower mudguard of the engine compartment (Fig. 3.4–11).





Remove the six nuts and bolts securing the power unit supports (Fig. 3.4–12).

Hook the lifting mechanism's grips onto the power unit and lift it so that the weight of the power unit is supported by the lifting mechanism.





Remove the lower bolts (Fig. 3.4–13) securing the engine to the lower frame. Make sure all electrical wires, hoses, pipes and lines are disconnected from the engine.

Remove the three torque compensator mounting bolts.

Lift the power unit and remove it forward from the engine compartment.

Installation

Installation is carried out in the reverse order of removal, taking into account the following.

When installing the engine, it is necessary to replace the self-locking nuts and bolts, which were tightened by turning them to a certain angle, with new ones, as well as the sealing rings and gaskets.

When installing, check for the presence of centering bushings that determine the relative position of the engine and gearbox.

When connecting the engine to the gearbox, be careful not to damage it engine speed sensor.

To attach the torque converter to the drive disk, it is necessary to use bolts of the original design.





Check the correct installation of the torque converter. If the distance between the supporting surface for the torque converter mounting bolts and the housing surface is 19 mm, then the torque converter is installed correctly. If the torque converter is installed incorrectly, this distance is about 22 mm (Fig. 3.4–14), and the leading part of the torque converter and the automatic transmission pump are destroyed.

Place the engine in place and rock it from side to side to ensure it is correctly positioned on the supports.

Install cardan shaft.

Install and adjust the automatic transmission control cable.

Fill the cooling system with coolant. Do not reuse coolant if the cylinder head has been removed or the cylinder block has been replaced.

Check that the exhaust system components are correctly installed on the suspensions and that they do not touch the body when rocking.

Fill the power steering system with oil and bleed the air from it.

Fill the engine with oil.

Check that the electrical connectors are connected correctly.

Install the air conditioning compressor.

Install and adjust the tension of the poly V-belt.

Install the front cross member.

Connect the ground wire to the battery.

Turn on radio and enter the code into it.

Raise the power windows all the way up. Then press all the power window switches again for at least 1 second to the closed position to activate the power window control unit.

Set the time on the clock.

Before starting the engine, check the presence and level of oil in the engine.

[The article was copied from the website Audimanual.ru]