Audi Workshop Service and Repair Manuals

Vehicles with 4.2 ltr. MPI engine - Audi S4 Special tools and workshop equipment required

t  Used oil collection and extraction unit -V.A.G 1782-

t  Drip tray for workshop hoist -VAS 6208- Removing –  With ignition switched off, disconnect earth cable at battery → Chapter. –  Use oil collection and extraction unit -V.A.G 1782- to draw off hydraulic fluid for power steering from reservoir.   WARNING Hot steam or hot coolant may escape when opening coolant expansion tank. Cover cap with cloth and open carefully. –  Open filler cap for coolant expansion tank.

–  Remove front wheel (right-side). –  On vehicles with auxiliary heater, unscrew bolts -arrows- for exhaust pipe of auxiliary/supplementary heater at noise insulation.

–  Unfasten bolts/quick release fasteners -1- and -2- and detach noise insulation (front).

–  Remove air duct (right-side) -arrow- in front of auxiliary radiator.

–  Remove air duct (left-side) -arrow- in front of auxiliary radiator.

–  Place drip tray for workshop hoist -VAS 6208- beneath engine. –  Unscrew drain plug -arrow- at thermostat housing and drain off coolant at engine.

–  Pull off coolant hose (bottom) from radiator -arrow- and drain off remaining coolant.

–  Place used oil collection and extraction unit -V.A.G 1782- underneath. –  Detach the hydraulic lines leading to cooling pipe (rear) at lock carrier -arrows-.

–  Detach cover (right-side) -1- in engine compartment.

–  Unscrew bolts -arrows-. –  Detach activated charcoal filter solenoid valve 1 -N80--item 1- at air duct. –  Remove air duct -2-.

–  Detach coolant hose (top) -arrow- from radiator.

–  Detach cover (left-side) -1- in engine compartment.

–  Take electrical connectors -1- and -2- out of retainer and disconnect them. –  Move wiring leading to lock carrier clear.

–  Unplug headlight connector -arrow- on both sides of vehicle.

–  Unplug electrical connector -arrow- for airbag sensors (left and right) at lock carrier. –  Move wiring clear. –  Detach bonnet cable at lock carrier → Rep. Gr.55.

–  Unplug electrical connector -arrow- for fan (right-side).

–  Unscrew air ducts (left and right) at radiator -arrows-.

–  Unclip ambient temperature sensor -G17--item 1- from retainer and move wiring clear. –  Unscrew cooling pipe for power steering hydraulic fluid -arrows-.

–  Unbolt radiator fan control unit -J293- from radiator -arrow-.   WARNING Do not open refrigerant circuit of air conditioner.   Note

To avoid damage to the condenser and refrigerant pipes/hoses, take care not to strain, kink or bend pipes and hoses. –  Unplug electrical connector -1- at high pressure sender -G65-. –  Unscrew bolts -arrows-. –  Detach condenser and pivot downwards with lines still attached and radiator fan control unit -J293- still installed.

–  Unscrew bolts -arrows- at lock carrier (left and right). –  Pull off bonnet seal at lock carrier and wing panel edges.

–  Unscrew bolts at impact dampers -arrows- (left and right).   Note A second mechanic is required for removing lock carrier. –  Remove lock carrier and place down aside (secure against falling).

–  Release hose clip -2- and detach coolant hose at coolant pipe (right-side). –  Release hose clips -1- pull off coolant hose.   Note Illustration shows engine removed for greater clarity.   Note

Before removing, mark running direction of poly V-belt with chalk or felt-tipped pen. If the belt runs in the wrong direction when it is refitted, this can cause breakage. –  Loosen socket head bolt -arrow-. –  Remove poly V-belt from alternator pulley.

–  Remove tensioning roller -arrows-.

–  Unscrew bolts -arrows-. –  Detach alternator from bracket and pull forwards.   Note t  If alternator sticks in bracket, screw bolt back in again down to the last 2 turns. t  Tap carefully on bolt heads with flat side of hammer to release threaded bushes of alternator mount.

–  Detach coolant hose -3- at alternator. –  Unplug electrical connector -1-. –  Unscrew wire -2- at alternator. –  Remove alternator.

Installing Installation is carried out in the reverse order; note the following:   Note Secure all hose connections with the correct type of hose clips (same as original equipment) → Parts catalogue. –  To facilitate positioning of alternator, drive back bushings for securing bolts slightly.   Note Stiff alternator mount bushes must be released as otherwise the clamping force of the bush will not be adequate even if tightened to correct torque. –  Make sure poly V-belt is properly positioned and correctly routed. 1 -  Alternator 2 -  Poly V-belt 3 -  Idler roller 4 -  Vibration damper 5 -  Tensioning roller

–  Apply torque wrench to hexagon flats on tensioning roller and tension with a torque of 70 Nm. –  At the same time tighten socket head bolt -arrow- to 22 Nm. –  Install lock carrier with attachments → Rep. Gr.50. –  Install front bumper cover → Rep. Gr.63. –  Before starting the engine for the first time, top up power steering reservoir with hydraulic fluid; power steering pump must NOT run dry. –  Connect the battery. Additional steps required → Anchor. –  Fill with coolant → Rep. Gr.19. –  Start engine and check that belt runs properly. –  Adjust headlights → Booklet803 Tightening torques

Component	Nm
Coolant pipes to alternator	9
Terminal 30/B+ to alternator	16
Alternator to engine	22
Tensioning roller to engine	22