Part 2
Engine, Removing - (Continued)
- Disconnect fuel supply line - arrow - at fuel rail.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Remove rubber seal and remove plenum chamber cover - 1 - forward - arrows -.
- Pry off cover caps - 3 - from wiper arms with a screwdriver.
- Loosen nuts - 4 - several turns.
- Loosen wiper arms - 2 - one after another by tilting wiper axles slightly.
- Remove nuts completely and remove wiper arms.
• If wiper arm cannot be removed in this way, use a standard puller.
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 (ECM) from E-Box.
• Engine Control Module (ECM) remains connected at wiring harness.
- Release retaining hooks - arrows - toward outside and remove retaining bracket.
- Disconnect all electrical harness connectors on connector station - 2 -.
- Unbolt 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.
- Disconnect the connectors - 1 - and - 2 -.
- Free up the wiring harness.
- Set electrical wiring harness on engine and secure Engine Control Module (ECM) against falling down.
- Remove the bolts - arrows -.
- Remove engine control module (ECM) 2 bracket.
- Place ECM 2 on engine and secure it against falling down.
- Remove ground pin - 1 - and remove ground line underneath.
- Remove bolt - 2 - and disengage positive terminal pick-off at mount.
- Release retaining clip and open cover - 2 - over positive terminal pick-off.
- Release cover - 3 - over electrical lines.
- Remove nut - 1 - on positive line.
- Pull plus wire through bulkhead toward front.
- Free up the wiring harness.
• Ignore - 4 -.
- Remove heat insulation sleeve over coolant hoses to heat exchanger.
- Remove lower coolant hose - arrow - at heat exchanger.
- Slide coolant hose back down slightly through rubber grommet.
- Disconnect electrical harness connector - 1 - at Secondary Air Injection (AIR) Pump Motor (V101).
- Remove Ground (GND) wire - 2 - on longmember.
- Disconnect electrical connectors - 3 - and - 4 - at right engine bracket and at generator (D+).
- Free up wiring harness upward.
- Place the Used Oil Collection and Extraction Device (V.A.G 1782) under the disconnection point.
- Disconnect hydraulic pressure line for power-steering - arrow - at left next to oil pan.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Remove bolts and nuts - arrows - uniformly at left and right.
- Remove stabilizer.
• To prevent damage to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
- Remove the 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 the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Remove bracket for refrigerant lines at left front on oil pan - arrow -.
- Remove bracket for refrigerant lines at left rear on oil pan - arrow -.
- Remove bracket for refrigerant lines at right on oil pan - arrow -.
- Remove coolant line retaining clamp at right of auxiliary cooler - arrow -.
- Remove bolt - arrow - and disconnect refrigerant line to A/C compressor.
- Seal the open lines and connections with clean plugs from the Engine Bung Set (VAS 6122).
- Have a second technician press the 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 -.
- Disconnect the electrical harness connector - 2 - at Left Front Level Control System Sensor (G78).
- Unclip securing clip - 1 - at Left Front Level Control System Sensor (G78) actuating rod at bottom of control arm.
- Unbolt suspension strut from control arm - arrow -.
- Remove expanding clips - arrows -.
- Remove nut - 1 - and remove cover behind wheel housing.
- Unbolt guide control arm - 1 - and control arm - 2 - on subframe.
- Swing 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.
- Unbolt 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 clamping sleeves - 1 - and - 2 -.
- Remove heat shield - A - for driveshaft - arrows -.
- Remove bolts at transmission/driveshaft flange.
- Push driveshaft together with rear final drive. The constant velocity (CV) joints can move axially.
- Tie up driveshaft to body.
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 left and right on tunnel cross member 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).
- Mark installation position of subframe and of both engine mount brackets to longitudinal members using a felt-tip marker.
- Remove bolts - 1 to 4 - in diagonal sequence and in stages.
• Verify that all hoses and lines between engine/transmission subassembly and body have been disconnected.
• While lowering, carefully guide engine/transmission subassembly with subframe out of engine compartment in order to prevent damage.
- First lower engine/transmission assembly using Scissor Lift Platform (VAS 6131 A) only approximately by dimension - a -.
• Dimension - a - = max. 100 mm.
- Disconnect connecting rod - 2 - of shift rod.
- Remove socket head bolt of pivot rod - 1 -.
- Remove the nut - arrow - and remove the transmission shift lever from the selector shaft.
- Remove clutch slave cylinder - arrow -, do not disconnect lines.
- Tie up clutch slave cylinder together with shift rods.
CAUTION!
Do not operate the clutch pedal anymore after slave cylinder has been removed. At a pedal pressure of approximately 300 N, the clutch slave cylinder is destroyed.
- Remove coolant hose - arrow - to heater core on rear coolant pipe.
- Lower engine/transmission subassembly downward.
- Push Scissor Lift Platform (VAS 6131 A) with engine/transmission subassembly under vehicle.