Audi Workshop Service and Repair Manuals

Special tools and workshop equipment required

• ◆ Puller T10051

• ◆ Counterhold T10052

Sequence of operations

• ● Engine in position
• ● Lock carrier in service position =>Page 13-1.

Note:

All cable ties unfastened or cut open on removal are to be re-attached in same position on installation.

• ‒ Heed (if necessary obtain) code for vehicles with encoded radio/radio navigation system (RNS).
• ‒ Disconnect battery earth strap with ignition switched off.

• ‒ Unscrew cap of coolant expansion tank.

• ‒ → Pull dipstick -1- out of guide tube.
• ‒ Unclipcaps.
• ‒ Remove nuts -arrows- and detach engine cover.
• ‒ Remove insulation lying below.
• ‒ Re-insert dipstick into guide tube.

• ‒ Unclipcaps.
• ‒ → Remove bolts -arrows- and detach air cleaner cover.

• ‒ → Disconnect vent hose -2- from air cleaner housing.
• ‒ Unplug electrical connector -4- from air-mass meter.
• ‒ Detach EGR valve -N18-3- from air cleaner housing.
• ‒ Detach wiring harness from air cleaner housing -arrow-.
• ‒ Pull off air hose -5-.
• ‒ Screw out bolt -1-.
• ‒ Detach air cleaner housing.

• ‒ → Detach vacuum hose -1- from charge pressure control vacuum unit.
• ‒ Detach vacuum hose -2- from intake manifold flap vacuum unit.

• ‒ → Screw out turbocharger/catalytic converter nuts -arrows-.
• ‒ Detach front exhaust system clamp.
• ‒ Push clamp back to separate exhaust system.
• ‒ Disconnect catalytic converter with exhaust pipe from turbocharger.

Note:

To avoid damage, decoupling element of exhaust system is never to be tilted by more than 10 °.

Vehicles with air conditioner:

Note:

Before removing, mark direction of ribbed belt with chalk or felt-tipped pen. Running a used belt in the opposite direction could destroy it.

• ‒ → Slacken off bolts of tensioning roller for air-conditioner compressor ribbed belt -arrows-, slacken off ribbed belt and detach.
• ‒ Detach air conditioner compressor from bracket and secure to body with wire.

All models:

• ‒ → Remove right side air hose -arrows-.

• ‒ → Slacken bolt -1- of soundproofing cover over right side drive shaft at front.
• ‒ Unhook catch -2- and detach soundproofing cover.

• ‒ → Remove bracket for turbocharger -arrows-.

• ‒ → Detach oil return pipe from cylinder block -arrow-.

• ‒ Drain off coolant => Page 19-7.
• ‒ Detach coolant hoses to expansion tank and to radiator from coolant pipe at top.
• ‒ → Detach coolant hoses and fuel hoses -1 ... 6-.
• ‒ Screw out bolt -arrow-.
• ‒ Pull fuel filter upwards out of holder.

• ‒ → Detach air hose from charge air cooler-arrow-.

• ‒ → Disconnect vent line -1- to air cleaner and vacuum line -2- to mechanical EGR valve.
• ‒ Detach air hose -3- from intake manifold.

• ‒ → Unplug connectors -2- and -4-.
• ‒ Pull off vacuum hose -5-.
• ‒ Screw out bolt -1-.
• ‒ Detach air pipe -3-.

• ‒ → Disconnect hose connections -arrows-.
• ‒ Detach vacuum line -1-.

• ‒ → Turn knurled screw -3- for centre connector anti-clockwise.
• ‒ Detach centre connector.
• ‒ Disconnect fuel hoses -1- and -2-.

• ‒ → Unbolt fuel filter holder -arrows-.

• ‒ Detach coolant hoses from upper coolant pipe.
• ‒ → Unscrew nut -arrow-.
• ‒ Detach coolant pipe -1-.
• ‒ Disconnect connectors from glow plugs.

• ‒ → Unbolt oil supply pipe from oil filter holder -arrow-.

• ‒ → Detach coolant hose -1- from rear of cylinder head.
• ‒ Unplug connector -3-.

Vehicles with manual gearbox:

• ‒ Detach coolant hose -4-.
• ‒ Unscrew electric wires -2- from heating elements of supplementary heater.

Vehicles with automatic gearbox:

• ‒ → Detach coolant hose from EGR cooler -arrow-.

All models:

• ‒ Remove toothed belt => Page 13-36.
• ‒ → Screw out camshaft sprocket bolts -1-.
• ‒ Detach camshaft sprocket from hub.

• ‒ → Slacken hub bolt -1-. Use counterhold T10051.
• ‒ Screw out hub bolt approx. 2 turns.

• ‒ → Position puller T10052 in alignment with holes on hub.
• ‒ Screw bolts -1- into hub.
• ‒ Tension the hub by steadily tightening centre bolt -2- until hub separates from camshaft cone.

Note:

Hold the puller firm with a A/F 30 mm spanner while doing so.

• ‒ Detach hub from camshaft cone.

• ‒ Removing toothed belt tensioning roller.
• ‒ → Screw out bolts -2 ... 4-.
• ‒ Screw out stud bolt -1- with two locked M8 nuts.

• ‒ → Detach hose of crankcase breather from pressure control valve
  -arrow-.
• ‒ Remove cylinder head coverbolts in sequence: -13 ... 1- and remove cylinder head cover.

• ‒ → Heed slackening off sequence for cylinder head bolts.
• ‒ Raise cylinder head with the assistance of a second mechanic and lift out.