Part 2
Engine (vehicles with automatic transmission), removing, Continued
CAUTION! Note rules of cleanliness for working on the fuel injection system.
CAUTION! Fuel system is under pressure! Before opening system, place clean rags around the connection. Then release pressure by carefully loosening connection.
- Remove fuel hose from connection on fuel rail line. To do so, counter hold using an open-end wrench at hex head -1 - and - 3 - and remove union nut - 2 - .
- Disconnect electrical harness connector - 2 - from Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 .
- Disconnect electrical harness connector - 3 - at Mass Air Flow (MAF) Sensor G70 .
- Disconnect hose - 1 - to Secondary Air Injection (AIR) pump.
- Disconnect air guide hose - 4 - at Mass Air Flow (MAF) sensor.
- Move wiring harness clear at air filter housing.
- Remove clip - arrow - and remove air filter housing with Mass Air Flow (MAF) sensor.
- Disconnect air hose - arrow - at right on engine.
- Remove bracket for electrical harness connectors - 1 to 4 - at right from bulkhead.
- Remove nut - 1 - and remove fuse strip on plus wire terminal clamp.
- Disconnect battery positive (+) cable - 2 - on battery positive terminal.
- Pull battery positive (+) cable through bulkhead toward front.
- Free up the wiring harness.
Note:
- Disregard item - 3 - .
- Pry off both covers - 3 - using a screwdriver.
- Loosen hex-nuts - 4 - by several turns.
- Loosen wiper arms - 2 - from respective wiper axle by tilting slightly.
- Remove nuts completely and remove wiper arms.
CAUTION! To prevent the cowl grille - 5 - from tearing when removing, coat transition between windshield and cowl grille with a soapy solution and pull grille up vertically out of fastening strip beginning at edge of window.
- Disconnect securing clips - 1 - and remove cowl grille - 5 - .
- Remove cover for E-Box in plenum chamber - arrows - .
- Using a screwdriver, carefully pry off mounting bracket - arrow - and remove Engine Control Module (ECM) from E-Box.
Note:
- Engine Control Module (ECM) remains connected at wiring harness.
- Release retaining hooks - arrow - toward outside and remove retaining bracket.
- Disconnect all electrical harness connectors on connector station - 2 - using spark plug connector pliers V.A.G 1922 .
- Remove electrical wire connection - 1 - .
- Disengage locking mechanisms - arrows - and remove secondary relay carrier in E-Box toward top.
- Disengage engine wiring harness at E-Box and bulkhead.
- Remove Ground (GND) connection - arrow - .
- Remove bracket for electrical harness connectors - 1 to 4 - at left from bulkhead.
- Free up wiring harness.
- Set electrical wiring harness on engine and secure Engine Control Module (ECM) against falling down.
- Disconnect electrical harness connector - 1 - at Secondary Air Injection (AIR) Pump Motor V101 .
- Remove Ground (GND) wire - 2 - on long member.
- Place old oil collecting and extracting device V.A.G 1782 under engine.
- Disconnect hydraulic pressure line for power-steering - arrow - at left next to oil pan.
Note:
- To prevent damage to condenser and also to the refrigerant lines/hoses, ensure that the lines and hoses are not stretched, kinked or bent.
- Remove bolts - 1 - and - 2 - .
- Remove right refrigerant line from A/C compressor.
Note:
- The left refrigerant line will be removed at a later point in time.
- Seal open connections on A/C compressor using clean plugs.
- Remove left bracket for refrigerant line - arrows - .
- Remove refrigerant line on bracket - arrow - .
- Remove bolt - arrow - and disconnect refrigerant line to A/C compressor.
- Have a second technician press brake pedal.
CAUTION! To loosen collar bolt for drive axle, the wheel bearing must not be under load (vehicle must not be standing on its wheels).
- Remove collar bolt - 2 - at left and right drive axles - 1 - .
- Remove bolts and nuts - arrows - uniformly at left and right.
- Remove stabilizer.
- Disconnect electrical harness connector at Level Control System Sensor.
- Unclip operating rod for Left Front Level Control System Sensor G78 at bottom on control arm.
- Remove outer suspension strut bolt from left and right of engine compartment.
- Rotate Lifting Eyebolt 3368 at left and right in suspension strut mount hole from below.
CAUTION! Only install Lifting Eyebolt 3368 until it is flush with upper edge of suspension strut mount so that hood is not damaged when closed.
- Tie up wheel bearing housing at left and right with Tensioning Strap T10038 as shown in illustration.
CAUTION! To prevent upper control arm joints from being damaged, wheel bearing housing must be supported before loosening lower suspension strut bolts.
- Remove bolt and remove suspension strut from control arm - arrow - .
- Remove expanding clips - arrows - .
- Remove nut - 1 - and remove cover behind wheel housing.
- Remove guide control arm - 1 - and control arm - 2 - on subframe.
- Pivot guide control arm - 1 - and control arm - 2 - outward.
CAUTION! Repeat work procedure on opposite side of vehicle. Guide control arm and control arm must not hang free. Tie up both control arms on wheel bearing housing - arrows - as shown in illustration.
- Repeat work procedure on opposite side of vehicle.
- Remove heat shield - 1 - for left drive axle.
- Remove drive axle from transmission flanged shaft.
- Swing left wheel bearing housing outward and remove drive axle.
- Repeat work procedure on opposite side of vehicle.
Note:
- Flex joint in front exhaust pipe must not be bent more than 10 � , otherwise it may be damaged.
- Disconnect exhaust system at double clamps - arrows- .
- Remove heat shield - A - for drive shaft - arrows - .
- Remove bolts at transmission/driveshaft flange.
- Push driveshaft together with rear final drive. The constant velocity (CV) joints can move axially.
- Tie up driveshaft to body.
Note:
- Mark the installation position of bracket for selector lever cable using a felt-tip marker.
- Press ball socket - 1 - of selector lever cable from selector shaft lever.
- Remove bracket on transmission - arrows - .
- Move selector lever cable clear.
Note:
- To improve clarity, the transmission supports are shown removed in the illustration.
Prepare scissor lift platform:
- Equip scissor lift platform VAS 6131 A with support set for Audi VAS 6131/10 as follows:
- Install attachments on scissor lift table by hand first.
- Place scissor lift platform VAS 6131 A in horizontal position.
- Note bubble level (sight glass) on support platform.
- Drive scissor lift platform VAS 6131 A under engine/transmission subassembly.
- Position support elements from VAS 6131/10 at front on engine as shown in illustration.
- Position support elements from VAS 6131/10 at left and right on subframe as shown in illustration.
- Position support elements from VAS 6131/10 at rear on transmission as shown in illustration.
- Turn all spindles of support elements upward far enough until all support pins make contact at support points.
- Tighten base plates for support elements to 20 Nm on scissor lift platform VAS 6131 A .
- Turn both spindles at subframe 2 rotations upward.
- Turn both spindles at transmission 4 rotations upward.
- Remove bolts - 1 - .
- Mark installation position of subframe and of both engine mount plates to long members using a felt-tip marker.
- Remove bolts - 2 - , - 3 - and - 4 - in diagonal sequence and in stages.
Note:
- Verify that all hoses and lines between engine, transmission, subframe and body have been disconnected.
- While lowering, carefully guide engine/transmission subassembly with subframe out of engine compartment in order to prevent damage.
- Slowly lower engine/transmission subassembly downward.
- Push scissor lift platform VAS 6131 A with engine/transmission subassembly under vehicle.