Service: Audi A6 1998

Service
Workshop Manual
Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI),
mechanics
Engine ID AFN AVG
Edition 02.2005
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
26 - Exhaust system
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Audi AG, Ingolstadt A0056005820

Audi A6 1998 ➤
4-cylinder diesel direct injection engine (TDI), mechanics - Edition 02.2005
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.1 Poly V-belt drive for power steering pump, alternator, coolant pump and viscous fan -
exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2 Poly V-belt drive for air conditioner - exploded view of components . . . . . . . . . . . . . . . . . . 26
1.3 Routing of poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.7 Toothed belt drive - exploded viewpermitted
of components
unless authorised. by . .AUDI
. . .AG.. .AUDI
. . .AG. .does
. . not
. . guarantee
. . . . . .or.accept
. . . .any. .liability
34
1.8 Removing and installing toothed beltwith .respect. . . .to. the
. . correctness
. . . . . . .of.information
. . . . . .in. this
. . document.
. . . . . . Copyright
. . . . . by
. .AUDI
. . . AG.
. 37
1.9 Checking semi-automatic tensioning roller for toothed belt . . . . . . . . . . . . . . . . . . . . . . . . 43
1.10 Positioning crankshaft at TDC with engine removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2 Removing and installing sealing flanges and dual-mass flywheel/drive plate . . . . . . . . . . 45
2.1 Sealing flanges and dual-mass flywheel/drive plate - exploded view of components . . . . 45
2.2 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.3 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.4 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.1 Crankshaft - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.2 Removing and installing sender wheel for engine speed sender G28 . . . . . . . . . . . . . . . . 54
3.3 Extracting and driving in needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.4 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.1 Pistons and conrods - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.2 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.4 Measuring radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.1 Cylinder head - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
1.3 Removing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.4 Installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
1.5 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.1 Valve gear - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.2 Checking axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
2.3 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.4 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Contents i
Audi A6 1998 ➤
2.5 Renewing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

2.6 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.7 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.8 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.9 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.1 Sump, oil pump - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.2 Oil filter bracket, oil filter - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.6 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1.7 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.1 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.2 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.3 Coolant pump and thermostat - exploded view of components . . . . . . . . . . . . . . . . . . . . . . 118
1.4 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.5 Removing, installing and checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.6 Removing and installing coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.7 Removing and installing viscous fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.8 Removing and installing bearing for viscous fan in bracket . . . . . . . . . . . . . . . . . . . . . . . . 124
1.9 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
1.10 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1 Checking charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.2 Requirements for turbocharging check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.3 Effects of leaks in the intake and exhaust systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.4 Checking turbocharger and charge pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.5 Hose connection diagram for charge pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.6 Checking solenoid valve for charge pressure control N75 . . . . . . . . . . . . . . . . . . . . . . . . 142
1.7 Checking intake manifold pressure sender G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2 Servicing charge air system with turbocharger Protected by. copyright.
. . . . . .Copying
. . . . for
. .private
. . . .or.commercial
. . . . . . purposes,
. . . . . .in .part
. . or. in149
whole, is not
2.1 Rules for cleanliness . . . . . . . . . . . . . . . .with
. . respect
. . . . to. .the. .correctness
. . . . . .of. information
. . . . . . in. this
. . .document.
. . . . . Copyright
. . . . . .by 149 AUDI AG.
2.2 Turbocharger - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2.3 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.4 Charge air cooler - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.5 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.1 Exhaust system - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.2 Separating centre and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.3 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.4 Removing and installing catalytic converter with front exhaust pipe . . . . . . . . . . . . . . . . . . 163
1.5 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.1 Exhaust gas recirculation system - exploded view of components . . . . . . . . . . . . . . . . . . 167
2.2 Hose connection diagram for exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
ii Contents
Audi A6 1998 ➤
2.3 Checking mechanical exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

2.4 Checking exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.5 Checking exhaust gas recirculation valve N18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Contents iii
Audi A6 1998 ➤
iv Contents
Audi A6 1998 ➤
00 – Technical data
1 Technical data
1.1 Engine number

The engine number (“Engine code” and “Serial number”) can be
found on the left of the cylinder block.
Additionally there is a sticker on the toothed belt cover showing
the “engine code” and “serial number”.
The engine code is also indicated on the vehicle data stickers.
1.2 Engine data

Code letters AFN AVG
Capacity ltr. 1.9 1.9
Power output kW at rpm 81/4150 81/4000
Torque Nm at rpm 235/1900 235/1900
Bore ∅ in mm 79.5 79.5
Stroke mm 95.5 95.5
Compression ratio 19.5 19.5
CN At least 45 45
Exhaust gas recirculation yes yes
Turbocharging/supercharging yes yes
Catalytic converter yes yes
Charge air cooling yes yes
Firing order 1-3-4-2 1-3-4-2
1. Technical data 1
Audi A6 1998 ➤
10 – Removing and installing engine

1 Removing and installing engine
1.1 Removing engine
Special tools and workshop

equipment required Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Support bracket -10-222 A- with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Lifting tackle -2024 A-

♦ Gearbox support -3147-
♦ 2-hole pin wrench -3212-
♦ Workshop hoist -V.A.G
1202 A- or -VAS 6100-
♦ Drip tray -V.A.G 1306- or
drip tray for workshop hoist
-VAS 6208-
2 Rep. Gr.10 - Removing and installing engine

Audi A6 1998 ➤
♦ Used oil collection and ex‐

traction unit -V.A.G 1782-
♦ Hose clip pliers -V.A.G
1921-
♦ Removing tool -VAS
1978/8- from the wiring har‐
ness repair set -VAS
1978- .
♦ 15 mm socket insert -Matra
V/175- for vehicles with au‐
tomatic gearbox 01N
Procedure
Note
♦ The engine is removed from the front without the gearbox.

♦ All cable ties which are released or cut open when removing
must be fitted in the same position when installing.
♦ Collect drained coolant in a clean container for re-use or dis‐
posal.
Caution
Observe notes on procedure for disconnecting the battery ⇒

Electrical system; Rep. Gr. 27 .
1. Removing and installing engine 3

Audi A6 1998 ➤
– Detach rubber seal from plenum chamber cover in direction of

-arrow-.
– Detach plenum chamber cover -1- towards the front.
– With ignition switched off, disconnect battery earth cable

-arrow-.
WARNING
Hot steam/hot coolant may escape when opening expansion

tank; cover filler cap with cloth and open carefully.
– Open filler cap on coolant expansion tank.
– Unscrew bolts -arrows-.

– Remove air ducts -1- and -2-.
– Remove cover -arrow- at power steering fluid reservoir.

Audi A6 1998 ➤
– Remove front bumper ⇒ General body repairs, exterior; Rep.

Gr. 63 .
– Vehicles with auxiliary heater: remove bolts -arrows- securing
exhaust pipe for auxiliary/additional heater to noise insulation.
– Release quick-release fasteners -1 … 3- and take off front and

rear noise insulation.
– Unbolt bracket for noise insulation -arrow-.
– Remove air duct in front of charge air cooler -arrows-.

Audi A6 1998 ➤
– Unclip ambient temperature sensor -G17- from bracket.

– Unscrew bolts -arrows- and move cooling pipe for power steer‐
ing clear; hydraulic fluid system remains closed.
– Place drip tray -V.A.G 1306- or -VAS 6208- under engine.

– Turn drain plug -arrow- on radiator anticlockwise and drain
coolant (attach hose to connection if necessary).
– Pull off retaining clip for coolant hose (bottom) -arrow- and re‐
move coolant hose from radiator.
– Unscrew bolts -arrows- and take out hose connection with O-

ring and thermostat to drain remaining coolant.

Audi A6 1998 ➤
– Detach air intake hose going to charge air cooler at lock carrier
(bottom left) -arrow-.
– Detach turbocharger air intake hose at lock carrier (bottom
right).
Vehicles with automatic gearbox:
Note
Note the rules for cleanliness when working on the automatic

gearbox ⇒ Automatic gearbox 01N; Rep. Gr. 37 .
– Place used oil collection and extraction unit -V.A.G 1782- un‐
der engine.
– Disconnect ATF pipes at connection point.
– Unbolt bracket for ATF pipe at engine.
All models:
– Unplug electrical connector (green) -arrow- for magnetic
clutch of air conditioner compressor at lock carrier (bottom
right) and move electrical wire clear.
– Unplug electrical connector -arrow- for headlights on both

sides.
– Detach bonnet cable at lock carrier ⇒ General body repairs,
exterior; Rep. Gr. 55 .
– Unplug electrical connectors -arrows- at front of ABS unit.

– Unplug electrical connector for anti-theft alarm at lock carrier
(top left).
– Move wiring clear.

Audi A6 1998 ➤
– Remove top coolant hose at radiator.

– Remove the left and right-hand air ducts from the radiator.
– Unplug electrical connector -1- at low pressure switch for air
conditioner -F73- .
– Release both retaining pins -2- and pull out to side -arrows-.
WARNING
The air conditioner refrigerant circuit must not be opened.
– Detach both brackets -3- and pull condenser upwards out of

bracket
Note
To prevent damage to the condenser and refrigerant pipes/hoses,

ensure that the pipes and hoses are not stretched, kinked or bent.
– Move condenser to side with pipes/hoses connected and tie

onto right front wheel with wire.
Note
Protect wing panels from damage.
– Remove bolts -arrows- at lock carrier (left and right).

– Remove engine compartment seal from lock carrier and wing
panel flanges.
– Unscrew bolts from impact absorbers -arrows- (left and right).
Note
A second mechanic is required for removing the lock carrier.
– Remove lock carrier and place down in a secure position.

Audi A6 1998 ➤
– Unclip cover caps.

– Unscrew nuts -arrows- and detach engine cover panel.
– Detach coolant hoses -1- and -3-.

– Unbolt coolant expansion tank -2- -arrows-.
– Unplug electrical connector for coolant shortage indicator
switch -F66- at expansion tank (below).
Fuel filter - version I:

– Detach fuel supply pipe -1- and fuel return pipe -2- from filter
cover and move clear to one side.
Fuel filter - version II:

– Disconnect fuel return hose -2- and fuel supply hose -1- from
fuel filter.

Audi A6 1998 ➤
All models:
– Remove air intake hose from charge air cooler -arrow-.
– Unplug electrical connectors -3- and -4-.

– Detach vacuum hose -6-.
– Detach vacuum hose -1- going to mechanical exhaust gas re‐
circulation valve.
– Loosen hose clip -2- to remove air intake hose at intake con‐
necting pipe.
– Unscrew bolt -5- and remove air pipe.
– Disconnect breather hose -3- from air cleaner housing.

– Unplug electrical connector -1- at air mass meter -G70- .
– Move wiring harness
permitted going tobyair
unless authorised cleaner
AUDI AG. AUDI clear
AG does-arrow-.
not guarantee or accept any liability
– Loosen hose clip -4- to remove air intake hose.
– Remove bolt -2-.
– Detach air cleaner housing.

Audi A6 1998 ➤

– Detach electrical connector -3- and cut open cable tie
-arrow-.
– Place wiring harness on engine.
– Unscrew bolts -5- and detach cover -4-.
– Move charge pressure control solenoid valve -N75- -item 1-
clear to one side with hoses connected.
– Detach coolant hoses -1- and -3- going to heat exchanger at

engine.
– Detach vacuum hose -2- going to brake servo.
– Unscrew bolts -arrows- and take off cover for electronics box
in plenum chamber.
– Pry off retainer bar with a screwdriver -arrow-.

Audi A6 1998 ➤
– Release retainer catches -arrows- and unplug connectors -1-

and -2- from engine control unit.
Note
Illustration shows vehicle manufactured from 07.1999.
– Release retainer -arrow- and pull auxiliary relay carrier in elec‐

tronics box upwards to remove.
– Pull off fuse.
– Release fuse holder at additional relay carrier and pull off from
above.
– Release electrical contact in chamber 2 with removing tool -
VAS 1978/8- and remove.
– Unplug electrical connectors at rear of connector console.
– Unscrew earth connection -1- from bulkhead.

– Disengage engine wiring harness at electronics box and bulk‐
head and move clear -arrows-.

Audi A6 1998 ➤
– Unplug electrical connector at speedometer sender -G22- at

left of gearbox -bottom arrow-.
– On vehicles with manual gearbox unplug electrical connector
at reversing light switch -F4- on gearbox -top arrow-.
Note
Before removing, mark direction of rotation of poly V-belt with

chalk or felt-tipped pen. If the belt runs in the opposite direction
when it is refitted, this can cause breakage.
– Turn the tensioner in the direction of the -arrow- to slacken the

poly V-belt.
– Remove poly V-belt from alternator pulley.
– Slacken nut -arrow- and remove fuel filter from bracket (fuel
hoses remain connected).
– Counterhold viscous fan pulley using 2-hole pin wrench -3212-

and unbolt viscous fan from bearing with an 8 mm hexagon
withkey.
respect to the correctness of information in this document. Copyright by AUDI AG.

Audi A6 1998 ➤
– Counterhold pulley with drift to unbolt power steering pump

pulley.
– Unbolt power steering pump -arrows- and tie up to one side;
the hoses/pipes remain connected.
– Unbolt cable clamp for positive wire to starter on engine at right

underneath exhaust manifold.
– Unscrew nuts securing turbocharger to catalytic converter
-arrows-.
– Loosen nuts on clamp -arrows-.

– Push the clamp back in order to separate the exhaust system.
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Do not bend the flexible joint (de-coupling element) in the exhaust

system more than 10°, otherwise it could be damaged.
– Disconnect catalytic converter with front exhaust pipe from

turbocharger.
Note

– Loosen securing bolts of tensioning roller for air conditioner

compressor poly V-belt -arrows-.
– Remove poly V-belt.
WARNING
– Unbolt air conditioner compressor from bracket.

– Tie up air conditioner compressor to vehicle, with lines attach‐
ed.

Audi A6 1998 ➤
– Remove bolt -1- from noise insulation cover above drive shaft
(right-side).
– Disengage hook -2- and detach noise insulation.
– Unscrew earth wire at engine support (right-side) -1-.

– Remove bracket -2- for turbocharger -arrows-.
– Detach electrical wires -1- and -2- at starter.

– Unscrew clamp -3-.
– Unbolt starter from gearbox and remove.

– Unscrew 3 nuts -arrow- for torque converter through opening
of removed starter using 15 mm socket insert -Matra V/175-
(turn crankshaft 1/3 turn each time).
Note
Counterhold at central bolt of vibration damper when unscrewing

nuts for torque converter.

Audi A6 1998 ➤
All models:
– Mark positions of bolt connections -1- and locating sleeves
-2- on bottom of engine mounts (left and right).
Note
Different mounting holes are provided for the different engine ver‐
sions.
– Loosen nut -1- at bottom of engine mountings (left and right)

several turns.
– Unscrew engine/gearbox securing bolts (accessible from be‐

low) -arrows-.
Note
♦ If it is not possible to remove bolts:

♦ Lift engine and gearbox by applying workshop hoist -
V.A.G 1202 A- or -VAS 6100- at bracket for torque reaction
support.
♦ Make sure no wires/pipes are damaged at the top on the bulk‐
head.
WARNING
To avoid injury, ensure adequate support.

– Unbolt bracket for ATF pipes (left-side) at engine.
All models:
– Lower the engine back down.

Audi A6 1998 ➤
– Unscrew the top nuts -arrow- from both engine mountings.

– Unscrew top engine/gearbox securing bolts. Leave one bolt in
place (finger-tight).
– Pull off engine compartment seals in area of suspension tur‐

rets.
– Set up support bracket -10-222 A- behind gas-filled strut on
suspension turrets. The spindle must be at the front.
– Insert gearbox support -3147- into bolt hole in gearbox bell
housing.
– Connect gearbox support -3147- to support bracket -10-222
A- .
Note
Illustration shows engine removed.


Audi A6 1998 ➤
– Hook lifting tackle -2024 A- onto engine and workshop hoist -

V.A.G 1202 A- or -VAS 6100- .
Note
To adjust to the centre of gravity of the assembly, the perforated

rails of the support hooks must be positioned as shown.
WARNING
The hook attachments and locating pins on the lifting tackle

must be secured with locking pins.
– Unscrew remaining securing bolt for engine/gearbox assem‐

bly. with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
Check that all hoses and other connections between engine and
body have been detached.
– Lift engine until studs are clear of engine mountings.

– Tension spindles of support bracket -10-222 A- again.
Note
Make sure no wires/pipes are damaged at the top on the bulk‐

head.
– Detach engine from gearbox and lift engine forwards out of

engine compartment.
– Secure torque converter in gearbox to prevent it falling out.
1.2 Securing engine to assembly stand

Special tools and workshop equipment required
♦ Support clamp -VW 313-

Audi A6 1998 ➤
♦ Engine and gearbox support -VW 540-
Procedure
– Secure engine with engine and gearbox support -VW 540- to
engine stand prior to performing assembly work.
1.3 Installing engine

Installation is carried out in the reverse order; note the following:
Note
♦ Renew self-locking nuts and bolts when performing assembly

work.
♦ Renew bolts which are tightened to a specified angle as well
as oil seals and gaskets.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly. Do not use lubricant.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.
♦ Fit all cable ties in the original position when installing.

Audi A6 1998 ➤
– Check whether both dowel sleeves for centring the engine/

gearbox assembly are fitted in the cylinder block; install if nec‐
essary.
– Ensure that the intermediate plate is engaged on the sealing
flange and pushed onto the dowel sleeves -arrows-.
Vehicles with manual gearbox:
– Check clutch release bearing for wear; renew if necessary.
– Lubricate splines of gearbox input shaft lightly with grease -G
000 100- . The guide sleeve for the release bearing should not
be lubricated.
– Check that the clutch plate is properly centralised (only nec‐
essary if you have carried out other work on the clutch).
– A needle bearing must be fitted in the crankshaft on vehicles
with manual gearbox; insert needle bearing if not yet fitted
⇒ page 55 .
– In vehicles with automatic gearbox, the needle bearing must
NOT be fitted in the crankshaft; remove needle bearing if fitted
⇒ page 55 .
– To secure the torque converter to drive plate, use only the
correct nuts (same as original equipment) ⇒ Parts catalogue .
– Tighten nuts for torque converter using 15 mm socket insert -
Matra V/175- .

Audi A6 1998 ➤
Checking installation depth of torque converter

If the torque converter has been inserted properly in the gearbox,
gap -A- between the contact surfaces at the studs on the torque
converter and the joint surface of the gearbox flange will be ap‐
prox. 23 mm.
If the torque converter has not been completely inserted, this dis‐
tance will be approx. 13 mm.
Caution
If the torque converter is not installed correctly, the drive lugs

of the torque converter and the ATF pump will be seriously
damaged when the gearbox is joined to the engine.
All models:
– Attach engine to gearbox and screw in one bolt finger-tight.
– Before securing engine mountings, align engine so that
mountings are free of stress by shaking back and forth.
– Install air conditioner compressor ⇒ Air conditioning system;
Rep. Gr. 87 .
– Install power steering pump ⇒ Running gear, front-wheel drive
and four-wheel drive; Rep. Gr. 48 .
– Align exhaust system free of stress ⇒ page 165 .
– Install poly V-belt ⇒ page 29 .
– Install lock carrier ⇒ General body repairs, exterior; Rep. Gr.
50 .
– Install front bumper ⇒ General body repairs, exterior; Rep.
Gr. 63 .
– Secure the ATF pipes ⇒ Automatic gearbox 01N; Rep. Gr.
37 .
All models:
– Connect hoses and pipes for exhaust gas recirculation system
⇒ page 168 .
– Connect hoses and pipes for charge pressure control
⇒ page 140 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Connect battery and observe notes on procedures required
after connecting battery ⇒ Electrical system; Rep. Gr. 27 .
Caution
Do not use a battery charger to boost starting. There is danger

of damaging the vehicle's control units.
– Check oil level ⇒ page 109 .

– Fill cooling system ⇒ page 115 .

Audi A6 1998 ➤
Note
♦ Drained-off coolant may only be used again if the original cyl‐

inder head and cylinder block are re-installed.
♦ Contaminated or dirty coolant must not be used again.
– Top up power steering fluid and bleed steering system: ⇒

Running gear, front-wheel drive and four-wheel drive; Rep.
Gr. 48 .
– Check headlight adjustment ⇒ Maintenance ; Booklet 402 .
– Check ATF level ⇒ Automatic gearbox 01N; Rep. Gr. 37
Tightening torques
Note
♦ Tightening torques only apply to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricant such as engine oil or gearbox oil may be
used, but do not use lubricant containing graphite.
♦ Do not use degreased parts.
♦ Tolerance for tightening torques ± 15 %.
Engine/gearbox connecting bolts (manual gearbox)

Item Bolt Nm
1, 3, 4 M12x67 65
2, 6 M12x90 65
5, 11 M12x110 65
7, 8, 9, 10 M10x45 45
A Dowel sleeves for centralising

Audi A6 1998 ➤
Engine/gearbox connecting bolts (automatic gearbox)

Item Bolt Nm
1, 8, 9, 10 M10x45 45
2, 3, 4, 11 M12x67 65
5 M12x110 65
6 M12x90 65
7 M10x60 45
A Dowel sleeves for centralising
Component Nm
Bolts/nuts M6 10
M8 20
M10 45
M12 65
Except for the following:
Engine mounting to subframe 23
Engine support to engine mounting 23
Catalytic converter to turbocharger 25 1)
Pulley to power steering pump 25
Bracket for torque reaction support to engine 23
Longitudinal member to bracket for torque re‐ 23
action support
engine support 23
Stop for torque reaction support to bracket for 23
torque reaction support
Drive plate to torque converter 85
Bracket for turbocharg‐ turbocharger 20
er to cylinder block 40
Viscous fan to bearing 45
Hose clips for air hoses 3.5
1) Renew nuts.

Audi A6 1998 ➤
13 – Crankshaft group
1 Dismantling and assembling engine
1.1 Poly V-belt drive for power steering pump, alternator, coolant pump and
viscous fan - exploded view of components
1 - 9 Nm
❑ Self-locking
❑ Renew
2 - Fan wheel for viscous fan
❑ Removing and installing
⇒ page 122
3 - 25 Nm
4 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tipped pen.
If the belt runs in the op‐
posite direction when it
is refitted, this can
cause breakage.
⇒ page 27
5 - Bolt
❑ If bolt strength rating is
8.8, tighten to 25 Nm
10.9, tighten to 35 Nm ⇒
Parts catalogue
❑ Renew
6 - Vibration damper
❑ With pulley for poly V-
belt
❑ Can only be installed in
one position
⇒ page 29
7 - Poly V-belt tensioner
❑ Can only be installed in one position
8 - Pulley for viscous fan
❑ Removing and installing ⇒ page 122
9 - RetainingProtected
ring for viscousCopying
by copyright. fan bearing
for private or commercial purposes, in part or in whole, is not
10 - O-ring
❑ Renew
11 - 25 Nm
❑ Tightening sequence ⇒ page 25
24 Rep. Gr.13 - Crankshaft group

Audi A6 1998 ➤
12 - Bracket for engine cover panel

13 - 25 Nm
❑ Tightening sequence ⇒ page 25
14 - Alternator
❑ Removing ⇒ Electrical system; Rep. Gr. 27
❑ To facilitate the positioning of alternator on bracket, knock back bush for retaining bolt slightly
15 - 45 Nm
16 - 25 Nm
17 - 45 Nm
18 - 25 Nm
19 - Mounting bracket for alternator, power steering pump and viscous fan
❑ With coolant pump and thermostat
20 - Power steering pump
❑ Removing and installing ⇒ Running gear, front-wheel drive and four-wheel drive; Rep. Gr. 48
21 - 25 Nm
22 - Bearing for viscous fan
23 - Ribbed bolt, 28 Nm
❑ Renew
24 - Pulley for power steering pump
❑ Counterhold with drift to unbolt
25 - 25 Nm
26 - Pulley for coolant pump
27 - Viscous coupling
Tightening sequence for bracket for ancillaries

– Fit bolts and tighten hand-tight initially.
– Tighten the bolts to 25 Nm in the sequence -1 … 5-.
1. Dismantling and assembling engine 25

Audi A6 1998 ➤
1.2 Poly V-belt drive for air conditioner - exploded view of components
1 - 25 Nm
❑ Bolt strength rating
10.9; use only genuine
bolts (same as original
equipment) ⇒ Parts
catalogue
2 - Refrigerant lines
❑ Do not unscrew/detach
3 - Dowel sleeve
❑ Check for correct seat‐
ing in bracket
4 - Bolt
8.8, tighten to 25 Nm
10.9, tighten to 30 Nm ⇒
Parts catalogue
5 - Bracket for air conditioner
compressor
6 - Tensioning roller for poly V-
belt
⇒ “1.4 Removing and in‐
stalling poly V-belt”,
page 27
7 - Washer
8 - 20 Nm
9 - Poly V-belt
❑ Check for wear
posite direction when it is refitted, this can cause breakage.
❑ Do not kink
❑ Routing of poly V-belt ⇒ page 27
10 - Air conditioner compressor
WARNING
The air conditioner re‐
frigerant circuit must not
be opened.
❑ After removing compressor from mountings, secure it to longitudinal member with wire or similar. Do not
leave it suspended from refrigerant pipes.
❑ Do not unscrew or disconnect refrigerant hoses or pipes.
❑ Removing and installing ⇒ Air conditioning system; Rep. Gr. 87
11 - Washer

Audi A6 1998 ➤
1.3 Routing of poly V-belt
1 - Air conditioner compressor

2 - Poly V-belt tensioner
3 - Pulley for viscous fan
4 - Alternator
5 - Poly V-belt for alternator,
power steering pump, coolant
pump and viscous fan
⇒ page 27
6 - Power steering pump
7 - Coolant pump
8 - Vibration damper
9 - Poly V-belt tensionerpermitted
for airunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
conditioner compressor with respect to the correctness of information in this document. Copyright by AUDI AG.
10 - Poly V-belt for air condi‐
tioner compressor
⇒ page 27
1.4 Removing and installing poly V-belt

Removing

Audi A6 1998 ➤
– Release quick-fasteners -1- and -2- and take off front noise
insulation. Leave rear noise insulation in position.
Note




Audi A6 1998 ➤
Note


poly V-belt.
– Release tensioner.
Installing
• Routing of poly-V belt ⇒ page 27 .
– Fit poly V-belt onto pulleys for crankshaft, coolant pump, vis‐
cous fan, power steering pump and tensioner (note direction
of rotation).
– Turn the tensioner in the direction of the -arrow- in order to fit
the poly V-belt.
– Then fit poly V-belt on alternator pulley and release tensioner.
– Fit poly V-belt for air conditioner compressor.

– Apply torque wrench to hexagon flats on tensioning roller in
“seven o'clock” position as shown and tension with a torque of
30 Nm in direction of -arrow-.
– At the same time tighten bolts -A-.
– Check both poly V-belts for proper seating.
– Start engine and check that belt runs properly.
Tightening torque
Component Nm
Tensioning roller to bracket 25
1.5 Removing and installing vibration damp‐

er
Removing
• Front bumper is removed ⇒ General body repairs, exterior;
Rep. Gr. 63 .
• Lock carrier is moved into its service position ⇒ General body
repairs, exterior; Rep. Gr. 50 .
• Poly V-belt must be removed ⇒ page 27 .
– Unbolt vibration damper; counterhold on centre bolt with ring
spanner.
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installation is carried out in the reverse order;
withnote
respectthe following:
to the correctness of information in this document. Copyright by AUDI AG.
– Use new bolts for securing.

Audi A6 1998 ➤
– When installing the vibration damper, use only genuine bolts

(same as original equipment): ⇒ Parts catalogue .
• The vibration damper can only be installed in one position. The
hole in the vibration damper must be located over the projec‐
tion on the toothed belt sprocket -arrow-.
50 .
Gr. 63 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Tightening torque with respect to the correctness of information in this document. Copyright by AUDI AG.
Component Nm
Vibration damper to crankshaft sprocket
Bolt strength 8.8 25
1.6 Removing and installing bracket for an‐

cillaries
♦ Drip tray -V.A.G 1306- or drip tray for workshop hoist -VAS
6208-

Audi A6 1998 ➤
Removing
Note
All cable ties which are released or cut open when removing must
be fitted in the same position when installing.
Caution


-arrow-.

-arrow-.



Audi A6 1998 ➤

poly V-belt.
Note
The air conditioner poly V-belt remains fitted.
key.
– Detach viscous fan from bearing and lay it forwards in radiator
cowl.
– Unscrew wire -1- at alternator.

– Detach electrical connector -2-.

Audi A6 1998 ➤
– Remove bolts -1- and -2-.

– Remove alternator.
– Counterhold pulley with drift to unbolt power steering pump

pulley.
– Unbolt power steering pump -arrows- and tie up to one side;
the hoses/pipes remain connected.
– Remove poly V-belt tensioner.

– Remove bolt -arrow- for toothed belt cover (bottom).
– Place drip tray -V.A.G 1306- or drip tray for workshop hoist -
VAS 6208- under engine.
– Drain off coolant ⇒ page 113 .
– Unscrew bolts -1 ... 5-.
– Disconnect both coolant hoses -arrows- at rear of bracket.
– Remove bracket for ancillaries.
Installing
Note
♦ Renew O-ring.
♦ When installing, pay attention to dowel sleeve at top right be‐
tween bracket and cylinder block.

Audi A6 1998 ➤
– Clean and smoothen sealing surface for O-ring as required.

– To make sure bracket is fitted to injection pump console free
of stress, knock back bush for top securing bolt slightly.
– Fit bolts and tighten hand-tight initially.
– Tighten bolts in the sequence -1 ... 5-.
– Install coolant hoses -arrows-.
– Tighten bolt -arrow- for toothed belt cover.

– Install viscous fan ⇒ page 122 .
Tightening torques
Component Nm
Bracket for ancilla‐ cylinder block 25
ries to injection pump console 25
Alternator to bracket for ancillaries 25
Terminal 30/B+ to alternator 16
Toothed belt
Protected cover (bottom)
by copyright. to bracket
Copying for private or commercial purposes,10in part or in whole, is not
Poly V-belt tensioner to bracket
of information in this document.45
with respect to the correctness Copyright by AUDI AG.
Power steering pump to bracket for ancillaries 25
Pulley to power steering pump 25
1.7 Toothed belt drive - exploded view of components

Audi A6 1998 ➤
1 - Toothed belt cover (top)

❑ To remove, remove poly
V-belt tensioner
⇒ Item 7 (page 24)
❑ Engage carefully in
toothed belt cover (bot‐
tom) when installing
2 - Toothed belt
❑ Check for wear
posite direction when it
is refitted, this can
cause breakage
❑ Removing ⇒ page 37
❑ Installing (adjusting
valve timing)
⇒ page 40
3 - 20 Nm
❑ Self-locking
❑ Renew
4 - Tensioning roller
❑ Checking semi-auto‐
matic tensioning roller
for toothed belt
⇒ page 43
❑ Installation position
⇒ page 36
5 - 45 Nm
❑ Use counterhold tool
-3036- to loosen and
tighten
6 - Camshaft sprocket
❑ Loosen camshaft sprocket from camshaft taper by applying a blow through mounting hole in toothed belt
cover using a hammer and a drift
7 - 25 Nm
8 - Idler roller
9 - 10 Nm
10 - Toothed belt cover (rear)
11 - 10 Nm
12 - 25 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
13 - Woodruff key
❑ Check that it is securely seated
14 - Injection pump sprocket
❑ Removing and installing injection pump sprocket ⇒ page 37
❑ Ensure that Woodruff key is fitted
15 - Intermediate shaft sprocket
❑ Installation position ⇒ page 36
❑ Ensure that Woodruff key is fitted

Audi A6 1998 ➤
16 - Crankshaft sprocket
❑ Contact surface between sprocket and crankshaft must be free of oil
❑ Can only be installed in one position
17 - 90 Nm +90° (1/4 turn) further
❑ Renew
❑ Do not lubricate with oil
❑ Use counterhold tool for toothed belt sprocket -3099- or counterhold tool -3415- to loosen and tighten
❑ Fit counterhold tool for toothed belt sprocket -3099- ⇒ page 47
❑ Remove bracket for torque reaction support ⇒ Item 11 (page 97) to secure counterhold tool
18 - 45 Nm
❑ Use counterhold tool -3036- to loosen and tighten
19 - 45 Nm
20 - 10 Nm
21 - Toothed belt cover (bottom)
❑ Unbolt vibration damper prior to removing
22 - Spreader clip
Installation position of semi-automatic tensioning roller

• Retaining lug -arrow- must engage in slot on toothed belt cover
(rear).
Installation position of intermediate shaft sprocket

• The deep shoulder -arrows- on the intermediate shaft sprocket
faces towards the front.
• The identification marking on the sprocket faces to the rear.

Audi A6 1998 ➤
Removing injection pump sprocket

• Toothed belt is removed ⇒ page 37 .
– Unscrew injection pump sprocket nut.
– Slacken arms of puller and fit puller -3032- .
– Align arms with drillings in injection pump sprocket and tighten.
– Screw in bolt on puller until injection pump sprocket is under
tension.
– Apply light blow onto spindle of puller -arrow- to release injec‐
tion pump sprocket from taper on injection pump shaft (hold
sprocket to prevent it from dropping).
1.8 Removing and installing toothed belt


equipment required
♦ Locking pin -2064-
♦ Setting bar -2065 A-
♦ Counterhold tool -3036-
♦ Special tool -Matra V/159-

Audi A6 1998 ➤
Removing
• Engine in vehicle.
Rep. Gr. 63 .
– Remove poly V-belt ⇒ page 27 .


key.
– Remove viscous fan from bearing.


Audi A6 1998 ➤
– Unbolt vibration damper; counterhold on centre bolt with ring

spanner.
– Remove toothed belt cover (top and bottom) -arrows-.

Caution permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
The engine must only be turned at the crankshaft, in the direc‐

tion of normal engine rotation (clockwise).
Note
Turn over the engine at the central bolt on the crankshaft.
– Position crankshaft at TDC for cylinder 1 (vehicles with manual

gearbox).
– Position crankshaft at TDC for cylinder 1 -arrow- (vehicles with

automatic gearbox).
Note
Positioning crankshaft at TDC for cylinder 1 with engine removed

⇒ page 43 .

Audi A6 1998 ➤
– Remove cylinder head cover ⇒ page 65 .

– Lock camshaft with setting bar -2065 A- .
– If the setting bar -2065 A- cannot be attached, turn crankshaft
one full turn (360°) in normal rotation direction.
– Centralise setting bar as follows: turn locked camshaft until

one end of setting bar makes contact with cylinder head.
Measure resulting clearance at other end of setting bar using
feeler gauge. Slide in a feeler gauge with half the measured
thickness between setting bar and cylinder head. Now turn
camshaft until setting bar makes contact with feeler gauge.
Insert a second feeler gauge of the same thickness between
the other end of the setting bar and the cylinder head.
– Lock injection pump sprocket in position with locking pin

-2064- .
– Mark the rotation direction of toothed belt with chalk or a felt-
tipped pen.
– Loosen securing nut for tensioning roller.
– Remove idler roller.
– Remove toothed belt.
Installing (adjusting valve timing)
• Camshaft locked in position with setting bar.
• Injection pump locked in position with locking pin -2064- . AG. AUDI AG does not guarantee or accept any liability
permitted unless authorised by AUDI
Note
♦ The toothed belt adjustment must also be performed as de‐

scribed below, even if the toothed belt has only been removed
from the camshaft sprocket.
♦ Toothed belt adjustment must always be performed when the
engine is cold.
♦ The crankshaft must not be at TDC at any cylinder when the
camshaft is turned. Otherwise, there is a risk of damage to
valves and piston crowns.
♦ Do NOT use the setting bar as a counterhold tool when loos‐
ening and tightening the camshaft sprocket. Counterhold us‐
ing counterhold tool -3036- .

Audi A6 1998 ➤
– Ensure that tensioning roller is seated properly in rear toothed

belt cover -arrow-.
– Loosen camshaft sprocket securing bolt a 1/2 turn.
– Detach camshaft sprocket from camshaft taper (apply a blow

through mounting hole in toothed belt cover (rear) using a
hammer and a drift).
– Check once again that TDC marking on dual-mass flywheel
and reference mark are aligned.
– Fit toothed belt on crankshaft sprocket, intermediate shaft, in‐
jection pump sprocket and tensioning roller (note direction of
rotation).
– Fit camshaft sprocket together with toothed belt and secure
lightly via securing bolt.
• The camshaft sprocket must just about still turn, and must not
tilt.
– Install idler roller.
– Turn eccentric adjuster of tensioning roller in clockwise direc‐

tion using pin wrench (e.g. special tool -Matra V/159- ), until
notch and lug -arrows- face each other.
Note
If the eccentric adjuster is turned in clockwise direction further

than intended, the tensioning roller must be turned all the way
back to its initial position. Then turn eccentric adjuster in clockwise
direction again.
– Tighten lock nut on tensioning roller.

– Check once again that TDC marking on dual-mass flywheel
and reference mark are aligned.
Note
Do NOT use the setting bar as a counterhold tool when loosening

and tightening the camshaft sprocket. Counterhold using coun‐
terhold tool -3036- .
– Tighten camshaft sprocket securing bolt.

– Remove setting bar -2065 A- .
– Remove
permitted lockingbypin
unless authorised AUDI-2064-
AG. AUDI.AG does not guarantee or accept any liability
– Turn crankshaft two rotations in normal direction of rotation
until the crankshaft is TDC again.

Audi A6 1998 ➤
– Check tension of toothed belt.

• The marks -arrows- must align.
– Tension toothed belt if necessary.
– Check whether it is possible to lock the injection pump sprock‐
et using locking pin -2064- .
– Check position of camshaft with setting bar -2065 A- .
Note
Repeat adjustment procedure if it is not possible to insert setting

bar -2065 A- or locking pin -2064- .
– Remove setting bar -2065 A- .

– Remove locking pin -2064- .
Assembling
Remaining installation steps are carried out in reverse sequence;
note the following:
Note
♦ Renew gaskets.
– Install toothed belt cover (bottom and top section).

50 .
Gr. 63 .
– Perform dynamic check of commencement of injection ⇒ Rep.
Gr. 23 .
Tightening torques
Component Nm
Tensioning roller for toothed belt to cylinder 20 2)
head
Camshaft sprocket to camshaft 45
Toothed belt cover (bottom) to cylinder block 10
Idler roller to console 25
Tensioner for poly V-belt to bracket for ancilla‐ 45
ries
Vibration damper to crankshaft sprocket
2) Renew nut.

Audi A6 1998 ➤
1.9 Checking semi-automatic tensioning

roller for toothed belt
Test requirement
• Toothed belt fitted and tensioned.
Test sequence
– Push in toothed belt with firm thumb pressure. Notch and lug
-arrows- should move out of alignment.
– Release thumb pressure on toothed belt. Tensioner should
return to initial position.
• The marks -arrows- must align.
1.10 Positioning crankshaft at TDC with en‐

gine removed

♦ TDC adjustment bar -2068 A-
Vehicles with manual gearbox:
• Oil filter must be removed.
– Fit TDC adjustment bar -2068 A- as shown in illustration.
– Set TDC adjustment bar -2068 A- to 107 mm (left notch on
vernier scale -arrow- is point of reference).
– Turn crankshaft until TDC marking “0” on dual-mass flywheel
and end of TDC adjustment bar -2068 A- are aligned.

Audi A6 1998 ➤

• Oil filter must be removed.
– Fit TDC adjustment bar -2068 A- as shown in illustration.
– Set TDC adjustment bar -2068 A- to 99 mm (left notch on ver‐
nier scale -arrow- is point of reference).
– Turn crankshaft until TDC marking “0” on drive plate and end
of TDC adjustment bar -2068 A- are aligned.
Note
The TDC marking “0” is stamped on the side of the drive plate
facing the cylinder block.

Audi A6 1998 ➤
2 Removing and installing sealing

flanges and dual-mass flywheel/drive
plate
2.1 Sealing flanges and dual-mass flywheel/drive plate - exploded view of com‐
ponents
Note
Service to the clutch ⇒ Manual gearbox; Rep. Gr. 30
1 - Oil seal
❑ Remove sealing flange
prior to removing
❑ Install using fitting tool
-10 - 203-
❑ Do not lubricate sealing
lip of oil seal
2 - Intermediate shaft sprocket
⇒ page 47
❑ Ensure that Woodruff
key
⇒ Item 25 (page 46) is
fitted
3 - 45 Nm
❑ Use counterhold tool
-3036- to loosen and
tighten
4 - 25 Nm
5 - Oil seal
❑ Renewing ⇒ page 47
❑ Do not lubricate sealing
lip of oil seal
6 - 10 Nm
7 - Sealing flange (front)
❑ Before fitting sump, ap‐
ply a thin coat of sealant
to sealing points be‐to the correctness of information in this document. Copyright by AUDI AG.
with respect
tween sealing flange
and cylinder block
❑ Apply sealant prior to in‐
stalling
❑ Sealant ⇒ Parts catalogue
8 - Gasket
❑ Renew
9 - Cylinder block
❑ Removing and installing crankshaft ⇒ page 53
❑ Dismantling and assembling pistons and conrods ⇒ page 57
2. Removing and installing sealing flanges and dual-mass flywheel/drive plate 45

Audi A6 1998 ➤
10 - Exhauster pump for brake servo

11 - O-ring
❑ Renew
12 - Cover
13 - 10 Nm
14 - 20 Nm
15 - Bracket for exhauster pump
16 - O-ring
❑ Renew
17 - Oil seal
❑ Renew
18 - 10 Nm
19 - Sealing flange (rear) with oil seal
❑ With gasket for cylinder block
❑ Do not lubricate sealing lip of oil seal
❑ Before fitting sump, apply a thin coat of sealant to sealing points between sealing flange and cylinder
block
❑ Apply sealant prior to installing
❑ Sealant ⇒ Parts catalogue
❑ To install, push guide sleeve from assembly kit onto crankshaft.
20 - Gasket
❑ Fit only if sealing flange has no sealing lip on cylinder block side
21 - Dual-mass flywheel/drive plate
❑ Removing
Protected and installing
by copyright. Copying for private or dual-mass flywheel
commercial purposes, ⇒inpage
in part or 50
whole, is not
❑ Removing and installing drive plate ⇒ page 51
22 - Securing bolt for dual-mass flywheel/drive plate
❑ Renew
❑ Tightening torque: vehicles with manual gearbox ⇒ page 51 ; vehicles with automatic gearbox
⇒ page 52
23 - Intermediate plate
❑ Must be positioned on dowel sleeves
❑ Do not damage/bend when assembling
❑ Is fitted on sealing flange ⇒ page 47
24 - Intermediate shaft
❑ Axial clearance: max. 0.25 mm
25 - Woodruff key
❑ Check for firm attachment
26 - O-ring
❑ Renew
27 - Sealing flange for intermediate shaft
28 - 25 Nm

Audi A6 1998 ➤
Installation position of intermediate shaft sprocket

• The deep shoulder -arrows- on the intermediate shaft sprocket
faces towards the front.
• The identification marking on the sprocket faces to the rear.
Installing intermediate plate

– Fit intermediate plate to sealing flange and push onto dowel
sleeves -arrows-.
2.2 Renewing crankshaft oil seal (pulley end)

Audi A6 1998 ➤

equipment required
♦ Oil seal extractor -2085-
♦ Oil seal fitting tool -3083-
Procedure
Rep. Gr. 63 .
– Remove toothed belt ⇒ page 37 .
– Unscrew bolts -arrows- and remove torque reaction support.

Audi A6 1998 ➤
– Remove crankshaft sprocket; use counterhold tool -3415- to

lock sprocket in place.
Note
Counterhold tool for toothed belt sprocket -3099- can be used as

an alternative.
– Screw socket head bolt from oil seal fitting tool -3083- 5 ... 6
turns into crankshaft before applying oil seal extractor.
– Unscrew inner section of oil seal extractor -2085- 2 turns out

of outer section and lock with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Clamp flats of oil seal extractor in vice.
– Remove oil seal with pliers.
Note
Do not lubricate sealing lip and outer rim of oil seal before press‐
ing in.
– Clean running surface and sealing surface.

– Place guide sleeve from oil seal fitting tool -3083- onto crank‐
shaft journal.

Audi A6 1998 ➤
– Slide oil seal over guide sleeve.

– Press oil seal in as far as the stop using press sleeve and bolt
from oil seal fitting tool -3083- .
– Renew centre bolt for toothed belt sprocket.

• Contact surface between toothed belt sprocket and crankshaft
must be free of oil.
• Do not lubricate bolt for crankshaft sprocket.
– Install crankshaft sprocket; use counterhold tool -3415- to lock
sprocket in place.
– Fit toothed belt (adjust valve timing) ⇒ page 40 .
50 .
Gr. 63 .
Tightening torques
Component Nm Copyright by AUDI AG.
with respect to the correctness of information in this document.

Toothed belt sprocket to crankshaft 90 + 90° 3) 4)
3) Renew bolt.
4) 90° = one quarter turn.
2.3 Removing and installing dual-mass fly‐

wheel
♦ Counterhold tool -10-201-

Audi A6 1998 ➤
Removing
• Gearbox removed.
– Mark installation position of dual-mass flywheel on engine.
– Attach counterhold tool -10-201- in order to loosen bolts.
– Unbolt dual-mass flywheel.
Installing
– Reverse position of counterhold tool -10-201- in order to tight‐
en bolts.
Tightening torque
Component Nm
Dual-mass flywheel to crankshaft
Bolt length 22.5 mm 60 + 90° 5) 6)
43 mm 60 + 180° 5) 7)
5) Renew bolts.
6) 90° = one quarter turn.
7) 180° = one half turn. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2.4 Removing and installing drive plate

♦ Counterhold for clutch -VW 558-
♦ M8×45 hexagon bolt and two M10 hexagon nuts

♦ Depth gauge
Removing
• Gearbox removed.
– Mark installation position of drive plate on engine.
– Secure counterhold tool for clutch -VW 558- to drive plate us‐
ing hexagon bolt M8x45. Insert two M10 hexagon nuts -1-
between counterhold tool and drive plate.
– Unbolt drive plate.

Audi A6 1998 ➤
Installing
– Install drive plate with shims -2- and -1-.
• Lug -arrow- on washer must face torque converter.
– Fit at least 3 old securing bolts and tighten to 30 Nm.
– Measure depth -a- at three points and calculate average value.

• Specification: 26 … 28 mm.
If specification is exceeded:
– Remove drive plate for a second time.
– Install drive plate without shim -2-. Re-tighten bolts in diagonal
sequence to 30 Nm.
– Repeat measurement.
If reading matches specification:
Tightening torque
Component Nm
Drive plate to crankshaft
Bolt length 17 mm 60 + 90° 8) 9)
8) 90° = a quarter of a turn.
9) Renew bolts.

Audi A6 1998 ➤
3 Removing and installing crankshaft
3.1 Crankshaft - exploded view of components
Note
When carrying out repairs, secure engine to assembly stand with engine and gearbox support -VW 540-
⇒ page 18 .
1 - Thrust washers for bearing

No. 3
❑ Different types for cylin‐
der block and bearing
cap
❑ Note location
2 - Bearing shell
❑ For cylinder block with
oil groove
❑ Do not interchange
used bearing shells
(mark positions)
3 -permitted
Crankshaft
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Axial clearance (new):
0.07 ... 0.17 mm; wear
limit: 0.37 mm
❑ Check radial clearance
with Plastigage (new):
0.03 ... 0.08 mm; wear
limit: 0.17 mm
❑ Do not rotate the crank‐
shaft when checking the
radial clearance
❑ Crankshaft dimensions
⇒ page 56
4 - Bearing shell
❑ For bearing cap without
oil groove
used bearing shells
(mark positions)
5 - Thrust washers for bearing
No. 3
❑ Different types for cylin‐
der block and bearing cap
❑ Note location
6 - 65 Nm +90° (1/4 turn) further
❑ Renew
❑ For measuring radial clearance of crankshaft, tighten to 65 Nm but not further
7 - Bearing cap
❑ Bearing cap 1: Pulley end
❑ Bearing cap 3 with recesses for thrust washers
❑ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side
3. Removing and installing crankshaft 53

Audi A6 1998 ➤
8 - 10 Nm +90° (1/4 turn) further

❑ Renew
❑ Sender wheel must be renewed if bolts are loosened
9 - Needle bearing on vehicles with manual gearbox
❑ Extracting and driving in ⇒ page 55
10 - Sender wheel
❑ For engine speed sender -G28-
❑ Can only be installed in one position. Holes are off-set
❑ Sender wheel must be renewed if bolts are loosened
11 - Dowel pin
❑ Checking projection from crankshaft ⇒ page 54
Checking dowel pin projection out of crankshaft

Projection of dowel pin -3- out of crankshaft
• Dimension -a- = 2.5 ... 3.0 mm.
3.2 Removing and installing sender wheel

for engine speed sender -G28-
Removing
– Unscrew bolts -2- and remove sender wheel -1- from crank‐
shaft.
Installing
– Sender wheel -1- must always be renewed after slackening off
bolts -2-.

Audi A6 1998 ➤
Note
♦ If the same sender wheel is installed again, the seat for the
countersunk bolts in the sender wheel will be deformed to such
an extent that the bolt heads make contact with crankshaft
-3- -arrows- and sender wheel -2- will be loose beneath bolts
-1- .
♦ Sender wheel can only be fitted in one position because holes
are offset.
Tightening torque
Component Nm
Sender wheel to crankshaft 10 + 90° 10) 11)
10) Renew bolts.
11) 90° = a quarter of a turn.
3.3 Extracting and driving in needle bearing

for crankshaft
Note
♦ A needle bearing must be fitted in the crankshaft on vehicles

with manual gearbox; insert needle bearing if not yet fitted.
♦ In vehicles with automatic gearbox, the needle bearing must
NOT be fitted in the crankshaft; remove needle bearing if fitted.

♦ Drift -VW 207 C- or centring drift -3176-
♦ 1 - Internal puller -Kukko 21/1-
♦ 4 - Counterhold -Kukko 22/1-
3. Removing and installing crankshaft 55

Audi A6 1998 ➤
♦ Depth gauge
Pulling out
– Remove needle bearing using internal puller -Kukko 21/1- and
counterhold tool -Kukko 22/1- .
Driving in
– Drive in needle bearing using drift -VW 207 C- or centring
mandrel -3176- .
• The lettering on the needle bearing must be visible when in‐
stalled.
• Needle bearing must be inserted to a depth of -a- = 1.5 mm
3.4 Crankshaft dimensions

Honing dimen‐ Crankshaft main Conrod
sion bearing journal ∅ bearing journal ∅
(in mm)
Basic dimen‐ 54.00 –0.022 47.80 –0.022
sion –0.042 –0.042
1st undersize 53.75 –0.022 47.55 –0.022
–0.042 –0.042
2nd undersize 53.50 –0.022 47.30 –0.022
–0.042 –0.042
3rd undersize 53.25 –0.022 47.05 –0.022
–0.042 –0.042

Audi A6 1998 ➤
4 Dismantling and assembling pistons

and conrods
Note
♦ The following alternative types of conrod can be installed:

♦ Conrod with dowel pin ⇒ Item 6 (page 58) . Use conrod bolts
without centralising function.
♦ Conrod without dowel pin. Use conrod bolts with centralising
function.
4.1 Pistons and conrods - exploded view of components
1 - Piston rings
❑ Offset gaps by 120°
❑ Remove and install us‐
ing piston ring clamp
❑ Marking “TOP” or in‐
scription must face pis‐
ton crown.
❑ Checking ring gap
⇒ page 58
❑ Checking ring-to-groove
clearance ⇒ page 59
2 - Piston
❑ With combustion cham‐
ber
❑ Mark installation posi‐
tion and cylinder alloca‐
tion
❑ Installation position and
allocation of piston/cyl‐
inder ⇒ page 59
❑ If cracking is visible on
piston skirt, renew pis‐
ton
❑ Arrow on piston crown
points to pulley end
❑ Install using piston ring
clamp
❑ Checking piston projec‐
tion at TDC
⇒ page 60
❑ Piston and cylinder di‐
mensions ⇒ page 61
❑ unless
permitted Checking
authorised⇒by page
AUDI AG. 59AUDI AG does not guarantee or accept any liability
3 - Piston pin
❑ If difficult to move, heat piston to approx. 60 °C
❑ Remove and install using drift -VW 222 A-
4 - Circlip
5 - Conrod
❑ See note ⇒ page 57
❑ Only renew as a complete set
4. Dismantling and assembling pistons and conrods 57

Audi A6 1998 ➤
❑ Mark cylinder allocation -A-

❑ Installation position: Marking -B- faces towards pulley end
❑ Measuring radial clearance ⇒ page 61
6 - Dowel pin
❑ Make sure that dowel pin is fitted securely in conrod and not in conrod bearing cap
7 - Bearing shell
❑ Note installation position
❑ Do not interchange used bearing shells (mark positions)
❑ Ensure tight fit in retaining lugs
❑ Axial clearance: Wear limit: 0.37 mm
8 - Cylinder block
❑ Checking cylinder bore ⇒ page 60
❑ Piston and cylinder dimensions ⇒ page 61
9 - Bearing shell
❑ Do not interchange used bearing shells (mark positions)
❑ Ensure tight fit in retaining lugs
❑ Axial clearance: Wear limit: 0.37 mm
10 - Conrod bearing cap
❑ Mark cylinder allocation -A-
❑ Installation position: Marking -B- faces towards pulley end
11 - Oil spray jet
❑ For piston cooling
❑ Renew if damage from piston seizure has occurred
12 - Pressure relief valve, 27 Nm
❑ Opens at: 1.3 ... 1.6 bar
❑ Insert without locking fluid
13 - Conrod bolt - 30 Nm + 90° (1/4 turn) further
❑ Renew
❑ Lubricate threads and contact surface
❑ To measure radial clearance, tighten used bolt to 30 Nm but not further
Checking piston ring gap

– Insert ring at right angle to cylinder wall from above and push
down into lower cylinder opening approx. 15 mm from bottom
of cylinder. To do so, use a piston without rings.
Piston ring New Wear limit
Dimensions in mm
1st compression ring 0.20 … 0.40 1.0
2nd compression ring 0.20 … 0.40 1.0
Oil scraper ring 0.25 … 0.50 1.0

Audi A6 1998 ➤
Checking ring-to-groove clearance

– Clean groove in piston before checking clearance.
Piston ring New Wear limit
Dimensions in mm
1st compression ring 0.06 … 0.09 0.25
2nd compression ring 0.05 … 0.08 0.25
Oil scraper ring 0.03 … 0.06 0.15
Piston installation position and piston/cylinder allocation

– Mark installation position and assignment on inside of pistons
(not on piston crown) with an electric marker or felt-tip pen.
Pistons in cylinders 1 and 2:
• Larger inlet valve chamber towards flywheel -arrows-.
Pistons in cylinders 3 and 4:
• Larger inlet valve chamber towards pulley end -arrows-.
Note
♦ With new pistons, cylinder allocation is indicated by a coloured

marking on piston crown.
♦ Piston for cylinder 1 and 2: marked 1/2.
♦ Piston for cylinder 3 and 4: marked 3/4.
Checking piston
– Using a micrometer (75 ... 100 mm), measure approx. 10 mm
from the lower edge, perpendicular to the piston pin axis.
• Maximum deviation from nominal dimension: 0.04 mm.
Nominal dimension ⇒ page 61 .

Audi A6 1998 ➤
Checking cylinder bore

– Use 50 ... 100 mm internal dial gauge to take measurements
at 3 points in transverse direction -A- and longitudinal direction
-B-.
• Maximum deviation from nominal dimension: 0.10 mm.
Nominal dimension ⇒ page 61 .
4.2 Checking piston projection at TDC

equipment required
♦ -VW 382/7- from measuring
tool -VW 382-
♦ -VW 385/17- from universal
measuring tool -VW 385-
♦ Dial gauge -VAS 6079-

Audi A6 1998 ➤
Test sequence
– Check piston projection at TDC when installing new pistons or
short engine.
– Install cylinder head gasket corresponding to individual piston
projection according to table below:
Piston projection above top surface of Identification
cylinder block (No. of holes)
0.91 mm … 1.00 mm 1
1.01 mm … 1.10 mm 2
1.11 mm … 1.20 mm 3
Identification of cylinder head gasket

♦ Part No. = arrow 1
♦ Holes = arrow 2
♦ Production code = arrow 3 (can be disregarded)
Note
If the measured values for piston projection are not the same for
all pistons, use the highest value to determine the correct gasket
size.
4.3 Piston and cylinder dimensions

Honing dimension Piston ∅ Cylinder bore ∅
(in mm)
Basic dimension 79.47 79.51
Repair oversize I 79.72 79.76
Repair oversize II 79.97 80.01
4.4 Measuring radial clearance of conrods

♦ Plastigage
Procedure
– Remove conrod bearing caps.
– Clean bearing caps and bearing journals.
– Place Plastigage onto bearing journal or into bearing shells
corresponding to width of bearing.
– Fit conrod bearing caps and tighten to 30 Nm without rotating
crankshaft.
– Remove conrod bearing caps once more.
– Compare width of width of Plastigage with measurement
scale:
• Radial clearance: Wear limit: 0.08 mm.

Audi A6 1998 ➤
– Renew bolts for conrod bearings.

Audi A6 1998 ➤
15 – Cylinder head, valve gear

1 Removing and installing cylinder
head
1.1 Cylinder head - exploded view of components
1 - Cylinder head
❑ Removing ⇒ page 66
❑ Checking for distortion
⇒ page 64
❑ Installing ⇒ page 74
❑ If renewed, refill system
with fresh coolant
2 - 25 Nm
3 - Lifting eye
4 - Tapered sealing element
(bottom)
5 - Gasket for cylinder head
cover
❑ Renew if damaged or
leaking
❑ Before fitting, apply
sealant at sealing points
⇒ page 65 and
⇒ page 65
❑ Insert lugs into holes on
cylinder head
6 - Cylinder head cover
⇒ page 65
7 - Sealing element (top)
❑ Renew if damaged
8 - Dished washer
9 - 10 Nm unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
10 - Cap
11 - Seal
❑ Renew if damaged or leaking
12 - Filler cap
13 - Vent hose
14 - Hose clip
❑ Fit hose clip and hose onto retaining tab on cylinder head cover
15 - Pressure control valve for crankcase breather system
16 - Seal
17 - Cylinder head bolt
❑ Renew
1. Removing and installing cylinder head 63

Audi A6 1998 ➤
❑ Note correct sequence when loosening ⇒ page 74

❑ Note correct sequence when tightening ⇒ page 76
18 - Injector pipes
❑ Tighten to 25 Nm
❑ Use ring spanner -3035- for removal
❑ Always remove pipework complete
❑ Do not alter shape.
19 - 10 Nm
20 - Coolant flange
21 - O-ring
❑ Renew
22 - Coolant flange
❑ With coolant temperature sender -G62-
23 - 10 Nm
24 - Connector
❑ For needle lift sender -G80-
25 - Return pipe
❑ To injection pump
26 - Cylinder head gasket
❑ Renewing ⇒ “1.3 Removing cylinder head”, page 66
❑ Note marking ⇒ page 65
❑ If renewed, refill system with fresh coolant
Checking cylinder head for distortion

– Use straight edge and feeler gauge to measure for distortion
at several points.
• Max. permissible distortion: 0.1 mm
Note
The cylinder heads of diesel engines must not be machined.
64 Rep. Gr.15 - Cylinder head, valve gear

Audi A6 1998 ➤
Cylinder head gasket identification

♦ Holes = arrow 2
Note
Cylinder head gaskets of different thicknesses are fitted depend‐

ing on the amount of piston projection ⇒ page 60 . Fit new gasket
with same identification if only gasket is renewed.
Sealing points between bearing cap and cylinder head

– Apply one drop of sealant each to sealing points between
bearing cap and cylinder head -arrows- (∅ approx. 5 mm);
sealant ⇒ Parts catalogue .
Sealing transitions
– Apply small quantity of sealant to transitions for semi-circular
seal -arrows- at sealing surfaces of cylinder head; sealant ⇒
Parts catalogue .
1.2 Removing and installing cylinder head

cover
Removing
– Unscrew nuts -arrows- andProtected
detach engine cover panel.
by copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi A6 1998 ➤
– Slacken hose clips -arrows- and detach crankcase breather

hoses from pressure control valve.
– Remove caps -7-.

– Unscrew nuts -6- for cylinder head cover.
– Detach dished washer -5- and sealing element (top) -4-.
– Remove cylinder head cover -3-.
– Detach gasket -2- and tapered
Protected sealing
by copyright. element
Copying (bottom)
for private or commercial-1-.
purposes, in part or in whole, is not
Installing with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
Renew gasket for cylinder head cover, sealing element (top) and
tapered sealing element if damaged.
– Apply one drop of sealant each to sealing points between

bearing cap and cylinder head -arrows- (∅ approx. 5 mm);
sealant ⇒ Parts catalogue .
– Apply small quantity of sealant to transitions for semi-circular

seal -arrows- at sealing surfaces of cylinder head; sealant ⇒
Parts catalogue .
– Fit cylinder head cover with relevant components.
Tightening torque
Component Nm
Cylinder head cover to cylinder head 10
1.3 Removing cylinder head

Audi A6 1998 ➤

equipment required
♦ Ring spanner -3035-
♦ Guide pin -3070-
-VAS 6208-
Procedure
Rep. Gr. 63 .
Note
Caution


Audi A6 1998 ➤

-arrow-.

-arrow-.

– Move wiring harness going to air cleaner clear -arrow-.
– Disconnect air intake hose from turbocharger -arrows-.

Audi A6 1998 ➤
– Detach vacuum hose -2- from vacuum unit for charge pressure
control.
– Remove bolt -1- on bracket for oil supply pipe.
– Unscrew oil supply pipe -3- at turbocharger.
-arrows-.

Note

– Disconnect catalytic converter with front exhaust pipe from

turbocharger.
Note


– Remove
Protected poly
by copyright. V-belt.
Copying for private or commercial purposes, in part or in whole, is not
WARNING

ed.
– Disconnect air intake hose from turbocharger (bottom)

-arrows-.

Audi A6 1998 ➤
(right-side).
– Remove bracket for turbocharger -arrows-.
– Detach oil return pipe at cylinder block -arrow-.
– Detach fuel hose -1- going to injectors/injection pump.

– Unplug electrical connectors -2 ... 5-.
– Detach rear coolant hose from cylinder head -arrow-.

Audi A6 1998 ➤
– Detach coolant hose (left-side) from cylinder head and expan‐

sion tank -arrows- and move clear to one side.
– Remove injector pipes using ring spanner -3035- .
Note
Always remove complete set of pipes.
– Detach electrical connectors at glow plugs.
– Detach coolant hose (bottom left) from cylinder head -arrow-.

circulation valve.
necting pipe.
– unless
permitted Unscrew bolt
authorised -5- AG.
by AUDI andAUDI
remove
AG doesair pipe. or accept any liability
not guarantee
Caution


Audi A6 1998 ➤
Note

gearbox).

automatic gearbox).
– Remove oil supply pipe for turbocharger.

– Centralise setting bar as follows:
1. Turn locked camshaft until one end of setting bar makes
contact with cylinder head.
2. Measure resulting clearance at other end of setting bar us‐
ing feeler gauge.
3. Slide in a feeler gauge with half the measured thickness be‐
tween setting bar and cylinder head.
4. Now turnunless
permitted camshaft until
authorised setting
by AUDI barAG
AG. AUDI makes
does notcontact with
guarantee or feel‐
accept any liability
er gauge.
1. Insert a second feeler gauge of the same thickness between

the other end of the setting bar and the cylinder head.
– Remove viscous fan (with pulley) ⇒ page 122 .

Audi A6 1998 ➤
– Remove toothed belt cover (top) ⇒ Item 1 (page 35) .

– Remove bolts -arrows- for toothed belt cover (rear) at both
sides of cylinder head.

-2064- .
– Remove toothed belt from camshaft sprocket.
– Remove toothed belt tensioning roller.
Note



– Remove camshaft sprocket.

Audi A6 1998 ➤
– Loosen cylinder head bolts in the sequence -1 ... 10-.

– Carefully lift off the cylinder head with the assistance of a 2nd
mechanic.
1.4 Installing cylinder head

Note
♦ Carefully remove any sealant residue from the cylinder head

and cylinder block. Ensure that no long scores or scratches
are made on the surfaces.
♦ Carefully remove any remaining emery and abrasive material.
♦ No oil or coolant must be allowed to remain in the blind holes
for the cylinder head bolts in the cylinder block.
♦ Renew the cylinder head bolts.
♦ Renew self-locking nuts and bolts when performing assembly
work.
♦ Renew bolts which are tightened to a specified angle as well
as oil seals and gaskets.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ Handle gasket very carefully. Damage to the silicone coating
or the indented area will lead to leaks.
♦ When installing a replacement cylinder head with fitted cam‐
shaft, the contact surfaces between hydraulic tappets and cam
running surfaces must be oiled after installing the cylinder
head.
♦ The plastic protectors fitted to protect the open valves should
not be removed until the cylinder head is ready to be fitted.

Audi A6 1998 ➤
– Check whether the camshaft is still positioned at TDC.

• It should be possible to attach setting bar -2065 A- into cam‐
shaft.
Note
If the setting bar -2065 A- cannot be attached, turn camshaft 1/2

turn (180°) in normal rotation direction.
– Check whether the crankshaft is still positioned at TDC.

• The TDC marking should align with the point of reference.
Note
Illustration shows vehicle with manual gearbox.

– Note identification markings on cylinder head gasket.

♦ Holes = arrow 2
Note
♦ If the cylinder head gasket or cylinder head have been re‐

placed, select the new cylinder head gasket according to the
number of holes on the old gasket.
♦ If parts of the crankshaft drive have been renewed, the new
cylinder head gasket must be selected by measuring the pis‐
ton projection at TDC ⇒ page 60 .
– Fit guide pins -3070/9- into outer drillings in cylinder block to

position cylinder head gasket
– Fit cylinder head gasket.
• Note position of centring sleeve in cylinder block.
• Check installation position of cylinder head gasket: the word
“oben” (top) or the Part No. should face towards the cylinder
head.
– Fit the cylinder head.
– Insert 8 new cylinder head bolts and tighten finger-tight.
– Remove guide pins -3070/9- (insert pin driver -3070- through
bolt holes) and fit remaining cylinder head bolts.

Audi A6 1998 ➤
– Tighten cylinder head bolts in 4 stages in the sequence shown:

1. Tighten with torque wrench to 40 Nm.
2. Tighten with torque wrench to 60 Nm.
3. Turn 90° (1/4 turn) further using a rigid wrench.
4. Turn 90° (1/4 turn) further using a rigid wrench.
Note
Cylinder head bolts do not have to be torqued down again
permitted unlesslater
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
after repair work. with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
Follow all instructions for removing and installing toothed belt.
– Install cylinder head cover ⇒ page 66 .

50 .
Gr. 63 .
– Install exhaust system and align it free of stress
⇒ page 165 .
Note
If engine oil is contaminated, perform oil change ⇒ Maintenance ;

Booklet 402 .

– Fill cooling system with fresh coolant ⇒ page 115 .

Audi A6 1998 ➤
Tightening torques
Component Nm
Rear toothed belt cover to cylinder head 10
Oil return pipe to cylinder block 30
Injection pipes to injectors and injection pump 25
Idler roller to console 25
Tensioner for poly V-belt to bracket for ancilla‐ 45
ries
Oil supply pipe to turbocharger 22
Toothed belt sprocket to camshaft 45
Catalytic converter to turbocharger 2512)
Bracket for turbocharger turbocharger 25
to cylinder block 25
12) Renew self-locking nuts.
1.5 Removing and installing intake manifold

Removing
– Remove exhaust gas recirculation pipe with mechanical ex‐
haust gas recirculation valve -arrows-.
Note
Vacuum hose -1- remains connected.
– Move exhaust gas recirculation pipe withbymechanical

Protected exhaust
copyright. Copying for private or commercial purposes, in part or in whole, is not
gas recirculation valve clear to onepermitted
side. unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi A6 1998 ➤
– Loosen hose clip -1- to remove air intake hose from intake
manifold.
– Unfasten bracket for oil supply pipe from exhaust manifold,
slacken clip and move bracket clear to one side.
– Remove intake manifold.
Installing
Note
♦ Renew gaskets and self-locking nuts.

♦ Note the installation position of intake manifold gasket.
Tightening torques
Component Nm
Intake manifold to cylinder head 25
Connecting pipe for exhaust gas recirculation to 25
exhaust manifold
Mechanical exhaust gas recirculation valve to 25 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
intake manifold with respect to the correctness of information in this document. Copyright by AUDI AG.
Bracket for oil supply pipe to exhaust manifold 25
1.6 Checking compression

Audi A6 1998 ➤

equipment required
♦ Jointed spanner -3220-
♦ Compression tester -
V.A.G 1763-
♦ Adapter -V.A.G 1381/12-
Test requirements
• Engine oil temperature at least 30 °C
• Battery voltage at least 12.5 V
Test sequence
– Detach electrical connector for fuel shut-off valve -N109- at
injection pump.
– Detach electrical connector for metering adjuster -N146- at in‐
jection pump.

Audi A6 1998 ➤

– Unscrew all glow plugs using jointed spanner -3220- .
– Screw in adapter -V.A.G 1381/12- in place of the glow plug in
each cylinder.
– Test the compression pressure with the compression tester -
V.A.G 1763- .
Note
Using the compression tester ⇒ operating instructions .
– Have a 2nd mechanic operate starter until tester shows no

further pressure increase.
Compression pressure bar
When new 25 … 31
Wear limit 19
Difference between cylinders 5 (maximum)
– Install glow plugs ⇒ Rep. Gr. 28 .
– Interrogate and erase the fault memory for engine control unit,
as faults are stored when the electrical connectors are un‐
plugged ⇒ Vehicle diagnosis, testing and information system
VAS 5051.

Audi A6 1998 ➤
2 Servicing valve gear
Note
♦ After installing the camshaft, the engine must NOT be started

for about 30 minutes. Hydraulic valve compensation elements
have to settle (otherwise valves will strike pistons).
♦ After working on the valve gear, turn the engine carefully at
least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.
♦ Renew seals and gaskets.
♦ Cylinder heads with cracksProtected
between the valve
by copyright. seats
Copying may
for private be
or commercial purposes, in part or in whole, is not
used without reducing engine life, unless
permitted provided thebycracks
authorised AUDI AG. areAUDI AG does not guarantee or accept any liability
small and not more than 0.5 mm wide.
♦ Before applying sealant, check updated information: ⇒ Parts

catalogue
2.1 Valve gear - exploded view of components
1 - Bearing cap
⇒ page 82
❑ Installation sequence
stalling camshaft”,
page 83
❑ Applying sealant to
bearing cap 1
⇒ page 65
❑ Sealant ⇒ Parts cata‐
logue
2 - 20 Nm
3 - Camshaft
❑ Checking axial clear‐
ance ⇒ page 82
⇒ page 83
❑ Check radial clearance
with Plastigage
❑ Radial clearance: wear
limit: 0.11 mm
❑ Runout: max. 0.01 mm
❑ Valve timing ⇒ page 1
4 - Hydraulic bucket tappet
❑ Checking ⇒ page 87
stalling camshaft”,
page 83
(mark allocation)
❑ Place down with contact
surface facing down‐
wards
2. Servicing valve gear 81

Audi A6 1998 ➤
❑ Before installing check camshaft axial clearance ⇒ page 82

❑ Lubricate contact surface
5 - Valve cotters
6 - Upper valve spring plate
7 - Valve spring
❑ Removing and installing with cylinder head installed ⇒ “2.5 Renewing valve stem oil seals”, page 88
❑ Remove and install with cylinder head removed using valve spring compressor -2037-
8 - Valve stem oil seal
❑ Renewing ⇒ page 88
9 - Valve guide
❑ If wear limit is exceeded, renew cylinder head
10 - Oil seal
❑ Different versions possible ⇒ Parts catalogue
❑ Remove bearing cap and toothed belt sprocket to remove and install
❑ Removing and installing toothed belt ⇒ page 37
❑ Before installing, use clean cloth to wipe oil residue off camshaft journal.
❑ When fitting, mask groove on taper of camshaft (using transparent adhesive tape, etc.)
11 - Cylinder head permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Checking valve guides ⇒ page 94
❑ Machining valve seats ⇒ page 92

12 - Valve
❑ Do not machine, only grinding-in is permitted
❑ Valve dimensions ⇒ page 92
Installation position of camshaft bearing caps

– Make sure bearing cap drillings are not offset when installing
bearing cap.
– Before installing, fit bearing cap and determine correct position
for installation.
2.2 Checking axial clearance of camshaft


Audi A6 1998 ➤
♦ Universal dial gauge bracket -VW 387-

Test sequence
– Measure with bucket tappets removed and with first and last
bearing caps fitted.
• Wear limit: 0.15 mm.
2.3 Removing and installing camshaft

Audi A6 1998 ➤

equipment required
Procedure
• Cylinder head installed
Rep. Gr. 63 .
– Remove toothed belt cover (top) ⇒ Item 1 (page 35) .
Caution


Audi A6 1998 ➤
Note

gearbox).

automatic gearbox).

-2064- .
– Remove toothed belt from camshaft sprocket.

Audi A6 1998 ➤
Note


– Remove camshaft sprocket.
– First remove the bearing caps 1, 3 and 5.
– Then loosen bearing caps 2 and 4 alternately in diagonal se‐
quence.
– Remove camshaft.
Installing
Note
♦ Renew camshaft oil permitted

seal. unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Before installing, fit bearing caps and determine correct posi‐
tion for installation; make sure they are not offset.

Audi A6 1998 ➤
– Lubricate contact surfaces of camshaft.

– Install camshaft in TDC position:
• The cams for cylinder 1 must point upwards on camshaft
-arrows-.
– Tighten bearing caps 2 and 4 alternately in diagonal se‐
quence.
– Apply a thin and even coat of sealant to surfaces on bearing
cap 1; sealant ⇒ Parts catalogue .
– Install bearing caps 1, 3 and 5 and tighten in the same way.
Note
♦ Follow all instructions for removing and installing toothed belt.

for about 30 minutes. The hydraulic tappets have to settle
(otherwise valves will strike pistons).
– Install cylinder
Protected headCopying
by copyright. coverfor ⇒ page
private 66 . purposes, in part or in whole, is not
or commercial
– Perform
with dynamic
respect to thecheck of of
correctness commencement of injection
information in this document. Copyright ⇒ Rep.
by AUDI AG.
Gr. 23 .
Tightening torque
Component Nm
Bearing cap to cylinder head 20
2.4 Checking hydraulic bucket tappets

♦ Feeler gauge
♦ Wooden or plastic wedge
Note
♦ Hydraulic bucket tappets cannot be serviced.

♦ Irregular valve noises when starting engine are normal.
Test sequence
– Start engine and run until coolant temperature reaches ap‐
prox. 80 °C.
– Increase engine speed to about 2500 rpm for approx. 2 mi‐
nutes; perform test drive if necessary.
Note
If the irregular valve noises stop but recur repeatedly during short
journeys, then the oil retention valve is defective. Fitting location:
in oil filter bracket ⇒ Item 4 (page 99) .

Audi A6 1998 ➤
If the hydraulic tappets are still noisy, locate defective tappet as

follows:
– Turn crankshaft until cam of the bucket tappet to be checked
faces upwards; to do so, push vehicle forwards with 4th gear
engaged and ignition switched off.
insulation.
– Rotate crankshaft clockwise at centre bolt for toothed belt
sprocket until cams of cylinder to be checked are pointing up‐
wards.
All models:
– Determine clearance between cams and bucket tappets.
– Push tappet down with a wooden or plastic wedge.
If it is possible to insert a feeler gauge of 0.20 mm between cam‐
shaft and bucket tappet:
– Renew hydraulic bucket tappet
⇒ “2.3 Removing and installing camshaft”, page 83 .
Note

(otherwise valves will strike pistons). with respect to the correctness of information in this document. Copyright by AUDI AG.

2.5 Renewing valve stem oil seals

Audi A6 1998 ➤

equipment required
♦ Fitting tool -10-204-
♦ Puller -3047 A-
♦ Jointed spanner, 10 mm
-3220-
♦ Disassembly and assembly
tool -VAS 5161-
Removing
• Cylinder head installed.
Note
If cylinder head is removed, the valve stem oil seals can be re‐
newed using valve spring compressor -2037- .
– Remove the camshaft ⇒ page 83 .
Note
Make sure that the hydraulic bucket tappets are not interchanged;
mark allocation on rear with a waterproof felt-tipped pen.

Audi A6 1998 ➤
– Remove bucket tappets out of guides.

– Place bucket tappets down on a clean surface with contact
surface facing downwards in the order in which they were re‐
moved.
– Insert punch -VAS 5161/3- into bucket tappet guide.
– Knock loose valve cotters on all valves using a plastic ham‐
mer.
– Unscrew all glow plugs using jointed spanner -3220- .
– Set piston of the respective cylinder to “bottom dead centre”.
– Screw adapter -VAS 5161/11- finger-tight into the glow plug

hole of the relevant cylinder.
– Screw snap-in device -VAS 5161/6- with interlocking fork (M6)
-VAS 5161/4- into threaded hole on cylinder head.
– Push guide bush -VAS 5161/16- as far as it will go into bucket
tappet guide of the valve to be removed.
• Installation position of guide bush: hatched areas are perpen‐
dicular to driving direction.
– Insert assembly cartridge -VAS 5161/15- into guide bush.
– Connect adapter -VAS 5161/11- to compressed air supply us‐
ing a commercially available connection piece.
• Air pressure: at least 6 bar
– Attach pressure fork -VAS 5161/2- to snap-in device -VAS
5161/6- and push assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth slightly; the valve cotters
are thus forced apart and taken up by the cartridge.
– Release the pressure fork.
– Remove assembly cartridge, guide bush, valve spring plate
and valve springs.
– Detach valve stem oil seals using puller -3047 A- .

Audi A6 1998 ➤
Installing
Note
A plastic sleeve -A- is included with the new valve stem oil seals.
– Insert plastic sleeve -A- onto the valve stem to prevent dam‐
age to the new valve stem oil seal -B-.
– Lightly lubricate sealing lip of valve stem oil seal.
– Slip valve stem oil seal over plastic sleeve.
– Carefully press valve stem oil seal down onto valve guide us‐
ing fitting tool -10-204- .
– Remove the plastic sleeve.
– If valve cotters have been removed from assembly cartridge,

they need to be put into insertion device -VAS 5161/18- first.
Note
Larger diameter of valve cotters faces upwards.
– Press assembly cartridge -VAS 5161/15- onto insertion device

from above and take up valve cotters.
– Reinstall the assembly cartridge -VAS 5161/15- into guide

bush -VAS 5161/16- .
– Push pressure fork down and pull knurled screw upwards
while turning to left and right - this will insert the valve cotters.
– Release the pressure fork with knurled screw still in pulled po‐
sition.
– Insert bucket tappets.
– Install camshaft ⇒ page 86 .
– Install glow plugs ⇒ Rep. Gr. 28 .
Note

(otherwise valves will strike pistons).

Audi A6 1998 ➤
2.6 Valve dimensions

Dimension Inlet valve Exhaust valve
∅a mm 35.95 31.45
∅b mm 6.963 6.943
c mm 96.85 96.85
α ∠° 45 45
Note
Valves are not to be machined. Only grinding-in is permitted.
2.7 Machining valve seats
Note
If a good seating pattern cannot be obtained by grinding the valve

seats (lapping), they must be refaced (machined):

♦ Depth gauge
♦ Valve seat machining tool
Note
♦ When servicing engines with leaking valves, it is not sufficient

to machine (reface) the valve seats and renew the valves. The
valve guides must also be checked for wear. This is particu‐
larly important on high-mileage engines ⇒ page 94 .
♦ Valve seats should only be machined to the extent required to
give a proper seating pattern.
♦ The maximum permissible machining dimension must be cal‐
culated before starting work. with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ If the machining dimension is exceeded, the function of the

hydraulic valve play compensation can no longer be guaran‐
teed and the cylinder head must be renewed.

Audi A6 1998 ➤
Calculating maximum permissible machining dimension

– Insert valve and press firmly against valve seat.
Note
If the valve has to be renewed as part of a repair, use a new valve

for the measurement.
– Measure distance -a- between end of valve stem and upper

cylinder head surface with a depth gauge.
– Calculate the maximum permissible machining dimension us‐
ing the measured distance and the minimum dimension.
• Minimum dimension for inlet valve: 35.8 mm.
• Minimum dimension for exhaust valve: 36.1 mm.
Measured distance minus minimum dimension = max. permissi‐
ble machining dimension.
Example for inlet valve:
Measured distance 36.5 mm
– Minimum dimension – 35.8 mm
= Maximum permissible machining dimen‐ = 0.7 mm
sion
Note
If the maximum permissible machining dimension is 0 mm or less

than 0 mm, repeat the measurement with a new valve. If the
measured result is again 0 mm or less than 0 mm, renew the cyl‐
inder head.
Machining inlet valve seat

a - ∅ 35.7 mm
b - 1.6 mm
45° - Valve seat angle
Note
♦ Calculating maximum permissible machining dimension

⇒ page 93 .
♦ The 30° lower valve seat chamfer is necessary to ensure that
the inlet channel flow characteristics are maintained.

Audi A6 1998 ➤
Machining exhaust valve seat

a - ∅ 31.4 mm
b - 2.7 mm
45° - Valve seat angle
Note
Calculating maximum permissible machining dimension

⇒ page 93 .
2.8 Checking valve guides

♦ Universal dial gauge bracket -VW 387-
Test sequence
– Insert valve into valve guide.
• End of valve stem must be flush with guide.
– Determine amount of sideways play.
• Wear limit (sideways play): 1.3 mm.
Note
♦ If the wear limit is exceeded, repeat the measurement with

new valves. Renew cylinder head if wear limit is still exceeded.
♦ If the valve has to be renewed as part of a repair, use a new
valve for the measurement.

Audi A6 1998 ➤
2.9 Checking valves

– Visually inspect for scoring on stem and surface of seat.
– Renew valves with significant score marks.

Audi A6 1998 ➤
17 – Lubrication
1 Removing and installing parts of lu‐
brication system
Note
♦ If large quantities of metal particles are found in the engine oil

when repairing the engine, the oil passages must be cleaned
carefully, and the oil cooler renewed in order to prevent further
damage.
♦ The oil level must not be above the max. mark – otherwise the
catalytic converter can be damaged.
♦ Before applying sealant, check updated information: ⇒ Parts
catalogue
Viscosity grades and oil specifications ⇒ Maintenance ; Booklet

402 .
Oil capacities ⇒ Data sheets for exhaust emission test.
1.1 Sump, oil pump - exploded view of components
96 Rep. Gr.17 - Lubrication

Audi A6 1998 ➤
1 - Sump
⇒ page 100
❑ Clean sealing surface
before installing
stalling
logue
2 - Gasket
❑ Renew
❑ Install dry
stalling
logue
3 - Intake pipe
❑ Clean strainer if dirty
4 - 10 Nm
5 - 23 Nm
6 - Longitudinal strut (right-
side)
7 - 23
withNm
8 - Stop for torque reaction

support
❑ Allow stop for torque re‐
action support to rest on
rubber buffer for torque
reaction support under
its own weight, and
tighten bolts.
9 - 23 Nm
10 - 23 Nm
11 - Bracket for torque reaction support
12 - Shim
13 - 23 Nm
14 - Longitudinal strut (left-side)
15 - 23 Nm
16 - Oil pump housing
17 - Gears
❑ Checking backlash ⇒ page 98
❑ Checking axial clearance ⇒ page 98
18 - Oil pump cover with pressure relief valve
❑ Opening pressure: 5.7 ... 6.7 bar
19 - 10 Nm
20 - 25 Nm
21 - O-ring
❑ Renew
1. Removing and installing parts of lubrication system 97

Audi A6 1998 ➤
22 - Engine/gearbox support
❑ Unbolt to remove sump ⇒ page 100
❑ When installing engine/gearbox support with engine removed from vehicle, make sure engine/gearbox
support is positioned flush with intermediate plate at flywheel end, i.e. engine/gearbox support should
protrude 0.8 mm from cylinder block
23 - 45 Nm
24 - 45 Nm
25 - Oil drain plug, 30 Nm
26 - Seal
❑ Renew
27 - 18 Nm
❑ Tighten in stages and in diagonal sequence
Checking backlash of oil pump

• New: 0.05 mm.
Checking axial clearance of oil pump


Audi A6 1998 ➤
1.2 Oil filter bracket, oil filter - exploded view of components
1 - O-ring
❑ Renew
❑ Engage in lugs on oil
cooler
2 - 25 Nm
3 - Gasket
❑ Renew
4 - Oil retention valve
❑ Tighten to 8 Nm
5 - Oil filter bracket
6 - Seals
❑ Renew
7 - Banjo bolt, 25 Nm
8 - Oil supply pipe
❑ To turbocharger
9 - 20 Nm
10 - Coolant pipe
11 - 0.9 bar oil pressure switch
-F1-
❑ Different versions possi‐
ble ⇒ Parts catalogue
12 - Seal
❑ If seal is leaking, cut
open and renew
13 - Oil temperature sender -
G8-
14 - Seal
❑ If seal is leaking, cut open and renew
15 - Oil cooler
16 - 25 Nm
17 - Oil filter
❑ Observe change intervals ⇒ Maintenance ; Booklet 402
❑ Loosen with strap wrench
❑ Observe installation instructions on oil filter

Audi A6 1998 ➤
1.3 Removing and installing sump

equipment required
♦ Support bracket -10-222 A-
♦ Lifting tackle -2024 A-
♦ Jointed spanner -3185-
♦ Hexagon key extension, 5
mm -3249-
♦ Workshop hoist -V.A.G
1202 A- or -VAS 6100-
♦ Used oil collection and extraction unit -V.A.G 1782-
♦ Electric drill with plastic brush attachment

♦ Safety goggles
♦ Sealant ⇒ Parts catalogue

Audi A6 1998 ➤
Removing


– Set up support bracket -10-222 A- on wing panel flanges.

• The spindle must be at the front.

Audi A6 1998 ➤
– Remove eyelets of lifting tackle -2024 A- .

– Re-insert pin -1- in centre hole of lifting tackle and secure with
split pin.
– Hang the pin of lifting tackle -2024 A- onto the spindle of sup‐
port bracket -10-222 A- .
– Engage lifting tackle -2024 A- in front and rear lifting eyes on
engine.
WARNING
The support hooks and retaining pins on the lifting tackle must
be secured with locking pins -arrows-.
– Take up weight of engine with the spindle of support bracket,

but do not lift.

– Release quick-release fasteners -1 … 3- and take off front and

rear noise insulation.
– Drain engine oil.
Note

– Unbolt bracket for ATF pipe at engine.
All models:
– Unbolt bracket for noise insulation -arrow-.

Audi A6 1998 ➤
(left-side).
Note


– Remove tensioning roller.
– Unscrew bolts -arrows- and remove torque reaction support.
– Remove longitudinal strut (left and right) and unbolt bracket

for torque reaction support from engine -arrows-.
Note
Illustration shows engine removed.

Audi A6 1998 ➤
– If fitted, unclip actuator rod for vehicle level sender at bottom

transverse link -arrow-.
– Cut through cable ties -arrows-. Open retainer for starter wiring
and take out wiring.
– Unbolt bracket for wiring harness at left engine mounting.

– Mark positions of bolt connections -1- and locating sleeves
-2- on bottom of engine mounts (left and right).
Note
Different mounting holes are provided for the different engine ver‐
sions.
– Remove bottom nut -1- at engine mounting (left and right).
– Support subframe using workshop hoist -V.A.G 1202 A- or -

VAS 6100- .

Audi A6 1998 ➤
– First remove front subframe bolts -2- and -3- (left and right).
Then unscrew bolts -1-.
Note
To avoid having to check and adjust wheel alignment, only loosen

the front subframe mountings and lower the subframe at the front.
– Loosen rear bolt -2- for gearbox mounting (right-side) a few

turns, then unscrew front bolt -1- for gearbox mounting (right-
side).
– Loosen nut -arrow- for gearbox mounting (left-side) until it

aligns with the lower edge of the bolt (turned approx. 4
threads).
– Carefully lower subframe using workshop hoist -

V.A.G 1202 A- or -VAS 6100- .
– Remove workshop hoist and move anti-roll bar downwards.

Audi A6 1998 ➤
– Unscrew bolts -1 ... 8- securing engine/gearbox support.
Note
On removal, note down bolt lengths and original installation po‐

sition for re-installation.
– Guide engine/gearbox support to rear and take out.
– Unscrew bolts securing sump.
Note
Use hexagon key extension -3249- to unscrew the two rear sump
bolts -1- and -2-. For this purpose, turn the dual-mass flywheel
-3- (on vehicles with manual gearbox) until the recess -arrow- is
aligned with the bolt.
– Take off sump; if necessary loosen it by striking lightly with a

rubber hammer.
Installing
Note
Renew gaskets and seals.
– Clean sealing surfaces; they must be free of oil and grease.

– Apply a thin coat of sealant to front and rear sealing flange/
cylinder block transitions at sealing surface of sump; sealant
⇒ Parts catalogue .
– Fit sump and tighten bolts in two stages and diagonal se‐
quence.
Note
When installing the engine/gearbox support -3- with the engine

removed from the vehicle, make sure that it is positioned flush
with the intermediate plate -1- at the flywheel end. In other words,
the engine/gearbox support should protrude by 0.8 mm (dis‐
tance -a-) from cylinder block -2-.
– Install subframe ⇒ Running gear, front-wheel drive and four-

wheel drive; Rep. Gr. 40

Audi A6 1998 ➤
– Allow stop for torque reaction support to rest on rubber buffer

for torque reaction support under its own weight and tighten
bolts -arrows-.
– Install tensioning roller for poly V-belt and poly V-belt for air
conditioner compressor ⇒ page 29 .
37 .
– Fill up with engine oil and check oil level.
Tightening torques
Securing engine/gearbox support
Item Bolt Nm
1 M10x28 45
2, 4, 5, 6 M10x45 45
3, 7 M10x95 45
8 M10x65 45
Component Nm
Sump to cylinder block 18 13)
Bracket for torque reaction support to engine 23
Engine mounting to subframe 23
Longitudinal strut to bracket for torque reaction 23
support
Longitudinal strut to engine support 23
Oil drain plug 30
13) Special bolts; use only genuine bolts ⇒ Parts catalogue .
1.4 Removing and installing oil pump

Removing
– Remove sump ⇒ page 100 .
– Unscrew bolt -arrows-.
– Press subframe down and remove oil pump.
Installing
– Install sump ⇒ page 106 .
– Fill up with engine oil and check oil level.
Tightening torque
Component Nm
Oil pump to cylinder block 25
1.5 Checking oil pressure and oil pressure switch

Audi A6 1998 ➤

equipment required
♦ Oil pressure tester -
V.A.G 1342-
♦ Voltage tester -V.A.G 1527
B-
♦ Auxiliary measuring set -
V.A.G 1594 C-
Test requirements
• Oil level OK
• Engine oil temperature approx. 80 °C
• Oil pressure warning lamp -K3- should come on when ignition
is switched on.
• On vehicles with driver information system (DIS), the message
“OK” should light up in the display.

Audi A6 1998 ➤
Preparation for test

– Unplug electrical connector at oil pressure switch -F1- .
– Unscrew oil pressure switch.
– Connect oil pressure tester -V.A.G 1342- to threaded hole for
oil pressure switch.
– Screw oil pressure switch -F1- -Item 2- into oil pressure tester
-V.A.G 1342- .
Checking oil pressure switch
– Connect brown wire -1- of oil pressure tester to earth (–).
– Connect voltage tester -V.A.G 1527 B- with test leads from
auxiliary measuring set -V.A.G 1594 C- to oil pressure switch
and battery positive (+).
• LED should not light up.
If LED lights up now:
– Renew oil pressure switch.
– Start engine.
Note
Observe tester and LED while starting, as switching point of oil

pressure switch may already be exceeded when starting.
• LED should light up at 0.75 ... 1.05 bar.

If the LED does not light up:
– Renew oil pressure switch.
Checking oil pressure
– Start engine.
• Minimum oil pressure at idling speed: 0.8 bar.
• Minimum oilbypressure
Protected at 2000
copyright. Copying rpm:
for private 2.0 bar. purposes, in part or in whole, is not
or commercial
• Maximum oil pressure
with respect at higher
to the correctness engine
of information speeds:
in this document.7.0 bar by AUDI AG.
Copyright
The pressure relief valve or oil pump is defective if the specifica‐

tions are not attained.
– Renew the oil pump ⇒ page 107 .
Assembling
Assemble in reverse order.
1.6 Engine oil

Viscosity grades and oil specifications
⇒ Maintenance ; Booklet 402 .
1.7 Checking oil level

Test requirements
• Engine oil temperature at least 60 °C.
• Vehicle must be level (horizontal)
• Wait a few minutes after switching off the engine to allow the
oil to flow back into the sump.

Audi A6 1998 ➤
Test sequence
– Pull out the dipstick, wipe off with a clean cloth and insert it
again as far as it will go.
– Pull out the dipstick again and read off the oil level.
Markings on oil dipstick:
a - Do not top up oil.
b - Oil may be topped up. The oil level may rise as far as area
-a- after topping up. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
c - Oil must be topped up. It with
is sufficient if the oil level is some‐
where in area -b- after topping up.
Note
The oil level must not be above the MAX marking -a- and not
below the MIN marking -c-.

Audi A6 1998 ➤
19 – Cooling
1 Removing and installing parts of cool‐
ing system
WARNING

Note
♦ The cooling system is under pressure when the engine is hot.

If necessary, relieve pressure before commencing repair work.
♦ Renew gaskets and seals.

♦ The arrow markings on coolant pipes and on ends of hoses

must align.
1.1 Coolant hose connection diagram
1. Removing and installing parts of cooling system 111

Audi A6 1998 ➤
1 - Radiator
⇒ page 127
with fresh coolant
2 - Coolant hose
❑ To expansion tank
3 - Expansion tank
4 - Filler cap
❑ With pressure relief
valve
❑ Checking pressure re‐
lief valve ⇒ page 133
5 - Oil cooler
6 - Bleed hole
❑ In return pipe from heat
exchanger for heater
7 - Heat exchanger for heater
with fresh coolant
8 - Coolant hose
❑ To heat exchanger
9 - Coolant pump/thermostat
coolant pump
⇒ page 119
thermostat ⇒ page 120
❑ Checking thermostat
⇒ page 121
112 Rep. Gr.19 - Cooling

Audi A6 1998 ➤
1.2 Draining and filling cooling system

equipment required
♦ Adapter for cooling system
tester -V.A.G 1274/8-
♦ Pipe for cooling system
-VAS 6208-
♦ Hose clip pliers -
V.A.G 1921-
♦ Cooling system charge unit
-VAS 6096-
♦ Refractometer -T10007-
Draining
Note
Collect drained coolant in a clean container for re-use or disposal.
WARNING
Hot steam/hot coolant may escape

Protected when
by copyright. opening
Copying expansion
tank; cover filler cap with permitted
cloth and open
unless carefully.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi A6 1998 ➤

insulation.
– Pull off retaining clip -arrow- for coolant hose (bottom)

– Disconnect coolant hose from radiator and drain off coolant.
Note
When the bumper is removed the coolant can also be drained

from the radiator via the drain plug -arrow-.

Audi A6 1998 ➤

ring and thermostat to drain remaining coolant.
Filling
Note
♦ The cooling system is filled all year round with a mixture of

water and antifreeze/corrosion protection agent.
♦ It is important to use only coolant additive Plus -G 012 A8F
A1- (also designated as “G12+”) “meeting specification
TL VW 774 F”. Other coolant additives could seriously impair
in particular the anticorrosion properties. The resulting dam‐
age could lead to loss of coolant and consequently to serious
engine damage.
♦ Coolant additive “G12+” may be mixed with additives “G11”
and “G12”.
♦ “G12+” and coolant additives marked “Conforming with spec‐
ification TL VW 774 F” prevent frost and corrosion damage
and stop scale from forming. Such additives also raise the
boiling point of the coolant. For these reasons the cooling sys‐
tem must be filled all year round with the correct antifreeze and
anticorrosion additive.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Frost protection is required down to about –25 °C (in countries
with arctic climate: down to about –35 °C).
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The
antifreeze percentage must be at least 40 %.
♦ If greater frost protection is required in very cold climates, the
proportion of “G12+” can be increased, but only up to 60 %
(this gives frost protection to about –40°C). If the antifreeze
percentage exceeds 60%, frost protection is reduced again
and cooling efficiency is also impaired.
♦ Use only clean tap water for mixing coolant.
♦ If radiator, heat exchanger, cylinder head, cylinder head gas‐
ket or cylinder block have been renewed, do not re-use old
coolant.
♦ Contaminated or dirty coolant must not be used again.
♦ To check frost protection level of coolant additive “G12+” you
must use a refractometer -T10007- .

Audi A6 1998 ➤
Procedure
– Re-connect coolant hose to radiator -arrow-.
– Tighten drain plug on radiator, if coolant was drained via drain
plug.
– Fit hose connection and thermostat with new O-ring -arrows-.
– Install front noise insulation by locking fasteners -1- and -2-.
– Fill reservoir of -VAS 6096- with at least 10 litres of premixed

coolant (according to recommended ratio):
• “G12+” (40 %) and water (60 %) for frost protection to -25 °C
– Screw adapter for cooling system tester -V.A.G 1274/8- onto
coolant expansion tank.
– Fit cooling system charge unit -VAS 6096- onto adapter -
V.A.G 1274/8- .
– Run vent hose -1- into a small container -2-. (The vented air
draws along a small amount of coolant, which should be col‐
lected.)
– Close
Protectedboth valves
by copyright. -A- and
Copying -B-or(turn
for private lever
commercial perpendicular
purposes, to di‐
in part or in whole, is not
rection
permittedof flow).
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Connect hose -3- to compressed air.
• Pressure: 6 ... 10 bar.

Audi A6 1998 ➤
– Open valve -B- (turn lever in direction of flow).

The suction jet pump generates a partial vacuum in the cooling
system.
• The needle on the gauge should move into the green zone.
– Also briefly open valve -A- (turn lever in direction of flow) so
that hose on charge unit reservoir -VAS 6091- can fill with
coolant.
– Close valve -A- again.
– Leave valve -B- open for another 2 minutes.
• The suction jet pump will continue generating a vacuum in the
cooling system.
• The needle on the gauge should remain in the green zone.
– Close valve -B-.
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
If the needle does not reach the green zone, repeat the process.
If the vacuum level drops, there is a leak in the cooling system.
– Detach compressed air hose.
– Open valve -A-.
The vacuum in the cooling system causes the coolant to be drawn
out of the reservoir for cooling system charge unit -VAS 6096- ;
the coolingProtected
system is thenCopying
by copyright. filled.for private or commercial purposes, in part or in whole, is not
– Detach cooling system
with respect chargeof unit
to the correctness -VAS
information 6096-
in this from
document. expan‐
Copyright by AUDI AG.
sion tank.
– Fit pipe -V.A.G 1274/10- onto adapter -V.A.G 1274/8- .

-arrow-.

Audi A6 1998 ➤
– Fold back bellows at heat exchanger connection in plenum

chamber.
– Loosen coolant hose going to heat exchanger and pull back
hose until bleeder hole in hose -arrow- is no longer blocked by
the connection.
– Fill up with coolant until it flows out at bleeder hole in coolant
hose.
– Push coolant hose onto connection and secure with hose clip.
– On vehicles with auxiliary heater, switch heater on (for about
30 seconds) and then off again.
– Tighten filler cap on expansion tank.
– Start engine and maintain an engine speed of about 2,000 rpm
for approx. 3 minutes.
– Then allow engine to idle until bottom coolant hose at radiator
becomes hot.
WARNING

– Check coolant level.

• The coolant level must be at the MAX marking when the en‐
gine is cold.
• The coolant level can be above the MAX marking when the
engine is warm.
– Switch engine off.
Tightening torque
Component Nm
Hose connection to bracket for ancillaries 10
1.3 Coolant pump and thermostat - exploded view of components


Audi A6 1998 ➤
1 - Pulley
2 - 25 Nm
3 - 10 Nm
4 - Coolant pump
⇒ page 119
5 - O-ring
❑ Renew
6 - O-ring
❑ Renew
7 - Bracket for ancillaries
⇒ page 30
8 - Thermostat
⇒ page 120
9 - O-ring
❑ Renew
10 - 10 Nm
11 - Hose connection
1.4 Removing and installing coolant pump


Audi A6 1998 ➤
Removing
Rep. Gr. 63 .
Note

– Counterhold coolant pump pulley using 2-hole pin wrench
-3212- and unbolt coolant pump pulley from bearing with an 8
mm hexagon key.
– Unbolt coolant pump from bracket for alternator, power steer‐

ing pump and viscous fan -arrow-.
– Remove coolant pump.
Installing
Note
Renew O-ring.

Tightening torques
Component Nm
Coolant pump to bracket for alternator, power 10
steering pump and viscous fan
Pulley to coolant pump 25
1.5 Removing, installing and checking ther‐

mostat
Removing
WARNING



Audi A6 1998 ➤

ring and thermostat.
Installing
Note
Renew O-ring.

– Fit thermostat with new O-ring into hose connection.
– Install hose connection for thermostat -arrows-.
– Fill cooling system ⇒ pagepermitted
115 . unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Tightening torque
Component Nm
Hose connection to bracket for ancillaries 10
Checking thermostat
– Heat thermostat in water bath.
Starts to open Fully open Opening travel
approx. 87 °C approx. 102 °C 14)
at least 8 mm
14) Cannot be tested.
1.6 Removing and installing coolant pipe

♦ Hose clip pliers -V.A.G 1921-
Removing
– Release air hose (left-side) at rear air pipe and move hose
clear to one side.
circulation valve.
necting pipe.
– Unscrew bolt -5- and remove air pipe.

Audi A6 1998 ➤


– Detach coolant hose (left-side) from cylinder head and expan‐
sion tank -arrows- and move clear to one side.
– Unplug electrical connector for injection pump and disengage
from retainer.
– Move wiring harness secured to coolant pipe clear.
– Disconnect coolant hose -4- going to oil cooler at coolant pipe.

– Disconnect coolant hose -5- (leading to heat exchanger) from
coolant pipe.
– Loosen hose clip -1- to remove coolant hose going to coolant
pump.
– Unscrew bolt -3- and detach coolant pipe -2- from oil filter
bracket.
Installing
Tightening torque
Component Nm
Coolant
permittedpipe
unlessto oil filter
authorised bracket
by AUDI AG. AUDI AG does not guarantee or accept20 any liability
1.7 Removing and installing viscous fan


Audi A6 1998 ➤
Removing
Caution


-arrow-.

-arrow-.

poly V-belt. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove poly V-belt from alternator pulley. with respect to the correctness of information in this document. Copyright by AUDI AG.
Note

Audi A6 1998 ➤

key.
– Detach viscous fan from bearing and lay it forwards in radiator
cowl.
– Remove bolts -1- and -2-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove alternator and lay it aside with wires connected.

– Take viscous fan out of radiator cowl.

Installing
– Place viscous fan in radiator cowl prior to installing alternator.
– To facilitate positioning of alternator, drive back bushes for
securing bolts slightly.
– Install alternator ⇒ Electrical system; Rep. Gr. 27
– Install viscous fan.
Tightening torques
Component Nm
Fan to viscous coupling 9 15)
Viscous coupling to pulley 28 16)
Alternator to bracket 25
15) Renew self-locking bolts.
16) Renew ribbed bolt.
1.8 Removing and installing bearing for viscous fan in bracket

Audi A6 1998 ➤

equipment required
♦ Assembly tool -3301-
♦ Assembly tool -3350-
♦ Viscous fan fitting tool
-3367-
Removing
Rep. Gr. 63 .
poly V-belt.
Note


Audi A6 1998 ➤

key.
– Remove viscous fan from bearing.
– Use angled circlip pliers to remove circlip -arrow- from bearing

bush.
– Pull viscous fan bearing out of bracket using nut from assem‐
bly tool -3301- , bolt -3367/3- and assembly tool -3350- .

Audi A6 1998 ➤
Installing
– Press viscous fan bearing in, using viscous fan fitting tool
-3367/1- , -3367/2- and -3367/3- with nut from assembly tool
-3301- .
– Use angled circlip pliers to install circlip -arrow- in bracket for

viscous fan.
– Install viscous fan.
50 .
Gr. 63 .
Tightening torque
Component Nm
1.9 Removing and installing radiator

Audi A6 1998 ➤

equipment required
♦ Used oil collection and ex‐
traction unit -V.A.G 1782-
♦ Hose clip pliers -V.A.G
1921-
♦ Drip tray for workshop hoist
-VAS 6208- or drip tray -
V.A.G 1306-
Removing
Gr. 63 .
WARNING


Audi A6 1998 ➤
– Unclip ambient temperature sensor -G17- from bracket.

– Unscrew bolts -arrows- and move cooling pipe for power steer‐
ing clear; hydraulic fluid system remains closed.
– Turn drain plug -arrow- on radiator anticlockwise and drain
coolant (attach hose to connection if necessary).
– Pull off retaining clip for coolant hose (bottom) -arrow- and re‐
move coolant hose from radiator.
– Remove top coolant hose at radiator.


Audi A6 1998 ➤
Note

– Place used oil collection and extraction unit -V.A.G 1782- un‐
der engine.
– Remove ATF pipes (top -arrow- and bottom) from radiator: ⇒
Automatic gearbox 01N; Rep. Gr. 37 .
– Tie ATF pipes up onto longitudinal member to prevent fluid
escaping.
All models:
– Remove the left and right-hand air ducts from the radiator.
– Unplug electrical connector -1-byat
Protected low pressure
copyright. switch
Copying for private for air purposes, in part or in whole, is not
or commercial
conditioner -F73- . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Release both retaining pins -2- and pull out to side -arrows-.
WARNING
– Detach both brackets -3- and pull condenser upwards out of

bracket
Note
To prevent damage to the condenser and refrigerant pipes/hoses,

ensure that the pipes and hoses are not stretched, kinked or bent.
– Pivot condenser downwards with pipes/hoses attached.

Audi A6 1998 ➤
– Release two retaining pins for radiator and pull out upwards
-arrows-.
– Swivel radiator forwards and lift off.
Installing
Gr. 63 .
Note
The coolant in the entire system must be changed if the radiator

is renewed.

37 .
Tightening torques
Component Nm
Condenser to radiator 10
Air cowls to radiator 2
1.10 Checking cooling system for leaks

Audi A6 1998 ➤

equipment required
♦ Cooling system tester -
V.A.G 1274-
Test requirement
• Engine must be warm.
Test sequence
WARNING


– Attach cooling system tester -V.A.G 1274- with adapter -
V.A.G 1274/8- to expansion tank.
– Use hand pump on cooling system tester to create a pressure
of approx. 1.0 bar.
If the pressure drops:
– Trace leak and repair.

Audi A6 1998 ➤
Checking pressure relief valve in filler cap

– Attach cooling system tester -V.A.G 1274- with adapter -
V.A.G 1274/9- to filler cap.
– Use hand pump on cooling system tester to create pressure.
• The pressure relief valve should open at pressure of 1.4 ... 1.6
bar.
If the relief valve does not open as described:
– Renew filler cap.

Audi A6 1998 ➤
21 – Turbocharging/supercharging
1 Checking charge air system with tur‐
bocharger
Note
♦ Observe rules for cleanliness ⇒ page 149 .

♦ Renew gaskets, seals and self-locking nuts.
♦ Charge air system must be free of leaks.
1.1 Safety precautions

Note the following if testers and measuring instruments have to
be used during a road test:
WARNING
♦ Test equipment must always be secured on the rear seat

and operated from that position by a second person.
♦ If test and measuring instruments are operated from front
passenger's seat and the vehicle is involved in an acci‐
dent, the person sitting in this seat could be seriously
injured when the airbag is triggered.
1.2 Requirements for turbocharging check

• Coolant temperature at least 85 °C.
• Fault memory of engine control unit interrogated.
• Exhaust gas recirculation system OK, checking ⇒ page 170 .
Note
If there is a fault in the exhaust gas recirculation, it is not possible

to achieve reliable values when checking exhaust turbocharging.
• No leaks in the intake and exhaust systems. Effects of leaks

⇒ page 134 .
• Vacuum pipe to charge pressure regulating valve not obstruc‐
ted, loose or leaking.
• No faults on engine or injection system (e.g. compression
pressure or injectors).
1.3 Effects of leaks in the intake and ex‐

haust systems
A - Leaks after air mass meter -G70-
Possible causes of trouble:
134 Rep. Gr.21 - Turbocharging/supercharging

Audi A6 1998 ➤
1- Connecting hose between air mass meter -G70- and turbo‐

charger
2- Connecting hose to crankcase breather
Effect: Loss of power
B - Leaks after turbocharger (intake side)
1- Hoses connecting air intake pipe in lock carrier to turbo‐
charger or charge air cooler
2- Air intake hoses and pipes between charge air cooler and
intake manifold
3- Charge air cooler
4- Gasket below intake manifold pressure sender -G71- and
intake manifold temperature sender -G72- .
5- Gasket between inlet connection flange and intake manifold
6- Gasket between intake manifold and cylinder head
Effect: inadequate charge pressure
C - Leaks after turbocharger (exhaust side)
1- Components of exhaust gas recirculation system
2- Connection between turbocharger and exhaust manifold
3- Connection between exhaust manifold and cylinder head
Effect: inadequate charge pressure; possible smell of exhaust
gas, traces of soot in engine compartment
1.4 Checking turbocharger and charge

pressure
♦ Vehicle diagnosis, testing and information system -
VAS 5051 A- with diagnosis lead -VAS 5051/1-
1. Checking charge air system with turbocharger 135

Audi A6 1998 ➤
♦ Hand-operated vacuum pump -V.A.G 1390-
Test requirements
• All hoses, pipes and wiring are checked for tight fit and leak‐
ages.
• No leaks in the intake and exhaust systems.
• No faults in engine or injection system, e.g compression pres‐
sure or injectors.
• Fault memory interrogated.
Test sequence
WARNING
To avoid accident risks when road testing the vehicle with test
equipment, always observe the relevant safety precautions
⇒ page 134 .
• Vehicle diagnostic, testing and information system -

VAS 5051 A- with diagnosis lead -VAS 5051/1- is connected;
vehicle self-diagnosis and vehicle system “01 - Engine elec‐
tronics” is selected. Engine must be idling.
Display on -VAS 5051 A- :
– From list -1- select diagnostic function “04 - Basic setting”.

Audi A6 1998 ➤

1 - Enter display group (highest possible entry = 255)
– Use keypad -2- to enter “11” for “Display group number 011”
and confirm by touching the Q key.

– Activate basic setting by touching Activate key -A-.
• The engine speed is increased to 1380
Protected by copyright. rpmfor...
Copying 1420
private rpm. purposes, in part or in whole, is not
or commercial
• The vacuum unit for charge pressure
with respect controlofisinformation
to the correctness actuated indocument.
in this in‐ Copyright by AUDI AG.
tervals.
– Compare displays in zones -2- and -3-.
Display zones Explanatory notes

2 … Activation of charge pressure control solenoid valve -N75- alternating between
• “Off”
• “On”
3 ... mbar Intake manifold pressure (charge pressure) alternating between

• Specification for status “off”: approx. ambient pressure
• Specification for status “on”: 100 ... 200 mbar above ambient pressure


Audi A6 1998 ➤
– In addition, check whether the turbocharger actuating rod

moves -arrows-.
– End function “04 - Basic setting” by pressing the ← key.
If the specified value in display zone “3” is not achieved, or if the
operating rod on the turbocharger does not move smoothly:
– Check linkage and vacuum unit for charge pressure control
⇒ page 139 .
– Continue the test as follows:

Display on -VAS 5051 A-
– From the list -1- select diagnostic function “08 - Read meas‐
ured value block”.


1 - Enter display group
– Engage third gear or move selector lever to position 2 and
accelerate at full throttle (without kickdown) from 2000 rpm.
Observe rev counter (2nd mechanic required).
– The 2nd mechanic must press keypad “Print out - store test
result” on -VAS 5051 A- at an engine speed of approx. 3000
rpm.

Audi A6 1998 ➤
• Specification in display zone -1- (engine speed): approx. 3000

rpm
• Specification in display zone -3- (actual charge pressure):
800 ... 2200 mbar.
– Press the ← button to exit from the function “08 - Read meas‐
– Press “06 - End output”.
– Switch off ignition.
If charge pressure is not within the specified range:
– Check charge air system for leaks.
– Check linkage and vacuum unit for charge pressure control
⇒ page 139 .
– Check intake manifold pressure sender -G71- ⇒ page 145 .
– Check charge pressure control solenoid valve -N75-
⇒ page 142 .
If all the above items are OK, but the charge pressure is too low:
– Renew turbocharger ⇒ page 151 .
Checking linkage and vacuum unit for charge pressure control
Problems with linkage/vacuum unit for charge pressure control
result in the following faults:
1- Not achieving the specified charge pressure values.
2- Loss of power.
3- Uneven power delivery at part throttle
4- Jolts when throttle is opened or closed.
• Check that all vacuum hoses are fitted and not leaking
⇒ page 140 .
• Vacuum must be available in vacuum reservoir. Run engine
for a short period of time to build up vacuum if necessary.
• Air duct (right-side) in engine compartment removed.
tronics” is selected. When doing this, the ignition must be
switched on.

– From the menu -1- select the diagnostic function “03 - Final
control diagnosis”. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Press the button → until the charge pressure control solenoid
valve -N75- is actuated.
• Solenoid valve for charge pressure control -N75- should op‐
erate audibly.

Audi A6 1998 ➤
– Also observe linkage at turbocharger.

• Simultaneously, the linkage rod of the vacuum unit for charge
pressure control on the turbocharger should move back and
forth (at least 3 ... 4 times until the vacuum supply in the res‐
ervoir is exhausted).
If linkage does not move because the solenoid valve is not work‐
ing:
– Check charge pressure control solenoid valve -N75-
⇒ page 142 .
If linkage does not move, even though solenoid valve is working:

– Disconnect hose -arrow- from vacuum unit for charge pres‐
sure control.
– Connect hand-operated vacuum pump -V.A.G 1390- to charge

pressure regulating valve and check that linkage moves freely
between both end stops.
Note
Observe the movement of the linkage over the complete range of

travel. It should move steadily and smoothly.
If the specified values are not achieved or if the linkage does not
move smoothly:
– Renew turbocharger ⇒ page 151 .
1.5 Hose connection diagram for charge pressure control

Audi A6 1998 ➤
1 - To exhaust gas recircula‐

tion valve -N18-
2 - Vacuum connection for air
conditioning system
❑ With cap for vehicles
without air conditioning
system
3 - Vacuum hose for brake ser‐
vo
4 - Exhauster pump
5 - Vacuum unit for charge
pressure control
6 - Vacuum hose
❑ To vacuum reservoir
7 - Vent pipe
❑ Between charge pres‐
sure control solenoid
valve -N75- and air
cleaner
8 - Solenoid valve for charge
pressure control -N75-
9 - Vacuum reservoir
10 - Vacuum hose
❑ From solenoid valve for
charge pressure control
-N75- to vacuum unit for
charge pressure control
11 - Vacuum hose
❑ Between charge pres‐
sure control solenoid
valve -N75- and non-re‐
turn valve
12 - Non-return valve
❑ White connection facing charge pressure control solenoid valve -N75- ⇒ Item 8 (page 141) and vacuum
reservoir
13 - Vent pipe
❑ To air cleaner
14 - Vent pipe
❑ From exhaust gas recirculation valve -N18-

Audi A6 1998 ➤
1.6 Checking solenoid valve for charge pressure control -N75-

equipment required
♦ Hand-held multimeter -
V.A.G 1526 A- or -V.A.G
1526 B-
♦ Voltage tester -
V.A.G 1527 B-
V.A.G 1594 A- or -V.A.G
1594 C-
♦ Test box -V.A.G 1598/22-
for vehicles to 06.1999
♦ Test box -V.A.G 1598/31-
for vehicles from 07.1999
♦ Vehicle diagnosis, testing
and information system - with respect to the correctness of information in this document. Copyright by AUDI AG.
VAS 5051 A- with diagnosis
lead -VAS 5051/1-
Test sequence

Audi A6 1998 ➤
Checking internal resistance

– Disconnect electrical connector at charge pressure control
solenoid valve -N75- .
– Connect hand-held multimeter -V.A.G 1526 A- or -V.A.G 1526
B- between contacts 1 and 2 of charge pressure control sole‐
noid valve -N75- to measure resistance.
• Specification: 14 ... 20 Ω
If specification is not obtained:
– Renew charge pressure control solenoid valve -N75- .
Checking voltage supply

B- between contact -1- and earth to measure voltage.
– Switch on ignition.
• Specification: approx. battery voltage
– Check for open circuit in wiring (see current flow diagram) and
repair if necessary.
Checking activation
switched on.
– Connect voltage tester -V.A.G 1527 B- between contacts -1-
and -2-.

Audi A6 1998 ➤

control diagnosis”.
– Press the button → until the charge pressure control solenoid
valve -N75- is actuated.
• LED should flash slowly.
Note
Voltage testers with a low current draw do not go out completely

between activation signals from engine control unit, but continue
to glow slightly and become distinctly brighter on activation.
– Press the ← key to exit from function “03 - Final control diag‐
nosis”.
If LED does not react as described:
Vehicles to 06.1999:
– Connect test box -V.A.G 1598/22- to connectors of wiring har‐
ness; do not connect engine control unit. Connect earth clip of
test box to earth (not shown in illustration) ⇒ Rep. Gr. 23 .
Caution
To prevent damage to electronic components,

Protected byselect
copyright.appro‐
Copying for private or commercial purposes, in part or in whole, is not
priate measuring range before connectingwithmeasuring leads of information in this document. Copyright by AUDI AG.
respect to the correctness
and observe test requirements.
– Check for open circuit and short to positive or earth in the fol‐
lowing wiring:
Connector Test box -V.A.G 1598/22-
Contact Socket
-2- 15
– Repair wiring connection if necessary.
Vehicles from 07.1999:

Caution
To prevent damage to electronic components, select appro‐

priate measuring range before connecting measuring leads

Audi A6 1998 ➤
lowing wiring:
Contact Socket
-2- 62
1.7 Checking
permitted unless intake
authorised bymanifold pressure sender
does not guarantee -G71-
AUDI AG. AUDI AG or accept any liability

equipment required
V.A.G 1526 A- or -V.A.G
1526 B-
V.A.G 1594 A- or -V.A.G
1594 C-
♦ Test box -V.A.G 1598/22-
♦ Test box -V.A.G 1598/31-
and information system -
lead -VAS 5051/1-

Audi A6 1998 ➤
Note
♦ Fitting location of intake manifold pressure sender -G71-

-arrow-: in rear air intake pipe.
♦ The intake manifold pressure sender -G71- is combined as
one unit with intake manifold temperature sender -G72- .
Test sequence
switched on.

– From the list -1- select diagnostic function “08 - Read meas‐


– Compare display in zones -2- and -3-.
• Specification: The pressures should be the same; tolerance:
± 30 mbar.
– Use current flow diagram to check wiring.
– Press the ← button to exit from the function “08 - Read meas‐

Audi A6 1998 ➤
Checking wiring
Caution

– Unplug electrical connector -arrow- at charge air pressure

sender -G71- .
lowing wiring:
Contact Socket
-1- 1, 25 or 27
-3- 39
-4- 40
If no fault is found:
– Renew the unit containing charge air pressure sender -G71- /
intake air temperature sender -G72- .

Cautionof information in this document. Copyright by AUDI AG.
with respect to the correctness


Audi A6 1998 ➤
– Unplug electrical connector -arrow- at charge air pressure

sender -G71- .
lowing wiring:
Contact Socket
-1- 52
-3- 31
-4- 71
If no fault is found:
– Renew the unit containing charge air pressure sender -G71- /
intake air temperature sender -G72- .

Audi A6 1998 ➤
2 Servicing charge air system with tur‐

bocharger
2.1 Rules for cleanliness

When working on the turbocharger, pay careful attention to the
following “5 rules”:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place parts that have been removed on a clean surface and
cover them over. Use only lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).
♦ When the system is open: Do not work with compressed air if
Protectedthis can beCopying
by copyright. avoided. Doornot
for private move purposes,
commercial the vehicle
in part unless absolutely
or in whole, is not
necessary.
2.2 Turbocharger - exploded view of components
2. Servicing charge air system with turbocharger 149

Audi A6 1998 ➤
1 - Bracket
2 - 20 Nm
3 - Turbocharger
⇒ page 151
4 - Gasket
❑ Renew
5 - Catalytic converter
6 - 25 Nm
❑ Renew
7 - Seal
❑ Renew
8 - Screw connection
❑ Garret version: tighten
to 23 Nm
❑ KKK version: tighten to
40 Nm
9 - Hose
❑ From charge pressure
control solenoid valve -
N75-
10 - Oil supply pipe
❑ Tighten union nut to 22
Nm
11 - 25 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
12 - To oil filter bracket with respect to the correctness of information in this document. Copyright by AUDI AG.
13 - Bracket
14 - 10 Nm
15 - Exhaust manifold
16 - 25 Nm
❑ Renew
❑ Coat thread and contact surface of bolt head with high-temperature paste.
❑ High-temperature paste ⇒ Parts catalogue
17 - Intake manifold
18 - Gasket
❑ Renew
19 - 22 Nm
20 - Gasket
❑ Renew
21 - Bracket
❑ For heat shield ⇒ Item 24 (page 151)

Audi A6 1998 ➤
22 - Washer
23 - 25 Nm
❑ Renew
24 - Heat shield
❑ Engage in bracket ⇒ Item 21 (page 150)
25 - 25 Nm
❑ Renew
26 - Gasket
❑ Renew
27 - Oil return pipe
❑ To cylinder block
❑ Tighten banjo bolt to 30 Nm
28 - Seal
❑ Renew
29 - Banjo bolt, 30 Nm
30 - 15 Nm
31 - 40 Nm
2.3 Removing and
permitted unless installing
authorised turbocharger
by AUDI AG. AUDI AG does not guarantee or accept any liability
Removing
Note

insulation. Leave rear noise insulation in position.

Audi A6 1998 ➤
Note


WARNING

ed. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Disconnect air intake hose from turbocharger
with respect to(bottom)
the correctness of information in this document. Copyright by AUDI AG.
-arrows-.
(right-side).
– Remove bracket for turbocharger -arrows-.

Audi A6 1998 ➤
– Detach oil return pipe at cylinder block -arrow-.

– Unscrew turbocharger/exhaust manifold securing nut (acces‐
sible from below).

– Unscrew
Protected nuts
by copyright. -arrows-
Copying and
for private detachpurposes,
or commercial enginein cover
part or inpanel.
whole, is not



Audi A6 1998 ➤
– Disconnect air intake hose from turbocharger -arrows-.
– Remove exhaust gas recirculation pipe with mechanical ex‐

haust gas recirculation valve -arrows-.
– Move exhaust gas recirculation pipe with mechanical exhaust
gas recirculation valve clear to one side (vacuum hose -1- re‐
mains connected).
– Detach heat shield from exhaust manifold -arrows-.

– Remove oil supply pipe bracket from exhaust manifold.

Audi A6 1998 ➤
– Detach vacuum hose -2- from vacuum unit for charge pressure
control.
– Unscrew bolt -1- from bracket for oil supply pipe.
– Unscrew oil supply pipe -3- at turbocharger.
-arrows-.
– Unscrew top turbocharger securing nut from exhaust manifold.
– Detach turbocharger.
Installing
Note
♦ Renew seals, gaskets and self-locking nuts.

♦ Pay attention to installation position of exhaust manifold/tur‐
bocharger gasket.
♦ Fill turbocharger with engine oil at connection for oil supply
pipe.
free of oil and grease before assembly.
– Install exhaust system and align it free of stress

⇒ page 165 .
Note
After installing turbocharger, allow engine to idle for approx. 1 mi‐

nute and do not rev up immediately to ensure turbocharger is
supplied with oil.

Audi A6 1998 ➤
Tightening torques
Component Nm
Turbocharger to exhaust manifold 25 17) 18)
Turbocharger to catalytic converter 25 17)
Bracket for turbocharger to turbocharger 20
Bracket for turbocharger to cylinder block 40
Oil return pipe to cylinder block 30
A/C compressor to bracket 25
Oil supply pipe to turbocharger 22
Oil supply pipe to bracket 10
Connecting pipe for exhaust gas recirculation to 25
exhaust manifold
Mechanical exhaust
Protected by copyright. Copyinggas recirculation
for private or commercial valve to in part or in whole,
purposes, 25 is not
intake
permittedconnecting
unless authorisedpipe
by AUDI AG. AUDI AG does not guarantee or accept any liability
Heat shield to exhaust manifold 25
17) Renew nuts.
18) Coat thread and contact surface of bolt head with high-temperature paste;
High-temperature paste ⇒ Parts catalogue .
2.4 Charge air cooler - exploded view of components

Audi A6 1998 ➤
1 - Air duct
❑ For charge air cooler
2 - Air intake hose
❑ To lock carrier
3 - Air intake hose
❑ To air pipe
4 - O-ring
5 - Charge air cooler
❑ Different
permitted unless authorised byversions
AUDI AG. AUDI possi‐
AG does not guarantee or accept any liability
with respect toble ⇒ Partsof catalogue
the correctness information in this document. Copyright by AUDI AG.

⇒ page 157
6 - Retainer
7 - Bracket for charge air cooler
8 - Rubber grommet
9 - Bracket for refrigerant lines
10 - 10 Nm
2.5 Removing and installing charge air cool‐

er
Removing

Audi A6 1998 ➤

Gr. 63 .
– Detach bottom air intake hose -arrow- going to charge air

cooler from charge air cooler.
– Disengage charge air cooler and take out from underneath.
Installing
Note

free of oil and grease before assembly.

Gr. 63 .
Tightening torque
Component Nm

Audi A6 1998 ➤
26 – Exhaust system
1 Removing and installing parts of ex‐
haust system
Note
♦ Do not bend the flexible joint (de-coupling element) in the ex‐

haust system more than 10°, otherwise it could be damaged.
♦ Renew gaskets and self-locking nuts.
♦ After working on the exhaust system, ensure that the system
is not under stress and that it has sufficient clearance from the
body. If necessary, loosen clamp and align silencers and ex‐
haust pipe so that sufficient clearance is maintained to the
body at all points and the mountings are evenly loaded.
♦ Use screwdriver to unfasten and tighten lock washers for heat
shields. Tightening torque: 2 Nm
1.1 Exhaust system - exploded view of components
1 - 25 Nm
❑ Renew
2 - Gasket
❑ Renew
3 - Bolt
4 - 25 Nm
❑ Renew
5 - Turbocharger
6 - Gasket
❑ Renew
7 - Catalytic converter
❑ With flexible joint
❑ Do not bend flexible joint
more than 10° - other‐
wise it can be damaged
❑ Protect against knocks
and impact
⇒ page 163
8 - Front exhaust pipe
⇒ page 163
9 - Clamp (front)
❑ Align exhaust system so
it is free of stress before
tightening clamp
⇒ page 165
❑ Tighten bolt connec‐
tions evenly.
❑ Installation position: bolt
1. Removing and installing parts of exhaust system 159

Audi A6 1998 ➤
connection facing to the

left.
❑ Installation position of bolts ⇒ page 160
10 - 40 Nm
11 - Mounting
12 - Mounting
13 - 25 Nm
14 - Rear silencer
❑ Combined in one unit with centre silencer as original equipment. Can be renewed individually for repair
purposes
❑ Cutting location ⇒ page 161
❑ Align exhaust system so it is free of stress ⇒ page 165
15 - 25 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
16 - Clamp (rear) with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ For separate replacement of centre and rear silencers
❑ Align exhaust system so it is free of stress before tightening clamp ⇒ page 165
❑ Tighten bolt connections evenly.
❑ Tighten bolt connections evenly.
17 - 40 Nm
18 - 25 Nm
19 - Mounting
20 - Centre silencer
❑ Combined in one unit with rear silencer as original equipment. Can be renewed individually for repair
purposes
❑ Cutting location ⇒ page 161
❑ Align exhaust system so it is free of stress ⇒ page 165
Installation position of front clamp

– Install clamp so that the bolt ends do not protrude beyond bot‐
tom of clamp.
• Bolt connection faces to left.
160 Rep. Gr.26 - Exhaust system

Audi A6 1998 ➤
Installation position of rear clamp

• -α- = 25 … 35°.
• Bolt heads -arrow- face fuel tank -1-.
1.2 Separating centre and rear silencers

♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.
♦ Cutting location is marked by an indentation on circumference
of exhaust pipe.

♦ Chain-type pipe cutter -VAS 6254-
Procedure
– Cut through exhaust pipe at a right angle at cutting point
-arrow- using chain-type pipe cutter -VAS 6254- .
– When reassembling, position the clamp -1- centrally over the

cutting point. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi A6 1998 ➤
– Install clamp so that bolt heads -arrow- face fuel tank -1-.
• -α- = 25 … 35°.
– Tighten bolt connections on clamp evenly to 40 Nm.
1.3 Removing and installing exhaust mani‐

fold
Removing
– Remove turbocharger ⇒ page 151 .
– Move catalytic converter with front exhaust pipe aside or to‐
wards front.
– Unscrew all nuts -arrows- on exhaust manifold.

– Detach washers, heat shield bracket (where fitted) and ex‐
haust manifold. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Installing with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
Renew gaskets and self-locking nuts.
– Install turbocharger ⇒ page 155 .

– Install catalytic converter together with front exhaust pipe.
Tightening torques
Component Nm
Exhaust manifold to cylinder head 25 19)
Heat shield to exhaust manifold 25
Bracket for oil supply pipe to exhaust manifold 25

Audi A6 1998 ➤
1.4 Removing and installing catalytic con‐

verter with front exhaust pipe
Removing
– Release quick-release fasteners -2- and -3- and detach rear
section of noise insulation.


– Remove air intake duct going to air cleaner.

Audi A6 1998 ➤


-arrows-.
– Raise vehicle approx 550 mm, measured at bottom edge of
bumper.

Audi A6 1998 ➤
Note

– Turn front exhaust pipe to left slightly, at the same time lifting
it slightly.
– To prevent damage, place a cloth over the lock carrier at the
front right.
– Place catalytic converter flexible joint on cloth.
– To separate flange connection, unscrew nuts -arrows-.
– Take out catalytic converter and front exhaust pipe separately.
Installing
Note
Renew gaskets and self-locking nuts.

Tightening torques Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Component Nmof information in this document. Copyright by AUDI AG.
Catalytic converter to turbocharger 25 20)

Front exhaust pipe to catalytic converter 25
Clamp 40
1.5 Stress-free alignment of exhaust system

Vehicles without clamp between centre silencer and rear silencer
• The exhaust system must be aligned when it is cool.
– Loosen bolt connections of front clamp ⇒ Item 9 (page 159) .
– Push exhaust system towards front of vehicle -arrow-, so that
rubber mounting (right-side) for centre silencer is preloaded
by dimension -a- = 5 ... 9 mm.
– Tighten bolts on front clamp ⇒ Item 9 (page 159) evenly to
40 Nm.
– Align tailpipes ⇒ page 166 .

Audi A6 1998 ➤
Vehicles with clamp between centre silencer and rear silencer

• On vehicles with clamp fitted between centre silencer and rear
silencer, it is also necessary to align the centre silencer.
– Loosen bolts for front clamp ⇒ Item 9 (page 159) and rear
clamp ⇒ Item 16 (page 160) .
– Push front section of exhaust system towards front of vehicle
-arrow-, so that rubber mounting (right-side) for centre silencer
is preloaded by dimension -a- = 5 ... 9 mm.
– Tighten bolts on front clamp ⇒ Item 9 (page 159) evenly to
40 Nm.
– Push rear section of exhaust system towards front of vehicle

-arrow-, so that rear rubber mounting for rear silencer is pre‐
loaded by dimension -a- = 12 mm.
– Tighten bolts on rear clamp ⇒ Item 16 (page 160) evenly to
40 Nm.
Aligning tailpipes
– Align rear silencer so that there is an equal distance -a- and
-b- between the cut-out in the bumper and the pipe ends.
– If necessary, loosen mounting for rear silencer to adjust the
tailpipes.
1.6 Checking exhaust system for leaks

– Start engine and run at idling speed.
– Plug tailpipes during leak test (e.g. with cloth or plug).
– Listen for leaks at connection points between cylinder head/
exhaust manifold, exhaust manifold/turbocharger and turbo‐ of information in this document. Copyright by AUDI AG.
charger/catalytic converter etc.
– Repair any leaks that are found.

Audi A6 1998 ➤
2 Exhaust gas recirculation system
2.1 Exhaust gas recirculation system - exploded view of components
1 - 25 Nm
2 - Bracket
❑ For oil supply pipe going
to turbocharger
3 - Connecting pipe
❑ When installing, first
tighten all bolted con‐
nections
Protected by copyright. lightly
Copying (compo‐
nents must just still
move in relation to each

other). Only then should

joints be tightened, with‐
out straining
4 - 25 Nm
5 - Gasket
❑ Renew
6 - Intake manifold
⇒ page 77
7 - Mechanical exhaust gas re‐
circulation valve
❑ Checking exhaust gas
recirculation system
⇒ page 170
8 - Exhaust manifold
⇒ page 162
9 - Gasket
❑ Renew
2. Exhaust gas recirculation system 167

Audi A6 1998 ➤
2.2 Hose connection diagram for exhaust gas recirculation
1 - Rear air pipe

2 - Vacuum connection for air
conditioning system
❑ With cap for vehicles
without air conditioning
system
3 - From brake servo
4 - Vacuum unit for charge
pressure control
5 - Exhauster pump for brake
servo
6 - Vent pipe
❑ To charge pressure
control
7 - Vent pipe
❑ To air cleaner
8 - Mechanical exhaust gas re‐
circulation valve
9 - Exhaust gas recirculation
valve -N18-
❑ Fitting location: on rear
of air pipe

Audi A6 1998 ➤
2.3 Checking mechanical exhaust gas recir‐

culation valve
Note
♦ The exhaust gas recirculation system is actuated from the die‐

sel direct injection system control unit -J248- via the exhaust
gas recirculation valve -N18- and the mechanical exhaust gas
recirculationProtected
valve.by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ The tapered plunger
with respectintothe mechanical exhaustin thisgas recircula‐
the correctness of information document. Copyright by AUDI AG.
tion valve varies the opening cross section according to valve
travel.
♦ Pulsed actuation makes it possible to obtain any required
valve position.
♦ The exhaust gas recirculation is switched off after approx. 10
minutes at idling speed.
♦ Restart engine or briefly increase engine speed above 1500
rpm when longer checks are necessary. Then repeat meas‐
urement.

♦ Hand-operated vacuum pump -V.A.G 1390-
Test sequence
– Detach vacuum hose at mechanical exhaust gas recirculation
valve.
– Connect hand vacuum pump -V.A.G 1390- to valve.
– Create vacuum with hand-operated vacuum pump.
• The diaphragm rod must move in direction of vacuum con‐
nection.
Note
The movement of the diaphragm rod in the exhaust gas recircu‐

lation valve can be observed through the opening -arrow-.
– Detach hose of hand pump at exhaust gas recirculation valve.

• The closing of the valve should be clearly audible. The dia‐
phragm rod should move towards intake manifold

Audi A6 1998 ➤
2.4 Checking exhaust gas recirculation

Checking of exhaust gas recirculation is done with the vehicle
diagnosis, testing and information system -VAS 5051 A- under
the function “basic setting”. The EGR valve is pulsed every 10
seconds, so that the extreme values for the EGR ( air mass meter
-G70- ) can be read.
♦ Vehicle diagnosis, testing and information system -
VAS 5051 A- with diagnosis lead -VAS 5051/1-
Test requirement
tronics” is selected. Engine must be idling.
Test sequence
– From the selection menu -1- select diagnostic function “04 -
Basic setting”.

and confirm
Protected by touching
by copyright. Copying forthe Q orkey.
private commercial purposes, in part or in whole, is not

Audi A6 1998 ➤
– Activate basic setting by touching Activate key -A-.

– Check display in zones -2- and -3-.
Display zones Explanatory notes

2 … Activation of exhaust gas recirculation valve -N18- alternating every 10 seconds
between
• “EGR active”
• “EGR not active”
3 … mg/H 21) Intake air mass, alternating every 10 seconds

• Specification for status “EGR active”: 180 ... 280 mg/H
• Specification for status “EGR not active”: above 370 mg/H
21) mg/H = milligrammes/stroke

Note
If display zone 3 constantly indicates 550 mg/H, possible causes

can be a sticking mechanical exhaust gas recirculation valve or a
defective air mass meter. If the latter applies, check whether a
corresponding fault is stored in the fault memory ⇒ Rep. Gr. 01 .
– End function “04 - Basic setting” by pressing the ← key.

If the specifications are not obtained:
– Check mechanical exhaust gas recirculation valve
⇒ page 169 .
– Check vacuum hose connections ⇒ page 168 .
– Check exhaust gas recirculation valve -N18- ⇒ page 171 .
2.5 Checking exhaust gas recirculation valve -N18-

Audi A6 1998 ➤

equipment required
V.A.G 1526 A- or -V.A.G
1526 B-
♦ Voltage tester -
V.A.G 1527 B-
V.A.G 1594 A- or -V.A.G
1594 C-
♦ Test box -V.A.G 1598/22-
♦ Test box -V.A.G 1598/31-
and information system -
lead -VAS 5051/1-
Checking internal resistance

– Protected
Unplugbyelectrical connector
copyright. Copying for private at exhaustpurposes,
or commercial gas recirculation valve
in part or in whole, is not
-N18-
permitted .unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
B- to valve to measure resistance.
• Specification: 14 ... 20 Ω
Note
At room temperature the resistance is in the lower tolerance

range; at operating temperature it is in the upper tolerance range.

– Renew exhaust gas recirculation valve -N18- .

Audi A6 1998 ➤
Checking voltage supply

B- to contact -1- and earth to measure voltage.
– Switch on ignition.
• Specification: approx. battery voltage
– Check for open circuit in wiring (see current flow diagram) and
repair if necessary.
Checking activation
switched on.
– Connect voltage tester -V.A.G 1527 B- between contacts -1-
and -2-.

control diagnosis”.
– Press the button → repeatedly until the exhaust gas recircu‐
lation valve -N18- is actuated.
• LED should flash slowly.
Note
Voltage testers with a low current draw do not go out completely

between activation signals from engine control unit, but continue
to glow slightly and become distinctly brighter on activation.
– Press the ← key to exit from function “03 - Final control diag‐
nosis”.
If LED does not react as described:
Caution

priate measuring with
range
respectbefore connecting
to the correctness measuring
of information leads
in this document. Copyright by AUDI AG.

Audi A6 1998 ➤
lowing wiring:
Contact Socket
-1- 2 or 28
-2- 29

Caution

lowing wiring:
ProtectedContact Socketin part or in whole, is not
by copyright. Copying for private or commercial purposes,
-1-to the correctness of information in this document.

1 or 2Copyright by AUDI AG.
with respect
-2- 61

Service: Audi A6 1998

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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.5 Renewing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

2.3 Checking mechanical exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

1.1 Engine number

1.2 Engine data

10 – Removing and installing engine

1.1 Removing engine

Special tools and workshop

♦ Lifting tackle -2024 A-

2 Rep. Gr.10 - Removing and installing engine

♦ Used oil collection and ex‐

♦ The engine is removed from the front without the gearbox.

Observe notes on procedure for disconnecting the battery ⇒

1. Removing and installing engine 3

– Detach rubber seal from plenum chamber cover in direction of

– With ignition switched off, disconnect battery earth cable

Hot steam/hot coolant may escape when opening expansion

– Open filler cap on coolant expansion tank.

– Unscrew bolts -arrows-.

– Remove cover -arrow- at power steering fluid reservoir.

4 Rep. Gr.10 - Removing and installing engine

– Remove front bumper ⇒ General body repairs, exterior; Rep.

– Release quick-release fasteners -1 … 3- and take off front and

– Unbolt bracket for noise insulation -arrow-.

– Remove air duct in front of charge air cooler -arrows-.

1. Removing and installing engine 5

– Unclip ambient temperature sensor -G17- from bracket.

– Place drip tray -V.A.G 1306- or -VAS 6208- under engine.

– Unscrew bolts -arrows- and take out hose connection with O-

6 Rep. Gr.10 - Removing and installing engine

Note the rules for cleanliness when working on the automatic

– Unplug electrical connector -arrow- for headlights on both

– Unplug electrical connectors -arrows- at front of ABS unit.

1. Removing and installing engine 7

– Remove top coolant hose at radiator.

The air conditioner refrigerant circuit must not be opened.

– Detach both brackets -3- and pull condenser upwards out of

To prevent damage to the condenser and refrigerant pipes/hoses,

– Move condenser to side with pipes/hoses connected and tie

Protect wing panels from damage.

– Remove bolts -arrows- at lock carrier (left and right).

– Unscrew bolts from impact absorbers -arrows- (left and right).

A second mechanic is required for removing the lock carrier.

– Remove lock carrier and place down in a secure position.

8 Rep. Gr.10 - Removing and installing engine

– Unclip cover caps.

– Detach coolant hoses -1- and -3-.

Fuel filter - version I:

Fuel filter - version II:

1. Removing and installing engine 9

– Unplug electrical connectors -3- and -4-.

– Disconnect breather hose -3- from air cleaner housing.

10 Rep. Gr.10 - Removing and installing engine

– Detach vacuum hose -2-.

– Detach coolant hoses -1- and -3- going to heat exchanger at

– Pry off retainer bar with a screwdriver -arrow-.

1. Removing and installing engine 11