Removing engine, vehicles with manual gearbox — AUDI

🧭 Before you start

Fits: Audi A5 (8T, 2007–2016), Audi A5 Cabriolet (8F), Audi A4 B8 (8K, 2007–2015)

• Opens: refrigerant (A/C), power steering fluid
• Special tools named: 3094, T40149/1, T40149/2, T40160, T10172/5, VAS 6131/13, VAS 6131/10, 5 mm ring spanner

Don't miss

• On four-wheel drive vehicles the electromechanical parking brake must be released before disconnecting the battery, so that the propshaft can be turned during removal.
• Disregard (item 2).
• Lay a cloth under the separating point to catch escaping hydraulic fluid.
• Disregard (items 3, 5).
• Disregard (item 1).

🔧 Engine codes this applies to

🔩 Torque settings

Values can differ between engine variants — check the code stamped on your block.

ℹ️ Always cross-check the exact figure against your vehicle's factory manual before final tightening — a wrong torque can damage the engine. These values are extracted from workshop data and may not cover every variant or revision.

📋 Procedure

1. ⚠ Make sure the vehicle cannot tip over when the engine is removed.Secure the vehicle, to do so, the luggage compartment must be empty. — Set front wheels to straight-ahead position. [Note: On four-wheel drive vehicles the electromechanical parking brake must be released before disconnecting the battery, so that the propshaft can be turned during removal.]
2. ⚠ Electronic components are susceptible to damage.Observe notes on procedure for disconnecting the battery. — Switch off ignition and take out ignition key.
3. Disconnect earth wire (2) from battery terminal Electrical system27Battery, Disconnecting and connecting battery.
4. Discharge refrigerant circuit Heating, air conditioning87Refrigerant circuit.
5. Extract hydraulic fluid for power steering from reservoir using used oil collection and extraction unitV.A.G 1782.

6. Remove engine cover panel (arrows).
7. ⚠ Hot steam/hot coolant can escape - risk of scalding.The cooling system is under pressure when the engine is hot.To allow pressure to dissipate, cover filler cap on coolant expansion tank with cloth and open carefully. — Open filler cap on coolant expansion tank.
8. Remove both front wheels.
9. Remove wheel spoilers (front) on both sides General body repairs, exterior66Wheel housing liners; Exploded view - wheel housing liner (front).
10. Remove noise insulation (1) and (2)General body repairs, exterior66Noise insulation; Exploded view - noise insulation.
11. Place drip tray for workshop hoistVAS 6208 beneath engine.
12. Remove drain plug (arrow) at connection and drain off coolant.
13. Then detach connection from radiator (lift retaining clip).
14. Release hose clip (arrow), disconnect coolant hose from coolant pipe (left-side) and drain off coolant.
15. Vehicles with plug-in connector at coolant pipe (bottom right): Lift retaining clip (arrow), disconnect coolant hose and drain off coolant.
16. Vehicles with plug-in connector at longitudinal member: Lift retaining clip (arrow), disconnect coolant hose and drain off coolant.
17. Position used oil collection and extraction unitV.A.G 1782 below connection point.
18. Disconnect hydraulic fluid return line (arrow) for power steering.
19. Seal off open pipes/lines and connections with clean plugs from engine bung setVAS 6122.
20. Unplug electrical connector (1) at charge pressure sender G31 and move electrical wiring clear. [Note: Disregard (item 2).]
21. Unscrew nut (arrow) on longitudinal member (right-side) and move earth cables clear.
22. Unplug electrical connector (1) and, if fitted, (2) for radiator fan (push retainer to the rear (arrow) and press down release catch).
23. Move electrical wiring clear.
24. Release hose clip (arrow), disconnect air hose from air pipe and move to one side.
25. On vehicles with auxiliary heater: remove nut (1), loosen clamp (3) and detach exhaust pipe (2) for auxiliary heater
26. Remove bolt (1) and nut (3) on both sides and detach strut (2) for lock carrier.
27. Remove air duct (arrow).
28. Unplug electrical connector (1) from air mass meter G70.
29. Unscrew bolt (3) and move clear exhaust gas pressure sensor 1G450(item 4) at air pipe.
30. Unplug electrical connector (2) and move air pipe clear.
31. Remove air hose and air mass meter G70. To do so, release hose clip (5) and clamps (arrows).
32. Disconnect vacuum line (1).
33. Detach air cleaner housing, unplug electrical connector (2) at air filter bypass flap valve N275 on reverse side of air cleaner and move electrical wiring clear.
34. ⚠ Take care to keep components clean.Observe rules for cleanliness when working on the fuel supply system . — Disconnect fuel supply hose (1) and fuel return hose (2).
35. If fitted, disconnect vacuum line (arrow).
36. If fitted, pull out oil dipstick (1).
37. Release hose clip (3) and detach air hose.
38. Unplug electrical connector (4).
39. Remove bolts (2) and detach throttle valve module J338(item 5). [Note: Lay a cloth under the separating point to catch escaping hydraulic fluid.]
40. Cut open cable tie (4).
41. Clamp off hydraulic hose (1) using hose clamp 3094, release hose clip (2) and disconnect hose from power steering pump.
42. Seal off open pipes/lines and connections with clean plugs from engine bung setVAS 6122. [Note: Disregard (items 3, 5).]
43. If fitted, unplug electrical connector (2). [Note: Disregard (item 1).]
44. ⚠ Danger of damage to refrigerant lines and hoses.Do NOT stretch, kink or bend refrigerant lines and hoses. — Remove bolt (2), disconnect refrigerant line from air conditioner compressor and move to one side.
45. Seal off open pipes/lines and connections with clean plugs from engine bung setVAS 6122. [Note: Disregard (items 1, 3).]
46. Disconnect coolant hose (3) from coolant expansion tank. [Note: Disregard items marked (1, 2) and (arrows).]
47. Remove seal (arrow).
48. Remove plenum chamber cover General body repairs, exterior50Bulkhead; Removing and installing plenum chamber cover.
49. Release retainer (arrow A) and open cover (arrow B).
50. Remove nuts (1 ... 3) for electrical wiring.
51. Detach electrical connector (4) from bracket and unplug.
52. Remove bolt (5) and detach terminal 30 wiring junction 2TV22 from body brace (arrow).
53. Working from wheel housing, release catches using a 5.5 mm ring spanner (item 1) and remove wiring protector (2) from above.
54. Release wiring harness (3) leading to alternator and starter using removal lever80 - 200 and move clear.
55. Wiring duct (version 1): release catch (arrow B) and move wiring duct clear by pulling it towards front (arrow A).
56. Wiring duct (version 2): release catch (arrow) to open wiring duct (1) and move wiring harness clear.
57. Press refrigerant lines (A) and (C) by hand as far as stop into connection piece (B) for refrigerant line with internal heat exchanger.
58. Spray area around refrigerant lines with silicone-free lubricant.
59. Fit release tool for air conditioner line T40149/1 onto refrigerant line (A) and release tool for air conditioner line T40149/2 onto refrigerant line (C) so that both tools engage audibly. This releases the retaining lugs.
60. Using release tools for air conditioner line, pull refrigerant lines (A) and (C) out of connection piece (B) for refrigerant line with internal heat exchanger. [Note: If it is not possible to pull out the refrigerant lines, do NOT attempt to turn the refrigerant lines in connection piece (C). In this case you will have to cut open the connectors (B) and take out the retaining rings (A).When cutting open the connectors, take care not to damage the connection piece (C) for the refrigerant line with internal heat exchanger.]

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