Filed Under (Audi) by admin on 24-03-2011
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Removing Cylinder head installed Remove noise insulation panel -arrows-. Remove front bumper => Repair Manual, Body Exterior, Repair Group 63 Move lock carrier to service position => Repair Manual, Body Exterior, Repair Group 50 Remove ribbed belt => Page 13-1. Remove toothed belt => Page 13-4. Left cylinder head Remove left-hand cylinder head cover => Page 15-22. Right cylinder head Remove right-hand cylinder head cover => Page 15-25 All: Unbolt Hall sensor housing (10 Nm). Remove bolt securing Hall sensor rotor (20 Nm) and carefully lever off rotor using a screwdriver. Insert camshaft clamp 3391 in securing plates of two camshafts. Loosen both camshaft bolts and remove approx. 5 turns. Take out camshaft clamp 3391. Pull off both camshaft sprockets with special tool T40001. Using a screwdriver, carefully pry oil feed lines for camshaft bearings out of camshaft bearings. Make sure that the retaining catches do not break off when prying out the oil lines. Secure camshaft adjuster using retainer for chain tensioner 3366. Note: Do not over tighten retainer for chain tensioner, otherwise camshaft adjuster can be damaged. Check TDC position of camshafts once again. Note: The two markings on the camshafts must be in line with the two arrows on the bearing caps. Clean drive chain and camshaft chain sprockets in vicinity of arrows on bearing caps and mark position of chain on sprockets with paint opposite two arrows. Note: The distance between the two arrows (and thus between the paint markings) is 16 rollers on the chain. The notch on the exhaust camshaft is offset slightly towards the inside in relation to chain roller -1-. Do not mark the chain with a center punch or by making a notch or similar.
Filed Under (Audi) by admin on 23-03-2011
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Removing Note: Do not disassemble instrument cluster. Instrument clusters contain no field serviceable components. Should malfunctions occur, replace complete instrument cluster. If instrument cluster is to be replaced, connect VAS 5051/5052 and initiate OBD program option “Instrument cluster, replacing” On Board Diagnostic (OBD), Function CAUTION! Switch off all electrical consumers. Switch ignition off and remove ignition key. Note: Steering wheel does not need to be removed in order to remove instrument cluster. Pull steering wheel with adjusting mechanism fully out and move it downward. Pull off gap cover – 1 – in direction of – arrow – . Place gap cover on top trim cover for steering column. Remove screws – arrows – . Pull out instrument cluster until contacts steering wheel. Reach behind instrument cluster to access electrical connections. On electrical connection, depress retainer – 1 – and release connector lock in direction of – arrow – . Disconnect electrical connection from instrument cluster. Remove instrument cluster towards drivers side between steering wheel and instrument panel. Installing Install in reverse order of removal. Tightening Torque Component – Fastener Instrument cluster to instrument panel – screw Nm 3.5
Filed Under (Audi) by admin on 23-03-2011
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Special tools, testers and auxiliary items required Removal lever 80-200 Removing Note: In order to prevent potential damage to wiper arms, the windshield wipers will not function, or will cease functioning should the front hood be opened. If Wiper Motor Control Module J400 is to be replaced, connect VAS 5051/5052 and initiate OBD program. option “J400 – replacing” Switch on ignition. Actuate touch-wipe function and allow wiper motor to move to end position. CAUTION! Switch off all electrical consumers. Switch ignition off and remove ignition key. Use screwdriver to pry off wiper arm caps. Loosen nuts – arrows – (do not remove). Loosen wiper arms from wiper shaft by tilting slightly, remove nuts and remove wiper arms. Unclip washer jets – arrow – . Push washer jet (with hoses connected) through mounting opening into plenum chamber. Pull off rubber seal – 1 – for plenum chamber cover. Remove plenum chamber cover – 2 – . Note: Use adhesive tape to prevent fender from becoming scratched.
Filed Under (Audi) by admin on 22-03-2011
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Note: All cable ties opened or cut during engine removal must be reinstalled at the same locations. Remove engine without transmission toward the front. Drained coolant must be stored in a clean container for disposal or reuse. Always replace seals and gaskets. Do not open coolant circulation system. Removing First determine whether a coded radio is installed. If so, determine the correct coding. Switch ignition off and disconnect battery Ground (GND) strap. Remove bolts (arrows) and remove engine covers -A- and -B-. Remove cover above air filter. Remove plenum cover. Remove sound-proofing material (arrows). Remove bracket for sound-proofing at unit support. Drain engine coolant => page 19-19 Remove front bumper: => Repair Manual, Body Exterior, Repair Group 63 Remove lock carrier: => Repair Manual, Body Exterior, Repair Group 50 Remove viscous fan counter-hold using 3212 spanner wrench. Note: The viscous fan has a left-handed thread. Mark direction of rotation of ribbed belt To loosen ribbed belt, turn clockwise using 17 mm box wrench until two holes are aligned (arrow). Counter-hold in position using 3204 drift. Note: Mark direction of rotation of ribbed belt. Reversing the direction in which it runs can ruin it. Remove ribbed belt. Cut coolant hoses -1- and -2- Remove coolant reservoir (arrows). Disconnect connector for coolant level display. Remove valve cover (cylinder bank 4-6).
Filed Under (Audi) by admin on 22-03-2011
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Special tools, testers and auxiliary items required Thrust Plate VW 401 Thrust Plate VW 402 Assembly Tool T10065 Tube 37mm dia. VW 416 B Punch VW 411 Thrust Pad VW 447 H Special tools, testers and auxiliary items required Assembly/removal tool T40018 Disassembling Clamp drive shaft horizontally into vise. Note: Use protective jaws. Make sure the drive axle is not damaged. Mark position of joint piece to drive axle. If installation positions are not marked and components are not reinstalled in previous positions, noises may occur later during driving operation. A water-proof felt pen is well-suited for marking. Remove clamps – arrows – . Slide back CV boot. Guide Assembly/Removal tool T40018 in behind joint piece. Guide pin – 1 – must make contact with exterior of joint piece. Bring Assembly/Removal tool T40018 into contact at joint piece by turning knurled bolt – 2 – . Note: Joint piece must be secured in Assembly/Removal tool T40018 without play. Only hand tighten bolts – 2 – . Screw Slide Hammer-complete Set VW 771 into Assembly/Removal tool T40018 . Pull off joint piece horizontally using Slide Hammer-complete Set VW 771 . Keep joint piece in Assembly/Removal tool T40018 . Mark installation position of parts – 1 – and – 2 – with lines. If the parts are not marked and the parts are not reinstalled in their previously installed positions, noises may occur later during driving operation. A water-proof felt pen is well-suited for marking. 1 – Drive shaft 2 – Triple roller star Remove grease with a lint free rag.
