Audi A4 2008+ - 6 Cylinder Direct Petrol Injection With Supercharger (3.0 LTR 4-Valve)

Service a Workshop Manual Audi A4 2008 > Audi Ad Cabriolet 2009 > Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with h Edition 11.2010 Service Department. Technical Informationprod Service List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups Repair Group 00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17 - Lubrication 19 - Cooling 211 - Turbocharging/supercharging 26 - Exhaust system Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2010 Audi AG, Ingolstadt 03E801823¢3Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor Contents 00 - Technical data 1 1 Engine number 1 2 Engine deta 2 3 Safety precautions 3 3.1 Working on the fuel system 3 32 Procedure before opening high-pressure section of injection system 4 33 Working on the cooling system 4 3.4 Working on vehicles with staristop system 4 3.5 Using testers and measuring instruments during a road test 5 3.6 Working on the exhaust system 5 3.7 Working on the subframe 5 4 General repair instructions. 6 4.1 Rules for cleanliness when working on fuel supply system, injection system: and: turbocharger! supercharger 6 42 Checking fuel system for leaks 6 43° Foreign paricles in engine 7 44 Contact corrosion! 7 4.5 Routing and attachment of pipes, hoses and wiring 7 4.6 Installing radiators and condensers 7 4.7 Checking vacuum system 7 40 - Removing and installing engine /, C/G 9 4. Removing and insaling enging {vehiclea wah manual gearbox 9 1.4 Removing engine ‘ 9 1.2 Separating engine from manual gearbox. - 29 1.3 Installing engine 4 2 Removing engine - vehicles with dual clutch gearbox 08s 42 2.14 Removing engine . 42 2.2 Separating engine and dual clutch gearbox BS 62 23 _ Instaling engine 67 3 Securing engine to engine and gearbox support 7S 4 Assembly mountings .. t cr 79 4.4 Assembly mountings - exploded Wie ose 73 4.2 Removing and installing engine mounting (left-side) 20 4.3. Removing and installing engine mounting right-side) 3 13 - Crankshaft group : 86 1 Cylinder block (pulley nd) a 86 1.1 Poly V-belt drive for supercharger exploded view 87 1.2 Removing and installing poly V-belt for supercharger nee 87 1.3 Removing and installing poly V-belt tensioner for supercharger 89 1.4 Poly V-belt drive - exploded view . . 90 15 Removing and installing poly V-belt 92 18 Removing and installing tensioner for pely V-belt 3 1.7 Removing and installing vibration damper 96 1.8 Renewing sealing flange (pulley end) with crankshaft oil seal 97 2 Cylinder block (gearbox end) 101 24 Drive plate - exploded view 101 22 Removing and instaling drive plate 101 2.3 Pressing out and pressing in drive plate needle bearing 102 24 — Renewing crankshaft oil seal (gearbox end) 104 3. Crankshaft 106 contanis iAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Avor_ 11.2010 3.1. Crankshaft - exploded view 108 3.2 Grankshaft dimensions 109 3.3 Measuring axial clearance of crankshaft... beet eteee eve ee cee = 109 3.4 Measuring radial clearance of crankshaft . . . . . a 110 4 Pistons and conrods- we bee eeeeeee settee 112 44 Pistons and conrods - exploded view ... . wee ae 112 4.2 Piston and cylinder dimensions . . . wee . . 115 4.3. Measuring radial clearance of conrods: . . cee 115 15 - Cylinder head, valve gear .......... Fee eee eee nena 116 1 Chain drive 116 44 ‘Timing chain covers - exploded view 47 1.2 Removing and installing timing chain covers (left and right) 119 4.3. Removing and installing timing chain cover (bottom) . . - » 122 1.4. Camshaft timing chains - exploded view . a . . . 128 1.5 Removing timing chains from camshafts cee eee teeee . 130 1.6 Removing and installing camshaft timing chains . . . . . 139 1.7 Drive chain for valve gear - exploded view ... ae . . . 142 1.8 Removing and installing drive chain for valve gear ..-... 200s eseeveve » 143 19 Drive chain for auxiliary drives - exploded view 145 4.10 Removing and installing drive chain for auxiliary drives, 145 1.11 Balance shaft - exploded view 149 1.12 Removing and installing balance shaft 149 2 Cylinder head ahha Spee cece eee - wees wee 154 24 Cylinder head - exploded v view . . nee ee 154 2.2 Removing and installing cylinder head cover (loft side) - seeeeee sees . 184 2.3. Removing and installing cylinder head cover (right-side) 155 2.4 Removing and installing cylinder heads 156 25 Checking compression 162 3 Valve gear .. . . 165 3.4 Valve gear - exploded view a 166 3.2 Measuring axial clearance of camshafts 168 3.3. Measuring radial clearance of camshafts a a . nee . 169 3.4 Removing.and installing camshatis. * . eee 169 3.5 Ohecking’hydraulievalvecompensation’ elements Dy . . . 175 3.6 Renewing valve stem cil seals with cylinder head installed eee . 178 3.7 Renewing valve stem oil seals with cylinder head removed ...... . 182 3.8 Valve dimensions 185 3.9 Checking valve guides 185 3.10 Checking valves 188 AT = Lubrication 6.6.6 e eee e ence nee erence ene 187 1 ‘Sump (bottom section), sump (top section), oil pump, engine oil cooler . . . 187 1.1 Sump (bottom section), sump (top section), oil pump, engine oil cooler - exploded view .. 188 1.2 Removing and installing engine oil cooler 190 1.3. Removing and installing ol level and oil temperature sender G265 192 1.4 Removing and installing sump (bottom section) 192 1.5 Removing and installing oll pump ...... 2. ...6. cee ceecee eee sseeseeceeeees 195 1.6 Removing and installing sump (top section) . . . . . wee. 195 2 il filter housing, oil pressure switch . eee . 199 24 il filter housing, oil pressure switch - exploded view settee eee . 199 2.2 Removing and installing oil filter housing wee. 200 2.3 Checking oil pressure switch F22 / oil pressure switeh for reduced oil pressure F378 . 202 2.4 Removing and installing oil pressure switch F22. . . . . 203 25 Removing and instaling ol pressure switch for reduced ol pressure F378 203 Ti contents‘Audi 44 2008 > , Audi A5 Cabriolet 2009 > . Audi AS Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD ‘Aver 2.6 Removing and installing valve for oll pressure control N428 205 2.7 Checking oll pressure 206 3 Oilretention vaives, oil separator 208 3.4 Oilretention valves, oil separator - exploded view 208 3.2 Removing and installing crankcase breather hoses - not on USA models 208 3.3. Removing and installing cover with oil separator 210 34 Engine oil . 210 35 Checking oil level 210 19-Cooling .... 6... 0e cece cece eee ee : 2211 1 Cooling system an 1.1 Diagram of coolant hose connections 212 1.2 Draining and filing cooling system 218 1.3. Checking cooling system for leaks 222 2 Coolant pump and thermostat 225 2.4 Coolant pump, thermostat and connection - exploded view 225 22 Removing and installing coolant pump. 225 23. Removing and installing thermostat 227 24 Checking thermostat. 228 3 Coolant pipes and continued coolant circulation pump V51 229 3.1. Coolant pipes - exploded view 230 32 Removing and installing coolant temperature sender G62 231 3.3. Removing and installing coolant pipes (left-side) 232 3.4. Removing and installing coolant pipes (front left) 234 3.5 Removing and installing coolant pipe (front) 237 «cs B.6,yRemoving.and installing. coolant pine. (top), 240 == 3:7" “Removing ant istaling coolant pipes'on supercharger 2a 3.8” Removing and installing charge air cooling pump V188 244 38 Continued coolant circulation pump V1 - exploded view 246 3.40 Removing and installing continued coolant circulation pump V51 246 4 Radiator and radiator fans 249 4.4. Radiator and radiator fans - exploded view 250 42 Removing and installing radiator with radiator cow! 252 4.3 Removing water radiator (front) for charge air cooling circuit... 258 4.4 Removing and installing water radiator (ift-side) for charge air cooling circuit 261 45 Removing and installing radiator fans V7 / V177 263 21 - Turbocharging/supercharging 264 1 Supercharger 264 1.1 Supercharger - exploded view 285 1.2 Removing and installing charge pressure sender G31 / G447 287 1.3. Removing and installing supercharger 287 14 Charge air coolers - exploded view 272 15 Securing supercharger to engine and gearbox support for assembly work 273 1.6 Securing supercharger to engine and gearbox support for leak test 274 1.7 Removing and installing charge air cooler 275 1.8 Drive unit exploded view 279 1. Removing and installing drive unit and damper spring 279 4.10 Checking supercharger for leaks 281 26 - Exhaust system 2.22.0... ee eee eee eee eee neers - 284 1 Silencers 284 1.4 Silencers - exploded view 284 1.2 Removing and installing catalytic converter (left-side) 288 1.3. Removing and installing catalytic converter (right-side) 289 consents HiiAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 1.4 Removing and installing front silencer 289 1.5 Separating centre and rear silencers 291 1.6 Renewing tailpipe ..... cece . cece eeee eee 293 4.7 Stressctree alignment of exhaust system .osccvcseesssvsee cee 293 1.8 Aligning teilpioes SS ee 294 119 Checking exhaust system for leaks 0000... } wees 294 2 Exhaust manifold .. - 296 2.1 Exhaust manifold - exploded view... } f... : - 296 22 Removing and installing exhaust manifold (let-side) 0. --soseeveevvevsees 297 2.3 Removing and installing exhaust manifold (right-side) . - 299 3 Secondary air system ..... feet iteeeeeenes vee - 302 3.1 Secondary air system - exploded view 302 3.2 Checking combinetion valves for secondary ai system for correct operation and leakage 3.3. Removing and installing combination valve for secondary air system (left-side) 305 3.4 — Removing andiinstaliing combination vaive for-secondary-ait-system right-side) 307 3.5 Removing and instaliig secbridaty ait phim tdtor 10 , 308 3.6 Removing and installing sender 1 for secondary air pressure G09" 310 IV contantsAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD wy} Technical data 1 Engine number (Fs Pull off engine cover panel (front) to make the engine number visible. @ The engine number (,engine code" and ,serial number’) can be found on the front of the cylinder block beneath the cylinder head (right-side) -arrow. Starting with the letter ,C*, the engine codes consist of 4 let- ters. The first 3 characters of the engine code stand for the-engine capacity and the mechanical construction and design. They are stamped on the cylinder block, together with the serial number. The 4th character indicates the power output and torque of the engine, and is determined by the engine control unit fa) Note ¢ The 4-character engine code can be found on the type plate (in versions for some countries only) and on the vehicle data ‘sticker and the engine control unit. ¢ Fitting locations of the type plate (certain countries only) and the vehicle data sticker Maintenance ; Booklet 811 ;= Main- tenance ; Booklet 812 or > Maintenance ; Booklet 818 14.2010 Aver 1. Engine numbor 1Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition vor 11.2010 2 Engine data [Code tatters CAKA ‘CCBA (Capacity ir 2.995 2.995 Power output kW at rom 24577000 1245/7000 Torque Nm at rpm 44012900 ... 8300 44072900 ... 5300 Bore 2 in mm] 845 845 Stroke mm 89.0 89.0 ‘Compression ratio 105 105 RON atleast 95) 950 Injection/ignition system Simos Simos Firing order 143625 143625 Exhaust gas recirculation no no Turbocharging/supercharging Supercharger Supercharger Knock control 2 sensors 2 sensors [Charge air cooling yes yes Lambda contro! Variable vaive timing Intake manifold change-over |Secondary air system Valves per cylinder /2/probes before catalyticconverter 2 probes after catalytic converter: Inlet no yes 4 probes before catalytic converter| 2iprobes after catalytic converter Inlet no yes 4 1) Unleaded regular grade petrol (RON 91) can also be used, but this will result in a loss of power 2 Rep. 07: 00- Technical dataAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 11.2010 “Aver 3 Safety precautions Overview =.3.1 Working on the fuel system’. page 3 2.3.2 Procedure before opening high-pressure section of in- es @ =.3.4 Working on vehicles with start/stop system page 4 © 2.3.5 Using testers and measuring instrur ring ar feat"_page 5 ‘@ =..3.6 Working on the exhaust system’, page 5 © =.3.7 Working on the subframe’, page 5 34 Working on the fuel system ‘When working on the fuel system note'the ‘following’ waren? ne , LX _ wornine The fuel system operates at extremely high pressure. This can cause injury. ¢ The fue! pressure in the high-pressure section of the in- Jection system must be reduced to a residual pressure ‘prior to opening the system. ¢ Wrap a clean cloth around the connection and carefully loosen the connection to allow the residual pressure tO dissipate. = Procedure before opening high-pressure section of injection system = Rep. gr. 24 Observe the following to prevent injuries to persons and damage to the injection and ignition system: ¢ Always switch off the ignition before connecting or disconnecting electrical wiring for the injection or ignition system or tester cables. ‘¢ Always switch off ignition before washing engine. Entries are stored in event memory of engine control unit if electrical connectors were unplugged and engine wes stated Ss > Vehicle diagnostic, testing and information system VAS 5051 A Caution To prevent irreparable damage to the electronic components when disconnecting the battery: Observe notes on procedure for disconnecting the battery. ¢ Always switch off the ignition before disconnecting the battery. = Disconnect battery = Electrical system; Rep. gr. 27 58. Safaty precautions 3Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 3.2 Procedure before opening high-pressure section of injection system ZY wenn The injection system consists of a high-pressure section (maximum approx. 120 bar) and a low-pressure section (approx. 6 bar). ¢ The fuel pressure in the high-pressure section must be reduced to @ residual pressure of approx. 6 bar prior to ‘opening the system. Procedure > Rep. gr. 24 3.3 Working on the cooling system When working on the cooling system note the following warnings: ZX warns Hot steam/hot coolant can escape - risk of scalding. # The cooling system is under pressure when the engine is hot. ¢ To-llow pressure to dissipate, cover filer cap on coolant ‘expansion tank with cloth and open carefully. Risk of injury as the radiator fans may start up automatically. + Unplug electrical connectors before starting to work in the area of radiator cowl. LY canton Overheating can occur if the filer cap is not fitted properly. + The filler cap must engage positively and audibly when it is closed. 34 Working on vehicles with start/stop system When performing repairs on vehicles with start/stop system, note the following: A wn Risk of injury due to automatic engine start on vehicles with start/stop system. On vehicles with activated start/stop system (this is indi- cated by a message in the instrument cluster display), the ‘engine may start automatically on demand, % Therefore it is important to ensure that the start/stop sys- tom is deactivated when performing repairs (switch off ‘ignition, if required switch on ignition again). 4 Rp. 07:00- Technical dataAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 41.2010 “Aver 35 Using testers and measuring instruments during a road test Note the following if testers and measuring instruments have to be used during ¢ road test: A WARNING Accidents can be caused if the driver is distracted by test equipment while road-testing, or if test equipment Is not properly secured. Persons sitting in the front passenger's seat could be injured if the airbag is triggered in an accident. + The use oftest equipment while driving causes distraction, + There is an increased risk of injury iftest equipment is not to came : secured. ¢ Test equjoment must always be secured on the rear seat with a strap and operated from the rear seat by a second person. 36 Working on the exhaust system When working on the exhaust system please note the following: BL caion Avoid damage to flexible joint. Donot bend flexible joint more than 10°. # Install flexible joint so that itis not under tension. ¢ Take care not to damage wire mesh on flexible joint. 3.7 Working on the subframe Please note the following warnings when working on the subframe: Ay cw Risk of damage to running gear components. # The vehicle must NOT be lowered onto its wheels if the engine/gearbox mountings, steering box or subframe crass brace are not properly install ¢ The vehicle must NOT be supported by applying a trolley Jack or similar to the subframe or subframe cross brace. 58. Safaty precautions 5Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 4 General repair instructions Overview # =.4.1 Rules for cleanliness when working on fuel supply system. injection system and turbocharger/supercharger” page 6 2 7 I =..4.3 Foreign particles in engine’, page 7 =.4.4 Contact corrosion!", page 7 >..4.5 Routing and attachment of pipes, hoses and wiring”, page 7. @ ==.4.6 Installing radiators and condensers, page 7 @ =.4.7 Checking vacuum system‘, page 7 44 Rules for cleanliness when working on fuel supply system, injection system and turbocharger/supercharger Even small amounts of dirt can cause malfunctions. For this reason, please observe the following rules when working on the fuel supply system, injection system and turbocharger: # Carefully clean connection points and the surrounding area with engine cleaner or brake cleaner and dry thoroughly before: opening: # Seal off open pipesilines and connections immediately with clean plugs, e.g. from engine bung set -VAS 6122- # Place parts that have been removed on a clean surface and cover them over. Use only lint-free cloths. wees # Carefully cover or seal open components if repairs cannot be carried out immediately. # Only install clean components; replacement parts should only be unpacked immediately prior to installation. Do not use parts that have not been stored in their packing (e.g. in tool boxes etc.). + When the system is open, do not work with compressed air and do not move the vehicle. 4 Make sure that no fuel runs onto the fuel hoses. Should this ‘occur, the fuel hoses must be cleaned again immediately. Re- new fuel hoses if damaged # Protect unplugged electrical connectors against dirt and mois- ture and make sure connections are dry when attaching, 42 Checking fuel system for leaks = Allow engine to run for several minutes at moderate rom. — Switch off ignition. - Check complete fuel system for leaks. = If leaks are found although the connections have been tight ‘ened to the correct torque, the relevant component must be renewed = Read-test vehicle and accelerate with ul hrotte atleast once. ~ Then inspect high-pressure section of uel system again for leaks. 6 op. o:00- Technical dataAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 11.2010 “Aver 43 Foreign particles in engine ¢ When performing assembly work on engine, all open passag- es in the intake and exhaust systems must be sealed with suitable plugs (e.g. from engine bung set -VAS 6122- ) to prevent foreign particles from entering the engine. Inthe event of mechanical damage to one of the cylinder banks, the intake and exhaust systems and combustion cham- bers of the opposite cylinder bank must always be examined for foreign particles to prevent further damage occurring later. 44 Contact corrosion! Contact corrosion can occur if unsuitable fasteners are used (e.g. bolts, nuts, washers, etc.) For this reason, only fasteners with @ special surface coating are used. ditionally, all rubber and plastic parts and all adhesives are made of non-conductive materials, Always install new parts if you are not sure whether used parts can be re-fitted = Electronic parts catalogue Note the following: @ We recommend using only genuine replacement parts; these have been tested and are compatible with aluminium. © We recommend the use of Audi accessories, ¢ Damage caused by contact corrosion is not covered under warranty. 45 Routing and attachment of pipes, hoses and wiring © Mark fuel lines, hydraulic lines, vacuum lines, lines for activated charcoal filter system and electrical wiring ete. before removal so they can be re-installed in the original positions and correctly connected. Make sketches or take photographs if necessary. ¢ To prevent damaging pipes, hoses and wiring, ensure suff. cient clearance from all moving or hot components in engine compartment (ttle space in engine compartment) 46 Installing radiators and condensers * ne ora Even when the radiator and condenser are correctly installed, slight impressions may be visible on the fins of these components. This does not mean that the components are damaged. If the fins are only very slightly distorted, this does not justify renewal of the radiator or the condenser. Aq Checking vacuum system Special tools and workshop equipment required 4 Gonaralrepairinsuctions 7Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 4 Hand vacuum pump -VAS 6213- Procedure (Check all vacuum lines in the complete vacuum system for: Cracks Traces of animal bites Kinked or crushed lines Lines porous or leaking woes = Check vacuum line to solenoid valve and from solenoid valve to corresponding component. = Ifa faultis stored in the memory, check the vacuum lines leading to the corresponding component and also check the remaining vacuum lines in the system, ~_ Ifitis not possible to build up a vacuum with the hand vacuum pump -VAS 6213. or if the vacuum pressure drops again immediately, check the hand vacuum pump and connecting hoses for leaks. 8 Rep. 0: 00- Technical dataAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 lt. 4-valve), mechanics - Edition GEED 11.2010 “Aver moving and installing engine 1 Removing and installing engine - vehicles with manual gearbox (F) woe ¢ The engine is removed from undemeath together with the gearbox and subframe (vith lock carrier installed), © Collect drained coolent in @ clean container for re-use or dis- posal. ¢ Fit cable ties in the original positions when installing. 1A Removing engine Special tools and workshop equipment required ‘@ Removal lever -80 - 200- Used oil collection and extraction unit -V.A.G 1782- # Stepladder -VAS 5085- © Engine bung set -VAS “s e122. sor Scissor-type assembly platform -VAS 6131 A- with Support set for Audi - VAS 6131/10- and supplementary set -VAS 6131/13- © Drip tray for workshop hoist -VAS 6208- 80-200 VAG 1782 VAS 5085 VAS 6208 1. Removing and instaling engine - vehicles with manual gearbox Q)Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 # Hose clip pliers -VAS 6362- # Puller -T40160- Procedure ZA wamne ‘Make sure the vehicle cannot tip over when the engine is removed. @ Secure the vehicle, to do so, the luggage compartment must be empty. The fuel system operates at extremely high pressure. This can cause injury. % The fuel pressure in the high-pressure section of the in- Jection system must be reduced to a residual pressure ‘prior to opening the system. = Reduce fuel pressure in high-pressure section of injection system= Rep. gr. 24 =. Set front wheels to straight-ahead position, en The electromechanical parking brake must be released before disconnecting the battery so that the propshaft can be turned during removal. Ta0160 10 ep. o.10-Removing and insaling engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD A Caution Electronic components are susceptible to damage. # Observe notes on procedure for disconnecting the battery. — Switch off ignition and take out ignition key. = Disconnect earth wire -2- from battery terminal = Electrical system; Rep. gf. 27 ~ Discharge retrigerantsystem » Air conditioner wih erigerant a = Extract hydraulic fluid for power steering from reservoir using Used oil collection and extraction unit -V.A.G 1782- = Liftoff engine cover panels -1- and ~ A WARNING Hot steam/hot coolant can escape - risk of scalding. # The cooling system is under pressure when the engine is ¢ Toallow pressure to dissipate, cover filer cap on coolant expansion tank with cloth and open carefully. = Open filer cap on coolant expansion tank. p=) ness none) 14.2010 Aver 1. Removing and instaing engine - vehicles wih manual gearbox 1 4Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 ~ Remove both front wheels > Wheels and tyres; Rep. gr. 44 ~ Remove front let and front right whee! housing liners = Rep. or - Remove noise insulation panels -1- and -2-> Rep. gr. 66 — Place drip tray for workshop hoist -VAS 6208- beneath engine. Remove drain plug -1- and drain off coolant. = Lift retaining clip -2- and disconnect coolant hose from radiator. tee by copy. Copying tr vate or cm = Release hose clip -arrow-, disconnect coolant hose from engine oil cooler and drain off coolant. = Release hose clips -1- and -3., disconnect coolant hoses from coolant pipes (front left) and drain off remaining coolant. Note ¢ Foriilustration purposes, the installation position is shown with the engine removed. © Disregard item 2. 12 Rep. o.10-Removing and insaling engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 14.2010 Aver Unplug electrical connector -3- from charge air cooling pump -V488- and move clear. (B) Note Disregard -items 1, 2. = Position used oil collection and extraction unit -V.A.G 1782- below connection point. = Disconnect supply hose -2- and return hose -1- for power Steering hycraulc fui in front left wheel housing and move clear. = Seal off open pipesilines and connections with clean plugs from engine bung set -VAS 6122- Vehicles with coolant circulation pump -V50- = Unplug electrical connector -2.. — Place drip tray for workshop hoist-VAS 6208- beneath engine, = Release hose clip -1- and disconnect coolant hose fram coolant circulation pump -V50- (Fre Disregard -items 3, 4-. ‘Pemmog urens auorse AUDI AG 1. Removing and instaling engine - vehicles wth manual gearbox 13Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 All vehicles (continued): Unplug electrical connectors -1- and -2- for radiator fan (push retainer to the rear -arrow. and press down release catch). Move clear electrical wiring harness. = Unplug electrical connector -3- at secondary air pump motor - V101- and move electrical wiring clear. Press release tabs, disconnect secondary air hose -1- and move hose clear. Disregard -item 2. — Remove bolt -1- and nut -3- on both sides and detach strut -2: for lock carrier. = Unscrew nut -arrow- on longitudinal member (right-side) and move earth cables clear. 14 ep. o.10-Removing and instaling engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor = Pull seal off plenum chamber partition panel — Remove plenum chamber cover > Rep. gr. 50. — Remove air duct -arrow-. = Move fuel hose -1- and hose -2- leading to activated charcoal filter clear at air pipe. — Detach vacuum hose -3- from connection on air pipe. — Remove air pipe. To do so, release hose clip -4- and clamps -arrows- 1. Removing and instaling engine - vehicles wth manual gearbox 15Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 = Detach air cleaner housing and, iffitted, unplug electrical connector -arrow- at variable intake manifold changeover valve - N335- on reverse side of air cleaner. — Disconnect vacuum hose -1- on rear side of plenum chamber partition panel and detach vacuum connection -2- from ple- Aum chamber partition panel — Unplug electrical connector -3- at activated charcoal filter sol- ‘enoid valve 1 -N80- and detach vacuum hose -4-. otc by copy. Copying fr priate of commer i ecpect oe cores ot eaten USA models: = Disconnect vacuum hose leading to fuel system diagnostic pump -V144- -arrow-. All vehicles (continued): = Detach activated charcoal filter solenoid valve 1 -N8O- from bracket and move it cleer to the side with hoses stil attached. 16 ep. o.10-Removing and instaing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor A WARNING Risk of injury caused by fuel. % Toallow the fuel pressure to dissipate, wrap a clean cloth around the connection and carefully loosen the connection before opening the fuel system. A Caution Take care to keep components clean. Observe rules for cleanliness when working on the fuel supply system > page 6 — Disconnect fuel supply hose from high-pressure pump “arrow. and move clear to one side. Seal off open pipesilines and connections with clean plugs from engine bung set -VAS 6122- . = Liftretaining clip -arrow- and detach coolant hose going to heat ‘exchanger from rear of engine. (8) 6 For illustration purposes, the installation position is shown from the rear and with the engine removed. G) a otc Disregard -items 2, 3-. = Detach vacuum hose -1- and move clear. 1. Removing and instaling engine - vehicles wth manual gearbox 17Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 Vehicles not equipped with coolant circulation pump -V50- : — Lift retaining clip -arrow- and detach coolant hose (front right) from coolant pipe (front). All vehicles (continued): = Release hose clip -arrow- and detach coolant hose, (@) woe Disregard -items 1, 2. — Lift retaining clip -arrow-, detach coolant hose from coolant pipe (front) and move coolant hose cleer. = Disconnect coolant hoses -1- and -2- from coolant expansion tank. — Unscrew bolts -arrows-, unplug electrical connector at coolant shortage inicatorevitch -F68- and detach coclant excansion tenl Protec cop. Copying pra commer ups 18 ep. o.10-Removing and insaling engineAudi Ad 2008 > , Audi A5 Cabriolet 2008 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor — Onvehicles with dynamic steering, unplug electrical connector -arrow- at power steering pump. = Press hydraulic fluid hose down slightly B\ casion Danger of damage to refrigerant lines and hoses. DoNOT stretch, kink or bend refrigerant lines and hoses. = Remove bolts -arrows- end disconnect refrigerant lines from ‘AC compressor. — Seal off open pipesilines and connections with clean plugs from engine bung set -VAS 6122- = Release retainer -arrow A- and open cover -arrow B- = Remove nuts -1- and -2: for electrical wiring ~ Detach electrical connector -3- from bracket and Ungllg. — Remove bolt -4- and detach terminal 30 wiring junction 2° ‘TV22- from body brace -arrow. 1. Removing and insaling engine - vehicles wth manual gearbox 19Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 = Working from wheel housing, release catches using a 5.5 mm ring spanner -item 1- and remove wiring protector -2- from above, = Release wiring hamess -3- leading to alternator and starter Using removal lever -80 - 200- and move cleer. — Wiring duct (version 1): release catch -arrow B- and move wiring hamess clear by pulling it towards front -arrow A. — Wiring duet (version 2): release catch -arrow- to open wiring duct -1- and move wiring harness cleer. = Remove nut -1- and swivel filler neck ~ ervoir slightly upwards -arrow A. = Pull filler neck with filler pipe out of washer fluid reservoir and through opening in body -arrow B-. for washer fluid res- 20 0p. or.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor — Remove bolts -1- and nuts -2- and detach body brace -3-. — Remove bolts -arrows- and detach cover for electronics box in ‘engine compartment, = Remove nut -1- and move electrical wiring clear. — Release catches -arrows A- and take out engine control unit arrow B- = Iffitted, unplug electrical connector -2-. = Unplug electrical connectors -4- and unscrew nut-3-for wiring, — Release catches -arrow- and detach relay carrier with fuse holder -1- = Disengage engine wiring harness al electronics bax inengine. | ‘compartment and move Cleary insti stornn 1 Removing and instaling engine - vehicles wih manual gearbox 21Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 ~ Release catches -arrows A- and lift off wiring protector -2- -arrow B-. = Unscrew earth stud -1- and move witing harness clear. — Place wiring hares on engine and secure engine control unit, to prevent itfrom dropping. — Unplug electrical connectors -arrow- at front wheel speed sensors on both sides. = IFfited, unplug electrical connector -1- from front left vehicle level sender -G78- and front right vehicle level sender -G289- and move wiring clear -arrow.. = Release electrical connector -2- at bracket by pulling retainer catch to the rear -arrow A- and turning connector approx. 90° clockwise -arrow B- = Move clear electricel wire -3- and brake hose -4- at bracket. — Remove bolts -1- and tie up brake caliper in wheel Filising with wire (brake line remains attached), a 0 L\ caution Avoid damage to brake pistons. + Donot press brake pedal with brake caliper removed. opi 22 ep. or.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor ~ Remove nut -2- and pull out bolt ~ — Pull upper suspension links upwards out of wheel bearing housing -arrows- — Perform the same work steps on the other side of the vehicle. — Remove bolt -1- for anti-roll bar on both sides. = Remove nut -3- on both sides. [F) note The bolts -2- are removed at a later stage. LZ casion Risk of damage to running gear components. # The vehicle must NOT be lowered onto its wheels if the engine/gearbox mountings, steering box or subframe cross brace are not properly installed. AS (all): = Remove subframe cross brace > Rep. gr. 40 AS Cabriolet: — Remove bolts -1- and -2- on both sides and take off diagonal, strut 1. Removing and instaling engine - vehicles wth manual gearbox 23Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 = Remove subframe cross brace + Rep. gt. 40 by copyert.Cop Al vehicles (continued) = IF fitted, remove bolts -arrows- on both sides and detach heat shield “1- — If fitted, remove bolts -arrows- and detach front cross member. = Unscrew nuts -arrowe- for front silencer (left-side). 24 ep. or.10- Removing and installing engine‘Audi A4 2008 > , Audi A5 Cabriolet 2009 » , Audi A5 Coupe 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor = Unscrew nuts -arrows- for front silencer (right-side), ZX casion Risk of damage to flexible joints in front silencer. DoNOT bend the flexible joint in the front silencer more than 10°, = Loosen and push back clamps -1- and -2- and detach front silencers on both sides. — If fitted, remove bolts -arrows- and detach heat shield -1- for propshatt. yan n me cocaine. Cope auc = Unbolt propshaft from gearbox = Rear final drive OBC; Rep. gr. 39 or= Rear final drive OBF and OBE - sport differential; Rep. gr. 39 — Slide propshatt towards rear final drive; the constant velocity joints can be moved axially. — Tie up propshaft on one side. 1. Removing and instaling engine - vehicles wth manual gearbox 25Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 = Detach intermediate steering shaft from steering box and move clear by telescoping upwards > Running geer. front- wheel drive and four-wheel drive; Rep. gr. 48. — Remove bolt -2- and tie up clutch slave cylinder at side of engine compartment, L\ carton Avoid damage to clutch slave cylinder. # Do,not press clutch peda after removing clutch slave cyt. ler = Remove nut -1- for selector rod — Apply puller -T40160- and pull off selector rod ~ 26 op. or.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor Set up the scissor-type assembly platform as follows: — Setup scissor-type assembly platform -VAS 6131 A- with support set for Audi -VAS 6131/10- and supplementary set -VAS 6131/13. as follows: Platform | Parts of support set for Audi -VAS 6131/10- and [coordinates ‘supplementary set -VAS 6131/13- B4 13-4 10-4 0-5 H13-4 Gt i134 0-8 HOS 34 Be i104 0-2 nos | i10-14 6 HOt M02 nos | 10-11 aaeca | 113-6 = = 13.2 Fees | 136 4 - 132 cit HOA 03 MoS | i043 Fag 10-4 10-3 0-5 | 10-10 = Initially hand-tighten the support slemients‘on the seissorstype | Italy nana he support eames onthe sso tne = Position scissor-type assembly platform -VAS 6131 A- hori- zontally, + Take note of spirit level (bubble gauge). — Position scissor-type assembly platform -VAS 6131 A- below ‘engine/gearbox assembly. ZX waanine Accident risk if subframe mountings are detached. ‘¢ Subframe bolts -2- and -3- must not be loosened. = Remove subframe bolts -1- on both sides. = Position support elements from -VAS 6131/10- and -VAS. 6131/13. at front left and right of subframe as shown, - Make sure that threaded spindles are screwed in completely. VAS 6131/13-1 _—-VAS 6131/10-4 NAS 6131/13-4 1. Removing and instal ling engine - vehicles wth manual gearbox 27‘Audi A4 2008 > , Audi AS Cabriolet 2008 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3 Aver 11.2010 = Position support elements from -VAS 6131/10- (rear left and right) at front atchment points of subframe cross brace as shown, = Position support elements from -VAS 6131/13- under left and right wheel bearing housings as shown. — Detach retaining clips for noise insulation from cross member. ~ Position support elements from VAS 8131/10-at rear of cross member on both sides, as shown in illustration. Tum all spindles for support elements upwards unti all locat- ing lugs make contact with mounting points. = Tighten base plates for support elements to 20 Nm on scissor- type assembly platform -VAS 6131 A- = Mark installation position of subframe and tunnel cross member on longitudinal membere with felt-tip pen. ~ Unscrew subframe bolts -2- and -3- on both’sides'in several" stages and in diagonal sequence. bo ae aU A O itr. 4-valve), mechanics - Edition = vaset3in03 ior] 28 op. or.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor — Remove bolts -arrows- on tunnel cross member. — Remove bolt -2- on both sides ZX caston Danger of damage to hoses, pipes and wiring connections and {0 engine compartment. % Check that all hoses and wiring connections between engine, gearbox, subframe and body have been detached. Carefully guide out engine/gearbox assembly with subframe from engine compariment when lowering. Lower engine/gearbox assembly using scissor-type assembly Platform -VAS 6131 A- initially only as far as distance -a-. + Dimension -a- = 100 mm (maximum). — Remove bolts -1- and -3- for selector rod and push rod, — Lower engine/gearbox assembly further. = Pull out scissor-type assembly platform -VAS 6131 A with ‘engine/gearbox assembly from underneath vehicle. 1.2 Separating engine from manual gearbox Special fools and workshop equipment required ‘© Support set for Audi -VAS 6131/10-, supplementary set -VAS. 6134/13- and gearbox support -VAS 6131/14- 1. Removing and instaling engine - vehicles wth manual gearbox 29)Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 # Adapter -T40058- 740058 Procedure + Engineigearbox assembly removed and secured to scissor- type assembly platform -VAS 6131 A- — Remove electrical connector -3- for Lambda probe 2 after catalytic converter -G131- from bracket and unplug connecter. (F) me Disregard -items 1, 2. - Remove bolt -1- and nuts -arrows- and detach catalytic converter (left-side). = Remove electrical connector -1- for Lambda probe after cata- Iytic converter -G130- from bracket and unplug connector. ne oc Se Disregard -items 2, 3. 30 ep. or.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition GQGD 411.2010 Auor ~ Remove bolt -1- and nuts -arrows- and detach catalytic converter (right-side). — Unplug electrical connector -2- at engine speed sender -G28- ‘and move wiring clear. [F) Note Diora ee Ault Rabe i urn Se yt — Unplug electrical connector -2- at reversing light switch -F4- [B) nae Disregard -items 1, 3-. = Unbolt drive shafts (left and right) from gearbox flange shafts 1. Removing and instaling engine - vehicles wih manual gearbox 34Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 = Detach bottom cover -1- from gearbox -arrow. — Insert guide pin of adapter -T40058- as follows: + The larger-diameter section -arrow 1- faces towards the engine. + The smaller-diameter section -arrow 2- faces the adapter. - Counterhold crankshaft using adapter -T40058- and angled ring spanner when loosening bolts for drive plate. (@) note Only rotate crankshaft in direction of engine rotation -arrow-. — Remove 6 bolts -arrov for clutch module. Tum crankshaft ‘each time by 60° in direction of engine rotation. 32. op. or.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 2010 Aver ~ Setup scissor-type assembly platform VAS 6194 Ac with support set for Audi -VAS 6131/10- , supplementary set -VAS 6131/13- and gearbox support -VAS 6131/14- as follows: [F) note The other support elements remain unchanged. Platform | Parts of support set for Audi -VAS 6131/10- , sup- |coordinates| plementary set -VAS 6131/13- and gearbox support -VAS 6131/14 F2 M37 B10 0-4 MO-2 HOS: 4 G10 Hot M02 HOS — Secure support -VAS 6131/13-7- at tapped hole at front of engine (right-side) as illustrated. = Secure support -VAS 6131/13-7- to scissor-type assembly platform and tighten to 20 Nm, = Position support elements from -VAS 6131/10- and gearbox support -VAS 6131/14- at front of gearbox, asilllstisteden. = Screw spindles on both sida upwards until g2arbox support =... VAS 6131/14: makes fll contact with gearbox = Tighten base plates for support elements to 20 Nm on scissor- type assembly platform -VAS 6131 A- = Remove bolts -1- and -2- for starter. — Separate starter from gearbox and leave in position. ing bolts -3 ... 11- securing engine to gearbox. Disregard -item A. 44 = 1. Removing and instaling engine - vehicles wth manual gearbox 3S‘Audi A4 2008 > , Audi AS Cabriolet 2008 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 ~ Loosen clamping bolts -1- on sides of scissor-type assembly platform -VAS 6131 A. and pull rear section of platform together with gearbox towards rear -arrow-. 13 Installing engine ‘Special tools and workshop equipment required 4 Ring spanner insert AF 16 -V.A.G 1332/14 VAG 1332/14 # Assembly aid -T40169- T40169 # Transport lock -T40170- Ta0170 Wasa 34 op. 9:10- Removing and instaling engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor Tightening torques [@) Note Tightening torques apply only to lightly greased, oiled, phosphated or black-fnished nuts and bolts. ¢ Additional lubricants such as engine or gear oil may be used, ‘but do not use lubricants containing graphite, © Do notuse de-greased parts. ¢ Tolerance for tightening torques: + 15 %. [Component Nm Bolte/nuts Me|o M7 [15 wa |20 10/40 M12 cy ‘Assembly mountings = page 79 . Earth stud at suspension turret - tightening torque — Tighten earth stud -1- to @ Nm, Earth wiring at longitudinal member - tightening torque = Tighten nut -arrow- to 9 Nm. 1. Removing and insaling engine - vehicles wn manual gearbox 3SAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 Engine to manual gearbox Item Bolt Nm 1 M10 x50). 6 2...8 M12 x 1002) 30+ 90° 7 M12 x 1259) 30+ 90° 811 M10 x 602) 15+ 90" 9,10 M10 x 952) 15+ 90" A Dowel sleeves for centralising +) Property class 10.9, The steel bolt may be re-used as often| as necessary. + 2) Aluminium bolts must not be used more often than twice = page 36 # The aluminium bolts -2 ... 11- must not be used more often than twice. After the first use, the bolts must therefore be iden- tified with an ,.X' made by two chisel marks -arrove. # To avoid damaging the bolts when making this mark, do not clamp them directly in a vice. Clamp a 14 mm socket with | 2" drive in a vice and insert the bolt as shown. # Bolts already marked with an ,X" must not be used again. Procedure (@) note @ Renew the bolts tightened with specified tightening angle. # Renew self-locking nuts and bolts as well as seals, gaskets and O-rings. # On vehicles with manual gearbox, a neeale bearing is fitted in vodhe deve plate, Before installing, check that iheneedie bearing “ts ited, Removing-and.nstaling needle besringin-daye,pate “(pressing in-and out) s , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 14.2010 Aver — The following preparations are required before joining engine and gearbox. = Insert assembly aid -T40189- into gearbox housing and clutch module from below, as illustrated + The assembly aid must engage in the semi-circular recess -1- and in the inspection hole -2- (Bre There is only one inspection hole on the circumference; tum the ‘clutch module accordingly. — Insert pin of assembly aid into hole on gearbox housing. — Insert transport lock -T40170- into gearbox housing from below and clamp onto flange shaft -1-. = Check whether dowel sleeves -A- for centring engine and ‘gearbox are fitted in cylinder block; install missing dowel sleeves, = Check whether aluminium bolts securing engine to gearbox can be reused; if so, apply marking = page 36 ~ Bring gearbox nto postion on engine and fghten bots — Remove transport lock -T40170- and assembly aid -T40169- 1. Removing and instaling engine - vehicles wth manual gearbox 37Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 (@) note The following step is necessary to ensure that the clutch module is straight and that it makes even contact with the drive plate. ~ Insert guide pin of adapter -T40058- as follows: iameter section -arrow 1- faces towards the en- + The smaller-diameter section -arrow 2- faces the adapter. ~ Use adapter -T40058- and angled ring spanner to turn crankshaft one full turn (360°) in direction of engine rotation arrow vat eset +The inspection hole -arrow- should be visible again in the recess on the gearbox housing. 38 op. or.10- Removing and installing engine‘Audi A4 2008 > , Audi A5 Cabriolet 2009 » , Audi A5 Coupe 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 it. 4.valve), mechanics - Edition GED 411.2010 Auor Bolt clutch module onto drive plate as follows: (8) note Use ring spanner insert AF 16 -V.A.G 1332/14. to tighten bolts. ~ Handetighten first bolt -arrow: (2 Nm). — Tum crankshaft with adapter-740058- 180° further in direction of engine rotation, - Tighten bolt accessible in this position to specified torque = Rep. gr. 30 = Tum crankshaft by 60° each time and tighten remaining 5 bolts to specified torque = Rep. gr. 30 = Install hydraulic luid lines for power steering > Rep. gr. 48 — Bolt drive shafts (left and right) onto gearbox flange shafts = Rep. gr. 40 = Install catalytic converters: left-side = page 288 , right-side = page 289 — Raise engine/gearbox assembly using scissor-type assembly platform -VAS 6131 A- only until distance between subframe and body is -a. + Dimension -a- = min. 100 mm, = Install selector rod and push rod = Rep. gr. 34 Raise engins/gearbox assembly further using scissortype as- ‘sembly platform -VAS 6131 As. — Align subframe and gearbox carrier on longitudinal members ‘according to markings made before removal. - Tighten subframe bolts only to specified torque (do not turn further): the bolts ere only c be fully ightenes after performing only the wheel alignment chieck 5, REP..GE.. AV... soso macnn A WARNING ~ ~ : 1 Risk of accident because of loose bolt connections. % DoNOT drive the vehicle unless the subframe bolts have been finally tightened. 1. Removing and instaling engine - vehicles wth manual gearbox 3QAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 ~ Tiphten bots arrows: fortunne! cross member > Rep. gt Remaining installation steps are carried out in reverse sequence; note the following: = Install clutch slave cylinder = Rep. gr. 30. Secure intermediate steering shaft on steering box Rep. ar. = Install propshaft > Rear final drive OBC; Rep. gr. 39 or = Rear final drive OBD; Rep. gr. 39 — Install front silencer > page 269. — Align the exhaust system so it is free of stress = page 293 . = Install font eros member= Rep. gr. 6B. . = Install subframe cross brace, diagonal struts, upper suspen. sion links and anti-roll bar; secure susperision’strutto track deumend. Copy by A control link > Rep. or. 40. = Install brake calipers > Rep. gr. 46 = Install engine control unit > Rep. gr. 24 = Electrical connections and routing = Current flow diagrams, Electrical fault finding and Fitting locations. = Install electrical wiring, terminal 30 wiring junction 2 -TV22- and cover for electronics box in engine compartment = page 35, = page 35 and = Electrical system; Rep. gr. 97 = Install body brace = Rep. gr. 40 = Install filler neck for washer fuid reservoir = Electrical system; Rep. gr. 92 = Install refrigerant lines > Rep. gr. 87 — Observe notes on procedure for connecting the battery = Electrical system; Rep. gr. 27. A Caution Risk of irreparable damage to contro! units because of exces- sive voltage. + Never use battery charging equipment for boost starting. Install fuel supply hose and air cleaner housing > Rep. gf. 24 = Install struts for lock carrier > Rep. gr. 50 — Fill up with engine oil and check oil level = Maintenance ; Booklet 811, = Maintenance ; Booklet 812 or = Maintenance ; Booklet 618 ~ Before starting engine, top up hydraulic fluid in power steering reservoir = Rep. gr. 48 (@) Nowe The power steering pump must not be run when dry. 40 0p. r.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 414.2010 Audr = Connect coolant hose with plug-in connector = page 252 ~ Fillup with coolant = page 217 (Fe Donot use drained coolant again if. the cylinder head or cylinder block have been renewed. © =the coolant is contaminated or dirty. = Charge refrigerant system = Air conditioner with refrigerant Ri34a Install wheel housing liners > Rep. gr. 66. — Fit front wheels > Wheels and tyres; Rep. gr. 44. = Perform wheel alignment check > Rep. gr. 44 A WARNING Risk of accident because of loose bolt connections. % Tighten subframe bolts to final setting after performing wheel alignment check. = Install noise insulation panels = Rep. gr. 66. 1. Removing and instaling engine - vehicles wih manual gearbox 41Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 2 Removing engine - vehicles with dual clutch gearbox OBS (Free The engine is removed from underneath together with the gearbox and subframe (with lock carrer installed) % Collect drained coolant in a clean container for re-use or dis- posal, Fit cable ties in the original positions when installing. 24 Removing engine Special tools and workshop equipment required Vaa1e2 4 Removal lever -80 - 200- # Used cil collection and extraction unit -V.A.G 1782- # Stepladder -VAS 5085- + Engine bung set -VAS 6122- # Scissor-type assembly platform -VAS 6131 A- with Support set for Audi - VAS 8131/10- , support set -VAS 6131/11- and supplementary set -VAS 6131/13. + Dulp ray for workshop heist “VAS 6208- VAS 5085 TE 42. op. r.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor ¢ Hose clip pliers -VAS 6362- Make sure the vehicle cannot tip over when the engine is removed, Secure the vehicle, to do so, the luggage compartment must be empty. The fuel system operates at extremely high pressure. This can cause injury. % The fuel pressure in the high-pressure section of the in- Jection system must be reduced to a residual pressure ‘prior to opening the system. — Reduce fuel pressure in high-pressure section of injection system => Rep. gr. 24 fecal cop Set front wheels to straight-ahead position. nes to . @) Note The electromechanical parking brake must be released before disconnecting the battery so that the propshaft can be tumed during removal. LB casion Electronic components are susceptible to damage. # Observe notes on procedure for disconnecting the battery. = Switch off ignition and take out ignition key. Disconnect earth wire -2- from battery terminal + Electrical system; Rep. gr. 27 = Discharge refrigerant system = Air conditioner with refrigerant R134a — Extract hydraulic fluid for power steering from reservoir using Used cil collection and extraction unit -V.A.G 1782- 2, Removing engine - hic wih dual clutch gearbox ons 43‘Audi A4 2008 > , Audi AS Cabriolet 2008 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Avor_ 11.2010 ~ Lift off engine cover panels -1- and -2-. opt Coping or commercial pupses, pat rn wale, nat ZX waanine Hot steam/hot coolant can escape - risk of scalding. ¢ [he cooling system is under pressure wien the engine is ¢ To allow pressure to dissipate, cover filer cap on coolant ‘expansion tank with cloth and open carefully. = Open filer cap on coolant expansion tank. = Remove both front wheels > Wheels and tyres; Rep. gr. 44 ~ Remove front left anc fron right whee! housing liners > Rep. ar - Remove noise insulation panels -1- and -2-= Rep. gr. 66 44 0p. r.10- Removing ad instaling engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor = Place drip tray for workshop hoist-VAS 6208- beneath engine. — Remove drain plug -1-and drain off coolant, — Lift retaining clip -2- and disconnect coolant hose from radiator. Release hose clip -arrow-, disconnect coolant hose from engine oil cooler and drain off coolant. - Release hose clips -1- and -3., disconnect coolant hoses from coolant pipes (front left) and drain off remaining coolant. (B) note © Forillustration purposes, the installation position is shown with the engine removed. ¢ Disregard item 2. Unplug electrical connector -3- from charge air cooling pump -V188- and move clear. [F) Note Disregard -items 1, 2. tao commer pr 2, Removing engine - vehicles with dual clutch gearbox ons 45Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 = Position used oil collection and extraction unit -V.A.G 1782- below connection point, = Disconnect supply hose -2- and return hose -1- for power steering hydraulic fluid in front left wheel housing and move clear. — Seal off open pipesilines and connections with clean plugs from engine bung set -VAS 6122- . emits umes somone yi — Position used oil collection and extraction unit -V.AG 1782- below connection point. - Mark position of ATF line: disconnect ATF lines ~ Seal off open pipesilines and connections with clean plugs from engine bung set -VAS 6122- (@) note Disregard -arrow-. 4- and -2- for re-installation and Vehicles with coolant circulation pump -V50- : = Unplug electrical connector -2.. — Place drip tray for workshop hoist -VAS 6208- beneath engine. = Release hose clip -1- and disconnect coolant hose from coolant circulation pump -V50- Disregard -items 3, 4. 46 0p, or.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor All vehicles (continued): — Unplug electrical connectors -1- and -2- for radiator fan (push retainer to the rear -arrow. and press down release catch). — Move clear electrical wiring hamess. — Unplug electrical connector -3- at secondary air pump motor - \V101- and move electrical wiring clear. Press release tabs, disconnect secondary air hose -1- and move hose clear. [B) Note Disregard -item 2. Protect by copy Copy pr el uposes. parton -2: for lock cartier. = Unscrew nut -arrow- on longitudinal member (right-side) and move earth cables clear. 2, Removing engine - vahicles with dual clutch goarbox ons 47Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 = Pull seal off plenum chamber partition panel. — Remove plenum chamber cover > Rep. gr. 50. — Remove air duct -arrow:, = Move fuel hose -1- and hose -2. leading to activated charcoal filter clear at air pipe. — Detach vacuum hose -3- from connection on air pipe. Remove air pipe. To do so, release hose clip -4- and clamps “arrows 4B 0p. or.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor - Detach air cleaner housing and, if fitted, unplug electrical connector -arrow- at variable intake manifold changeover valve - N335- on reverse side of air cleaner. ~ Dianna acumhoe. gree eee partition panel and detach vee ‘connection -2- froM pie — Unplug electrical connector -3- at activated charcoal filter sol- ‘enoid valve 1 -N8O- and detach vacuum hose -4-. USA models: = Disconnect vacuum hose leading to fuel system diagnostic Pump -V144- -arrow. A\l vehicles (continued): = Detach activated charcoal filter solenoid valve 1 -N8O- from bracket and move it clear to the side with hoses stil attached. 2, Removing engine - hice with dual clutch goarbox ons 49Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 A WARNING, Risk of injury caused by fuel. @ Toallow the fuel pressure to dissipate, wrap a clean cloth around the connection and carefully loosen the connection before opening the fuel system. A Caution Take care to keep components clean. # Observe rules for cleanliness when working on the fuel supply system 2 page 6. — Disconnect fuel supply hose from high-pressure pump -arrow- and move clear to one sid = Seal off open pipesilines and connections with clean plugs from engine bung set -VAS 6122. . —_ Liftretaining clip -arrow- and detach coolant hose going to heat ‘exchanger from rear of engine. For illustration purposes, the installation position is shown from the rear and with the engine removed. = Disconnect vacuum hose -1- leading to Climatronic coolant shut-off valve -N422- end move hose clear. (Bro Disregard -items 2, 3.. Preto copy. Coping x pat comarca purpose, n part of AWARE A 50 ep. or.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor Vehicles not equipped with coolant circulation pump -V50- — Lift retaining clip -arrow- and detach coolant hose (front right) from coolant pipe (front) A\l vehicles (continued): = Release hose clip -arrow- and detach coolant hose. 4) Noten: Disregard -items 1, 2. bas ret guranoe acct any — Lift retaining clip -arrow., detach coolant hose from coolant pipe (front) and move coolant hose clear. = Disconnect coolant hoses -1- and -2- from coolant expansion tank. — Unscrew bolts -arrows-, unplug electrical connector at coolant shortage indleator switch -F66- and detach coolant expansion tani 2, Removing engine - vehicles wth dual clutch goarbox 08s 51Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 = Onvehicies with dynamic steering, unplug electrical connector -arrow- at power steering pump. = Press hydraulic fluid hose down slightly LX carton Danger of damage to refrigerant lines and hoses. DONOT stretch, kink or bend refrigerant lines and hoses. = Remove bolts -arrows- and disconnect refrigerant lines from ANC compressor. — Seal off open pipesilines and connections with clean plugs from engine bung set -VAS 6122- . = Release retainer -arrow A- and open cover -errow B- = Remove nuts -1- and -2- for electrical wiring. = Detach electrical connector -3. from bracket and- unplug. = — Remove bolt -4- and detach terminal 30 wiring junction 2 - ‘TV22- from body brace -arrow- 52 Rep. or.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD — Working from wheel housing, release catches using a 5.5 mm Ting spanner -item 1- and remove wiring protector -2- from above. = Release wiring harness -3- leading to alternator and sterter using removal lever -80 - 200- and move clear. - Wiring duct (version 1): release catch -arrow B- and move wiring harness clear by pulling it towards front -arrow A. — Wiring duct (version 2): release catch -arrow- to open wiring duct -1- and move wiring harness cleer. = Remove nut -1- and swivel filler neck - ‘ervoir slightly upwards -arrow A. ~ Full filer neck with filer pipe out of washer fuid reservoir and through opening in body -arrow B-. for washer fluid res- Wh respect te ences of oration et Capyrgt by AUDY AG 14.2010 Aver =] 2, Removing engine - vhicles with dual clutch gearbox 08s 93Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 = Remove bolts and nuts -2- and detach body brace -3.. — Remove bolts -arrows- and detach cover for electronics box in ‘engine compartment. = Remove nut -1- and move electrical wiring clear. — Release catches -arrows A- and take out engine control unit -arrow B-. = IFfited, unplug electrical connector -2.. = Unplug electrical connectors -4- and unscrew nut-3-for wiring, — Release catches -arrow- and detach relay carrier with fuse holder -1- ~ Disengage engine wiritt at Heed at sledtronics Bex in EAGINE!” ‘compartment and move.élear. 5. of efomation 54 op. or.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor Release catches -arrows A- and lift off wiring protector -2- -arrow B- = Unscrew earth stud -1- and move wiring hamess clear. — Place wiring hamess on engine and secure engine control unit to prevent it from dropping. — Unplug electrical connectors -arrow: at front wheel speed sensors on both sides = Iffitted, unplug electrical connector -1- from front left vehicle level sender -G78- and front right vehicle level sender -G289- ‘and move wiring clear -arrow.. ~ Release electrical connector -2- at bracket by pulling retainer ‘catch to the rear -arrow A- and turning connector approx. 90° clockwise -arrow B-, = Move clear electrical wire -3- and brake hose -4- at bracket, — Remove bolts -1- and tie up brake caliper in wheel housing ‘with wire (brake line remains attached). Donot press brake pedal with brake caliper removed. 2, Removing engine Voices wth dual clutch gearbox ops 5S‘Audi A4 2008 > , Audi AS Cabriolet 2008 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Avor_ 11.2010 ~ Remove nut -2- and pull out bolt = Pull upper suspension links upwards out of wheel bearing housing -arrows- — Perform the same work steps on the other side of the vehicle. — Remove bolt -1- for anti-roll bar on both sides. = Remove nut -3- on both sides. 1) Nove The bolts -2- are removed at a later stage. LY carton Risk of damage to running gear components. ¢ The vehicle must NOT be lowered onto its wheels ifthe engine/gearbox mountings, steering box or subframe cross brace are not properly installed. AA (all): = Remove subframe cross brace > Rep. gr. 40 AS Cabriolet: — Remove bolts -1- and -2- on both sides and take off diagonal strut is v1) 56 op. or.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor — Remove subframe cross brace > Rep. or. 40 A\l vehicles (continued): If fitted, remove bolts -arrows- on both sides and detach heat shield -1-. — If fitted, remove bolts -arrows- and detach front cross member. otc by copy Cxpyng ox prt = Unscrew nuts -arrows- for front silencer (left-side). 2, Removing engine - vahicles with dual clutch gearbox ons 7‘Audi A4 2008 > , Audi AS Cabriolet 2008 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Avor_ 11.2010 = Unscrew nuts -arrows- for front silencer (right-side), LX carton Risk of damage to flexible joints in front silencer. DoNOT bend the flexible joint in the front silencer more than 10°. = Loosen and push back clamps -1- end -2- and detach front silencers on both sides. — If fitted, remove bolts -arrows- and detach heat shield -1- for propshatt = Unbolt propshaft from gearbox = Rear final drive OBC; Rep. gr. 39 or Reer final drive OBF end OBE - sport differential: Rep. gr. 38. Prt = Slide propshaft towards rear final drive; the constant velocity joints ean be moved axially — Tie up propshaft on one side. 58 pop. or.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor = Detach intermediate steering shaft from steering box and move clear by telescoping upwards = Running gear, front- ‘wheel drive and four-wheel drive; Rep. gr. 48. Set up the scissor-type assembly platform as follows: = Setup scissor-type assembly platform -VAS 6131 A. with sup- SSTeE TT port set for Aud! -VAS 6131/10- , support set -VAS 6131/11 eeeee ees ‘and supplementary set -VAS 6131/13- as follows yt Platform | Parts of suppor set for audi -VASGISiMO-, eur] sof S| a ote [coordinates| port set=VAS'6131/41=and 3 ‘ae VAS 6131/15 ae 54 34 | M04 | 06 | M134 Mo cocccad G4 113-6 110-4 110-5 13-1 — 56 710-4 ro2 [ios | 140-14 epeeeeees G6 710-4 ro2 [0-5 | it0-14 teevevned nasca_| 1136 = = 132 oe Fes | 113-6 = = 113-2 ‘ee 14 710-1 roa | 05 | 10-7 eb vos ses 14 HOA 0-4 10-5 mA 7 — Initially hand-tighten the support elements on the scissor-type assembly platform = Position scissor-type assembly platform -VAS 6131 A- hori- zonally, + Take note of spirit level (bubble gauge) — Position scissor-type assembly platform -VAS 6131 A- below ‘engine/gearbox assembly. A WARNING Accident risk if subframe mountings are detached. % Subjrame bolts -2- and -3- must not be loosened. — Remove subframe bolts -1- on both sides. 2, Removing engine - vhicls with dual clutch gearbox ons SQAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 = Position support elements from -VAS 6131/10- and -VAS. 6131/13. at front left and right of subframe as shown. = Make sure thet threaded spindles are screwed in completely. ar sro n VAS 6131/13+4 VAS 6131/10-4 — Position support elements from -VAS 6131/10- (rear left and right) at front attachment points of subframe cross brace as shown, =. Position support elements from -VAS 6131/13- under left and right wheel bearing housings as shown. = Position support elements from -VAS 6131/10- and -VAS. 8131/11- (rear left and right) at tunnel cross member as shown, VAS. = Tum all spindles for suppot elements upwards until el lcet- — ||S19V107) ing lugs make contact with mounting points. E Sa ~ Tighten base plats for support elements to 20 Nm on sciseor- type assembly platform -VAS 6131 A-. 60 op. or.10- Removing an installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD - Mark installation position of subframe and tunnel cross member on longitudinal members with fel-tip pen. = Unscrew subframe bolts -2- and -3- on both sides in several ‘stages and in diegonal sequence. — Remove bolts -arrows- on tunnel cross member, roto copy. Cop — Remove bolt -2- on both sides. A Caution Danger of damage to hoses, pipes and wiring connections and f0 engine compartment. \¢ Check that all hoses and wiring connections between engine, gearbox, subframe and body have been detached. ¢ Carefully guide out engine/gearbox assembly with subframe from engine compartment when lowering. - Lower engine/gearbox assembly using scissor-type assembly platform -VAS 6131 A. initially only as far as distance -. + Dimension -a- = 100 mm (maximum). 14.2010 Aver 2, Removing engine - vehicles wth dual clutch goarbox 08s 641Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 = Pry ball socket -2- of selector lever cable off gearbox selector lever using removal lever -80 - 200- = Press off securing clip -1- and remove selector lever cable from gearbox. (F) me Take care not to bend or kink selector lever cable, = Lower engine/gearbox assembly further. — Pull out scissor-type assembly platform -VAS 6131 A. with ‘engine/gearbox assembly from underneath vehicle. 22 Separating engine and dual-clutch gearbox 0B5 ‘Special tools and workshop equipment required # Support set for Audi -VAS 6131/10- , supplementary set -VAS 6131/13- and gearbox support -VAS 6131/14- # Adapter -T40058- Procedure + Engine/gearbox assembly removed and secured to scissor- type assembly platform -VAS 6131 A- — Remove electrical connector -3- for Lambda probe 2 after catalytic converter -G131- from bracket and unplug connector. Disregard -items 1, 2. - Remove bolt -1- and nuts -arrows- and detach catalytic converter (left-side). yng pate crm pusposes, part whe et 62. op. or.10- Removing and installing engine‘Audi A4 2008 > , Audi A5 Cabriolet 20 109 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition GQGD 14.2010 Aver — Remove electrical connector -1- for Lambda probe after catalytic converter -G130- from bracket and unplug connector. = Remove bolts -3- and move bracket clear to one side. [) ne Disregard -item 2- — Remove bolt -1- and nuts -arrows- and detach catalytic converter (right-side), ‘wen respas fot cosctoe ce lomaton fh oeumen — Unplug electrical connector -2- at engine speed sender -G28- ‘and move wiring clear. Risk of ireparable damage to gearbox control unit (mecha- tronic unit) because of static discharge. ¢ Do NOT touch connector contacts in gearbox connector with your hands. — Touch gearbox housing with your hand (without wearing gloves) to eliminate static charge. - Tum retainer catch anti-clockwise -arrow- and unplug electrical connector at gearbox. = Move clear electrical wiring harness at gearbox. 2. Removing ang ine - vehicles with dual cutch gsarboxoBs 63,Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 Unbolt drive shafts (left and right) from gearbox flange shafts Detach bottom cover -1- from gearbox -arrow-. — Insert guide pin of adapter -T40058- as follows: +The larger-diameter section -arrow 1- faces towards the engine. + The smaller-diameter section -arrow 2- faces the adapter. — Counterhold crankshaft using adapter -T40058- and angled ring spanner when loosening bolts for drive plate, # (Ene oe (Only rotate crankshaft in direction of engine rotation -arrow-. 64. op. or.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor — Remove 6 bolts -arrow- for clutch module. Turn crankshaft ‘each time by 60° in direction of engine rotation. — Remove bolt -arrow- for ATF pipes. (B) Note Disregard -items 1, 2. (8) note Lay a cloth under the separating point to catch escaping ATF. - Remove bolts -arrows- and detach ATF pipe -1-from gearbox (8) ete Disregard -items 2, 3-. [omit ures son Dy AU A. AUDI A sot quart or Sop any = Remove bolt 1. = Pull out securing clip -arrow- and disconnect ATF pipe from ATF filter (8) note Disregard -item 2- 2, Removing engine - vehicles with dual clutch gearbox 08s 65Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 (B) soe ~ Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122. . — Setup scissor-type assembly platform -VAS 6131 A. with support set for Audi -VAS 6131/10-.. supplementary set -VAS 6131/13. and gearbox support VAS 6131/14. as follows: Note The other support elements remain unchanged. Platform | Parts of support set for Audi -VAS 6131/10- , sup- coordinates | plementary set -VAS 6131/13- and gearbox support -VAS 6131/14. 7 asa A Bron cae nog | nosey sr ‘ae G10 10-4 {10-2 10-5 weave = Secure support -VAS 6131/13-7- at tapped hole at front of engine (right-side) as illustrated — Secure support -VAS 6131/13-7- to scissor-type assembly platform and tighten to 20 Nm. 66 op. or.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 14.2010 Aver Position support elements from -VAS 6131/10- and gearbox support -VAS 6131/14- at front of gearbox, as illustrated. = Screw spindles on both sides upwards until gearbox support -VAS 6131/14- makes full contact with gearbox. Tighten base plates for support elements to 20 Nm on scissor- type assembly platform -VAS 6131 A- — Remove bolts -1- and -2- for starter. = Separate starter from gearbox and leave in position. = Unscrew remaining bolts -3 ... 10- securing engine to gearbox. Note Disregard -item A-. “ et, Copyg by ALD ~ Loosen clamping bolts -1- on sides of scissor-type assembly platform -VAS 8121 A and pull rear section of platform fo ‘ether with gearbox towards rear -errown. 23 Installing engine Special tools and workshop equipment required @ Ring spanner insert AF 16 -V.A.G 1332/14- VAG 1390/14 2, Removing engine - vehicles with dual clutch goarbox ons 67Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 # Assembly aid -T40169- Ta0169 ct » a ERS] # Transport lock -T40170- Tightening torques (a) Note Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. Additional lubricants such as engine or gear oil may be used, but do not use lubricants containing graphite. % Do not use de-greased parts. % Tolerance for tightening torques: + 15 %. [Component Nm Boltsinuts Me|9 7/15 Ma] 20 M10|40 M12 65. 68 op. or.10- Removing an installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor ‘Assembly mountings = page 79 Earth stud at suspension turret - tightening torque = Tighten earth stud -1- to 8 Nm, Earth wiring at longitudinal member - tightening torque = Tighten nut -arrow- to 9 Nm. Engine to dual-clutch gearbox OBS item Bolt Nm 4 M10 x 50 ?) 65 2..6 M12 x 1002) 30 + 90° 7 M12 x 1252) 30 + 90° 8 M10 x 602) 15 +90° 9,10 M10 x 952) 15+90° A Dowel sleeves for centraising Property lass 10.9. The steel bolt ay be re-used as often| as necessary + 2) Aluminium bolts must not be used more often than twice = page 70 2, Removing engine - ahicles wih dual clutch gearbox ons 6QAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Avor_ 11.2010 4 The aluminium bolts -2 ... 10- must not be used more often than twice. After the first use, the bolts must therefore be iden- tified with an ,.X" made by two chisel marks -arrove. # To avoid damaging the bolts when making this merk, do not clamp them directly in a vice. Clamp a 14 mm socket with | 2" drive in a vice and insert the bolt as shown. # Bolts already marked with an ,X* must not be used again. Procedure (@) now # Renew the bolts tightened with specified tightening angle. + Renew self-locking nuts and botts as well as seals, gaskets and O-rings. 4% On vehicles with dual clutch gearbox 085, a needle bearing is Mitedin the cve plate. Before instaling, check thatthe needle bearing is fitted. Removing and installing needle bearing in dhive plate (pressing in and out) = page 102. 4 Hose connections and air pipes and hoses must be free of oil ‘and grease before assembly. # Secure all hose connections with the correct type of hose clips (same as original equiament) > Electronic parts catalogue . # To secure the air hoses at their connections, spray rust re- mover onto the worm thread of the used hose clos before ‘nsialiing. Fitall cable ties in the original positions when installing. = Install engine supports and engine mountings > page 79 = Hold ATE pipes in installation position when joining engine and subframe. — Before installing gearbox, always clean threaded holes for engine/gearbox bolts in cylinder block using a thread tap. ~The following preparations are required before joining énging and gearbox. = Insert assembly aid -T40169- into gearbox housing and clutch module from below, as illustrated + The assembly aid must engage in the semi-circular recess A= and in the inspection hole -2- (Fre There is only one inspection hole on the circumference: turn the clutch module accordingly. —_ Insert pin of assembly aid into hole on gearbox housing, 70 ep. r.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD Insert transport lock -140170- into gearbox housing and clutch module from below and clamp onto flange shaf — Check whether dowel sleeves -A- for centring engine and gearbox are fitted in eylinder block; install missing dowel Sleeves. — Check whether aluminium bolts securing engine to gearbox can be reused; if so, apply marking > page 70. = Bring gearbox into position on engine and tighten bolts 1,6... 10. = Remove transport lock -T40170- and assembly aid -T40169- cpt ay icy The following step is necessary to ensure that the clutch module Js straight and that it makes even contact with the drive plate. ~ Using assembly lever 1, press clutch meciule-2- slighty against drive plate -3- -arrow-. = Bolt clutch module onto drive plate as follows: [&) note Use ring spanner insert AF 16 -V.A.G 1332/14. to tighten bolts. ~ Handttighten frst bolt -arrow- (2 Nm). 14.2010 Aver 2, Removing engine - ahicies wth dual clutch goarbox 08s 7 41Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 = Insert guide pin of adapter -T40058- as follows’ +The larger-slameter section -arrow 1- faces towards the engine. + The smaller-diameter section -arrow 2- faces the adapter. = Use adapter -40058- and angled ring spanner to turn crankshaft 180° further in direction of engine rotation -arrow- — Tighten bolt accessible in this crankshaft position to specified torque=> Rep. or. 34 — Tum crankshaft by 60° each time and tighten remaining 5 bolts to specified torque = Rep. gr. 34 ~ Install hydraulic fluid lines for power steering > Rep. gr. 48. = Install ATF pipes > Rep. gr. 34 = Bolt drive shafts (left and right) onto gearbox flange shafts > Rep. gr. 40 = Install catalytic converters: left-side = page 288 , right-side = page 289 = Reise engine/gearbox assembly using scissor-type assembly platform -VAS 6131 A- only until distance between subframe and body is -a-. + Dimension -a- = min, 100 mm, = Install and if necessary adjust selector lever cable = Rep. gr 34 — Ralse engine/gearbox assembly further using scissor-type assembly platform -VAS 6131 A-. — Align subframe and gearbox carrier on longitudinal. members, according to markings made before removal. joins nice atone = Tighten subframe bolts only to specified torque (do not turn further); the bolts are only to be fully tightened after performing the wheel alignment check > Rep. gt. 40 A WARNING Risk of accident because of loose bolt connections. ¢ DoNOT dhive the vehicle unless the subframe bolts have been finally tightened. 72. Rep. .10-- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor = Tighten bolts -arrows- for tunnel cross member > Rep. gf. 34 Remaining installation steps are carried out in reverse sequence: note the following: — Secure intermediate steering shaft on steering box = Rep. gr = Install propshaft = Rear final drive OBC; Rep. gr. 39 or = Rear final drive 0BD; Rep. gr. 39 Sy = Install front silencer > page 289 ag rir a le, — Align the exhaust system so itis free of stress > page 293 Pa AN bs ese — Install front cross member = Rep. gr. 66 = Install subframe cross brace, diagonel struts, upper suspension links and anti-roll bar, secure suspension strut to track ‘control link (left and right) > Rep. gr. 40 = Install brake calipers = Rep. gr. 46 = Install engine control unit > Rep. gr. 24 = Electrical connections and routing > Current flow diagrams, Electrical fault finding and Fitting locations. = Install electrical wiring, terminal 30 wiring junction 2 -TV22- ‘and cover for electronics box in engine compartment = page 69, = page 69 and = Electrical system: Rep. or. 97 — Install body brace = Rep. gr. 40 — Install filler neck for washer fluid reservoir Electrical system; Rep. gr. 92 = Install refrigerant lines = Rep. gr. 87 = Qbserve notes on procedure for connecting the battery = Electrical system; Rep. gr. 27 A Caution Risk of irreparable damage to control units because of exces- sive voltage. ¢ Never use battery charging equipment for boost starting. - tnstall fuel supply hose and air cleaner housing = Rep. gr. a = Install struts for lock carrier ROB. ge BO 00 A) cms gin an on = Fill up with engine oil and check oil level = Maintenance ; Booklet 811, = Maintenance ; Booklet 812or= Maintenance ; Booklet 818 — Before starting engine, top up hydraulic fluid in power steering reservoir> Rep. gr. 48 (Fr The power steering pump must not be run when dy. 2, Removing engine - hic wih dual clutch gearbox ons 73Audi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 Connect coolant hose with plug-in connector > page 252 Fill up with coolant > page 217 . (Bree ’ ’ * Do not use drained coolant again it: the cylinder head or cylinder block have been renewed. the coolant is contaminated or dirty. Charge refrigerant system = Air conditioner with refrigerant Ri34a Install wheel housing liners > Rep. gr. 66 Fit front wheels > Wheels and tyres; Rep. gr. 44 Perform wheel alignment check = Rep. gr. 44 A WARNING Risk of accident because of loose bolt connections. @ Tighten subframe bolts to final setting after performing wheel alignment check. Fill up with ATF > Rep. or. 34. Install noise insulation panels > Rep. gr. 66. 74. ep. .10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 11.2010 “Aver 3 Securing engine to engine and gearbox support Special tools and workshop equipment required vas 6005 © Lifting tackle -2024 A- Engine and gearbox support -VAS 6095- with uni- ‘versal mounting -VAS. 6095/1- and brackst for V6 FSI engine, Audi Aé -VAS 6095/1-5- ¢ Workshop hoist - VAS 6100- Lift arm extension (workshop hoist) -VAS 6101- VAS 6100 VAS 6101 Risk of accident. % The engine can only be transported with the gearbox removed using the method described. + Engine/gearbox assembly removed; engine separated from gearbox. + Engine secured with support -VAS 6131/13-7- ‘3. Securing engine o engine and gaarbox suppot 7DAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > GOED 6-cylinder direct petrol injection engine with supercharger (3.0 lr. 4-valve), mechanics - Edition Aver 11.2010 = Unplug electrical connector -arrow on steering box. CB) ws rs Lay 2 cloth under the separating pointto catch escaping hydraulic uid. — Unscrew connection -3.. — Seal off open pipes/lines and connections with clean plugs from engine bung set -VAS 6122. . The illustration shows the installation position on a vehicle with dynamic steering. Disregard -items 1, 2- and -arron, = Detach electrical connector -2- on solenoid valve (right-side) for electro-hydraulic engine mounting -N145- from bracket and unplug connector. Unscrew nut -1- and detach bracket with electrical wiring from subframe, (@) note The illustration shows the installation position with the engine installed. 76 ep. r.10- Removing and installing engineAudi A4 2008 > , Audi A5 Cabriolet 2009 > , Audi A5 Coupé 2008 > 6-cylinder direct petrol injection engine with supercharger (3.0 ltr. 4-valve), mechanics - Edition GETD 411.2010 Auor = Attach Iiting tackle -2024 A. to engine lifting eyes and workshop hoist as shown in illustration. [F) note To adjust to the centre of gravity of the assembly, the perforated rails of the support hooks must be positioned as shown. aoe The support hooks and retaining pins on the iting tackte ‘ust B6 secured with ong pis arouse = Take up weight of engine with workshop hoist, but do not lift — Unplug electrical connector -3- on left electrohydraulic engine mounting solenoid valve -N144-. - Remove bolt -4- for engine mounting (left-side). (Fs Disregard items 1, 2,5. m=Remove,bolt -2.for engine mounting (right-sid2) sn. Note ¢ The illustration shows the installation position with the engine installed. 4 Disregard -items 1, 3, 4 - Remove support -VAS 6131/13-7- from engine. — Lift off engine from engine cross member. VAS 6131/13-7 ‘3. Securing engine o engine and goarbox suppoa 77

Audi A4 2008+ - 6 Cylinder Direct Petrol Injection With Supercharger (3.0 LTR 4-Valve)

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Audi A4 2008+ - 6 Cylinder Direct Petrol Injection With Supercharger (3.0 LTR 4-Valve)

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