Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Lifting tackle 2024 A
• ◆ Guide pin 3070
• ◆ Pin 3359
• ◆ V.A.G 1306
• ◆ VAS 5024 A
• ◆ Camshaft straightedge T10098

• ◆ Two-arm puller T40001

Procedure

• ● Engine in vehicle

Note:

All cable ties which are released or cut open when removing must be fitted in the same position when installing.

• ‒ Refer to coding on vehicles with encoded radio/radio navigation system (RNS); if necessary, interrogate.
• ‒ With the ignition switched off disconnect the battery earth strap.

• ‒ → Remove oil dipstick -1- from guide tube.
• ‒ Unclip caps.
• ‒ Unscrew nuts -arrows- and remove engine cover.
• ‒ Reinsert oil dipstick in guide tube.

• ‒ Open the cover of the coolant expansion tank
• ‒ → Remove lower air duct pipe -arrows-.

• ‒ → Remove noise insulation in centre and on right -arrows-.

Note:

Mark the running direction with chalk or a felt-tipped pen before removing the ribbed belt. If the belt runs in the opposite direction when it is refitted, this can cause breakage.

• ‒ Fit flat 16 mm box wrench at hexagon of tensioner.
• ‒ → Swivel tensioning roller in direction of arrow to slacken ribbed belt.
• ‒ Remove ribbed belt.

• ‒ Place drip tray V.A.G 1306 below engine.
• ‒ → Turn drain plug -arrow- on radiator anti-clockwise. If necessary, fit drain hose on connection.

• ‒ → Also disconnect lower coolant hose on oil cooler -arrow-, and drain off remaining coolant.

• ‒ → Unbolt heat shield for right drive shaft -arrows-.

• ‒ → Unbolt bracket for exhaust system from assembly mounting -arrows-.

Note:

The isolating element in front exhaust pipe must not be deflected more than 10° to avoid damage..

• ‒ → Unscrew securing bolts -arrows- of front exhaust pipe/exhaust turbocharger.

• ‒ → Detach the exhaust system at the clamping sleeve -arrows-.
• ‒ Remove the front exhaust pipe.

• ‒ → Remove air duct hoses -2- and -3- from turbocharger.
• ‒ Unscrew turbocharger bracket -1-.
• ‒ Remove oil return pipe -4- at cylinder block.

• ‒ Detach the cover and the electrical connector at the right headlight unit.
• ‒ → Disconnect fuel-feed line -2- and fuel-return line -1- at injection pump.
• ‒ Disconnect the electrical connection -3- at the sender -G71/-G72.
• ‒ Expose the wiring at the air duct pipe.
• ‒ Remove the air duct pipe on right side -arrows-.

• ‒ → Pull off the vacuum hoses -2- at the exhaust gas recirculation valve or at the Y-piece -4-, respectively.
• ‒ Disconnect electrical connector for heating resistance (crankcase ventilation system) -N79 -Item 3-.
• ‒ Disconnect hose -6- to air cleaner housing.

• ‒ Pull crankcase ventilation pipe -7- off rear of air duct pipe.
• ‒ Unscrew bolts -1- and -5- and remove the air duct pipe at rear.

• ‒ → Remove the vacuum hose -arrow- and expose the vacuum hose.

• ‒ → Remove air duct hose -1- from air duct pipe.
• ‒ Detach connector of air mass meter -3-.
• ‒ Unscrew bolts -4- and -5-.
• ‒ Remove vent hose -2- from rear of air cleaner housing.
• ‒ Take out air cleaner housing.

• ‒ → Unscrew oil feed pipe from exhaust turbocharger and exhaust manifold -arrows-.

• ‒ → Unscrew oil feed line from oil filter bracket -arrow- and also on cylinder head and lay line aside.

• ‒ → Disconnect the electrical connections at the glow plugs (coolant) -Q7 -Item 4- (manual gearbox only).
• ‒ Disconnect the electrical connection -7- at the coolant temperature sender -G62 and expose wiring.
• ‒ Pull vacuum pipe -5- off at exhauster.
• ‒ Detach the coolant hoses -1-, -2-, -6- and -8-.

• ‒ Remove injector pipes.

Note:

Always remove complete pipe set. Use injector pipe spanner 3035.

• ‒ Detach injector/injection pump return line.
• ‒ Detach glow plug connector console.
• ‒ Take needle lift sender electrical connection from bracket and disconnect it.

• ‒ → Remove tensioner for ribbed belt -arrows-.
• ‒ Remove upper toothed belt guard.
• ‒ Unscrew 2 toothed belt guard bolts at rear on both sides of the cylinder head.

• ‒ → Turn crankshaft to TDC No. 1 cylinder -arrow- (vehicles with manual gearbox).

• ‒ → Turn crankshaft to TDC No. 1 cylinder -arrow- (vehicles with automatic gearbox).

Note:

Position crankshaft to TDC No. 1 cylinder 1 with engine removed.

• ‒ Remove the exhauster => Fig.15-8.
• ‒ → Turn the bolts -1- by hand up to stop into the cylinder head.
• ‒ Lock the camshaft using camshaft straightedge T10098 as shown in the illustration.
• ‒ If the camshaft straightedge T10098 cannot be inserted, rotate crankshaft 1 additional turn (360°).

• ‒ → Lock injection pump sprocket using pin 3359.
• ‒ Loosen injection pump sprocket securing bolts -arrows-.

Note:

→ Never loosen the injection pump sprocket central nut -2-. Otherwise the injection pump basic setting is incorrectly adjusted and cannot be corrected again using workshop equipment.

• ‒ → Unscrew the tensioning roller nut -arrow-.

• ‒ Remove the toothed belt from the camshaft toothed belt sprocket.
• ‒ → Unscrew the camshaft sprocket bolt by one half turn .
• ‒ Place the two-arm puller T40001 with claw T40001/2 -Item A- and the two-arm claw T40001/3 -Item B- centralised onto the camshaft sprocket.
• ‒ Pull off the camshaft sprocket using the two-arm puller. Counterhold using an open-end spanner -C- in the process.
• ‒ Removing camshaft toothed belt sprocket.
• ‒ Remove cylinder head cover => Page 15-9.

• ‒ → Loosen cylinder head bolts in the sequence 1 ... 10.

• ‒ → Attach lifting tackle 2024 A on cylinder head.

Note:

In addition, tie intake manifold to lifting tackle eye in order to obtain a stable centre of gravity position for the cylinder head.

• ‒ Slightly lift cylinder head using workshop crane.
• ‒ Simultaneously move cylinder head to the left out of rear of toothed belt guard and remove tensioning roller.