Vehicles with auxiliary heater

WARNING: This page is about a different car, the 2006 Audi A4, 2005 Audi A4, 2004 Audi A4, and 2003 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Removing Bolts Securing Exhaust Pipe Of Auxiliary/Additional Heater To Sound Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows - securing exhaust pipe of auxiliary/additional heater to sound insulation.

Fig 2: Removing Sound Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove sound insulation - arrows -.

Fig 3: Unbolting Sound Insulation Holder

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt sound insulation holder.

Fig 4: Removing Air Duct In Front Of Charge Air Cooler

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove air duct in front of charge air cooler - arrows -.
Place drip tray VAG1306 under engine.

Fig 5: Pulling Retaining Clip For Engine Coolant Temperature (ECT) Sensor G2 Off Lower Coolant Hose And Drain Coolant From Radiator

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull retaining clip - 1 - for Engine Coolant Temperature (ECT) sensor G2 - 2 - off lower coolant hose and drain coolant from radiator.
Remove lower coolant hose from radiator.

Fig 6: Disconnecting Coolant Hose From Oil Cooler

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Disconnect coolant hose from oil cooler - arrow - and drain remaining coolant.

Fig 7: Removing Air Hose To Charge Air Cooler At Bottom Left Of Lock Carrier

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Remove air hose - arrow - to charge air cooler at bottom left of lock carrier.

Fig 8: Removing Lower Air Hose Between Turbocharger And Lock Carrier

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Remove lower air hose - arrow - between turbocharger and lock carrier.

Fig 9: Using 3093 To Clamp Off Inlet And Outlet Pipe Of Cooling Coil For Power Steering Hydraulic Fluid

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Use 3093 to clamp off inlet and outlet pipe of cooling coil for power steering hydraulic fluid.
Place suitable container under hoses.
Disconnect hoses from cooling coil.

Fig 10: Removing Air Ducts On Left/Right Of Radiator

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Remove air ducts on left and right of radiator - arrows -.

Fig 11: Disconnecting Connector From A/C Pressure Switch F129 & Ambient Temperature Sensor

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Disconnect connector - 1 - from A/C pressure switch F129.
Disconnect connector - 2 - from ambient temperature sensor.
Move both wires clear.

CAUTION: Air conditioner refrigerant circuit must not be opened.

Unbolt condenser - arrows - from radiator.

NOTE:

To prevent damage to condenser and refrigerant lines/hoses ensure that lines and hoses are not stretched, kinked or bent.

Carefully swivel condenser downward and set down.

Fig 12: Removing Impact Absorber Bolts On Left/Right

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Remove impact absorber bolts on left and right - arrows -.
Remove hood lock cable from lock carrier: →
- 55 HOOD, LIDS
- 55 - HOOD, LIDS for CABRIOLET

Fig 13: Removing Top Coolant Hose From Radiator & Disconnecting Connectors For Left/Right Airbag Sensor

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Remove top coolant hose from radiator - 1 -.
Disconnect connectors - 2 - for left and right airbag sensor.

Fig 14: Unbolting Lock Carrier On Left/Right

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Unbolt lock carrier on left and right - arrows -.

NOTE:

A second technician is required to remove the lock carrier.
Place lock carrier in a secure position.

Remove lock carrier.

Vehicles with automatic transmission

NOTE:

Observe the rules for cleanliness when working on an automatic transmission:
→
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V
- 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 5 SPD. AUTOMATIC TRANSMISSION 01V FRONT AND ALL WHEEL DRIVE - INTERNAL COMPONENTS, SERVICING
- 37 CONTROLS, HOUSING for AUTOMATIC TRANSMISSION 09L, FOUR-WHEEL DRIVE

Place drip tray underneath.

Fig 15: Disconnecting ATF Lines

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Disconnect ATF lines - arrows -.
Unbolt bracket for ATF lines on left of engine.

Vehicles up to 06.03

CAUTION: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.

Fig 16: Disconnecting Fuel Supply Line And Set Aside

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect fuel supply line - 1 - and set aside.

NOTE:

Disregard - 2 -.

Vehicles as of 07.03

CAUTION: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.

Fig 17: Counterholding Using An Open-End Wrench At Each Hex Head & Unscrew Union Nut

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unscrew fuel hose from connection on fuel rail pipe. To do so, counterhold using an open-end wrench at each hex head - 1 - and - 3 - and unscrew union nut - 2 -.

All

Seal off line so that no dirt will get into fuel system.

CAUTION: Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.

Fig 18: Disconnecting Fuel Supply Line

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect fuel supply line.
Seal off line so that no dirt can enter fuel system.
Unbolt Ground connection from plenum chamber.
Remove vacuum line to brake servo from plenum chamber.

Fig 19: Disconnect Wires/Unplug Connectors From

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect wires/unplug connectors from:

EVAP canister purge regulator valve
Mass air flow sensor
Wastegate bypass regulator valve N75

Disconnect hoses 4...7.
Disconnect hose to secondary air injection pump motor - 8 -.
Move wires clear.
Unbolt air cleaner housing - 9 -.

Remove air cleaner.

NOTE:

Vacuum pipe to secondary air combination valve is clipped to underside of air intake hose.

Fig 20: Removing Both Coolant Hoses From Coolant Expansion Tank

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove both coolant hoses from coolant expansion tank.
Unbolt coolant expansion tank.
Lift coolant expansion tank slightly at bolt side and pull it out of catch on plenum chamber side.

Fig 21: Unbolting Cover Of Electronics Box In Plenum Chamber

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt cover of electronics box in plenum chamber.

Fig 22: Removing Engine Control Module

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Carefully pry off retainer bar with screwdriver - arrow -.

Fig 23: Disengaging Electrical Connector Retainers And Disconnecting Electrical Connectors From Engine Control Module (ECM) J623

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Release catches - arrows - and disconnect control module connectors - 1 - and - 2 -.

Fig 24: Disconnecting Connectors From Connector Rail

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Disconnect connectors 1...4 from connector rail.
Unbolt wire connector - 5 -.

Fig 25: Releasing Catches, Lifting Off Control Module Support & Pulling Auxiliary Relay Carrier In Electronics Box Upward To Remove

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Release catch - 1 - and lift off control module support.
Release catch - 2 - and pull auxiliary relay carrier in electronics box upward to remove.
Disengage wiring harness from electronics box housing and plenum chamber, and place on engine.

Fig 26: Disconnecting 4-Pin Connectors Of Oxygen Sensors

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove connectors 1...4 from mount.
Disconnect connectors.
Open cable ties and place wires to electrical engine components to one side.
Pull out retainers for both coolant hoses to heat exchanger at rear of engine.

Disconnect coolant hoses between engine and heat exchanger.

Fig 27: Disconnecting Connector From Secondary Air Injection (AIR) Pump Motor V101 & Hose From Pipe To Secondary Air Combination Valve

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect connector - arrow - from secondary Air Injection (AIR) pump motor V101 and move wire clear.
Disconnect hose - arrow - from pipe to secondary air combination valve.

Fig 28: Removing Wires From Starter & Insulator From Positive Connection On Starter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove wires - 1 - and - 2 - from starter, remove insulator from positive connection on starter.
Remove clamp from starter holder - 4 -.
Unbolt mount from cylinder block - 3 - and starter.
Unbolt starter from transmission and remove.

Unbolt Ground (GND) wire from right engine support.

Fig 29: Guiding Tube For Positive Wire To Starter Is Attached Using Bolt Securing Engine To Transmission

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Guide tube for positive wire to starter is attached using bolt securing engine to transmission.

Vehicles with automatic transmission

Fig 30: Removing Torque Converter Bolts Through Opening Of Removed Starter

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove 3 torque converter bolts through opening of removed starter using Matra V175 15 mm A/F socket attachment (rotate crankshaft by 1/3 turn each time).

NOTE:

When loosening torque converter bolts, counterhold the crankshaft by applying a wrench to the central bolt on the vibration damper.

All models

Fig 31: Separating Exhaust System At Clamp

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate exhaust system at clamp.

Fig 32: Removing Bolts Securing Catalytic Converter To Front Exhaust Pipe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove bolts - arrows - securing catalytic converter to front exhaust pipe.
Unbolt transmission bracket for exhaust system - arrow -.

NOTE:

To avoid damage, do not bend decoupling element of front exhaust pipe by more than 10 °.

Fig 33: Disconnecting Connectors From Transmission

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect both connectors - arrows - from transmission.

Fig 34: Swiveling Tensioner In

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Swivel tensioner in direction of - arrow - to loosen ribbed belt.
Remove ribbed belt from generator pulley.

Fig 35: Disconnecting Compressor Clutch Connector From Air Conditioning Compressor & Oil Level Gauge Connector From Oil Pan

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect compressor clutch connector from air conditioning compressor.
Disconnect oil level gauge connector from oil pan.

CAUTION: Air conditioner refrigerant circuit must not be opened.

Fig 36: Unbolting Air Conditioning Compressor From Bracket

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unbolt air conditioning compressor from bracket.
Hang air conditioning compressor together with condenser and connected wires at right of vehicle.
Use hose clamp 3093 to clamp off hose between expansion tank and power steering pump.
Place drip tray underneath.

Fig 37: Disconnecting ATF Lines From Power Steering Pump

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Disconnect ATF lines - arrows - from power steering pump.

NOTE:

Differing mounting holes are provided for different engine versions.

Fig 38: Threaded Connections And Positioning Sleeves On Lower Engine Mounts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Mark positions of bolted connections - 1 - and locating sleeves - 2 - on lower right and left engine mounts.
Remove lower nuts - 1 - on left and right engine mounts.

NOTE:

Illustration shows vehicle with engine removed.

Fig 39: Placing Support Bar 10-222A Behind Gas-Filled Strut On Suspension Strut Domes

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Place support bar 10-222A behind gas-filled strut on suspension strut domes. Spindle at front.
Engage transmission support 3147 in bolt hole of transmission bell housing.
Attach transmission support 3147 to support bar 10-222A.
Use support bar 10-222A to lift engine/transmission assembly until engine mount bolts are positioned approx. 1 cm above engine supports.

Remove engine/transmission connecting bolts accessible from below.
Remove upper engine/transmission securing bolts. Leave one bolt hand-tight in place.

Fig 40: Attaching Lifting Tackle 2024A To Engine And Hook Onto Workshop Crane VAG1202A

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Attach lifting tackle 2024A to engine and hook onto workshop crane VAG1202A.

NOTE:

To balance the center of gravity of the assembly, position hole rails of hook attachments as shown in the illustration.

CAUTION: Hook attachments and locating pins on lifting tackle must be secured with locking pins - arrows - in illustration.

Remove last securing bolt.

NOTE:

Check that all hoses and other connections between engine and body have been removed.

Lift engine over studs of engine mounts.
Loosen support bar 10-222A slightly.

Vehicles with automatic transmission

Fig 41: Separating Transmission From Engine And At Same Time Remove Torque Converter From Drive Plate

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Separate transmission from engine and at same time remove torque converter from drive plate.

All models

Pull engine away from transmission and lift engine toward front of vehicle out of engine compartment.

Vehicles with automatic transmission

If necessary, secure torque converter in transmission with wire to prevent it from falling out.