Part 2
- Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve (N80) - 1 - from air guide.
- Remove bolts - arrows -.
- Remove air duct - 2 -.
- Disconnect top coolant hose - arrow - from radiator.
- Remove electrical harness connectors - 1 - and - 2 - from bracket and disconnect them.
- Free up wires to lock carrier.
- Disconnect electrical harness connector - arrow - for headlights at both sides of the vehicle.
- Free up electrical wiring.
- Disconnect electrical harness connector - arrow - for left and right airbag sensors on lock carrier.
- Free up cables.
- Remove hood cable at lock carrier.
- Disconnect electrical harness connector - arrow - for right fan.
• To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.
- Remove refrigerant line - arrow - leading to A/C compressor.
- Remove refrigerant line - arrow - leading to A/C evaporator.
- Remove bolts - arrows - at left and right side of bumper.
- Pull off hood seal from lock carrier and fender edges.
- remove bolts at impact absorbers - arrows - at left and right.
• A second technician is required to remove the lock carrier.
- Remove lock carrier and set aside so it cannot fall.
- Remove rear engine cover - arrows -.
- Remove front engine cover - arrows 1 and 2 -.
- Remove coolant hoses - 1 - and - 2 -.
- Remove coolant expansion tank - arrow -.
- Disconnect electrical wiring to Engine Coolant Level (ECL) Warning Switch (F66) at bottom of expansion tank.
- Disconnect vacuum line - arrow - to brake booster at bulkhead.
- Unclip coolant hose - arrow - from bracket on bulkhead.
- If installed, disconnect vacuum line - arrow - to vacuum reservoir.
- Disconnect vacuum hose - arrow - from intake manifold.
- Disconnect coolant hose - arrow - to heater core at rear coolant pipe on engine.
- If installed, disconnect vacuum line at area designated with - arrow -.
- If installed, disconnect electrical harness connector - arrow - for After-Run Coolant Pump (V51) (behind auxiliary cooler at left) and free up electrical wire.
• Place a rag under separating point to catch escaping hydraulic fluid.
- Disconnect hose - 1 - from power steering fluid reservoir.
• Ignore - 2 -.
- Disconnect coolant hoses at positions indicated by - arrows -.
- Disconnect coolant hoses at positions indicated by - arrows -.
- Disconnect coolant hose to oil cooler - arrow -.
- Disconnect coolant hoses at positions indicated by - arrows -.
- Remove bolts - 1 - and - 2 -.
- Remove right auxiliary cooler together with coolant hoses.
• The hose - arrow - can remain connected at auxiliary cooler.
CAUTION!
Note rules of cleanliness for working on the fuel injection system. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
CAUTION!
Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening the connection.
- Remove fuel hose from connection on fuel rail pipe. To do so, counterhold using an open-end wrench at hex head - 1 - and - 3 - and remove union nut - 2 -.
- Disconnect electrical harness connector - 2 - from Evaporative Emission (EVAP) Canister Purge Regulator Valve ( N80).
- Disconnect electrical harness connector - 3 - at Mass Air Flow (MAF) Sensor (G70).
- Disconnect hose - 1 - to Secondary Air Injection (AIR) pump.
- Disconnect air guide hose - 4 - at Mass Air Flow (MAF) sensor.
- Move wiring harness clear at air filter housing.
- Remove clip - arrow - and remove air filter housing with Mass Air Flow sensor.
- Disconnect air hose - arrow - at right on engine.
- Remove bracket for electrical harness connectors - 1 to 4 - at right from bulkhead.
- Remove nut - 1 - and remove fuse strip on plus wire terminal clamp.
- Disconnect plus wire - 2 - on battery positive terminal.
- Pull plus wire through bulkhead toward front.
- Free up the wiring harness.
• Disregard - 3 -.
- Pry off both covers - 3 - using a screwdriver.
- Loosen hex-nuts - 4 - by several turns.
- Loosen wiper arms - 2 - from the respective wiper axle by tilting slightly.
- Remove nuts completely and remove wiper arms.
CAUTION!
To prevent the cowl grille - 5 - from tearing when removing, coat transition between windshield and cowl grille with a soapy solution and pull grille up vertically out of fastening strip beginning at edge of window.
- Disconnect securing clips - 1 - and remove cowl grille - 5 -.
- Remove cover for E-Box in plenum chamber - arrows -.
- Using a screwdriver, carefully pry off mounting bracket - arrow - and remove Engine Control Module from E-Box.
• Engine Control Module remains connected at wiring harness.
- Release retaining hooks - arrows - toward outside and remove retaining bracket.
- Disconnect all electrical harness connectors on connector station - 2 - using spark plug connector pliers (V.A.G 1922 ).
- Remove electrical wire connection - 1 -.
- Disengage locking mechanisms - arrows - and remove secondary relay carrier in E-Box toward top.
- Disengage engine wiring harness at E-Box and bulkhead.
- Remove Ground (GND) connection - arrow -.
- Remove bracket for electrical harness connectors - 1 to 4 - at left from bulkhead.
- Free up the wiring harness.
- Set electrical wiring harness on engine and secure Engine Control Module against falling down.
- Disconnect electrical harness connector - 1 - at Secondary Air Injection (AIR) Pump Motor (V101).
- Remove Ground (GND) cable - 2 - on longmember.
- Place old oil collecting and extracting device ( V.A.G 1782) under engine.
- Disconnect hydraulic pressure line for power-steering - arrow - at left next to oil pan.
• To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the pipes and hoses are not stretched, kinked or bent.
- Remove bolts - 1 - and - 2 -.
- Remove right refrigerant line from A/C compressor.
• The left refrigerant line will be removed at a later point in time.
- Seal open connections on A/C compressor using clean plugs.
- Remove left bracket for refrigerant line - arrows -.
- Remove refrigerant line on bracket - arrow -.
- Remove bolt - arrow - and disconnect refrigerant line to A/C compressor.
- Have a second technician press brake pedal.
CAUTION!
To loosen collar bolt for drive axle, the wheel bearing must not be under load (vehicle must not be standing on its wheels).
- Remove collar bolt - 2 - at left and right drive axles - 1 -.
- Remove bolts and nuts - arrows - uniformly at left and right.
- Remove stabilizer.
- Disconnect electrical harness connector at Level Control System Sensor.
- Unclip operating rod for Left Front Level Control System Sensor (G78) at bottom on control arm.
- Remove outer suspension strut bolt from left and right of engine compartment.
- Rotate Ring Screw (3368) at left and right in suspension strut mount hole from below.
CAUTION!
Only install Ring Screw (3368) until it is flush with upper edge of suspension strut mount so that hood is not damaged when closed.
- Tie up wheel bearing housing at left and right with Tensioning Strap (T10038) as shown in illustration.
CAUTION!
To prevent upper control arm joints from being damaged, wheel bearing housing must be supported before loosening lower suspension strut bolts.
- Remove suspension strut from control arm - arrow -.
- Remove expanding clips - arrows -.
- Remove nut - 1 - and remove cover behind wheel housing.
- Remove guide control arm - 1 - and control arm - 2 - on subframe.
- Pivot guide control arm - 1 - and control arm - 2 - outward.
CAUTION!
Guide control arm and control arm must not hang free. Tie up both control arms on wheel bearing housing - arrows - as shown in illustration.
- Repeat work procedure on opposite side of the vehicle.
- Remove heat shield - 1 - for left drive axle.
- Remove drive axle from transmission flanged shaft.
- Swing left wheel bearing housing outward and remove drive axle.
- Repeat work procedure on opposite side of the vehicle.
• Do not bend the flex joint in front of the exhaust pipe more than 10° or it could be damaged.
- Disconnect exhaust system at double clamps - arrows -.
- Remove heat shield - A - for driveshaft - arrows -.
- Remove bolts at transmission/driveshaft flange.
- Push driveshaft together with rear final drive. The constant velocity joints can move axially.
- Tie up driveshaft to body.
• Mark the installation position of bracket for selector lever cable using a felt-tip marker.
- Press ball socket - 1 - of selector lever cable from selector shaft lever.
- Remove bracket on transmission - arrows -.
- Move selector lever cable clear.
• To improve clarity, the transmission supports are shown removed in the illustration.
Prepare scissor lift platform:
- Equip scissor lift platform (VAS 6131 A) with support set for Audi (VAS 6131/10) as follows:
- Install attachments on scissor lift table by hand first.
- Place scissor lift platform (VAS 6131 A) in horizontal position.
• Note bubble level (sight glass) on support platform.
- Drive scissor lift table (VAS 6131 A) under engine/transmission subassembly.
- Position support elements from (VAS 6131/10) at front on engine as shown in illustration.
- Position support elements from (VAS 6131/10) at left and right on subframe as shown in illustration.
- Position support elements from (VAS 6131/10) at rear on transmission as shown in illustration.
- Twist all spindles of support elements upward far enough until all support pins make contact at support points.
- Tighten base plates for support elements to 20 Nm on scissor lift platform (VAS 6131 A).
- Twist both spindles at subframe 2 rotations upward.
- Twist both spindles at transmission 4 rotations upward.
- Remove bolts - 1 -.
- Mark installation position of subframe and of both engine mount brackets to longmembers using a felt-tip marker.
- Remove bolts - 2 -, - 3 - and - 4 - in diagonal sequence and in stages.
• Verify that all hoses and lines between engine, transmission, subframe and body have been disconnected.
• While lowering, carefully guide engine/transmission subassembly with subframe out of engine compartment in order to prevent damage.
- Slowly lower engine/transmission subassembly downward.
- Push scissor lift platform (VAS 6131 A) with engine/transmission subassembly under vehicle.