Audi Workshop Service and Repair Manuals

• ‒ Observe or obtain radio code on vehicles with coded radio.
• ‒ Disconnect earthing strap at battery with ignition switched off.

Vehicles with 4-cylinder normally aspirated engine:

• ‒ → Unplug connectors -2- and -3- at air mass meter and ACF valve.
• ‒ Pull ACF valve -1- off air cleaner housing.
• ‒ Loosen clamps on air duct -4-.
• ‒ Remove air cleaner housing -arrow-, but do not remove air duct -4-.

• ‒ Unscrew nuts securing front exhaust pipe to exhaust manifold.

=> 4 cylinder engine, Mechanics; Repair Group 26; Removing and installing parts of exhaust system, FWD

=> 4 cylinder engine, Mechanics; Repair Group 26; Removing and installing parts of exhaust system

=> 4 cylinder Engine (5-valve), Mechanical Components; Repair Group 26; Removing and installing exhaust system parts

Note:

Avoid excessive bending of the flexible pipe connection (decoupling element) on the front exhaust pipe. The angle between the catalytic converter and the front exhaust pipe must not exceed 10o,otherwise the flexible connection will be damaged.

Vehicles with 4 cylinder turbo engine:

• ‒ → Disconnect wires/unplug connectors as follows:

•     1 -    At solenoid valve for charge pressure control -N75
•     2 -    At ACF valve
•     3 -    At output stage -N122
•     4 -    At air mass meter

• ‒ Disconnect hoses and remove air cleaner housing -arrows-.
• ‒ Remove coolant system expansion reservoir and lay to one side.

• ‒ → Unplug connector for lambda probe -arrow- and move wiring clear.
• ‒ Unscrew nuts securing turbocharger to front exhaust pipe:

=> 4 cylinder Engine (5-valve turbo), Mechanics; Repair Group 26; Removing and installing parts of exhaust system

Note:

Avoid excessive bending of the flexible pipe connection (decoupling element) on the front exhaust pipe. The angle between the catalytic converter and the front exhaust pipe must not exceed 10o, otherwise the flexible connection will be damaged.

Vehicles with 6 cylinder engine:

• ‒ → Remove intake hose -A- (arrows).
• ‒ Unbolt coolant system expansion tank -B- (arrows) and lay to one side.
• ‒ Unscrew lambda probes on left and right exhaust pipes with special tool 3337 and move clear to the side.

All models:

• ‒ Unscrew engine/gearbox securing bolts accessible from above

• ‒ → Remove noise insulation -arrows-.

• ‒ → Unbolt bracket for noise insulation -arrow-.

Vehicles with 4 cylinder engine:

• ‒ → Detach heat shields -arrow 1- and -arrow 2- above the right-hand drive shaft.

• ‒ → Unbolt right-hand gearbox support complete with bonded rubber mounting -arrows-.
• ‒ Release clamping sleeves on exhaust system and push them towards the catalytic converter.
• ‒ Pull out catalytic converter together with exhaust pipe from underneath.

Vehicles with 6 cylinder engine:

• ‒ Detach heat shield above left and right drive shafts.

• ‒ → Unbolt front exhaust pipes with catalytic converters from left and right exhaust manifolds (3 nuts on each side) -arrows-:

=> 6 cylinder Engine (2-valve), Mechanics; Repair Group 26; Removing and installing exhaust system

=> 6 cylinder Engine (5-valve), Mechanical Components; Repair Group 26; Removing and installing exhaust system parts

• ‒ → Remove engine speed sender -G28 on left of gearbox -arrow- and lay to one side.

All models:

• ‒ Detach drive shafts from flange shafts and rest them on suspension links.

Note:

Take care not to damage protective coating on drive shafts.

• ‒ → Pull connector off sender for speedometer -arrow A-.
• ‒ Pull off connector on reversing light switch (multi-function sender) -arrow B-.
• ‒ Disconnect all other electrical connections and earth wires from gearbox and from the engine/gearbox securing bolts.

• ‒ → Unbolt starter from engine/gearbox and secure as necessary.

=> Electrical system; Repair Group 27; Removing and installing starter

Note:

Starter cables do not need to be disconnected.

Vehicles with standard-travel shift mechanism:

• ‒ → Unscrew bolt -2- at selector joint -1- on selector rod.

Vehicles with short-travel shift mechanism:

• ‒ → Detach selector rod -arrow A-.
• ‒ Unscrew hexagon socket head bolt on push rod -arrow B-.

All models:

• ‒ → Unscrew bottom engine/gearbox securing bolts, except for bolts indicated by arrows -A- and -B-.

• ‒ → Set up the gearbox support 3282 for removing the manual gearbox 012 with adjustment plate 3282/10 and attach to gearbox lifter V.A.G 1383 A.

•     A -     Attachments

Notes:

• ◆ Attachments -A- are shown in schematic form, arrow -B- points in the direction of travel.
• ◆ Adjustment plate 3282/10 only fits in one position.

• ‒ → Run gearbox lifter V.A.G 1383 A with gearbox support 3282 in under the gearbox and take up the weight of the gearbox.

Note:

If gearbox support 3282 is not available, gearbox can be removed and installed using gearbox lifter V.A.G 1383 A and universal support V.A.G 1359/2.

• ‒ Support gearbox with gearbox lifter V.A.G 1383 A.

• ‒ → Align adjustment plate parallel to gearbox and lock safety support -arrow- on gearbox.

Vehicles with 4 cylinder engine:

• ‒ → Unbolt left gearbox support from bonded rubber mounting -2-.

Vehicles with 6 cylinder engine:

• ‒ → Unbolt left and right gearbox supports complete with bonded rubber mountings from gearbox and subframe -1- and -2-.

All models:

• ‒ → Remove remaining engine/gearbox securing bolts (arrows -A- and -B-).
• ‒ Press gearbox off dowel sleeves and lower carefully with gearbox lifter V.A.G 1383 A just far enough for access to the slave cylinder.

Note:

When lowering gearbox ensure hydraulic pipe/hose to slave cylinder is not damaged.

• ‒ → Remove clutch slave cylinder (arrow) and secure with wire, do not disconnect pipes.

Note:

Do not depress clutch pedal after removing slave cylinder.

• ‒ Lower gearbox completely.

Note:

When lowering gearbox ensure there is sufficient clearance to drive shafts.