Removing engine - vehicles with engine code letters AJM — AUDI

🧭 Before you start

Fits: Audi A6 C5 (4B)

• Opens: coolant
• Timing position: the crankshaft or camshaft is set and locked during this job
• Special tools named: VAS 6100

Don't miss

• To prevent damage to the condenser and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.
• Protect wing panels from damage.
• A second mechanic is required for removing the lock carrier.
• Before removing, mark direction of rotation of poly V-belt with chalk or felt-tipped pen. If the belt runs in the opposite direction when it is refitted, this can cause breakage.
• Counterhold pulley with drift to unbolt power steering pump pulley.

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ On vehicles with telematics, activate service mode of telematics control unit before disconnecting battery Radio, telephone, navigation01Telematics self-diagnosis. — Obtain code on vehicles with coded radio / radio and navigation system (RNS).
2. Detach rubber seal from plenum chamber cover in direction of (arrow).
3. Detach plenum chamber cover (1) to front.
4. With ignition switched off, disconnect earth wire (arrow) at battery.
5. ⚠ Hot steam/hot coolant may escape when opening expansion tank; cover filler cap with cloth and open carefully. — Open filler cap on coolant expansion tank.

6. Pull dipstick (1) out of guide tube.
7. Unclip cover caps.
8. Unfasten nuts (arrows) and detach engine cover.
9. Remove insulation beneath cover.
10. Re-insert dipstick in guide tube.
11. Unclip cover caps.
12. Unscrew bolts (arrows) and remove air cleaner cover.
13. Unscrew bolts (arrows).
14. Remove air ducts (1) and (2).
15. Remove cover (arrow) at power steering fluid reservoir.
16. Remove front bumper General body repairs, exterior63.
17. Vehicles with auxiliary heater: remove bolts (arrows) securing exhaust pipe for auxiliary/additional heater to noise insulation.
18. Release quick-release fasteners (1 … 3) and take off front and rear noise insulation.
19. Unbolt bracket for noise insulation (arrow).
20. Remove air cowl in front of charge air cooler (arrows).
21. Unclip ambient temperature sensor G17 from bracket.
22. Unscrew bolts (arrows) and move cooling pipe for power steering clear; hydraulic fluid system remains closed.
23. Place drip trayV.A.G 1306 or drip trayVAS 6208 under engine.
24. Turn drain plug (arrow) on radiator anticlockwise and drain coolant (attach hose to connection if necessary).
25. Pull off retaining clip for coolant hose (bottom) (arrow) and remove coolant hose from radiator.
26. Detach air intake hose going to charge air cooler at lock carrier (bottom left) (arrow).
27. Detach turbocharger air intake hose at lock carrier (bottom right).
28. Unplug electrical connector (green) (arrow) for magnetic clutch of air conditioner compressor at lock carrier (bottom right) and move electrical wire clear.
29. Unplug electrical connector (arrow) for headlights on both sides.
30. Detach cable for bonnet at lock carrier General body repairs, exterior55.
31. Unplug electrical connectors (1 ... 3) at front of ABS unit.
32. Move wiring clear.
33. Detach upper coolant hose (arrow) from radiator.
34. Remove air ducts at radiator (left and right).
35. Unplug electrical connector (1) at low pressure switch for air conditioner F73.
36. Release both retaining pins (2) and pull out to side (arrows).
37. ⚠ Refrigerant circuit of air conditioner must not be opened. — Detach both brackets (3) and pull condenser upwards out of bracket [Note: To prevent damage to the condenser and refrigerant pipes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.]
38. Move condenser to side with pipes/hoses connected and tie onto right front wheel with wire. [Note: Protect wing panels from damage.]
39. Remove bolts (arrows) at lock carrier (left and right).
40. Remove engine compartment seal from lock carrier and wing panel flanges.
41. Unscrew bolts from impact absorbers (arrows) (left and right). [Note: A second mechanic is required for removing the lock carrier.]
42. Remove lock carrier and place down in a secure position.
43. Detach coolant hoses (1) and (3).
44. Unbolt coolant expansion tank (2)(arrows).
45. Unplug electrical connector for coolant shortage indicator switch F66 at expansion tank (below).
46. ⚠ In extreme cases the fuel lines and the fuel can reach a temperature of 100 °C on vehicles with unit injector engine. Allow the fuel to cool down before disconnecting the lines - danger of scalding.Wear protective gloves.Wear safety goggles. — Disconnect fuel return hose (1) and fuel supply hose (2) from fuel cooler.
47. Disconnect air intake hose at charge air cooler (arrow).
48. Disconnect vent pipe (1) leading to air cleaner and vacuum line (2) leading to mechanical EGR valve.
49. Loosen hose clip (3) to remove air intake hose at intake connecting pipe.
50. Unplug electrical connectors (2) and (4).
51. Detach vacuum hose (5).
52. Unscrew bolt (1).
53. Remove air pipe (3).
54. Disconnect hose connections (arrows).
55. Detach vacuum line (1).
56. Disconnect breather hose (2) from air cleaner housing.
57. Unplug electrical connector (4) at air mass meter G70.
58. Detach EGR valve N18(Item 3) from air cleaner housing and unplug electrical connector.
59. Move wiring harness going to air cleaner clear (arrow).
60. Loosen hose clip (5) to remove air intake hose.

Other AUDI procedures

• Checking UIS solenoid valves – Audi 1.9 TDI
• Testing unit injector solenoid valves – Audi 1.9 TDI
• Testing AC compressor signal and AC compressor shut-off
• Removing and installing fuel delivery unit - vehicles with 4-cylinder engine
• Checking accelerator position sender G79 - vehicles with 4-cylinder engine
• Removing and installing toothed belt – Audi · 56 torque figures
• Removing engine – Audi A8 D3 · 41 torque figures
• Removing camshaft timing chain from camshafts – Audi A6/A7 C7 · 38 torque figures
• Installing engine – Audi A8 D4 · 36 torque figures
• Removing and installing camshaft timing chain · 29 torque figures