Note. The engine with gearbox and subframe is removed downwards with the radiator frame installed. For disposal or reuse, coolant should be drained into a clean container. When reassembling, install all binders in the places where they were originally installed.
Warning! Risk of vehicle rollover when engine is removed. Secure vehicle by emptying luggage compartment. Risk of injury from fuel under very high pressure. Before depressurizing injection system, release fuel pressure to residual pressure.
Relieve fuel pressure in the high pressure sector.
Caution! Risk of damage to electronic components. Follow the instructions when disconnecting the battery terminals.
Move the front wheels into the straight ahead position.
Note: In order to turn the propeller shaft for removal, it is necessary to release the electromechanical parking brake before disconnecting the battery terminals. Switch off the ignition and remove the ignition key. Remove the trunk tray "3". Remove the Bassbox "2" if present. Unscrew the floor covering "1" above the cover.
Engine characteristics
| Letter designations | CALB |
| Working volume (l) | 3,197 |
| Power (kW at rpm) | 199/5000 |
| Torque (Nm at rpm) | 330/3000 |
| Cylinder diameter (mm) | 85,5 |
| Piston stroke (mm) | 92,8 |
| Compression | 12,5 |
| Octane number at least | 95 1) |
| Injection/ignition system | Simos |
| Cylinder firing order | 1-4-3-6-2-5 |
| Anti-knock control | 2 sensors |
| Lambda regulation | 4 lambda probes |
| Timing phase adjustment | Intake and exhaust |
| Changing the geometry of the intake manifold | provided |
| Secondary air supply system | provided |
| Number of valves per cylinder | 4 |
1) It is permissible to use unleaded petrol fuel with an octane rating of 91, however, this will reduce engine power
Unlock the "arrow" fasteners and install cover "1".
Remove cover "1" over the negative terminal of the battery. Disconnect the ground wire "arrow" from the battery terminal. Drain the air conditioning system circuit. Pump out the hydraulic oil of the power steering using a device for pumping oil out of the reservoir.
Remove the engine compartment covers.
Caution. Risk of burns from hot steam and hot coolant. When the engine is warm, the cooling system is under excess pressure. To relieve excess pressure, place a rag around the coolant expansion tank cap and carefully open it.
Open the expansion tank cap. Remove the front wheels: right and left. Remove the front right and left mudguard. Remove noise insulation screens "1" and "2".
Install the tray for service cranes "VAS 6208" under the engine. Unscrew the threaded plug of the drain hole "1" and drain the coolant. Remove the coolant hose "2" from the radiator by pressing the fastening bracket.
Remove the coolant hose from the engine oil radiator by loosening the hose clamp "arrow" and drain the remaining coolant.
Install a device for pumping and collecting oil under the disconnection point. Disconnect the feed hose "2" and the return hose "1" for the hydraulic oil of the power steering in the left front wheel arch and release. Close the open lines and pipes with clean plugs from the plug kit for the engine "VAS 6122".
Install a device for pumping and collecting oil under the disconnection point. Mark the installation position of ATF lines "1" and "2" for reinstallation and disconnect the ATF lines.
"Arrow" is not taken into account. Close open lines and pipes with clean plugs from the plug kit for the engine "VAS6122".
Cars with coolant circulation pump "V50": Disconnect electrical connector "1". Place the tray for service cranes "VAS 6208" under the engine. Disconnect the coolant hose from the coolant circulation pump "V50" "arrow on the right".
"Pos. 2" and "left arrow" should not be taken into account.
All
Disconnect the electrical plug connection "1" of the radiator fan, to do this, move the lock back "arrow" and press the stopper down. Release the wiring harness.
Disconnect plug connector "3" of the secondary air pump motor "V101" and release the electrical wiring. "Pos. 1, 2" do not take into account.
Unscrew bolts "1" and nut "3" on the left and right, remove the radiator frame crossbars "2".
Loosen the "arrow" nut on the right side member and release the ground cables.
Unscrew bolts "1", as well as nuts "2" and "3", remove the tensioner.
Remove the gasket "3". Release the fastening clamps "1" from the fasteners and remove the cover of the water drainage box "2".
Disconnect the vacuum hose "arrow" to the diagnostic pump of the fuel system "V144".
Remove the vacuum pipe "2" from the front wall, for this purpose remove the vacuum hose "1" on the back side. Release the fuel line and the line going to the absorber with activated carbon on the air duct tube. Do not take "Pos. 3,4" into account.
Remove the air duct "arrow".
Remove vacuum hose "3" from the branch pipe on the air duct. Remove the air duct tube, to do this, loosen clamp "4" and unlock the clamps "arrows". Release fuel hose "1" from the air duct tube. Do not take "Pos. 2" into account.
Remove the air filter housing and the secondary air supply hose "arrow" on the reverse side by pressing on the locking tabs.
Unscrew the fuel supply hose from the high-pressure pump "arrow" and put it aside.
Disconnect and release vacuum hose "1". Remove coolant hose "2" from the upper coolant pipe by pressing the fastening bracket.
Remove the secondary air hose "arrow" from the bracket in the forward direction by pressing on the locking tabs.
Cars without coolant circulation pump "V50": remove the front right coolant hose "arrow" from the coolant pipe, to do this, press the fastening bracket.
Remove the cooling system hose from the front coolant pipe; to do this, press the fastening bracket "arrow".
Remove the coolant hose by loosening the hose clamp "arrow".
Remove coolant hose "2" from the expansion tank. Unscrew the bolts "arrows", disconnect the electrical connector of the low coolant level indicator sensor "F66" and put aside the coolant expansion tank with the connected coolant hose "1".
If available, disconnect the "arrow" electrical connector from the power steering pump.
Slightly press down the hydraulic oil hose. Unscrew the bolts "arrows" and remove the coolant lines from the compressor. Close the open lines and pipes with clean plugs from the plug kit for the "VAS 6122" engine.
Unlock the lock "arrow A" and open the cover "arrow B".
Unscrew nuts "1" and "2" of the electrical wiring. Remove the electrical plug connection "3" from the holder and disconnect it. Unscrew bolt "4" and remove the 2-wire splitter 30 "TV22" from the "arrow" brace.
Remove foam block "1" upwards. "Pos. 2" is not taken into account
Unlock the wheel arch latches with a 5.5 union wrench "pos. 1" and remove the cable gland "2" in the upward direction. Release the wiring harness "3" going to the alternator and starter with the "80-200" release lever.
Open the wire channel "1" by unlocking the "arrow" lock and releasing the wiring harness.
Unscrew nut "3" and bolt "2". Remove filler neck "1" with filler tube from washer reservoir, passing it through body opening "arrow".
Unscrew bolts "1,2,4" and remove cover "3" of the engine compartment switching unit. Unscrew nut "5" and release the ground wire.
Unlock the clamps "arrow A" and remove the engine control unit "arrow B".
Disconnect (if available) plug connector "2". Disconnect plug connectors "4" and unscrew electrical wiring "3". Unlock the "arrow" latches and remove fuse block B "SB" "pos. 1". Remove and release the engine wiring harness secured in the switching block.
Unlock the clamps "arrow A" and remove the cable guide "2" in the upward direction "arrow B". Unscrew the ground bolt "1" and release the wiring harness. Place the wiring harness on the engine and secure the engine control unit from falling out.
Disconnect the "arrow" plug connector from the front speed sensors on the left and right.
If available, disconnect electrical connectors "1" of the front left vehicle level sensor "G78" and the front right vehicle level sensor "G289" and release the electrical cable "arrow".
Disconnect the plug connector "2" from the bracket by pulling the lock back "arrow A" and turning the plug connector "in the direction of arrow B" by approx. 90°. Release the electric wire "3" and the brake hose "4" on the bracket. Loosen the bolts "1" and hang the brake caliper with the connected turbo line of the brake drive on the wheel arch with wire.
Risk of damage to brake cylinder pistons. Do not press the brake pedal with the brake caliper removed. Unscrew nut "2" and remove bolt "1". Remove the upper suspension arm from the wheel hub bearing housing in the upward direction "arrows". Repeat the entire process on the other side of the car.
Unscrew bolt "1" of the stabilizer on the left and right. Unscrew nut "3" on the left and right.
Bolt "2" will be unscrewed later. Unscrew nut "1" securing the hydraulic line of the power steering.
Risk of damage to chassis components. If engine mounts, steering gear or subframe crosspiece are not installed properly, the vehicle must not be placed on wheels. It is prohibited to support the vehicle by the subframe or subframe crosspiece (for example, with a jack, etc.)! Unscrew the "arrow" bolts and remove the subframe brace.
Risk of damage to the coil spring contact of the Airbag. Disconnect the universal joint with the crosspiece from the steering gear only when the front wheels are in the straight-ahead position. Do not change the position of the steering wheel or the position of the steering gear. Unscrew the bolt "arrow" of the universal joint with the crosspiece. Press the universal joint with the crosspiece away from the steering gear and move the joint up to the stop.
Unscrew the nuts "arrows" of the left front muffler.
Unscrew the nuts "arrows" of the right front muffler.
Risk of damage to the release components in the front mufflers. Do not bend the release components in the front mufflers more than 10°. Loosen and move back the clamps "1" and "2", remove the left and right front mufflers.
If present, unscrew the "arrow" bolts and remove the heat shield "1" of the cardan shaft.
Loosen the bolts securing the propeller shaft to the gearbox; to do this, hold the propeller shaft from turning with the support "T10172" with "T10172/5". Move the propeller shaft toward the rear main gear housing; The CV joints are movable in the axial direction. Tie up the cardan shaft from the side.
Press the ball joint "1" of the gearbox selector cable with the "80-200" lever from the gearshift lever. Remove the locking bracket "2" and disconnect the gearbox selector cable from the gearbox.
The gear selector cable must not be bent or kinked. Prepare the lifting table "VAS 6131 A" with a set of fasteners for Audi "VAS 6131/10", additional set "VAS 6131/11" and "VAS 6131/13" as follows: First screw the fastening elements to the lifting table manually. Set the lifting table for the units horizontally. Monitor the level (with a peephole) on the receiving table. Place the lifting table under the power unit. Do not unscrew bolts "2" and "3" of the subframe. Unscrew bolt "1" of the subframe on the left and right.
Install conductors from "VAS 6131/10" and "VAS 6131/13" left and right on the front of the subframe, as shown in the picture.
Make sure the lead screws are fully screwed in.
Install conductors from "VAS 6131/10" at the rear left and right on the front threaded connections of the subframe brace, as shown in the figure.
Install conductors from "VAS 6131/13" left and right on the lower part of the wheel hub bearing housing, as shown in the figure.
Install conductors from "VAS 6131/10" and "VAS 6131/11" at the rear left and right on the tunnel cross member, as shown in the figure. Unscrew all the lead screws of the fastening elements upwards so that all the mounting protrusions enter the fastening points. Screw the support plates of the fastening elements to the lifting table "VAS 6131 A" with a torque of 20 Nm.
Mark the mounting position of the subframe and tunnel crossmember on the side members with a felt-tip pen. Crosswise unscrew bolts "2" and "3" of the subframe in several stages. Bolt "1" has already been unscrewed. Unscrew the bolts "arrows" of the tunnel crossmember.
Unscrew bolt "2" on the left and right. Nut "1" and bolt "3" have already been removed.
Risk of damage to hose and wire connections and engine compartment. Make sure that all hose and wire connections between the engine, gearbox, subframe and body are disconnected. Carefully remove the power unit with the subframe from the engine compartment when lowering. Lower the power unit using the lifting table "VAS 6131 A". Pull the lifting table with the power unit out from under the vehicle.