Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ V.A.G 1921

Removing

• ‒ Drain coolant => Page 19-7.
• ‒ → 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- off air cleaner housing.
• ‒ Remove air cleaner housing.

• ‒ → Detach connector-4-.
• ‒ Detach vacuum hose -3- at cutting point.
• ‒ Unscrew bolts -1- and -2-.
• ‒ Put solenoid valve brackets to side with hoses connected.

Vehicles with manual gearbox:

Detach both gear selector cables from gearbox as follows:

• ‒ → Mark installation position of thread rods -1- of both gear selector cables with a waterproof felt-tip pen.
• ‒ Pull the spring with the knurled piece in direction of arrow -2- towards spherical joint and then turn knurled piece clockwise to secure in engaged position -arrow 3-.
• ‒ Detach both gear selector cables.

• ‒ → Remove cable counterhold from gearbox and place to one side
  -arrows-.

Vehicles with engine code ATD, AXR:

• ‒ Unclip the clutch slave cylinder hose at the cable support bracket.

All models:

• ‒ Remove all hoses from coolant pipe.
• ‒ → Disconnect lower coolant hose -1- at coolant connection.
• ‒ Unplug connector -2- at coolant temperature sender -G62.

• ‒ Detach the heat protection sleeve at the speedometer sender -G22.
• ‒ → Detach connector -arrow- from speedometer sender -G22 from gearbox.
• ‒ Lay wiring aside.

Vehicles with engine code AXR:

• ‒ → Disconnect coolant hoses -1- and -2- at exhaust gas recirculation cooler.

All models:

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

• ‒ → Unscrew oil feed line from oil filter bracket -arrow- and also at coolant pipe and lay line aside.

• ‒ Unplug connector console from glow plugs.
• ‒ → Detach the following connectors:

•     1 -    Oil pressure switch -F1
•     2 -    Hall sender -G40
•     3 -    Engine speed sender -G28
•     4 -    Fuel temperature sender -G81

• ‒ Detach connectors -2- and -3- from the bracket at coolant pipe.

• ‒ Lay aside wiring at air coolant pipe.
• ‒ Remove the coolant pipe from cylinder block.
• ‒ → Take coolant pipe -2- from connection.

Installing

Installation is carried out in the reverse order; note the following:

Note:

Replace seals and gaskets.

• ‒ Before installing, clean and smooth down sealing surface for O-ring.
• ‒ → Coat new O-ring -1- with G 012 A8 D and push onto coolant pipe -2-.
• ‒ Push coolant pipe into opening in cylinder block.
• ‒ Top up coolant => Page 19-10.

Tightening torques