Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Support bar 10-222A
• ◆ Drip tray V.A.G 1306
• ◆ VAS 5024 A
• ◆ Bracket T10014
• ◆ Counterhold T10051
• ◆ Puller T10052

Procedure

• ‒ 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 ribbed belt => Page 13-10.

• ‒ → 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.

Vehicles with engine code AXR:

• ‒ → Detach the crankcase vent pipe -5- from air duct pipe.
• ‒ Release spring clamp on turbocharger using VAS 5024 A.
• ‒ Set aside the vacuum hoses.
• ‒ Unscrew bolts -1- and -2- and remove air duct pipe -3-.

• ‒ → Disconnect vacuum hoses -1 ... 3-.
• ‒ Set aside the vacuum hoses.

• ‒ → Detach connector -arrow- at intake manifold flap motor.

Vehicles with engine code ASZ, ATD:

• ‒ → Detach the crankcase vent pipe -6- from air duct pipe.
• ‒ If installed, detach connector for heating resistor (crankcase venting) -N79 -Item 3-.
• ‒ Release spring clamp on turbocharger using VAS 5024 A.
• ‒ Set aside the vacuum hoses.
• ‒ Unscrew bolts -1- and -2- and remove air duct pipe -4-.

• ‒ → Disconnect vacuum hoses -1... 3- at rear of intake manifold.

All models:

• ‒ Open the cover of the coolant expansion tank

• ‒ → Remove air duct pipe from right longitudinal member -arrows-.

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

• ‒ Place drip tray V.A.G 1306 below engine.

Vehicles with drain plug:

• ‒ → Turn drain plug -1- on radiator anti-clockwise, fit auxiliary hose to connection if necessary.

Vehicles without drain plug:

• ‒ Detach retaining clip -2- for bottom coolant hose and disconnect coolant hose from radiator.

All models:

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

Note:

Illustration shows an engine with code ASZ.

• ‒ → 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/turbocharger.

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

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

• ‒ → 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.

Vehicles with engine code AXR:

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

• ‒ → Disconnect coolant hose -arrow-.

Vehicles with engine code ASZ:

• ‒ → Disconnect coolant hose -1- at cylinder head.

All models:

• ‒ Detach vacuum hose -2- for brake servo at tandem pump.

• ‒ → Unscrew coolant connection -arrows. Do not detach hoses.
• ‒ Before removing the cylinder head, extract fuel from the tandem pump using hand vacuum pump V.A.G 1390 => Removing and installing tandem pump.

=> Fuel Supply - Diesel Engines; Repair group 20

• ‒ → Open the knurled nut -arrow- and unplug central connector.
• ‒ Unplug connector console from glow plugs.

• ‒ → Remove the vacuum hose -2- at vacuum reservoir and lay the vacuum hose aside.
• ‒ Detach the coolant hose at the bracket -1-.

Vehicles with engine code AXR:

• ‒ Detach upper coolant hose from coolant expansion tank.

All models:

• ‒ → Set up support bar 10-222 A on wing panel flanges.
• ‒ Spindle -1- is behind the square-section pipe
• ‒ Spindle -2- is in front of the square-section pipe
• ‒ Slightly raise engine with spindle -2- of support bar 10-222 A, spindle -1- remains free.

• ‒ Removing toothed belt => Page 13-51.
• ‒ Pull out mandrel 3359.
• ‒ → Unscrew bolts -1- of camshaft sprocket.
• ‒ Remove the camshaft sprocket from hub.

• ‒ → Undo the securing bolts -1- on the hub. Use counterhold T10051.
• ‒ Unscrew securing bolt of hub approx. 2 turns.

• ‒ → Attach puller T10052 and screw bolts -1- into hub.
• ‒ Pull off hub. For this counterhold on hexagon (A/F 30) of puller and screw in bolt -2-.

• ‒ Remove toothed belt tensioning roller.
• ‒ → Unscrew bolts -2 ... 4-.
• ‒ Unscrew stud bolt -1- with two countered M8 nuts.

• ‒ → Screw in bracket T10014 into threaded bore above coolant pump.
• ‒ Attach spindle -1- of support bar 10-222 A to bracket T10014.
• ‒ Lift engine above spindle -1- until spindle -2- has no more load.
• ‒ Remove spindle -2- from engine and push to the side.

• ‒ → Loosen cylinder head bolts in the sequence -13 ... 1- and remove the cylinder head cover.

• ‒ → Maintain sequence when loosening cylinder head bolts.
• ‒ Lift out cylinder head with the help of a 2nd mechanic.