Audi Workshop Service and Repair Manuals

Vehicles with 4.2 ltr. MPI engine 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/hot coolant can escape - risk of scalding. t  The cooling system is under pressure when the engine is hot. t  Cover cap for coolant expansion tank with a cloth and open carefully to release pressure. –  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-.

Caution Risk of damage to condenser and refrigerant lines/hoses. Take care to avoid straining, kinking or bending refrigerant lines/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.

Caution Risk of breakage if the poly V-belt runs in the opposite direction when refitted. Before removing, mark direction of operation of poly V-belt with chalk or felt-tipped pen in preparation for re-installation. –  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 electrical 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) → Electronic parts catalogue. –  Fit poly V-belt -2- on pulleys as illustrated. 1 -  Alternator 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 → 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 battery. Steps required → Anchor. –  Fill with coolant → Rep. Gr.19. –  Start engine and check that belt runs properly. Tightening torques

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