Part 2
Engine, removing (vehicles with manual transmission) Cont'd
Note: The Engine Control Module (ECM) remains connected at the wiring harness.
- Release retaining hooks - arrows - 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 bolt from electrical wiring connection - 1 -.
- Disengage locking mechanisms - arrows - and remove secondary relay carrier in electronics box toward top.
- Disengage engine wiring harness at electronics box and bulkhead.
- Disconnect Ground (GND) connection - arrow -.
- Remove bracket for electrical harness connectors - 1 to 4 - at left from bulkhead.
- Expose electrical wiring harness.
- Set electrical wiring harness on engine and secure Engine Control Module (ECM) to prevent it from falling.
- Disconnect electrical harness connector - 1 - at Secondary Air Injection (AIR) Pump Motor -V101-.
- Unscrew Ground (GND) wire - 2 - on longmember.
- Place 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: Do not bend or stretch lines or hoses as condenser and/or refrigerant lines/hoses may be damaged.
- 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 -.
- Unbolt refrigerant line on bracket - arrow -.
- Unscrew bolt - arrow - and disconnect refrigerant line to A/C compressor.
- Have a second technician press brake pedal.
CAUTION: To loosen the collar bolt for the drive axle, the wheel bearing must not be under load (vehicle must not be standing on its wheels).
- Unscrew 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 Left Front Level Control System Sensor -G78-.
- Unclip operating rod for Left Front Level Control System Sensor -G78- at bottom on control arm.
- Remove bolt and remove suspension strut from control arm - arrow -.
- Remove expanding clips - arrows -.
- Remove nut - 1 - and remove cover behind wheelhousing.
- Remove guide control arm - 1 - and control arm - 2 - from subframe.
- Swing guide control arm - 1 - and control arm - 2 - outward.
CAUTION: 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 bolts and 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 driveshaft - arrows -.
- Remove bolts at flange of transmission/drive shaft.
- Push driveshaft together toward rear final drive. Constant velocity joints can be adjusted axially.
- Tie up driveshaft to body.
Preparing scissor lift platform
- Equip scissor lift platform VAS 6131 with support set for Audi VAS 6131/10 as follows:
- Screw support elements first tightly by hand onto scissor lift platform.
- Place scissor lift platform VAS 6131 in horizontal position.
Note bubble level (sight glass) on support platform.
- Drive scissor lift platform VAS 6131 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 left and right on tunnel crossmember 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.
- Mark installation position of subframe and of both engine bearing consoles to longmembers using a felt-tip marker.
- Remove bolts - 1 to 4 - in diagonal sequence and in stages.
Note:
^ Verify that all hoses and lines between the engine/transmission subassembly and body have been disconnected.
^ While lowering, carefully guide the engine/transmission subassembly with subframe out of the engine compartment in order to prevent damage.
- Lower engine/transmission subassembly using scissor lift platform VAS 6131 only approximately dimension - a -.
^ Dimension - a - = 100 mm.
- Disconnect connecting rod - 2 - of shift rod.
- Remove socket head bolt of pivot rod - 1 -.
- Remove nut - arrow - and remove lever from shift lever shaft.
- Remove clutch slave cylinder - arrow -; do not disconnect hydraulic line.
- Tie up clutch slave cylinder together with shift rods.
- Lower engine/transmission subassembly downward.
- Push scissor lift platform VAS 6131 with engine/transmission subassembly under vehicle.