SM 9 PDF

Service
Workshop Manual
Audi A4 2001 ➤
Audi A4 Cabriolet 2003 ➤
4-cylinder engine (5-valve turbo), mechanics
Engine ID AVJ AMB BEX BFB BKB
Edition 06.2013
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 A0059007120

Audi A4 2001 ➤ , Audi A4 Cabriolet 2003 ➤
4-cylinder engine (5-valve turbo), mechanics - Edition 06.2013
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.1 LockProtected
carrier by -copyright.
exploded view
Copying . . or. commercial
for private . . . . . . .purposes,
. . . . . in. part
. . .or.in. whole,
. . . .is. not
...................... 26
1.2 Moving lock carrier into service position . . . . . . . . . . . . .
. . . . . ...................... 26
1.3 Poly V-belt for alternator, power steering pump and air conditioner compressor . . . . . . . . 29
1.4 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.7 Toothed belt drive - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.8 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.9 Detaching toothed belt from camshaft sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.10 Removing and installing tensioner for toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2 Removing and installing sealing flanges and flywheel/dual-mass flywheel/drive plate . . . . 52
2.1 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.2 Removing and installing sealing flange (front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.3 Removing and installing dual-mass flywheel - vehicles with manual gearbox . . . . . . . . . . 60
2.4 Removing and installing flywheel - vehicles with multitronic gearbox . . . . . . . . . . . . . . . . 61
2.5 Removing and installing drive plate - vehicles with automatic gearbox 01V . . . . . . . . . . . . 62
2.6 Removing and installing sealing flange (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1 Crankshaft - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.3 Extracting and driving in needle bearing for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.4 Removing and installing chain sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.1 Pistons and conrods - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.1 Cylinder head - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.1 Intake manifold - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3 Servicing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.1 Valve gear - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.2 Checking axial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.3 Renewing exhaust camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Contents i
3.4 Renewing inlet camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

3.5 Removing and installing camshafts and camshaft adjuster . . . . . . . . . . . . . . . . . . . . . . . . 103
3.6 Renewing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.7 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.8 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.9 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.10 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.11 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.1 Sump, oil pump - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.4 Oil filter and oil cooler - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
1.5 Removing and installing oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1.6 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.7 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.8 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.1 Diagram of coolant hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.2 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
1.3 Removing and installing coolant
Protected pump Copying
by copyright. . . . .for. private
. . . . or. commercial
. . . . . . .purposes,
. . . . .in. part
. . .or.in. whole,
. . . .is.not
....... 148
1.4 Removing and installingpermittedcoolant pipe
unless (top)by AUDI
authorised . . . AG.. . .AUDI
. . .AG. does
. . . not
. . guarantee
. . . . . or
. .accept
. . . any
. . liability
......... 150
1.5 Removing and installing coolant pipe (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.6 Thermostat housing - exploded view of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.7 Removing and installing thermostat housing with map-controlled engine cooling thermostat
F265 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.8 Checking map-controlled engine cooling thermostat F265 . . . . . . . . . . . . . . . . . . . . . . . . 154
1.9 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.10 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.11 Removing and installing radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.12 Renewing radiator fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.13 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1 Servicing charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.2 Connection diagram for charge pressure control and vacuum control - vehicles to 06.02
........................................................................ 164
1.3 Connection diagram for charge pressure control and vacuum control - vehicles from 07.02
onwards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.4 Checking turbocharger and charge pressure regulating valve . . . . . . . . . . . . . . . . . . . . . . 167
1.5 Effects of leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.6 Checking mechanical air recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.7 Turbocharger - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
1.8 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.9 Charge air cooling - exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.10 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
1.11 Removing and installing charge pressure sender G31 with intake air temperature sender G42
...................................................................... 182
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.1 Exhaust system on vehicles with front-wheel drive - exploded view . . . . . . . . . . . . . . . . . . 184
ii Contents
1.2 Disconnecting centre silencer and rear silencer - vehicles with front-wheel drive . . . . . . . . 187
1.3 Stress-free alignment of exhaust system - vehicles with front-wheel drive . . . . . . . . . . . . 188
1.4 Exhaust system on vehicles with four-wheel drive - exploded view . . . . . . . . . . . . . . . . . . 190
1.5 Disconnecting centre silencer and rear silencer - vehicles with four-wheel drive . . . . . . . . 193
1.6 Stress-free alignment of exhaust system - vehicles with four-wheel drive . . . . . . . . . . . . . . 194
1.7 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1.8 Removing and installing front exhaust pipe with catalytic converter . . . . . . . . . . . . . . . . . . 197
1.9 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
1.10 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
2.1 Secondary air system - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
2.2 Checking combination valve for secondary air system for proper operation and leakage . . 207
2.3 Removing and installing combination valve for secondary air system . . . . . . . . . . . . . . . . 209
2.4 Removing and installing secondary air pump motor V101 . . . . . . . . . . . . . . . . . . . . . . . . 210
Contents iii
iv Contents
00 – Technical data
1 Technical data
(ARL003411; Edition 06.2013)
1.1 Engine number

The engine number (“Engine code” and “Serial number”) can be
found on the rear left of the cylinder block.
Additionally there is a sticker on the toothed belt cover with “En‐
gine code” and “Serial number”.
The engine code is also included on the vehicle data sticker.
Note
The engine code is also stamped on the front engine lifting eye
(visible after detaching engine cover panel).
1.2 Engine data

Code letters AVJ AMB BFB BEX BKB
Capacity ltr. 1.781 1.781 1.781 1.781 1.781
Power out‐ kW at 110/5700 125/5900 120/5700 140/5700 120/5700
put rpm
Torque Nm at 210/1750 … 225/1950 … 225/1750 … 240/1980 … 225/1750 …
rpm 4600 5000 4600 5400 4600
Bore ∅ mm 81.0 81.0 81.0 81.0 81.0
Stroke mm 86.4 86.4 86.4 86.4 86.4
Compression ratio 9.5 unless authorised by9.5
permitted AUDI AG. AUDI AG does 9.5not guarantee or accept
9.5any liability 9.5
RON 98 2)
with respect
95 95 1)
to the correctness1)of information in this document.
98 2) AG.
Copyright by AUDI
95 1)
Injection/ignition sys‐ Bosch Motron‐ Bosch Motron‐ Bosch Motron‐ Bosch Motron‐ Bosch Motron‐
tem ic ic ic ic ic
Exhaust gas recircula‐ no no no no no
tion
Turbocharging/super‐ yes yes yes yes yes
charging
Self-diagnosis yes yes yes yes yes
Catalytic converter yes yes yes yes yes
Knock control yes yes yes yes yes
Lambda control yes yes yes yes yes
Variable valve timing yes yes yes yes yes
Intake manifold no no no no no
change-over
Secondary air system yes yes yes yes yes
1) Regular unleaded petrol RON 91 can be used, but will cause a slight loss of power.
2) Unleaded premium RON 95 can also be used, but results in reduced power
1. Technical data 1
10 – Removing and installing engine

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

equipment required
♦ Support bracket - 10-222 A-
♦ Shackle - 10-222 A/12-
♦ Lifting tackle - 2024 A-
♦ Hose clamps up to Ø
25 mm - 3094-
♦ Gearbox support - 3147-
♦ Engine/gearbox jack -
V.A.G 1383 A- for Audi
Cabriolet
2 Rep. gr.10 - Removing and installing engine

♦ Used oil collection and ex‐

traction unit - V.A.G 1782-
♦ Hose clip pliers - V.A.G
1921-
♦ Spark plug connector pliers
- V.A.G 1922-
♦ Workshop hoist - VAS
6100- or workshop hoist -
V.A.G 1202 A-
♦ Drip tray for workshop hoist
- VAS 6208- or drip tray -
V.A.G 1306-
♦ 15 mm socket insert - Matra V/175- for vehicles with automatic

gearbox 01V
1. Removing and installing engine 3

Procedure
Note
♦ The engine is removed from the front without the gearbox after
removing the lock carrier.
♦ 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.
– Move selector lever to position “N” on vehicles with multitronic/

automatic gearbox 01V.
Caution
Observe notes on procedure for disconnecting the battery ⇒

Electrical system; Rep. gr. 27 .
– Detach rubber seal from plenum chamber cover in direction of

-arrow-.
– Detach plenum chamber cover -1-, if fitted.
– With ignition switched off, disconnect battery earth cable

-arrow-.
WARNING
Hot steam or hot coolant can escape when expansion tank is

opened; cover filler cap with cloth and open carefully.
– Open filler cap on coolant expansion tank.
– Remove both front wheels.

– On vehicles with auxiliary/additional heater, Protected
remove bolts
by copyright. Copying for private or commercial purposes, in part or in whole, is not
-arrows- securing exhaust pipe for auxiliary/additional
with respect heater
to the correctness of information in this document. Copyright by AUDI AG.
to noise insulation.

– Release quick-release fasteners -1- and -2- and take off front
noise insulation.
– If fitted, open quick-release fasteners -3- and remove rear
noise insulation.
– Unbolt bracket for noise insulation -arrows-.

– Remove front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 .
– Remove air duct in front of charge air cooler -arrows-.
– Place drip tray for workshop hoist - VAS 6208- or drip tray -
V.A.G 1306- under engine.
Vehicles with coolant drain plug:
– Open coolant drain plug on coolant hose (bottom) at radiator.
– Unplug electrical connector at radiator outlet coolant temper‐
ature sender - G83- and move wiring clear.
Vehicles without coolant drain plug:
– Pull out retaining clip -1- for radiator outlet coolant temperature
sender - G83- -item 2-.
– Pull radiator outlet coolant temperature sender - G83- out of
hose connection and drain off coolant.
– Move wiring clear.

All vehicles:
– Detach coolant hose (bottom) from radiator -arrow-.
– Detach bottom air intake hose -1- from charge air cooler.
WARNING
The air conditioner refrigerant circuit must not be opened.
– Disengage refrigerant line at bracket -2-.
– Detach turbocharger air intake hose -1- at lock carrier (bottom
right).
– Clamp off hydraulic hoses going to cooling pipe for power

steering using hose clamps - 3094- .
– Place used oil collection and extraction unit - V.A.G 1782- un‐
der connection.
– Disconnect coolant hoses -arrows-.

Vehicles with automatic gearbox:

der connection.
Note
Observe rules for cleanliness when working on automatic gear‐

box ⇒ Rep. gr. 00 .
– Unscrew union nuts -1- and -2- and disconnect ATF lines.
– Unbolt bracket -arrow- for ATF lines at engine.
All vehicles:
– Release quick fasteners -arrows- and remove engine cover
panel.
– If fitted, detach cover -1- on right of engine compartment.
– Disengage solenoid valve 1 for activated charcoal filter system

- N80- at air duct.
– Remove bolts -arrows-.
– Remove
Protected air Copying
by copyright. duct -2-.for private or commercial purposes, in part or in whole, is not

– Remove cover -arrow- at power steering fluid reservoir.
– Disconnect top coolant hose -1- at radiator.

– Unplug electrical connector -2- for airbag sensors (left and
right) at lock carrier.
– Unplug electrical connector -arrow- for headlights on both

sides.
– Remove electrical connectors -1- and -2- from bracket.

– Unplug electrical connectors and move wiring clear.

– Unbolt air cowls (left and right) at radiator -arrows-.
– Unclip ambient temperature sensor - G17- -item 2- from brack‐

et.
– Unscrew bolts -3- and -4- and remove power steering cooling
pipe.
– Detach electrical connector -1- at high-pressure sender -
G65- .
WARNING
– Unscrew securing bolts -arrows- for condenser.
Note
To prevent damage to the refrigerant lines, ensure that the pipes

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

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

– Disconnect bonnet lock cable at bonnet lock.
– Pull bonnet seal off lock carrier and wing panels.
– Unscrew bolts -arrows- from impact dampers (left and right).
Note
A second mechanic is required for removing the lock carrier.
– Remove lock carrier and place down in a secure position.

– Detach vacuum hose -3- leading to brake servo at bulkhead.

– Detach vacuum hose leading to solenoid valve 1 for activated
charcoal filter system - N80- -item 1-.
– Unscrew earth connection -2- from bulkhead.
– Detach coolant hoses -1- and -2- and unfasten coolant ex‐
pansion tank -arrow-.
– Unplug electrical connector for coolant shortage indicator
switch - F66- at bottom of coolant expansion tank.
– Disconnect coolant hose from oil cooler -arrow-, and drain off
remaining coolant.
– Disconnect coolant hose (left-side) -arrow- from coolant pipe

(hose leads to heat exchanger for heater).
– Disconnect coolant hose (right-side) leading to heat exchang‐
er at cylinder head connection.

– Disconnect coolant hose from hose connection for thermostat

-arrow-.
– Detach coolant hose -1- from top coolant pipe.
Note
Disregard -item 2-.
– Detach air intake hose -1- at intake manifold.

– Unplug electrical connector -2- at charge pressure sender -
G31- and move wiring clear.
– If fitted, detach vacuum hose -arrow- leading to vacuum res‐

ervoir and move vacuum hose clear.

Note
Before removing, mark direction of rotation of poly V-belt with

chalk or felt-tip 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.
– Unscrew front bolts -arrows- for power steering
with pump.
respect to the correctness of information in this document. Copyright by AUDI AG.
– Unscrew rear bolt -arrow- for power steering pump.

– Move power steering pump aside and place onto longitudinal
member. Leave pipes connected.
– Unplug electrical connector -bottom arrow- at secondary air

pump motor - V101- and move wiring clear.
– Disconnect hose -top arrow- at pipe leading to combination
valve for secondary air.

– Unplug electrical connector -3- at solenoid valve 1 for activa‐

ted charcoal filter system - N80- and the electrical connector
-5- at air mass meter - G70- .
– Detach hoses -1-, -4-, -6- and -7-.
– Remove fastener -2- and detach air cleaner housing.
WARNING
The fuel system is pressurised. Wrap a cloth around the con‐

nection before opening the system. Then release pressure
with respect toby
the correctness of information in this document. Copyright by AUDI AG.
carefully loosening the connection.
– Detach fuel line -1- and move clear.
Note
Disregard -item 2-.
– Lever off both cover caps -3- with a screwdriver.

– Loosen hexagon nuts -4- several turns.
– Detach wiper arms -2- from wiper shafts by tilting slightly.
– Completely unscrew hexagon nuts and remove wiper arms.
– Pull off retaining clips -1- and detach cowl panel grille -5-.
– Remove cover for electronics box in plenum chamber

-arrows-.

– Pry off retainer with a screwdriver -arrows-.
– Release retainer catches -arrows- and unplug electrical con‐

nectors -1- and -2- from engine control unit.
Note
♦ On vehicles with engine control unit -1- with protective housing

-4- the electrical connectors remain plugged in.
♦ Place engine control unit on engine and secure it to prevent it
falling.
– Disconnect all electrical connectors from the connector point

-2- using spark plug connector pliers - V.A.G 1922- .
– Unscrew electrical wiring -1-.

– Release retainers -arrows- and push auxiliary relay carrier in

electronics box upwards to remove.
– Disengage engine wiring harness at electronics box and bulk‐
head and move clear.
– Detach electrical connectors -2- and -5- from retainer at left of

bulkhead and unplug electrical connectors.
– Remove connector retainer from bulkhead.
–Protected
Unscrew nutsCopying
by copyright. securing turbocharger
for private to catalytic
or commercial purposes, in part orconverter
in whole, is not
-arrows-.
– Unbolt heat shield -1- for drive shaft (right-side).

– Unscrew nut -arrow- at bracket for front exhaust pipe.
– Loosen bolt connections of front clamp -arrows-.

– Push the clamp back in order to separate the exhaust system.
Note
To avoid any damage, the flexible joint in the front exhaust pipe
must not be bent more than 10°.
– Disconnect catalytic converter with exhaust pipe from turbo‐

charger.
– 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-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Unplug electrical connector -arrow- at oil level and oil temper‐

ature sender - G266- .

– Unbolt refrigerant pipe bracket from sump -arrow-.
– Unplug electrical connector -1- for magnetic clutch on air con‐

ditioner compressor.
Caution
– Unscrew air conditioner compressor from bracket -arrows-.
Note

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

ed.
– Unscrew earth wire -1- at engine support (right-side).

– Detach electrical wires -2- and -3- at starter.
– Detach insulator at positive connection of starter.
– Unscrew clamp -4-.
– Unbolt bracket -5- for starter.
– Unbolt starter from gearbox and remove.
Vehicles with automatic gearbox 01V:

– Unscrew 3 bolts -arrow- for torque converter through opening
of removed starter using 15 mm socket insert - Matra V/175-
(turn crankshaft at crankshaft sprocket bolt 1/3 turn each time).

All vehicles:
– Mark position of nuts -1- and locating sleeves -2- on bottom of
engine mountings (left and right).
Note
Different mounting holes are provided for the different engine ver‐
sions.
– Unscrew nuts -1- (bottom) at engine mountings (left and right).

– Unscrew engine/gearbox securing bolts -arrows- accessible
from below.
Note
On removal, note down bolt lengths and original installation po‐

sition for re-installation.
Audi Cabriolet:
If the bottom bolts on engine/gearbox assembly flange cannot be
removed:
– Raise engine/gearbox assembly at torque reaction support
using engine and gearbox jack - V.A.G 1383 A- .
– Make sure no wires/pipes are damaged at the top on the bulk‐
head.
WARNING
To avoid injury, ensure adequate support.
– Lower the engine back down.
All vehicles:
– Slacken off top nut -arrow- on left-side engine mounting sev‐
eral turns.
– Unscrew top bolts on engine/gearbox assembly flange; leave
one bolt in place (finger-tight).

– Set up support bracket - 10-222 A- behind gas-filled strut on

wing panel flanges. The spindle is located at the front.
– Engage gearbox support - 3147- in bolt holes at top of bell
housing as shown in illustration.
– Connect the gearbox support - 3147- and support bracket -
10-222 A- using hooks - 10-222 A/2- .
Note
Shown in illustration with engine removed.
– Take up weight of engine using spindle of support bracket -

10-222 A- .
– Clear away any components from rear engine lifting eye.

– 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 support hooks and retaining pins on the lifting tackle must
be secured with locking pins -arrows-.
– Unscrew remaining bolt on engine/gearbox assembly flange.
Note
Check that all hoses and other connections between engine and
body have been detached.
– Lift engine until studs are clear of engine mountings.

– Turn spindle of support bracket - 10-222 A- to take up slack.
Note
Make sure no wires/pipes are damaged at the top on the bulk‐

head.


– Separate automatic gearbox from engine and simultaneously
detach torque converter from drive plate
All vehicles:
– Detach engine from gearbox and lift engine forwards out of
engine compartment.
– Secure the torque converter in the gearbox (using wire or sim‐
ilar) to prevent it falling out.
1.2 Securing engine to assembly stand

Special tools and workshop equipment required
♦ Engine and gearbox support - VW 540-
♦ Engine and gearbox support - VAS 6095-
Procedure
– Secure engine to engine and gearbox support - VAS 6095-
using -VW 540- prior to performing assembly work.

1.3 Installing engine
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, gaskets and O-rings.
♦ Hose connections and hoses for charge air system must be
free of oil and grease before assembly.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Parts catalogue.
♦ Fit all cable ties in the original positions when installing.
Vehicles with manual gearbox:

– When fitting a new clutch plate together with a used pressure
plate (self-adjusting clutch), the adjuster ring in the pressure
plate has to be reset by turning it back as far as it will go. If this
is not done, the pressure plate will operate with reduced
clamping force, causing clutch slip ⇒ Rep. gr. 30 .
Note
♦ If the clutch plate is not being replaced, it is not necessary to

reset the adjuster ring.
♦ New SAC pressure plates are already pre-set accordingly, and
do not have to be reset.
– Clean input shaft splines and (in the case of used clutch plates)
the hub splines. Remove corrosion and apply only a very thin
coating of grease - G 000 100- to the splines. Do not lubricate
guide sleeve. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Check that the clutch plate is properly centralised

with respect (only nec‐ of information in this document. Copyright by AUDI AG.
to the correctness
essary if you have carried out other work on the clutch).
– Check clutch release bearing for wear; renew if necessary.
If the plastic ring for release bearing is loose:

– Bond the plastic ring for release bearing to bearing race using
adhesive - AMV 195 KD1 01- .
• Three square lugs -arrows- on the plastic ring engage in the
recesses in the bearing race.
• The release bearing must be renewed if it has scoring deeper
than 0.5 mm.
– A needle bearing must be fitted in the crankshaft on vehicles
with manual gearbox. If necessary, install needle bearing
⇒ page 70 .
Vehicles with multitronic gearbox:
– Clean input shaft splines and splines of damper unit on fly‐
wheel; remove corrosion and apply only a very thin coating of
grease - G 000 100- to the splines. Remove any excess
grease.
– Engines for vehicles with automatic gearbox 01V must not be
fitted with a needle bearing in the crankshaft. If necessary, re‐
move needle bearing ⇒ page 70 .
– To secure torque converter on drive plate, use only bolts of the
correct type (same as original equipment) as specified in ⇒
Parts catalogue .
Checking installation position of torque converter:

If the torque converter has been correctly installed, the distance
between the bottom contact surfaces at the studs on the torque
converter and the contact surface on the torque converter bell
housing (with automatic gearbox) is approx. 23 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 vehicles: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Check whether dowel sleeves for centring the engine/gearbox
assembly are fitted in the cylinder block; install dowel sleeves

if necessary.

– Ensure that the intermediate plate is engaged on the sealing

flange and pushed onto the dowel sleeves -arrows-.
– Push intermediate plate between engine and gearbox onto
dowel sleeves.
– Attach engine to gearbox and screw in one bolt finger-tight.
– Release spindle of support bracket - 10-222 A- .
– Lower engine, inserting studs of engine mountings into con‐
soles for engine mountings as you do so.
Remaining installation steps are carried out in reverse sequence;
note the following:
– Install engine mountings free of stress. To do so, shake engine
before tightening engine mountings.
– Install exhaust system and align free of stress ⇒ page 188 .
– 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 .
– Install poly V-belt ⇒ page 31 .

– Install lock carrier with attachments ⇒ General body repairs,

exterior; Rep. gr. 50 .
– Allow stop for torque reaction support to rest on rubber buffer
for torque reaction support under its own weight and tighten
nuts -arrows-.
– Install front bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 .
– Secure ATF lines ⇒ Rep. gr. 37 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Observe notes on procedures required after connecting bat‐
tery ⇒ 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 138 .

– Fill cooling system ⇒ page 144 .
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.
– Check power steering fluid level: ⇒ Running gear, front-wheel

drive and four-wheel drive; Rep. gr. 48 .
– Check ATF level ⇒ Rep. gr. 37 .
– Check headlight adjustment ⇒ Maintenance ; Booklet 8E .
Tightening torques
Note
♦ Tightening torques apply only 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 %.

Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 45
M12 65
Except for the following:
Engine to gearbox M10 45 3)
M12 65 3)
Torque converter to drive plate 85 4)
Engine mounting to engine console 23
Engine mounting to engine support 23
Terminal B+ to starter 16
Drive shaft heat shield to gearbox 23
Fuel line to fuel rail 22
Stop for torque reaction support to lock carrier 28
Hose clips (9 mm wide) 3
Hose clips (13 mm wide) 5.5
3) Renew bolts on vehicles with multitronic gearbox.
4) Use only genuine bolts ⇒ Parts catalogue

13 – Crankshaft group
1 Dismantling and assembling engine
1.1 Lock carrier - exploded view
1 - 40 Nm
2 - Special tool, front-end serv‐
ice sleeves - 3369-
❑ Tighten to 10 Nm
3 - 10 Nm
4 - 10 Nm
5 - 10 Nm
6 - 10 Nm
7 - Special tool, front-end serv‐
ice sleeves - 3369-
8 - 40 Nm
1.2 Moving lock carrier into service position

26 Rep. gr.13 - Crankshaft group

♦ Front-end service sleeves - 3369-
Procedure
– Remove both front wheels.
– Vehicles with auxiliary heater: remove bolts -arrows- securing
exhaust pipe for auxiliary/additional heater to noise insulation.
noise insulation.
Rep. gr. 63 .
– Remove air duct in front of charge air cooler -arrows-.
1. Dismantling and assembling engine 27

– Remove electrical connectors -1- and -2- from bracket.

– Move wiring going to lock carrier clear.
– Disengage activated charcoal filter solenoid valve 1 - N80-

-item 1- at air duct.
– Remove air duct -2-.

– Remove bolts (left and right) -arrows-.

– Pull bonnet seal off lock carrier and wing panels.
– Screw in front-end service sleeves - 3369- (left and right) in

the holes.
– Remove bolts (left and right) -arrows-.
– Carefully pull the lock carrier forward.
Installing
Installation is carried out in the reverse order; note the following:
for torque
Protected reaction
by copyright. support
Copying for private orunder itspurposes,
commercial own weight
in part orand tighten
in whole, is not
nuts unless
permitted -arrows-.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Rep. gr. 63 .
Tightening torque
Component Nm
1.3 Poly V-belt for alternator, power steering pump and air conditioner com‐
pressor

1 - 25 Nm
2 - Tensioner
3 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen. If
the belt runs in the op‐
posite direction when it
is refitted, this can
cause breakage.
❑ Removing and installing
⇒ page 31
❑ When installing, make
sure it is properly seated
on pulleys.
4 - 25 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
5 - Bracket for ancillaries
⇒ page 33
6 - 40 Nm
❑ Install using locking flu‐
id; for locking fluid refer
to ⇒ Parts catalogue
7 - Alternator
⇒ Electrical system;
Rep. gr. 27
8 - 20 Nm
9 - 40 Nm
10 - 20 Nm
11 - Power steering pump
❑ Removing and installing ⇒ Running gear, front-wheel drive and four-wheel drive; Rep. gr. 48
12 - 40 Nm
13 - Air conditioner compressor
❑ On installation, pay attention to dowel sleeves in bolt holes
14 - 25 Nm
15 - Vibration damper/pulley
❑ Can only be installed in one position
❑ Removing and installing ⇒ page 32
16 - Flange bolts 10 Nm + 90° (1/4 turn) further
❑ Renew ⇒ Parts catalogue
17 - Idler roller
❑ Secured to bracket for ancillaries
18 - Special bolt, 25 Nm
❑ For idler roller
❑ Renew ⇒ Parts catalogue

1.4 Removing and installing poly V-belt

Removing

Note


poly V-belt.
– Remove poly V-belt from alternator pulley.
– Release tensioner. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove poly V-belt completely.
Note
Unscrew securing bolts of tensioner a few turns if poly V-belt can‐

not be removed from pulley.

Installing
– Installation is carried out in the reverse order; note the follow‐
ing:
Note
♦ Before fitting poly V-belt, make sure all mechanical units (al‐
ternator, air conditioner compressor, power steering pump)
are firmly in position.
♦ Make sure poly V-belt is properly positioned and correctly
routed.
– Fit poly V-belt.

– Start engine and check that belt runs properly.
1.5 Removing and installing vibration damp‐

er
Removing
– Move lock carrier to service position ⇒ page 26 .
Note


poly V-belt.
– Unbolt vibration damper from crankshaft.
Installing
– Installation is carried out in the reverse order; note the follow‐
ing:
Note
The vibration damper can only be installed in one position. The by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
hole -arrow- in the vibration damper must be located over permitted
the unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
projection on the toothed belt sprocket. with respect to the correctness of information in this document. Copyright by AUDI AG.


nuts -arrows-.
Rep. gr. 63 .
Tightening torques
Component Nm
Vibration damper/pulley to crankshaft 10 + 90° 5) 6)
5) Renew bolts.
6) 90° equals a 1/4 turn.
1.6 Removing and installing bracket for an‐

cillaries
Removing
Caution

Electrical system; Rep. gr. 27 .
– Disconnect earth wire at battery with ignition switched off.

– Drain off coolant ⇒ page 141 .
Note


poly V-belt.
– Unscrew bolts -arrows- and remove poly V-belt tensioner.

– Remove alternator ⇒ Electrical system; Rep. gr. 27

– Remove support for intake manifold (unscrew bolts -arrows-).
– Unscrew front bolts -arrows- for power steering pump.
– Unscrew rear bolt -arrow- for power steering pump.

– Move power steering pump aside and place onto longitudinal
member. Leave pipes/hoses connected.
– Remove coolant pipe (bottom) ⇒ page 151 .
– Remove thermostat housing ⇒ page 153 .
– Protected
Unplug electrical
by copyright. connector
Copying for private or-arrow-
commercialat oil level
purposes, and
in part or inoil temper‐
whole, is not
atureunless
permitted sender - G266-
authorised by AUDI . AG. AUDI AG does not guarantee or accept any liability


Caution
Note


ed.

– Remove bolts -1 ... 6- on bracket for ancillaries.

Installing
Note
♦ Always remove remaining locking fluid from the tapped holes

in the cylinder block prior to assembly. Otherwise the new bolts
can seize when screwed in, and then shear off if they have to
be subsequently removed.
♦ This can be done using a thread tap.
– Insert bolts securing bracket for ancillaries with locking fluid;

Locking fluid ⇒ Parts catalogue .
– Tighten bolts in the sequence -1 ... 6-.
Rep. gr. 87
– Install thermostat housing ⇒ page 153 .
– Install coolant pipe (bottom) ⇒ page 151 .
– Install power steering pump ⇒ Running gear, front-wheel drive
and four-wheel drive; Rep. gr. 48 .
– To facilitate positioning of alternator, power steering pump and
air conditioner compressor, drive back bush for securing bolt
slightly.
– Install alternator ⇒ Electrical system; Rep. gr. 27

– Allow stop for torque reaction support
permitted unless to rest on
authorised rubber
by AUDI buffer
AG. AUDI AG does not guarantee or accept any liability
for torque reaction support under its own
with respect weight and
to the correctness tightenin this document. Copyright by AUDI AG.
of information
nuts -arrows-.
Rep. gr. 63 .
– Observe notes on procedures required after connecting bat‐
tery ⇒ Electrical system; Rep. gr. 27 .
Tightening torques
Component Nm
Bracket for ancillaries to cylinder block 40 7)
Support for Bracket for ancillaries 23
Intake mani‐ Intake manifold 23
fold to:
Idler roller to bracket for ancillaries 25
Tensioner for poly V-belt to bracket for ancilla‐ 23
ries
7) Install using locking fluid; locking fluid ⇒ Parts catalogue .

1.7 Toothed belt drive - exploded view
1 - Toothed belt cover (bottom)

❑ Unbolt vibration damper
prior to removing
2 - 10 Nm
3 - Toothed belt cover (centre)
❑ To remove, unbolt poly
V-belt tensioner
4 - Toothed belt cover (top)
❑ Engage carefully in cen‐
tre toothed belt cover
when installing
5 - Toothed belt
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen. If
the belt runs in the op‐
posite direction when it
is refitted, this can
cause breakage.
❑ Check for wear
❑ Do not kink
❑ Removing, installing
and tensioning
⇒ page 38
6 - Idler roller
7 - 27 Nm
8 - 65 Nm
❑ Use counterhold tool -
3036- to loosen and
tighten
9 - Camshaft sprocket
❑ Removing and installing ⇒ “1.9 Detaching toothed belt from camshaft sprocket”, page 45
10 - TensioningProtected
roller by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Depending on version,
permitted 2 different
unless authorised by AUDI AG.tensioning
AUDI AG doesrollers mayorbe
not guarantee installed
accept any liability
11 - Washer
12 - Tensioner for toothed belt
❑ Depending on version, a toothed belt tensioner with idler roller or a bracket for idler roller may be installed
13 - O-ring
❑ Renew
❑ Lubricate with coolant prior to installing
14 - Coolant pump
15 - 15 Nm
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 - 3415- to loosen and tighten
18 - 15 Nm
19 - 25 Nm
1.8 Removing, installing and tensioning toothed belt

equipment required
♦ Torque wrench - V.A.G
1331-
♦ Pin wrench - 3387-
♦ Locking plate - T10008-
1332-

Removing
panel.
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

poly V-belt.

– Remove toothed belt cover (top).
– Rotate crankshaft to TDC by turning bolt for toothed belt

sprocket.
Caution
The engine must only be turned at the crankshaft, in the direc‐

tion of normal engine rotation (clockwise).
• Marking on camshaft sprocket and marking on crankshaft

must be aligned to TDC -arrows-.

– Counterhold by applying ring spanner to bolt for toothed belt

sprocket and unbolt vibration damper.
– Remove toothed belt cover (centre and bottom) -arrows-.

With hydraulic tensioning roller
Caution
♦ The toothed belt tensioner is oil-damped and can there‐

fore only be compressed slowly by applying constant pres‐
sure.
♦ To avoid damage, do not apply more force than necessary
when compressing the toothed belt tensioner.
– Applying constant and moderate force, use hexagon key to

press toothed belt tensioner anti-clockwise in direction of
-arrow- until piston of tensioner can be locked with locking
plate - T10008- .
– Insert locking plate - T10008- and make sure that it remains
in place.
Note
Do not to bend limit stop -A- of eccentric adjuster.
– To slacken toothed belt, loosen nut -1- on tensioning roller and

turn eccentric adjuster clockwise -arrow- using pin wrench -
3387- .

Without hydraulic tensioning roller

– Loosen nut -1- to slacken toothed belt.
All models:
– Mark direction of rotation of toothed belt with chalk or felt-tip
pen.
– Remove toothed belt.
Installing (adjusting valve timing)
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.
♦ 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.
– Fit toothed belt on crankshaft sprocket (note rotation direc‐

tion).
– Install
Protectedbottom toothed
by copyright. belt
Copying for cover.
private or commercial purposes, in part or in whole, is not
Note
The vibration damper/ pulley can only be installed in one position:

The hole -arrow- in the vibration damper must fit over the projec‐
tion on the toothed belt sprocket on the crankshaft.
– Secure vibration damper/ pulley. Note positive location

-arrow-.
– Align markings on camshaft sprocket / cylinder head cover and

markings on vibration damper / toothed belt cover -arrows-.
– Make sure that toothed belt tensioner is still locked with locking
plate - T10008- .
All models:
– Fit toothed belt onto coolant pump, then tensioning roller, and
finally camshaft sprocket.
Tensioning toothed belt
Note

– Turn eccentric adjuster anti-clockwise onto stop in direction of

-arrow- using pin wrench - 3387- .
– Hold eccentric adjuster in this position and pull out locking
plate - T10008- .
– Turn eccentric adjuster clockwise in direction of -arrow- until

gauge -2- with dimension -a- = 8 mm (e.g. drill bit) can be
pulled through between tensioning lever and housing of ten‐
sioner.
– Hold eccentric adjuster in this position and tighten nut -1- of
tensioning roller to 27 Nm.
Caution

– Turn crankshaft two rotations via toothed belt sprocket bolt

until it is positioned at TDC again.

– Use gauge -2- (e.g. drill bit) to check dimension -a- between
tensioning lever and housing of tensioner.
• Dimension -a- = 6 ... 10 mm.
If dimension -a- is achieved, see "Assembling" ⇒ page 45 .
If dimension -a- is not attained:
Caution

sure.

plate - T10008- .
– Loosen nut -1- for tensioning roller.

– Tension toothed belt ⇒ page 41 .

• Retaining lug -arrow- must engage in slot on cylinder head.

– Use a hexagon key to turn toothed belt tensioning roller in di‐

rection of -arrow- until dimension -a- is attained.
• Dimension -a- = 5 - 8 mm.
– Turn back toothed belt tensioning roller, but do not slacken

completely.
– Turn toothed belt tensioning roller in direction of -arrow- using
a hexagon key until markings -1 and 2- are aligned.
– Tighten nut -3- for tensioning roller.
Note
Marking -1- (right edge of projection) must coincide with marking

-2-.
Caution

– Turn crankshaft two rotations via toothed belt sprocket bolt

until it is positioned at TDC again.

– Check toothed belt tension: marking -1- must be between

markings -arrows-; correct tension if necessary.
Assembling
– Fit centre and top section of toothed belt cover.
– Install poly V-belt tensioner -arrows-.
– Install top section of toothed belt cover (make sure it engages
securely on centre section of toothed belt cover).

nuts -arrows-.
Rep. gr. 63 .
Tightening torques
Component Nm
Tensioning roller to cylinder head 27
Vibration damper to toothed belt sprocket 10 + 90° 9) 10)
Toothed belt cover (bottom and centre section) 10 8)
to cylinder block
ries
8) Install using locking fluid ⇒ Parts catalogue
9) Renew bolts.
1.9 Detaching toothed belt from camshaft

sprocket

♦ Pin wrench - 3387-
Detaching toothed belt

panel.
Note


poly V-belt.

– Rotate crankshaft to TDC by turning bolt for toothed belt

sprocket.
Caution


Caution

sure.

plate - T10008- . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
in place.
Note
– To slacken toothed belt, loosen nut -1- on tensioning roller and

turn eccentric adjuster clockwise -arrow- using pin wrench -
3387- .
– Loosen nut on tensioning roller to slacken toothed belt.
All models:
– Remove toothed belt from camshaft sprocket.

Fitting toothed belt

– Align markings on camshaft sprocket / cylinder head cover and
markings on vibration damper / toothed belt cover -arrows-.
– Make sure that toothed belt tensioner is still locked with locking
plate - T10008- .
All models:
– Fit toothed belt onto coolant pump, then tensioning roller, and
finally camshaft sprocket.
note the following:


nuts -arrows-.
Rep. gr. 63 .
Tightening torques
Component Nm
Tensioning roller for toothed belt to cylinder 27
head
1.10 Removing and installing tensioner for

toothed belt

Removing
panel.
Note


poly V-belt.

– Remove toothed belt cover (centre) -arrows-.

– Secure tensioning roller using e.g. cable tie -arrow- to prevent

it dropping.
Caution

sure.

plate - T10008- .
in place.
– Remove tensioner for toothed belt -arrows-.
Installing
– Install toothed belt tensioner.
– Remove cable tie -arrow-.

– Loosen nut -1- for tensioning roller.


nuts -arrows-.
Rep. gr. 63 .
Tightening torques
Component Nm
Tensioner for toothed belt to cylinder head 15
Tensioning roller for toothed belt to cylinder 27
head
Toothed belt cover (centre section) to cylinder 10 11)
head
ries

2 Removing and installing sealing

flanges and flywheel/dual-mass fly‐
wheel/drive plate
Note
Servicing clutch ⇒ Rep. gr. 30
1 - 15 Nm
2 - Oil seal Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Renewingwith⇒ respect
page to53
❑ Do not lubricate with oil
3 - Sealing flange (front)
❑ Must be positioned on
dowel sleeves
⇒ page 55
❑ Install using sealant;
sealant ⇒ Parts cata‐
logue
4 - Cylinder block
crankshaft ⇒ page 67
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 73
5 - Securing bolt for flywheel/
dual-mass flywheel/drive plate
❑ Renew
❑ Tightening torque for
dual-mass flywheel
⇒ page 61
❑ Tightening torque for fly‐
wheel ⇒ page 62
❑ Tightening torque for
drive plate ⇒ page 63
6 - Flywheel/dual-mass fly‐
wheel/drive plate
dual-mass flywheel on
vehicles with manual
gearbox ⇒ page 60
❑ Removing and installing flywheel on vehicles with multitronic gearbox ⇒ page 61
❑ Removing and installing drive plate on vehicles with automatic gearbox 01V ⇒ page 62
7 - Intermediate plate
❑ Must be positioned on dowel sleeves
❑ Do not damage/bend when assembling
❑ Is fitted onto sealing flange ⇒ page 53
8 - 15 Nm
9 - Sealing flange (rear) with oil seal
❑ Renew only as complete unit ⇒ page 63

❑ Use guide sleeve provided when fitting

❑ Do not lubricate/grease sealing lip of oil seal
❑ Before installing, remove oil residue from crankshaft journal with a clean cloth
❑ Guide sleeve is not to be removed until sealing flange has been slipped onto crankshaft journal
Installing intermediate plate

– Engage intermediate plate on sealing flange, and press onto
dowel sleeves -arrows-.
2.1 Renewing crankshaft oil seal (pulley end)

equipment required
♦ Oil seal extractor - 3203-
♦ Counterhold tool - 3415-
♦ Assembly tool - T10053-
1331-
♦ Torque wrench
with respect - V.A.G of information in this document. Copyright by AUDI AG.
to the correctness
1332-
2. Removing and installing sealing flanges and flywheel/dual-mass flywheel/drive plate 53

Removing
– Remove poly V-belt ⇒ page 31 .
– Remove toothed belt ⇒ page 38 .
– Remove crankshaft sprocket; use counterhold tool - 3415- to
lock sprocket in place.
– To guide oil seal
with respect to the extractor, screw central
correctness of information bolt into
in this document. crankshaft
Copyright by AUDI AG.
onto stop by hand.
– Unscrew inner part of oil seal extractor - 3203- 9 turns
(approx. 20 mm) from outer part of extractor and lock in posi‐
tion with knurled screw.
– Lubricate threaded head of oil seal extractor - 3203- , place it

in position and, while 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 and use pliers to remove
seal.
Installing
– Clean running surface and sealing surface.
– Remove oil residue from crankshaft journal with a clean cloth.
– Place guide sleeve - T10053/1- onto crankshaft journal.
– Slide oil seal over guide sleeve onto crankshaft journal.

– Press in oil seal flush using the centre bolt of toothed belt
sprocket and press sleeve from assembly tool - T10053- .
– Renew centre bolt for toothed belt sprocket.

– Install crankshaft sprocket; use counterhold tool - 3415- to lock
sprocket in place.
Note
♦ Contact surface between toothed belt sprocket and crankshaft

must be free of oil.
♦ Do not lubricate bolt for crankshaft sprocket.
– Install toothed belt (adjust valve timing) ⇒ page 41 .

– Install vibration damper ⇒ page 32 .
– Protected
Installbylock carrier with attachments ⇒ General body repairs,
copyright. Copying for private or commercial purposes, in part or in whole, is not
exterior;
with respect Rep. gr. 50 of
to the correctness . information in this document. Copyright by AUDI AG.
nuts -arrows-.
Rep. gr. 63 .
Tightening torques
Component Nm
Toothed belt sprocket to crankshaft 90 + 90° 12) 13)
12) Renew bolt.
2.2 Removing and installing sealing flange (front)


equipment required
1331-
1332-
♦ Electric drill with plastic
brush attachment
♦ Safety goggles
♦ Sealant ⇒ Parts catalogue
Removing
panel.

Note


poly V-belt.
– Unscrew bolt -arrow- and remove idler roller for poly V-belt.
– Remove toothed belt ⇒ page 38 .

– Remove crankshaft sprocket; use counterhold tool - 3415- to
lock sprocket in place.
– Remove bolts -1 ... 10-.

– Pull off sealing flange (front).
– Drive out oil seal with flange removed.
Installing
Note
Place a cloth over the exposed section of the sump.
– Carefully remove any sealant residue on the cylinder block

and sump.
WARNING
Wear safety goggles.

– Remove sealant residue from sealing flange with rotating plas‐

tic brush or similar.
– Clean sealing surfaces; they must be free of oil and grease.
– Cut off tube nozzle at front marking (diameter of nozzle ap‐

prox. 2 mm).
– Apply a thin bead of sealant at the edge of the joint between

the cylinder block and the sump -arrows-.
– Apply the bead of sealant onto the clean sealing surface of the
sealing flange as illustrated -arrow-.
• Thickness of sealant bead: 2 ... 3 mm
Note
The sealant bead must not be thicker than specified, otherwise

excess sealant could enter the sump and clog the strainer in the
oil pump.

– Coat the lower sealing surface on the sealing flange lightly with
sealant -hatched area-.
Note
The sealing flange must be installed within 5 minutes after apply‐

ing sealant.
– Push the sealing flange carefully onto the dowel pins on the
cylinder block.
– Tighten bolts in the specified sequence:

1. Tighten bolts -1 ... 6-.
– Install crankshaft oil seal (pulley end) ⇒ page 53 .
– 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.
note the following:


nuts -arrows-.
Rep. gr. 63 .
Tightening torques
Component Nm
Sealing flange to cylinder block 15
Toothed belt sprocket to crankshaft 90 + 90° 14) 15)
Idler roller to bracket for ancillaries 25
14) Renew bolt.
2.3 Removing and installing dual-mass fly‐

wheel - vehicles with manual gearbox
♦ Counterhold tool - 10-201-
Removing
• Engine or gearbox removed.
– Remove clutch pressure plate ⇒ Rep. gr. 30 .
– Mark installation position of dual-mass flywheel on crankshaft.
– Attach counterhold tool - 10-201- in order to loosen bolts.

Note
To prevent damage to the dual-mass flywheel when removing,

the bolts -B- must not be removed with an impact wrench or sim‐
ilar. The bolts may only be removed by hand using conventional
tools.
– Rotate the dual-mass flywheel -A- so that the bolts align with
the holes -arrows-.
– When
Protected unscrewing
by copyright. the bolts,
Copying for private makepurposes,
or commercial sure that
in partthe
or in bolt
whole,heads
is not do
not come into contact with the dual-mass flywheel; the
fly‐
wheel will otherwise be damaged as the bolts are screwed out.
Installing
– Use new securing bolts.
– Reverse position of counterhold tool - 10-201- in order to tight‐
en bolts.
– Install clutch pressure plate ⇒ Rep. gr. 30 .
Tightening torque
Component Nm
Dual-mass flywheel to crankshaft
Bolt length 22.5 mm 60 + 90° 16) 17)
35.0 mm 60 + 180° 16) 18)
43.0 mm 60 + 180° 16) 18)
16) Renew bolts.
18) 180° = one half turn.
2.4 Removing and installing flywheel - vehi‐

cles with multitronic gearbox
♦ Counterhold tool - 10-201-

Removing
• Engine or gearbox removed.
– Remove the damper unit -arrow- ⇒ multitronic gearbox 01J,
front-wheel drive; Rep. gr. 13 .
– Mark installation position of flywheel -arrow- on crankshaft.

– Attach counterhold tool - 10-201- in order to loosen bolts.
– Unbolt flywheel.
Installing
– Use new securing bolts.
– Reverse position of counterhold tool - 10-201- in order to tight‐
en bolts.
– Install damper unit ⇒ multitronic gearbox 01J, front-wheel
drive; Rep. gr. 13 .
Tightening torque
Component Nm
Flywheel to crankshaft
Bolt length 22.5 mm 60 + 90° 19) 20)
20) Renew bolts.
2.5 Removing and installing drive plate - ve‐

hicles with automatic gearbox 01V

♦ Clutch counterhold tool - VW 558-
♦ Depth gauge

Removing
• Engine/gearbox removed.
– Mark installation position of drive plate on engine.
– Attach clutch counterhold tool - VW 558- in order to loosen
bolts.
– Unbolt drive plate.
– Take out shim located behind.
Installing
– Fit shim -2- onto crankshaft.
– Install drive plate with washer -1-.
• Lug -arrow- must face torque converter.
– Fit at least 3 old bolts and tighten to 30 Nm.

– Measure distance through torque converter securing hole us‐
ing depth gauge.
• Specification: Distance -a- = 18.9 ... 20.5 mm.
If specification is not obtained:

– Remove drive plate and remove or add shim -2-.
– Repeat measurement (tighten bolts on drive plate to 30 Nm).
If specification is obtained:
– Renew all bolts and tighten to torque.
Tightening torque
Component Nm
Drive plate to crankshaft 60 + 90° 21) 22)
21) Renew bolts.
2.6 Removing and installing sealing flange

(rear)
♦ Electric drill with plastic brush attachment

♦ Safety goggles
Removing
• Gearbox removed.
– Remove dual-mass flywheel
⇒ “2.3 Removing and installing dual-mass flywheel - vehicles
with manual gearbox”, page 60 / flywheel
⇒ “2.4 Removing and installing flywheel - vehicles with multi‐
tronic gearbox”, page 61 / drive plate
⇒ “2.5 Removing and installing drive plate - vehicles with au‐
tomatic gearbox 01V”, page 62 .
– Detach intermediate plate at sealing flange and dowel sleeves
-arrows-.

– Pull off sealing flange (rear).
Installing
Note
Place a cloth over the exposed section of the sump.
– Carefully remove any sealant residue on the cylinder block

and sump.
prox. 2 mm).

– Apply a thin bead of sealant at the edge of the joint between

the cylinder block and the sump -arrows-.
– Coat the lower sealing surface on the sealing flange lightly with
sealant -hatched area-.
Note
The sealing flange must be installed within 5 minutes after apply‐

ing sealant.
– Carefully push sealing flange -2- together with guide sleeve

-1- (fitted on replacement part) onto crankshaft when instal‐
ling.
– Push the sealing flange carefully onto the dowel sleeves on
the cylinder block.
– Tighten bolts in the specified sequence:

2. Tighten bolts -7- and -8-.


note the following:
– Fit intermediate plate on sealing flange and push onto dowel
sleeves -arrows-.
– Install dual-mass flywheel
⇒ “2.3 Removing and installing dual-mass flywheel - vehicles
with manual gearbox”, page 60 / flywheel
⇒ “2.4 Removing and installing flywheel - vehicles with multi‐
tronic gearbox”, page 61 / drive plate
⇒ “2.5 Removing and installing drive plate - vehicles with au‐
tomatic gearbox 01V”, page 62 .
Tightening torque
Component Nm
Sealing flange to cylinder block 15

3 Removing and installing crankshaft
Note
♦ When carrying out repairs, secure engine to engine and gear‐

box support - VAS 6095- using -VW 540- ⇒ page 20 .
♦ If large quantities of metal shavings or particles are found in
the engine oil when repairing the engine, the oil passages
must be cleaned carefully, and the oil cooler must be renewed
in order to prevent further damage occurring later.
3.1 Crankshaft - exploded view
1 - Bearing shell
❑ For cylinder block (with
oil groove)
❑ Do not interchange
used bearing shells
(mark positions)
❑ Fit bearing shells for cyl‐
inder block with correct
colour-coding
⇒ page 69
2 - Chain sprocket
❑ For oil pump chain
❑ Renewing ⇒ page 71
3 - Bearing shell
❑ For bearing cap (without
oil groove)
used bearing shells
(mark positions)
❑ The crankshaft bearing
shells in the bearing
caps are only supplied
as spare parts with “yel‐
low” coloured markings.
4 - Thrust washers
❑ For bearing No. 3
❑ Note location
5 - 65 Nm + 90° (1/4 turn) fur‐
ther
❑ Renew Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For measuring radial with respect to the correctness of information in this document. Copyright by AUDI AG.
clearance of crankshaft,
tighten to 65 Nm but not
further
6 - 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
7 - 10 Nm + 90° (1/4 turn) further
❑ Renew
3. Removing and installing crankshaft 67

❑ Sender wheel must be renewed if bolts are loosened ⇒ page 68

8 - Needle bearing
❑ For vehicles with manual gearbox
❑ Extracting and driving in ⇒ page 70
❑ On vehicles with automatic gearbox 01V a centring sleeve for torque converter must be fitted instead of
the needle bearing ⇒ page 69
9 - 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
10 - Crankshaft
❑ Axial clearance (new): 0.07 ... 0.23 mm
❑ Axial clearance: wear limit: 0.30 mm
❑ Check radial clearance with Plastigage
❑ Radial clearance (new): 0.02 ... 0.04 mm
❑ Radial clearance: wear limit: 0.15 mm
❑ Do not rotate the crankshaft when checking the radial clearance
❑ Crankshaft dimensions ⇒ page 69
Removing and installing sender wheel

– Sender wheel -2- must always be renewed after slackening off
bolts -1-.
Note
♦ If the countersunk bolts are tightened a second time, the seats

for the bolt heads in the sender wheel will be deformed to such
an extent that the bolt heads make contact with the crankshaft
-3- -arrows- and the sender
Protected wheel
by copyright. Copyingbeneath the
for private or bolts will
commercial be in part or in whole, is not
purposes,
loose. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Sender wheel can only be installed in one position. Holes are
off-set.
Tightening torque
Component Nm
Sender wheel to crankshaft 10 + 90° 23) 24)
23) Renew bolts.

Matching crankshaft bearing shells to bearings in cylinder block

Bearing shells of the correct thickness are assigned to the cylin‐
der block at the factory. Coloured dots are used to identify the
thickness of the bearing shells.
Note
The -arrow- points in direction of travel.
Letter codes on lower sealing surface of cylinder block indicate

which bearing shell is to be fitted at each location.
Letter on cylinder block Colour coding of bearing
B= Blue
R = Red
S= Black
Note
♦ Letters must be visible when sump is installed.

♦ The crankshaft bearing shells in the bearing caps are only
supplied as spare parts with “yellow” coloured markings.
Centring sleeve for torque converter
Note
Short engines and reconditioned (exchange) engines, as well as

new and reconditioned crankshafts, are supplied without bush
-arrow-. The centring sleeve must therefore be knocked in before
fitting drive plate on vehicles with automatic gearbox 01V. This
bush must not be fitted in vehicles with manual gearbox.
3.2 Crankshaft dimensions

Honing dimen‐ Crankshaft main Conrod
sion bearing journal ∅ bearing journal ∅
(in mm)
Basic dimen‐ 54.00 –0.017 47.80 –0.022
sion –0.037 –0.042
1st undersize 53.75 –0.017 47.55 –0.022
–0.037 –0.042
2nd undersize
Protected by copyright. Copying 53.50
for private–0.017
or commercial purposes,47.30
in part or–0.022
in whole, is not
permitted unless authorised by AUDI AG. –0.037
AUDI AG does not guarantee or accept–0.042
any liability
3rd undersize 53.25 –0.017 47.05 –0.022
–0.037 –0.042

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 01V, the needle bearing
must NOT be fitted in the crankshaft; remove needle bearing
if fitted.

♦ Drift - VW 207 C- or centring mandrel - 3176-
♦ 1 - Internal puller - Kukko 21/1-
♦ 4 - Counter-support - Kukko 22/1-

♦ Depth gauge
Pulling out
– Remove needle bearing using internal puller - Kukko 21/1- and
counter-support - 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.
Installation depth of needle bearing

• Distance -a- = 1.5 mm
3.4 Removing and installing chain sprocket

♦ Drift sleeve - 30-100-
♦ Thrust plate - 40-105-
♦ Two-arm puller, commercially available

♦ Protective gloves

Removing
• Engine removed ⇒ page 2 .
– Remove sump ⇒ page 122 .
– Remove sealing flange (front) ⇒ page 55 .
– Remove drive chain for oil pump ⇒ Item 7 (page 120) .
– Pull off crankshaft chain sprocket using e.g. claw-type puller -
Kukko 44-1- -item 2- (protect end of crankshaft with thrust
plate - 40-105- -item 1-).
Installing
WARNING
Wear protective gloves.
– Heat chain sprocket in oven for approx. 15 minutes to 220°C.
– Using pliers, locate sprocket on end of crankshaft.
• Installation position: wide collar on sprocket faces engine.
– Push sprocket onto crankshaft as far as the stop using drift
sleeve - 30-100- .

4 Dismantling and assembling pistons

and conrods
4.1 Pistons and conrods - exploded view
Note
♦ Oil spray jet and pressure relief valve ⇒ page 75
1 - Conrod bolt, 30 Nm + 90°

(1/4 turn) further
❑ Renew
❑ Lubricate threads and
contact surface
❑ Use old bolts when
measuring radial clear‐
ance
❑ To measure radial clear‐
ance, tighten to 30 Nm
but do not turn further
2 - Conrod bearing cap
❑ Mark cylinder number
-B-
❑ Installation position:
Markings -A- face to‐
wards pulley end
3 - Bearing shells
❑ Upper bearing shell with
oil hole for piston pin lu‐
brication
❑ Installation position
⇒ page 75
used bearing shells
(mark positions)
❑ Axial clearance (new):
0.10 ... 0.35 mm; wear
limit: 0.40 mm
❑ Check radial clearance
with Plastigage: New:
0.01 ... 0.05 mm; Wear
limit: 0.12 mm. Do not
rotate crankshaft when
checking radial clear‐
ance
4 - Conrod
❑ Only renew as a complete set
❑ Mark cylinder number -B-
❑ Installation position: Markings -A- face towards pulley end
❑ With oil drilling for piston pin lubrication
4. Dismantling and assembling pistons and conrods 73

5 - Circlip
6 - Piston pin
❑ If difficult to move, heat piston to approx. 60 °C
❑ Remove and install using drift - VW 222 A-
7 - Piston
❑ Checking ⇒ page 75
❑ Mark installation position and cylinder number
❑ Arrow on piston crown points to pulley end
❑ Install using piston ring clamp
❑ Piston and cylinder dimensions ⇒ page 76
❑ Checking cylinder bore ⇒ page 75
8 - Piston rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to remove and install
❑ “TOP” must face towards piston crown
❑ Checking ring gap ⇒ page 74
❑ Checking ring-to-groove clearance ⇒ page 74
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. Use a piston without rings to push ring into bore.
Piston ring New Wear limit
(in mm)
1st compression ring 0.20 … 0.40 0.8
2nd compression ring 0.20 … 0.40 0.8
Oil scraper ring 0.25 … 0.50 0.8
Checking ring-to-groove clearance

– Clean groove in piston before checking clearance.
Piston ring New Wear limit
(in mm)
1st compression ring 0.06 … 0.09 0.20
2nd compression ring 0.05 … 0.08 0.20
Oil scraper ring 0.03 … 0.06 0.15

Checking piston
– Measure approx. 10 mm from the bottom edge, perpendicular
to the piston pin axis.
• Difference between measured value and nominal value: max.
0.04 mm
Checking cylinder bore

– Use 50 ... 100 mm internal dial gauge to take measurements
at 3 points in transverse direction -A- and longitudinal direction
-B-.
• Difference between measured value and nominal value: max.
0.08 mm
Installation position of bearing shell

– Insert bearing shells centrally in conrod/conrod bearing cap.
• Dimension -a- = 3.0 mm
Oil spray jet and pressure relief valve

1- Oil spray jet for piston cooling
2- Bolt with pressure relief valve, 27 Nm
• Opening pressure: 1.3 ... 1.6 bar.
4. Dismantling and assembling pistons and conrods 75

4.2 Piston and cylinder dimensions

Honing dimension Piston ∅ Cylinder bore ∅
(in mm)
Basic dimension 80.95 25) 81.01
1st undersize 81.45 25) 81.51
25) Dimension not including graphite coating (thickness 0.02 mm). The graphite
coating wears down in service.

15 – Cylinder head, valve gear

1 Removing and installing cylinder
head
1.1 Cylinder head - exploded view
1 - Cylinder head gasket

❑ Renewing
⇒ “1.3 Removing and in‐
stalling cylinder head”,
page 81
❑ Installation position:
Part No. towards cylin‐
der head
❑ If renewed, refill system
with fresh coolant
2 - Cylinder head
⇒ page 81
❑ Checking for distortion
⇒ page 78
❑ Machining limit
⇒ page 78
with fresh coolant
3 - Oil deflector
❑ Note installation posi‐
tion
4 - Cylinder head bolt
❑ Renew permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Note correct sequence with respect to the correctness of information in this document. Copyright by AUDI AG.
when loosening
⇒ page 85
❑ Note correct sequence
when tightening
⇒ page 87
5 - Cylinder head cover
⇒ page 79
6 - Ignition coil
7 - Filler cap
8 - Seal
❑ Renew if damaged or leaking
9 - 10 Nm
❑ Tighten inner nuts first
❑ Tighten outer nuts in diagonal sequence
10 - Gaskets for cylinder head cover
❑ Renew if damaged or leaking
❑ Before fitting, apply sealant at sealing points ⇒ page 78 and ⇒ page 79
1. Removing and installing cylinder head 77

11 - Gasket
❑ Renew
12 - Combination valve for secondary air system
❑ With connecting pipe
13 - 10 Nm
14 - Coolant flange
❑ With coolant temperature sender
15 - 10 Nm
16 - O-ring
❑ Renew
Checking cylinder head for distortion

– Use straight edge and feeler gauge to measure
with respect for distortion
at several points.
• Maximum permissible distortion: 0.1 mm.
Cylinder head machining limit

– Machining of the cylinder head (surface grinding) is only per‐
missible down to the minimum dimension -a-.
• Minimum dimension: -a- = 139.20 mm
Sealing points on double bearing cap/cylinder head

– Apply small quantity of sealant to transitions -arrows- at top
sealing surface of cylinder head; sealant ⇒ Parts catalogue .
78 Rep. gr.15 - Cylinder head, valve gear

Sealing points between camshaft adjuster and cylinder head

1.2 Removing and installing cylinder head

cover
♦ Puller - T40039-
Removing
panel.


– Remove crankcase breather pipe -2-.

– Remove crankcase breather
Protected by copyright. hose
Copying fromorcylinder
for private commercial head cover.
purposes, in part or in whole, is not
– Detach pipe with
-1-respect
on combination valve for secondary air from
cylinder head cover and heat shield -3-.

– Pivot secondary air pipe slightly to the side.
– Disconnect earth cable -2-.

– Unplug the electrical connectors -3- and move wiring clear.
– Pull out ignition coils -1-.
Note
Use puller - T40039- to remove ignition coils.

– Loosen two retaining clips for toothed belt cover (top section).
– Unscrew nuts -arrows- and remove cylinder head cover.
Installing
Note
♦ Renew gaskets and seals.

♦ Renew cylinder head cover gaskets if damaged.


– First tighten inner cylinder head cover nuts, then tighten outer
nuts in diagonal sequence.
Tightening torques
Component Nm
Cylinder head cover to cylinder head 10
Crankcase breather pipe to cylinder head cover 10
Secondary air pipe to cylinder head cover 10
1.3 Removing and installing cylinder head


♦ Puller - T40039-
Removing
Note
All cable ties which are released or cut open when removing must
be fitted in the same position when installing.
Caution

Electrical system; Rep. gr. 27 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Disconnect earth wire at battery with ignition switched off.
– Remove coolant pipe (top) ⇒ page 150 .
– Remove intake manifold ⇒ page 92 .
– Remove toothed belt from camshaft sprocket ⇒ page 45 .
– Detach hoses -1-, -4-, -6- and -7-.

– Remove crankcase breather pipe -2-.

– Remove crankcase breather hose from cylinder head cover.
– Detach pipe -1- on combination valve for secondary air from
cylinder head cover and heat shield -3-.
– Pivot secondary air pipe slightly to the side.
– Remove heat shield.
– Remove bolts -1- and -2- on oil supply line.

– Unscrew bolts -3- for turbocharger.
– Unplug electrical connector -arrow- at inlet camshaft control

valve 1 - N205- .
– Unplug electrical connector -arrow- at coolant temperature

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

– Disconnect vacuum hose -arrow- at combination valve for

secondary air.
– Remove coolant flange by unscrewing bolts -2- and -3-.
– Unbolt bracket -1- for oil supply line.
Note
Shown from rear with engine removed for illustration purposes.

– Unclip/release all electrical wires on the cylinder head with
andrespect to the correctness of information in this document. Copyright by AUDI AG.
move clear.
– Detach coolant hose for heat exchanger at rear of cylinder
head (release retaining clip on connecting flange).

Note
– Unscrew nuts -arrows- and remove cylinder head cover.

– Remove both oil deflectors.

– Remove cylinder head bolts in the sequence: -1 ... 10-.

– Remove the cylinder head with the assistance of a 2nd me‐
chanic.
Installing
Note
♦ Cylinder heads which have cracks between the valve seats or

between a valve seat insert and the spark plug thread can be
re-installed without reducing service life, provided the cracks
are only slight and do not exceed a maximum of 0.3 mm in
width, and no more than the first 4 turns of the spark plug
threads are cracked.
♦ Renew the cylinder head bolts.
♦ Renew self-locking nuts and bolts when
Protected performing
by copyright. Copying assembly
for private or commercial purposes, in part or in whole, is not
work. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Renew bolts which are tightened to a specified angle as well
as oil seals and gaskets.
♦ 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.
♦ When installing an exchange cylinder head with the camshafts
fitted, the contact surfaces between bucket tappet and cam
running surface must be oiled after installation of the cylinder
head.
♦ The plastic protectors fitted to protect the open valves must
only be removed immediately before fitting the cylinder head.
♦ 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 fitting a new cylinder head or cylinder head gasket, drain
off all the old coolant and refill with new coolant.

– Set camshaft to TDC -top arrow- before fitting cylinder head.

– Make sure that crankshaft is in TDC position -bottom arrow-;
turn crankshaft via toothed belt sprocket bolt if necessary.
– Unscrew bolts -1- and -2- on turbocharger bracket (about 2 full

turns each) to avoid stressing when installing the cylinder
head.
– Fit cylinder head gasket.

• Note position of centring pins in cylinder block -arrows-.
• Check installation position of cylinder head gasket; the Part
No. should be legible from inlet side. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Fit cylinder head.

– Insert and hand-tighten cylinder head bolts.

– Tighten cylinder head bolts in 3 stages in the sequence indi‐

cated:
Stage Tightening
I – Tighten with torque wrench to 40 Nm.
II – Turn 90° (1/4 turn) further using a rigid wrench.
III – Turn 90° (1/4 turn) further using a rigid wrench.
Note
Cylinder head bolts do not have to be torqued down again later

after repair work.

note the following:
– Secure turbocharger with new gasket to exhaust manifold and
secure bracket to cylinder block ⇒ page 172 .
– Install cylinder head cover ⇒ page 79 .
– Install intake manifold ⇒ page 92 .
– Install coolant pipe (top) ⇒ page 150 .
– Install front exhaust pipe together with catalytic converter
⇒ page 197 .
– Align exhaust system so it is free of stress ⇒ page 188 .


nuts -arrows-.
Rep. gr. 63 .
– Connect battery. Procedures required ⇒ Electrical system;
Rep. gr. 27 .
Note
If engine oil is contaminated, perform oil change ⇒ Maintenance ;

Booklet 8E .
– Fill cooling system with fresh coolant ⇒ page 144 .

Tightening torque
Component Nm
Turbocharger to exhaust manifold 35 26) 27)
Bracket for Cylinder block 25

Turbocharger to: Turbocharger 30
Support for Intake manifold 23
Intake manifold Bracket for ancillaries 23
to:
26) Renew bolts.
27) Coat thread and contact surface of bolt head with high-temperature paste; ⇒
Parts catalogue
1.4 Checking compression


equipment required
♦ Spark plug socket and ex‐
tension - 3122 B-
♦ Compression tester - V.A.G
1763-
♦ Puller - T40039-
Test conditions
• Engine oil temperature at least 30 °C
• Battery voltage at least 12.5 V
Test sequence
panel.

– Unplug electrical connectors -2- on injectors.
Note
Disregard items -1- and -3-.


Note
– Remove spark plugs with spark plug socket - 3122 B- .

– Test the compression pressure with the compression tester -
V.A.G 1763- .
Note
Using the compression tester ⇒ operating instructions .
– Have a 2nd mechanic press down the accelerator pedal com‐

pletely and simultaneously operate the starter until the pres‐
sure no longer increases on thethe tester display.

with respect to correctness of information in this document. Copyright by AUDI AG.
Compression pressure:
New Wear limit Permissible differ‐
pressure in bar bar ence between cylin‐
ders
bar
9.0 … 14.0 7.5 3.0 (maximum)
– Install spark plugs and ignition coils.
Note
Renew gaskets for ignition coils if damaged.
– Interrogate and erase the fault memory for engine control unit,
as faults are stored when the electrical connectors are un‐
plugged ⇒ Vehicle diagnostic tester.
Tightening torque
Component Nm
Spark plugs in cylinder head 30

2 Removing and installing intake mani‐

fold
2.1 Intake manifold - exploded view
1 - Gasket
❑ Renew
2 - 10 Nm
3 - O-rings
❑ Renew
4 - Fuel rail
❑ With injectors
5 - 10 Nm
6 - Fuel line
❑ Tighten union nut to 22
Nm
7 - 10 Nm
8 - Bracket for dipstick guide
tube
9 - Intake manifold
⇒ page 92
10 - 23 Nm
11 - Support for intake mani‐
fold
12 - 23 Nm
2.2 Removing and installing intake manifold

Removing
– Remove coolant pipe (top) ⇒ page 150 .

– Detach vacuum hose -1- from intake manifold.

– Detach air intake hose -3- at intake manifold.
– Unplug electrical connectors -2- and -4-.
– Detach vacuum hoses -arrows- at intake manifold.
– Remove retaining plate for turbocharger air recirculation valve

- N249- -item 1- and secondary air inlet valve - N112-
-item 2- below intake manifold (unscrew bolts -arrows-).
Note
Leave connectors and vacuum hoses attached.
2. Removing and installing intake manifold 93

– Unplug electrical connector -1- at Hall sender - G40- .

– Remove securing bolts -3- of fuel rail and detach fuel rail to‐
gether with injectors -2- from intake manifold.
– Place fuel rail on a clean cloth at rear in engine compartment.
Note
Make sure the removed injectors do not become soiled.
– Pull out dipstick -1-.

– Unscrew bracket for dipstick guide tube.
– Unscrew and remove intake manifold -arrows-.
Note
Block off intake ports in cylinder head with clean rags.

Installing with respect to the correctness of information in this document. Copyright by AUDI AG.
Note
♦ Renew gaskets, seals and O-rings.

– Install coolant pipe (top) ⇒ page 150 .

Tightening torques
Component Nm
Intake manifold to cylinder head 10
Support for Intake manifold 23
Intake mani‐ Bracket for ancillaries 23
fold to:
Fuel rail to intake manifold 10
Retaining plate to intake manifold 10

3 Servicing valve gear
Note
♦ Cylinder heads which have cracks between the valve seats or

between a valve seat insert and the spark plug thread can be
re-installed without reducing service life, provided the cracks
are only slight and do not exceed a maximum of 0.3 mm in
width, and no more than the first 4 turns of the spark plug
threads are cracked.
♦ After installing camshafts, wait for approx. 30 minutes before
starting engine. 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.
♦ Always renew seals and gaskets.
3.1 Valve gear - exploded view
1 - 65 Nm
❑ Use counterhold tool -
3036- to loosen and
tighten
2 - Camshaft sprocket for ex‐
haust camshaft
❑ Note installation posi‐
tion: The camshaft
sprocket is installed with Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
the smaller web facing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
out and the TDC mark‐ with respect to the correctness of information in this document. Copyright by AUDI AG.
ing for cylinder 1 visible
from the front
⇒ page 101
3 - Oil seal for exhaust cam‐
shaft
4 - Cylinder head
❑ See note ⇒ page 95
❑ Checking valve guides
⇒ page 117
❑ Machining valve seats
⇒ page 115
❑ Dowel sleeves for bear‐
ing caps must be posi‐
tioned in cylinder head
❑ Before fitting, apply
sealant at sealing points
⇒ page 78 and
⇒ page 79
5 - Valve guide
6 - Valve stem oil seal
3. Servicing valve gear 95

7 - Valve spring
8 - Valve spring plate
9 - Valve cotters
10 - Hydraulic bucket tappet
❑ Place down with contact surface facing downwards
❑ Before installing, check camshaft axial clearance ⇒ page 97
❑ Lubricate contact surface
11 - Inlet camshaft
❑ Check radial clearance with Plastigage (bucket tappets removed)
❑ Runout: max. 0.035 mm
❑ Checking axial clearance ⇒ page 97
❑ Removing and installing camshafts ⇒ page 103
12 - Bearing cap for inlet camshaft
❑ Dowel sleeves must be positioned in cylinder head
❑ Note installation position
❑ Installation sequence ⇒ page 107
13 - Double bearing cap
❑ Before installing,
Protected byapply small
copyright. Copyingquantity
for private of sealantpurposes,
or commercial to sealing
in partsurface
or in whole, is not
❑ Sealing points between
with respect to the double
correctnessbearing cap/cylinder
of information in this document.head ⇒ by
Copyright page 78
AUDI AG.
14 - Exhaust camshaft
❑ Check radial clearance with Plastigage (bucket tappets removed)
❑ Runout: max. 0.035 mm
❑ Checking axial clearance ⇒ page 97
❑ Removing and installing camshafts ⇒ page 103
15 - Bearing cap for exhaust camshaft
❑ Installation sequence ⇒ page 107
16 - 10 Nm
17 - 10 Nm
18 - Drive chain
❑ Check for wear
❑ Removing and installing ⇒ “3.5 Removing and installing camshafts and camshaft adjuster”, page 103
❑ Mark installation position prior to removal if old drive chain is to be reused ⇒ page 105
19 - Camshaft adjuster
❑ With inlet camshaft control valve 1 - N205-
❑ Before removing, lock in position with chain tensioner retainer - 3366-


❑ Sealing points between camshaft adjuster and cylinder head ⇒ page 79
❑ Checking variable valve timing in “Guided Fault Finding” ⇒ Vehicle diagnostic tester
20 - Rubber/metal gasket
❑ Apply sealant before installing ⇒ page 106
21 - Seal
❑ Renew
22 - Exhaust valve
❑ With sodium filling
❑ Note safety requirements when disposing of valves with sodium filling ⇒ page 114
❑ Do not machine, only grinding-in is permitted
❑ Valve dimensions ⇒ page 114
❑ Checking valve guides ⇒ page 117
❑ Machining valve seats ⇒ page 115
23 - Inlet valve
❑ Do not machine, only grinding-in is permitted
❑ Valve dimensions ⇒ page 114
❑ Checking valve guides ⇒ page 117
❑ Machining valve seats ⇒ page 115
24 - Oil seal for inlet camshaft
25 - Rotor for Hall sender
❑ Note installation position: insert lug into notch on camshaft
26 - Washer
❑ With taper
27 - 25 Nm
28 - Hall sender - G40-
permitted housingby AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
29 - 10 Nm
3.2 Checking axial clearance of camshafts

♦ Universal dial gauge bracket - VW 387-

♦ Dial gauge - VAS 6079-
Test sequence
– Remove camshafts ⇒ pageCopying
Protected by copyright. 103 .for private or commercial purposes, in part or in whole, is not
Note
♦ Take care not to interchange bucket tappets.

♦ Use waterproof felt-tip pen to mark assignment of bucket tap‐
pets on back of tappets.
– Take bucket tappets out of guides and set them down with
contact surface facing downwards.
– Insert camshafts in cylinder head and fit bearing cap at chain
sprocket end and fit double bearing cap.
– Secure universal dial gauge bracket - VW 387- with dial gauge
- VAS 6079- to cylinder head:
Inlet camshaft
Exhaust camshaft
– Press the camshaft that is to be checked against the dial
gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
• Axial clearance: wear limit for inlet and exhaust camshaft: 0.20
mm.
3.3 Renewing exhaust camshaft oil seal


equipment required
♦ Fitting sleeves - 3241-
Procedure
– Loosen camshaft sprocket using counterhold tool - 3036- .
– Detach camshaft sprocket.

– To guide oil seal extractor, screw securing bolt for camshaft

sprocket -arrow- into camshaft as far as it will go until finger-
tight.
– Unscrew inner part of oil seal extractor - 2085- 2 turns (approx.
3 mm) from the outer part and lock in position with the knurled
screw.

in position and screw it into oil seal as far as possible (apply
firm pressure).
– Loosen knurled screw and turn inner section against camshaft
until oil seal is pulled out.
– Clamp flats of oil seal extractor in vice and use pliers to remove
seal.
– Place guide sleeve - T10071/1- onto camshaft journal.
Note
Do not lubricate sealing lip of oil seal.
– Slide oil seal over guide sleeve onto camshaft journal.

– Detach guide sleeve.
– Press oil seal in as far as the stop using press sleeve -

T10071/3- and bolt - T10071/4- .

– Install camshaft sprocket.

• Installation position: The thinner web of the camshaft sprocket
faces outwards -arrows- and the marking for TDC is visible.
– Tighten securing bolt of camshaft sprocket (use counterhold

tool - 3036- ).
Note
If a piston is at TDC the valves could strike the piston when turning
the camshaft. Pistons must therefore not be at TDC This could
otherwise result in damage to valves and pistons.

nuts -arrows-.
Rep. gr. 63 .
Tightening torques
Component Nm
Camshaft sprocket to camshaft 65
3.4 Renewing inlet camshaft oil seal


♦ Bolt M8x60 with respect to the correctness of information in this document. Copyright by AUDI AG.
Procedure
panel.
– Unplug electrical connector -arrow- at Hall sender - G40- .

– Remove Hall sender housing and also washer and rotor for
Hall sender.
– To guide oil seal extractor, screw bolt - 2085/1- into camshaft

as far as it will go until finger-tight.
– Unscrew inner part of oil seal extractor - 2085- 2 turns (approx.
3 mm) from the outer part and lock in position with the knurled
screw.


in position and, exerting firm pressure, screw it into oil seal as
far as possible.
– Loosen knurled screw and turn inner section against camshaft
until oil seal is pulled out.
– Place guide sleeve - T10071/5- onto camshaft journal.
Note
Do not lubricate sealing lip of oil seal.
– Slide oil seal over guide sleeve onto camshaft journal.

– Detach guide sleeve.
– Press oil seal in as far as the stop using press sleeve -

T10071/3- and bolt M8x60.
– Install Hall sender ⇒ Item 25 (page 97) .
Tightening torques permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Component Nm
Hall sender rotor to camshaft 25
Hall sender housing to cylinder head 10
3.5 Removing and installing camshafts and

camshaft adjuster

♦ Chain tensioner retainer - 3366-

Removing
– Turn the crankshaft approx. 45° anti-clockwise at the toothed
belt sprocket bolt so that all pistons are clear of TDC position.
– Loosen camshaft sprocket using counterhold tool - 3036- .
– Detach camshaft sprocket.
– Unplug electrical connector -arrow- at inlet camshaft permitted
controlunless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
valve 1 - N205- . with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove cylinder head cover ⇒ page 79 .

– Remove both oil deflectors.
– Unplug electrical connector -arrow- at Hall sender - G40- .

– Remove Hall sender housing and also washer and rotor for
Hall sender.

– Check TDC position of camshafts again:

• The two marks on the camshafts must be opposite the two
arrows on the bearing caps.
If old drive chain is to be reused:

– Clean drive chain and sprockets of camshafts opposite the two
arrows on the bearing caps and mark installation position with
a coloured dot.
• The distance between the two arrows (and thus between the
coloured markings) is 16 rollers on the chain.
• Notch on exhaust camshaft has a slight inward offset with re‐
spect to chain roller -1-.
Note
Do not mark chain with a centre punch or by making a notch or

similar.
Continued for all drive chains:

– Secure camshaft adjuster with chain tensioner retainer -
3366- .
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Over-tightening retainer for chain tensioner can damage the cam‐

shaft adjuster.

– First remove bearing caps 3 and 5 on inlet and exhaust cam‐

shafts.
– Remove double bearing cap.
– Remove the two bearing caps next to the chain sprockets on
the inlet and exhaust camshafts.
– Unscrew securing bolts for camshaft adjuster.
– Slacken off bearing caps 2 and 4 of inlet and exhaust cam‐
shaftsProtected
alternately in diagonal
by copyright. sequence,
Copying for private andpurposes,
or commercial remove.in part or in whole, is not
– Removewith
inlet and
respect exhaust
to the camshafts
correctness with
of information in camshaft
this document. adjuster.
Copyright by AUDI AG.
Installing
• Pistons must not be at TDC.
– Renew rubber/metal gasket for camshaft adjuster and apply a
thin coat of sealant to the hatched area; Sealant ⇒ Parts cata‐
logue .
– Position drive chain on camshaft chain sprockets as follows:

If old drive chain is to be reused:
– Adjust the colour markings -arrows- so they are aligned.

If new drive chain is being used:
Caution
♦ The stated number of rollers merely provides assistance

for fitting the drive chain onto the camshafts.
♦ Make sure that the arrows on the bearing caps and the
notches on the camshafts align when installing camshafts
(with drive chain) in cylinder head ⇒ page 108 .
• The distance between notches -A- and -B- on the camshafts

must be 16 drive chain rollers. The illustration shows the exact
positions of the 1st and 16th rollers on the sprockets.
• Notch -A- is offset slightly inwards in relation to chain roller
-1-.
Continued for all drive chains:
– Insert camshaft adjuster into the drive chain (2nd mechanic
required).
– Insert camshafts with drive chain and camshaft adjuster into
cylinder head.
– Lubricate running surfaces of camshafts.
• Dowel sleeves for bearingwith
caps and
respect camshaft
to the correctness adjuster
of informationmust
in this document. Copyright by AUDI AG.
be positioned in cylinder head
Note
When installing bearing caps ensure that the identification mark

is readable from the inlet side of cylinder head.
– Secure camshaft adjuster (watch position of dowel sleeves).
– Tighten bearing caps 2 and 4 of inlet and exhaust camshafts

alternately and in diagonal sequence (pay attention to dowel
sleeves).
– Install the two bearing caps next to the chain sprockets on the
inlet and exhaust camshafts.
– Remove chain tensioner retainer - 3366- .

– Check correct setting of camshafts:

• The two marks on the camshafts must be opposite the two
arrows on the bearing caps -arrows-.
Note
If necessary, turn camshaft slightly backwards or forwards so that

the two marks coincide.
– Apply a small quantity of sealant to the hatched area of the

double bearing cap and the outer bearing cap adjacent to the
camshaft adjuster; Sealant ⇒ Parts catalogue .
– Install remaining bearing caps (pay attention to dowel
sleeves).
– Renewing camshaft oil seals:
⇒ “3.3 Renewing exhaust camshaft oil seal”, page 98 or
⇒ “3.4 Renewing inlet camshaft oil seal”, page 101 .
– Torque down remaining bearing caps.
– Install camshaft sprocket.

• Installation position: The thinner web of the camshaft sprocket
faces outwards -arrows- and the marking for TDC is visible.

– Tighten securing bolt of camshaft sprocket (use counterhold

tool - 3036- ).
– Install Hall sender ⇒ Item 25 (page 97) .
– Install cylinder head cover ⇒ page 79 .
– Turn crankshaft approx. 45° clockwise to TDC position via se‐
curing bolt for toothed belt sprocket.
Note


nuts -arrows-.
Rep. gr. 63 .
Tightening torques
Component Nm
Bearing cap to cylinder head 10
Camshaft adjuster to cylinder head 10
Hall sender rotor to camshaft 25
Hall sender housing to cylinder head 10
Camshaft sprocket to camshaft 65
3.6 Renewing valve stem oil seals


equipment required
♦ Pressure hose - VW 653/3-
♦ Spark plug socket and ex‐
tension - 3122 B-
♦ Valve stem seal puller -
3364-
♦ Valve stem seal fitting tool -
3365-
♦ Removal and installation
device for valve cotters - by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
VAS 5161- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Procedure
– Remove camshafts and camshaft adjuster ⇒ page 103 .
Note
♦ Take care not to interchange bucket tappets.

♦ Use waterproof felt-tip pen to mark assignment of bucket tap‐
pets on back of tappets.
– Take bucket tappets out of guides and set them down with
contact surface facing downwards.
– Remove spark plugs with spark plug socket - 3122 B- .
– Set piston of the respective cylinder to “bottom dead centre”.

– Screw pressure hose - VW 653/3- into spark plug hole and

connect to compressed air supply.
• Minimum pressure: 6 bar.
– Insert punch -VAS 5161/3- in bucket tappet guide.
– Knock valve cotters on all five valves loose using a plastic
hammer.
Exhaust side:
– Screw snap-in device - VAS 5161/6- with interlocking fork -
VAS 5161/4- onto stud on cylinder head.
– Push guide bush - VAS 5161/14- as far as it will go into bucket
tappet guide for valve to be removed.
• Installation position: knurled surfaces face perpendicular to
directionProtected
of travel.
– Slide knurled spacer ring - VASof5161/17-

information inonto assembly car‐
with respect to the correctness this document. Copyright by AUDI AG.
tridge - VAS 5161/8- .
– Insert assembly cartridge into guide bush.
– 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 pressure fork.
– Take out assembly cartridge with spacer ring, guide bush,
valve spring plate and valve spring.
Inlet side
– Screw snap-in device - VAS 5161/6- with interlocking fork -
VAS 5161/4- onto stud on cylinder head.
– Push guide bush - VAS 5161/13- as far as it will go into bucket
tappet guide for valve to be removed.
♦ Installation position: knurled surfaces face perpendicular to
direction of travel.
– Slide knurled spacer ring - VAS 5161/17- onto assembly car‐
tridge - VAS 5161/8- .
– Insert assembly cartridge into guide bush.
– 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 pressure fork.
– Take out assembly cartridge with spacer ring, guide bush,
valve spring plate and valve spring.

Continuation for both sides:

– Remove valve stem oil seals using the valve stem seal puller
- 3364- .
Note
A plastic sleeve -A- is included with the new valve stem oil seals.
– Fit plastic sleeve -A- onto the valve stem to prevent damage
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 onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve.
– If valve cotters have beenwithremoved
respect to thefrom assembly
correctness cartridge,
of information in this document. Copyright by AUDI AG.
they need to be put into insertion device - VAS 5161/18- first.
• Larger diameter of valve cotters faces upwards.
– Press assembly cartridge - VAS 5161/8- onto insertion device
from above and pick up valve cotters.

– Re-insert cartridge into guide bush - VAS 5161/13- or -

VAS 5161/14- .
– Push pressure fork down and pull knurled screw upwards
while turning to left and right - this will insert the valve cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Insert bucket tappets.
– Install camshafts and camshaft adjuster ⇒ page 103 .
Note

3.7 Checking hydraulic bucket tappets

♦ Feeler gauge
♦ Wooden/plastic wedge
Test sequence
Note
♦ Hydraulic bucket tappets cannot becopyright.

Protected by serviced.Copying for private or commercial purposes, in part or in whole, is not
♦ Irregular valve noises when with
starting engine
respect to are normal.
– Start engine and let it run until the radiator fan has switched
on once.
– Increase engine speed to approx. 2500 rpm for 2 minutes
(perform road test if necessary).
Note
If the irregular valve noises stop but recur repeatedly during short
trips, renew the oil retention valve. The oil retention valve is lo‐
cated in the oil filter bracket ⇒ Item 24 (page 133) .
If the hydraulic tappets are still noisy, locate defective tappet as

follows:
– Remove cylinder head cover ⇒ page 79 .
– Turn crankshaft until cams of bucket tappets to be checked
are pointing upwards.
♦ Vehicles with manual gearbox: push vehicle forwards with 4th
gear engaged and ignition switched off.
♦ Vehicles with multitronic/automatic gearbox 01V: remove
noise insulation and rotate crankshaft in clockwise direction
via crankshaft sprocket central bolt.

– Push bucket tappet down with a wooden or plastic wedge to

determine play between cam and bucket tappet.
If it is possible to insert a feeler gauge of 0.20 mm between cam‐
shaft and bucket tappet:
– Renew bucket tappet
⇒ “3.5 Removing and installing camshafts and camshaft ad‐
juster”, page 103 .
Note

3.8 Checking valves

– Visually inspect for scoring on valve stem and on seating sur‐
face.
– Renew valves with significant score marks.
3.9 Valve dimensions
Note
Inlet and exhaust valves must not be machined. Only grinding-in

is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 26.80 … 27.00 29.80 … 30.00
∅b mm 5.95 … 5.97 5.94 … 5.95
c mm 104.84 … 105.34 103.64 … 104.14
α ∠° 45 45
WARNING
♦ Care must be taken when disposing of old sodium-cooled

exhaust valves.
♦ The valves must be sawn in two with a metal saw between
the centre of the stem and valve head. When doing so, the
valves must not comeProtected
into contact with water. After pre‐
paring the valves, throwwith

a maximum of ten into a bucket
of water. Then step away immediately, since a chemical
reaction will occur in which the sodium filling burns.
♦ After performing these steps the valves can be disposed
of in the normal way.

3.10 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
Noteto the correctness of information in this document. Copyright by AUDI AG.

with respect
♦ 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 117 .
♦ 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.
♦ If the machining dimension is exceeded, the function of the
hydraulic valve clearance compensation can no longer be en‐
sured and the cylinder head must be renewed.

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 dimensions
Inlet valves (outer) Inlet valve (centre) Exhaust valves
31.0 mm 32.2 mm 31.9 mm
Measured distance minus minimum dimension = max. permissi‐
ble machining dimension.
Example for inlet valve (outer):
Measured distance 31.4 mm
– Minimum dimension – 31.0 mm
= Maximum permissible machining dimen‐ = 0.4 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 result
is again 0 mm or less than 0 mm, renew the cylinder head.
Machining inlet valve seat

a - ∅ 26.2 mm
b - 1.5 … 1.8 mm
Z - Bottom surface of cylinder head
α - 45° valve seat angle
β - 30° upper correction angle permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
γ - 60° lower correction angle
Note

⇒ page 116 .

Machining exhaust valve seat

a - ∅ 29.0 mm
b - 1.8 mm
Z - Bottom surface of cylinder head
α - 45° valve seat angle
β - 30° upper correction angle
γ - 60° lower correction angle
Note

⇒ page 116 .
3.11 Checking valve guides

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge - VAS 6079-

Test sequence
– Insert valve into valve guide.
• End of valve stem must be flush with valve guide.
Note
Only insert inlet valve into inlet guide and exhaust valve into ex‐
haust guide, as the stem diameters are different.
– Determine amount of sideways play.

• Wear limit (sideways play) for inlet and exhaust valve guide:
0.8 mm.
Note
♦ If the wear limit is exceeded, repeat the measurement with

new valves. Renew cylinder head if wear limit is still exceeded.
Valve guides cannot be renewed.
♦ If the valve has to be renewed as part of a repair, use a new
valve for the measurement.

17 – Lubrication
1 Removing and installing parts of lu‐
brication system
Note

♦ The oil level must not be above max. mark on dipstick – danger
of damage to catalytic converter.
♦ Oil spray jet and pressure relief valve ⇒ page 121
♦ Removing and installing the oil level/temperature sender -
G266- ⇒ page 121
Viscosity grades and oil specifications ⇒ Maintenance ; Booklet

8E .
Oil capacities ⇒ Maintenance tables .
1.1 Sump, oil pump - exploded view
1. Removing and installing parts of lubrication system 119

1 - Sump
⇒ page 122
❑ Install using sealant;
sealant ⇒ Parts cata‐
logue
2 - Torque reaction support
3 - 23 Nm
4 - Oil pump
❑ With pressure relief
valve (12 bar)
⇒ page 131
❑ Before installing, check
that the two dowel
sleeves
⇒ Item 12 (page 120)
for centring oil pump/
cylinder block are fitted.
❑ Renew if running surfa‐
ces and gears are scor‐
ed
❑ Tightening torque for oil
pump cover to oil pump
housing: 10 Nm
5 - Chain sprocket for oil pump
❑ Sprocket can only be fit‐
ted on oil pump shaft in
one position.
6 - 22 Nm
7 - Drive chain for oil pump
❑ Mark direction of rota‐
tion before removing
❑ Check for wear
8 - 15 Nm
9 - Sealing flange (front)
❑ Install using sealant; sealant ⇒ Parts catalogue
❑ Renewing crankshaft oil seal on pulley end ⇒ page 53
10 - Chain tensioner
❑ Do not dismantle
❑ When installing, pre-tension spring and engage
❑ If the spring is broken, renew chain tensioner as complete unit
11 - Chain sprocket for oil pump
12 - Dowel sleeves
❑ 2x
13 - O-ring
❑ Renew
120 Rep. gr.17 - Lubrication

14 - 16 Nm
15 - Suction pipe
❑ Clean strainer if dirty
16 - Baffle plate
17 - 16 Nm
18 - 15 Nm
❑ Tighten in stages and in diagonal sequence
❑ Observe correct tightening sequence ⇒ page 130
19 - 40 Nm
20 - Seal
❑ Renew
21 - Gasket
❑ Renew
22 - Oil return line
❑ From turbocharger
23 - 10 Nm
Oil spray jet and pressure relief valve
1 - Oil spray jet (for cooling of pistons)
2 - Bolt with pressure relief valve, 27 Nm
• Opening pressure: 1.3 ... 1.6 bar.
Removing and installing oil level/temperature sender - G266-

1- Bolt, 10 Nm (self-locking); renew
2- Seal; renew
3- Electrical connector
4- Oil level and oil temperature sender - G266-

1.2 Removing and installing sump

equipment required
♦ Support bracket - 10-222 A-
♦ Socket - 3249- or - T10058-
♦ Used oil collection and ex‐
traction unit - V.A.G 1782-
♦ Workshop hoist - VAS
6100-
♦ Mud wing compensation
plate - T40045-
♦ Electric drill with plastic
brush attachment
♦ Safety goggles
♦ Lifting tackle - 2024 A-

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

panel.
– If fitted, detach
permitted cover by
unless authorised -1-AUDI
onAG.
right ofAGengine
AUDI compartment.
does not guarantee or accept any liability

- N80- at air duct.
Note


poly V-belt.
– Remove poly V-belt from alternator pulley.
– Release tensioner.
– Remove poly V-belt completely.
Note
Unscrew securing bolts of tensioner a few turns if poly V-belt can‐

not be removed from pulley.

– Pull off bonnet seal at wing mounting flanges.

– Place compensation plates - 10-222 A- between the wing
mounting flange and the body flange underneath, so that the
support bracket - T40045- does not damage the wing mount‐
ing flanges.
– Set up support bracket - 10-222 A- on wing panel flanges.
– Remove eyelet 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 using support bracket spindle (do

not raise).


– Release quick-release fasteners -1- and -2- AG.

andAUDI
take AG off
doesfront
permitted unless authorised by AUDI not guarantee or accept any liability
noise insulation. with respect to the correctness of information in this document. Copyright by AUDI AG.

noise insulation.
– Unbolt bracket for noise insulation -arrows-.
der engine and drain engine oil.
– Remove oil return line from sump (unscrew bolts -arrows-).

– Unplug electrical connector -arrow- at oil level and oil temper‐

ature sender - G266- .

Caution permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note


ed.
– Unscrew bolts -arrows- and remove torque reaction support.

– If fitted, unclip actuator rod for vehicle level sender (front left)
- G78- at bottom transverse link -arrow-.
– Remove bolts -1- and -2- from anti-roll bar mounting.
– Cut open the cable ties -arrows-, open bracket for starter wire
and take out the electrical wire.
– Support subframe using workshop hoist - VAS 6100- or -

V.A.G 1202 A- .

– Unscrew nut -3- at bottom of engine mounting.

– Unscrew bolts -4- and -5- on console for engine mounting.
– Unscrew bolt -1- (front) for subframe and remove console for
engine mounting -2-.
– Repeat procedure on other side of vehicle.
– Carefully lower subframe using workshop hoist - VAS 6100-
or -V.A.G 1202 A- .
– Lift engine up slightly using spindle of support bracket - 10-222

A- ; make sure the selector linkage and exhaust system do not
become trapped.
– Unscrew gearbox/sump bolts -arrows-.

– Unscrew M10 bolts -arrows-.

– Slacken bolts -1 ... 18- in diagonal sequence.
Note
Use hexagon key extension - 3249- or - T10058- 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.
– Remove all bolts and take off sump; if necessary loosen it by

striking lightly with a rubber hammer.
Installing
Note
♦ Renew gaskets and seals.

– Carefully remove sealant residues from cylinder block. For this

purpose,
Protected by remove
copyright. Copying baffle
for private plate. purposes, in part or in whole, is not
or commercial
with–respect
Remove sealantof residue
to the correctness from
information in sump,Copyright
this document. e.g. with rotating
by AUDI AG. plastic
brush or similar.
WARNING
Wear safety goggles.


prox. 2mm).
– Apply bead of sealant onto the clean sealing surface of the

sump as shown in the illustration.
• Thickness of sealant bead: 2 ... 3 mm
Note
♦ The sealant bead must not be thicker than specified, otherwise

excess sealant could enter the sump and clog the strainer in
the oil pump.
♦ Take particular care when applying sealant bead in area of
rear sealing flange -arrows-.
♦ The sump must be installed within 5 minutes after applying
sealant.
– Immediately install sump and tighten bolts in the sequence in‐

dicated:
1. Pre-tighten bolts -1 ... 18- to 5 Nm in diagonal sequence.
2. Tighten bolts securing sump to gearbox to 45 Nm.
3. Tighten bolts M10 -arrows- to 40 Nm.
4. Tighten bolts -1 ... 18- to 15 Nm in diagonal sequence.

Note
♦ When installing the sump -3- with the engine removed from
the vehicle, make sure that it is positioned flush with the inter‐
mediate plate -1- at the flywheel end. In other words, the sump
should protrude by 0.8 mm (distance -a-) from cylinder
block -2-.
♦ After fitting sump assembly, the sealant must dry for approx.
30 minutes. Then (and only then) fill the engine with engine
oil.
– Install subframe ⇒ Running gear, front-wheel drive and four-

wheel drive; Rep. gr. 40 .
– Install anti-roll bar ⇒ Running gear, front-wheel drive and four-
wheel drive; Rep. gr. 40 .
Rep. gr. 87 .
– Fill up with engine oil and check oil level.
Tightening torques
Component Nm
Sump to: M7 15
Cylinder block M10 40
Sump to gearbox 45
Oil return line to sump 10
Torque reaction support to sump 23
Engine mounting to subframe 23
Oil drain plug 30
1.3 Removing and installing oil pump

Removing
– Remove sump and baffle plate ⇒ page 122 .
– Remove bolt -2-.
– Pull chain sprocket off oil pump shaft.
– Unscrew bolts -1- and -3- and remove oil pump.
permittedInstalling
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Insert dowel sleeves ⇒ Item 12 (page 120) at top of oil pump.
• Chain sprocket can only be fitted in one position on oil pump
shaft.
– Install sump ⇒ page 129 .
Tightening torques
Component Nm
Chain sprocket to oil pump shaft 22
Oil pump to cylinder block 16
1.4 Oil filter and oil cooler - exploded view of components

1 - Screw plug, 40 Nm
2 - Seal
❑ Renew
3 - Spring
❑ For pressure relief
valve, approx. 4 bar
4 - Piston
❑ For pressure relief
valve, approx. 4 bar
5 - Gasket
❑ Renew
6 - Oil retention valve
❑ Tighten to 8 Nm
❑ Integrated into oil filter
bracket
7 - O-ring
❑ Renew
❑ Slip on as far as collar of
crankcase breather pipe
8 - Retaining clip
9 - Crankcase breather pipe
10 - 20 Nm
11 - Coolant pipe (bottom)
12 - Screw plug, 15 Nm
13 - Seal
❑ If seal is leaking, cut open and renew
14 -permitted
Oil supply line
❑ To turbocharger
15 - Banjo bolt - 30 Nm
16 - Seals
❑ Renew
17 - Oil pressure switch - F1-
❑ Opening/closing pressure 1.4 bar
❑ Black insulation
18 - Seal
19 - 15 Nm + 90° (1/4 turn) further
❑ Renew
20 - Seal
❑ Renew
❑ Engage in lugs on oil cooler

21 - Oil filter
❑ Observe change intervals ⇒ Maintenance ; Booklet 8E
❑ Observe installation instructions on oil filter
22 - 25 Nm
23 - Oil cooler
❑ See note ⇒ page 119
❑ Ensure
permitted unless authorised clearance from
by AUDI AG. AUDI surrounding
AG does not guaranteecomponents
or accept any liability
❑ Diagram of coolant hose connections ⇒ page 139
24 - Oil filter bracket

❑ With pressure relief valve, approx. 4 bar
1.5 Removing and installing oil filter bracket

♦ Used oil collection and extraction unit - V.A.G 1782-
Removing
der engine and remove oil filter -1-.
– Note installation position and remove oil cooler -2-.

– Unplug electrical connector -3-.

– Remove bolt -1- for oil supply line on oil filter bracket.
– Detach clip -2- and remove crankcase breather pipe.
– Unscrew bolts -arrows- and remove oil filter bracket.
Installing
Note
Renew gaskets, seals and O-rings.

Tightening torques
Component Nm
Oil filter bracket to cylinder block 15 + 90° 28) 29)
Oil supply line to oil filter bracket 30
Oil cooler to oil filter bracket 25
Oil filter to oil cooler 20
28) Renew bolts. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
29) 90° equals a 1/4 turn. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1.6 Checking oil pressure and oil pressure switch


equipment required
♦ Oil pressure tester - V.A.G
1342- with adapter - V.A.G
1342/14-
♦ Voltage tester -
V.A.G 1527 B-
♦ Auxiliary measuring set -
V.A.G 1594 C-
Test conditions
• Oil level OK
• Engine oil temperature approx. 90 °C (radiator fan must have
run once)
Test sequence
– unless
permitted Release quick
authorised fasteners
by AUDI AG. AUDI AG -arrows- and remove
does not guarantee engine
or accept any liability cover
panel.

– Unbolt coolant expansion tank -arrow-.

– Unplug electrical wire for coolant shortage indicator switch -
F66- at bottom of expansion tank and move expansion tank to
one side with coolant hoses -1- and -2- attached.
– Unplug electrical connector at oil pressure switch - F1- .

– Unscrew oil pressure switch - F1- -arrow-.

– Connect oil pressure tester - V.A.G 1342- with adapter - V.A.G

1342/14- to bore for oil pressure switch.
– Screw oil pressure switch -2- into oil pressure tester - V.A.G
1342- .
– Connect brown wire of oil pressure tester to earth (“–”).
Checking oil pressure switch
– Connect voltage tester - V.A.G 1527 B- -item 1- with adapter
leads from auxiliary measuring set - V.A.G 1594 C- to oil pres‐
sure switch and battery positive (“+”).
• LED should not light up.
If the LED lights up:
– 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 1.2 ... 1.6 bar.

If LED does not light up:
– Renew oil pressure switch.
Checking oil pressure
– Start permitted
engine. unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
• Minimum oil pressure at 2000 rpm: 1.3 bar
• Minimum oil pressure at 3500 rpm: 3.5 ... 4.5 bar.
The pressure relief valve or oil pump is defective if the specifica‐
tions are not attained.
Assembling
Note
Renew seal when installing oil pressure switch.
Tightening torque
Component Nm
Oil pressure switch to oil filter housing 20
1.7 Engine oil

Viscosity grades and oil specifications ⇒ Maintenance ; Booklet
8E .

1.8 Checking oil level
Note
The oil level must not be above max. mark on dipstick – danger
of damage to catalytic converter.
Test conditions
• Engine oil temperature at least 60 ℃.
• Vehicle must be level (horizontal)
• Wait a few minutes after switching off the engine to allow the
oil to flow back into the sump.
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
-c- after topping up.
c - Oil must be topped up. It 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-.

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, seals and O-rings.
♦ When installing coolant hoses, position them so they are free
of tension and do not come into contact with other compo‐
nents.
♦ The arrow markings on coolant pipes and on ends of hoses
must align.
1.1 Diagram of coolant hose connections
1. Removing and installing parts of cooling system 139

1 - Radiator
⇒ page 155
with fresh coolant
2 - Coolant pipe (top)
⇒ page 150
3 - Thermostat housing with
map-controlled engine cooling
thermostat - F265-
⇒ page 153
❑ Checking thermostat
⇒ page 154
4 - Coolant pump
⇒ page 148
5 - Turbocharger
6 - Cylinder head/cylinder
block with respect to the correctness of information in this document. Copyright by AUDI AG.
with fresh coolant
7 - Bleeder hole
8 - Heat exchanger
with fresh coolant
⇒ page 151
10 - Oil cooler
Removing and installing ⇒ “1.5 Removing and installing oil filter bracket”, page 133
❑ If renewed, refill system with fresh coolant
11 - Expansion tank
❑ With filler cap
❑ Checking pressure relief valve in filler cap ⇒ page 163
12 - Intake manifold
140 Rep. gr.19 - Cooling

1.2 Draining and filling cooling system

equipment required
♦ Adapter - V.A.G 1274/8-
♦ Pipe - V.A.G 1274/10-
♦ Drip tray - V.A.G 1306- or
drip tray for workshop hoist
- 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



noise insulation.
– Place drip tray - V.A.G 1306- or drip tray for workshop hoist -
VAS 6208- under engine.
All vehicles:
panel.


– Unplug electrical connector for coolant shortage indicator
switch - F66- at bottom of expansion tank and move coolant
expansion tank to one side with coolant hoses -1- and -2- at‐
tached.

– Disconnect coolant hose from oil cooler -arrow-, and drain off
remaining coolant.
Filling
Note
♦ The cooling system is filled all year round with a mixture of

water and radiator antifreeze/anti-corrosion 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 anti-corrosion 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. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Frost protection is required down to about
with respect –25 °Cof(in
to the correctness countries
information in this document. Copyright by AUDI AG.
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 concentration must be at least 40 %.
♦ If greater frost protection is required in very cold climates, the
amount of »G12+« can be increased, but only up to 60% (this
gives frost protection to about -40 ℃). If antifreeze concentra‐
tion exceeds 60%, frost protection decreases again and cool‐
ing 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- .

Procedure
– Close coolant drain plug at coolant hose (bottom) on radiator.
– Insert radiator outlet coolant temperature sender - G83-
-item 2- with new O-ring into connection and locate with re‐
taining clip -1-.
All vehicles:
– Install front noise insulation by locking quick release fasteners
-1- and -2-.
– Connect coolant hose to oil cooler -arrow-.

– Fill reservoir of cooling system charge unit - VAS 6096- with

at least 10 litres of premixed coolant (based on recommended
ratio):
• »G12+« (40 %) and water (60 %) for frost protection to –25 °
C
C
C
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank.
– Attach 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 the two valves -A- and -B- by setting lever at right angle
to direction of flow.
– Connect hose -3- to compressed air.
• Pressure: 6 ... 10 bar.
– Open valve -B- by setting 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 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 greenpermitted
zone. unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– 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 cooling system charge unit - VAS 6096- ; the cooling
system is then filled.
– Detach cooling system charge unit - VAS 6096- from expan‐
sion tank.

– Fit pipe - V.A.G 1274/10- onto adapter - V.A.G 1274/8- .
– Open bleeder screw -arrow- at coolant pipe.

– Fill up with coolant until it flows out at bleeder holes.
– Close bleeder screw.
– Detach rubber seal from plenum chamber cover in direction of

-arrow-.
– Detach plenum chamber cover -1-.

– 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.
– Set heater/air conditioner to “HI”.
– Run the engine for 3 minutes at 2000 rpm.
– Allow the engine to run at idling speed until the two large cool‐
ant hoses at main radiator become warm.
– Run the engine for 1 minute at 2000 rpm.
– Switch off ignition and allow engine to cool down.
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.
1.3 Removing and installing coolant pump

Removing
Note

poly V-belt.


– Remove toothed belt cover (centre) (unscrew bolts -arrows-).
Note
♦ Vibration damper and toothed belt cover (bottom) can remain
installed.
♦ The toothed belt should be left in position on the crankshaft
sprocket.
♦ Before removing coolant pump, cover toothed belt with a cloth
to protect against coolant.
– Remove bolts -1- and detach coolant pump -2-.

– Remove O-ring -3-.
Installing
Note
Renew O-ring.
– Clean and smoothen sealing surface for O-ring as required.

– Lubricate new O-ring -3- with coolant additive »G12+«.
– Fit coolant pump -2-.
• Installation position: Sealing plug in housing faces down‐
wards.
– Tighten bolts -1- for coolant pump.


nuts -arrows-.
Rep. gr. 63 .
Tightening torques
Component Nm
Toothed belt cover (centre) to cylinder block 10 30)
ries
Coolant pump to cylinder block 15
1.4 Removing and installing coolant pipe

(top)
♦ Hose clip pliers - V.A.G 1921-

Removing
– Unscrew bolts -1- and -2- and detach top coolant pipe from
coolant hoses -arrows-.
Installing
Note
Secure all hose connections with the correct type of hose clips
– Fill cooling system ⇒ page
permitted 144 . by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
Tightening torques
Component Nm
Coolant pipe (top) to intake manifold 10
1.5 Removing and installing coolant pipe

(bottom)
♦ Hose clip pliers - V.A.G 1921-
Removing

– Move wiring clear of bottom coolant pipe.

– Detach coolant hoses -arrows- from coolant pipe (bottom).
– Unscrew bolts -1- and -2- and pull coolant pipe out of thermo‐
stat housing.
Installing
Note
♦ Renew O-rings.

Tightening torques
Component Nm
Coolant pipe Thermostat housing 10
(bottom) to: Oil cooler 23 31)
Support for in‐ Intake manifold 23

take manifold Bracket for ancillaries 23
to:
1.6 Thermostat housing - exploded view of components

1 - O-ring
❑ Renew
2 - Thermostat housing
⇒ page 153
3 - O-ring
❑ Renew
⇒ page 151
5 - 10 Nm
6 - 15 Nm
7 - O-ring Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Renew with respect to the correctness of information in this document. Copyright by AUDI AG.
8 - Heating element connec‐

tion
❑ 14 … 16 Ω at a temper‐
ature of 25 °C
❑ Cannot be renewed
separately
9 - Electrical connector
10 - Map-controlled engine
cooling system thermostat -
F265-
❑ With hose connection
⇒ page 153
❑ Starts to open at approx.
105 °C
❑ Opening travel at least 7 mm
1.7 Removing and installing thermostat

housing with map-controlled engine
cooling thermostat - F265-
Removing
– Detach coolant hoses -1- and -4-.
– Remove bolts -2- and -3- and detach thermostat housing.

– Remove bolts -1-.

– Remove the thermostat -2- with O-ring -3- from the thermostat
housing -4-.
Installing
Note
♦ Renew O-rings.

Tightening torques
Component Nm
Thermostat to housing 10
Thermostat housing to cylinder block 15
1.8 Checking map-controlled engine cool‐

ing thermostat - F265-
♦ Hand-held multimeter - V.A.G 1526 B-
♦ Auxiliary measuring set - V.A.G 1594 C-

Test condition
• Engine cold
Testing internal resistance of heating element
– Unplug connector -2- at map-controlled engine cooling ther‐
mostat - F265- .
– Connect multimeter to thermostat to measure resistance.
• Specification: 14 … 16 Ω at a temperature of 25 °C.
– Renew thermostat ⇒ page 153 .
Function test of thermostat

– Remove map-controlled engine cooling thermostat - F265-
⇒ page 153 .
– Check the thermostat when cold.
• The large valve head -arrow- must seal off the connection
flange all the way round.
If not:
– Connect the contacts of the thermostat with a battery using

test leads from -V.A.G 1594 C- .
– Using pliers, carefully place the thermostat vertically into a pot
of boiling water up to the flange.
Note
♦ The electric heating element now additionally heats the wax

in the thermostat.
♦ Do not expose the thermostat to air during this test, otherwise
the expansion element can become damaged.
– CheckProtected
whether the minimum
by copyright. Copying fortravel
private orof -a- = 7purposes,
commercial mm isinattained
part or in whole, is not
after 10 minutes.
If minimum travel is attained:
– Disconnect voltage supply from battery.
If the minimum travel is not attained:
– Interrogate and, if necessary, erase the fault memory for the
engine control unit, as faults are stored when the connector is
unplugged ⇒ Vehicle diagnostic tester.
1.9 Removing and installing radiator


♦ Used oil collection and extraction unit - V.A.G 1782- (only for
vehicles with multitronic/automatic gearbox 01V):
♦ Drip tray for workshop hoist - VAS 6208- or drip tray -

V.A.G 1306-
Removing
Note
Collect drained coolant in a clean container for re-use or disposal.
WARNING

opened; cover
Protected by filler
copyright. capforwith
Copying cloth
private and open
or commercial carefully.
purposes, in part or in whole, is not

– Release quick-fasteners -1- and -2- and take off front noise
insulation.
Rep. gr. 63 .

All vehicles:
– Detach coolant hose (bottom) from radiator -arrow-.
– Detach top coolant hose from radiator -arrow-.
Vehicles with multitronic/automatic gearbox 01V:



- N80- at air duct.
Note
Observe rules for cleanliness when working on automatic gear‐

box ⇒ Rep. gr. 00 .
derneath.
– Detach ATF lines (top -arrow- and bottom) from radiator: ⇒
Rep. gr. 37 .
– Tie ATF lines up onto longitudinal member to prevent fluid es‐
caping.
All vehicles:
– Unbolt air cowls (left and right) at radiator -arrows-.

– Unclip ambient temperature sensor - G17- -item 2- from brack‐

et.
– Unscrew bolts -3- and -4- for power steering cooling pipe; the
hydraulic hoses remain attached.
– Detach electrical connector -1- at high-pressure sender -
G65- .
WARNING
– Unscrew securing bolts -arrows- for condenser.
Note

– Pivot condenser downwards with pipes/hoses attached.
– Release two retaining pins for radiator and pull out upwards
-arrows-.
– Swivel radiator forwards and lift off.
Installing
Rep. gr. 63 .
Note
The coolant in the entire system must be changed if the radiator

is renewed.
Vehicles with multitronic/automatic gearbox 01V:

– Secure ATF lines ⇒ Rep. gr. 37 .
– Check ATF level ⇒ Rep. gr. 37 .
Tightening torques
Component Nm
Condenser to lock carrier 6
Power steering cooling pipe to lock carrier 9
1.10 Removing and installing radiator cowl

Removing
– Move lock carrier to service position ⇒ page
Protected 26 .Copying for private or commercial purposes, in part or in whole, is not
by copyright.

– Unplug electrical connectors -1- and -2-.

– Unplug electrical connector -1- for bonnet lock and move wir‐
ing clear.
– Unscrew bolts -arrows- and lift out radiator cowl.
Installing
InstallationProtected
is carried out in the reverse order; note the following:

nuts -arrows-.
Rep. gr. 63 .
Tightening torques
Component Nm
Radiator cowl to M6 11
Lock carrier Panel bolt 2
1.11 Removing and installing radiator fan

Removing
– Remove radiator cowl ⇒ page 159 .


– Remove radiator fan with control unit.
Installing
– Install radiator cowl ⇒ page 159 .
Tightening torque
Component Nm
Radiator fan Single fan 3
to radiator cowl Dual fan 4.5
1.12 Renewing radiator fan motor

♦ Wiring harness repair set - VAS 1978-
Procedure
Note
♦ Replacement radiator fan control units and radiator fan motors

are supplied without connectors.
♦ Perform repairs on wiring harness and connectors only with
wiring harness repair set - VAS 1978- .
Detailed instructions for using wiring harness repair set - VAS

1978- are given in the manual supplied with the repair set.
The repairing of open circuits and defective connectors is also
explained by way of examples.
1.13 Checking cooling system for leaks


equipment required
♦ Cooling system tester -
V.A.G 1274-
♦ Adapter for cooling system
tester - V.A.G 1274/8-
♦ Adapter for cooling system
tester - V.A.G 1274/9-
Test condition
• 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.

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 a pressure of
1.4 ... 1.6 bar.
If the pressure relief valve does not open as described:
– Renew filler cap.

21 – Turbocharging/supercharging
1 Servicing charge air system with tur‐
bocharger
1.1 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. Do not use fluffy 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
this can be avoided. Do not move the vehicle unless absolutely
necessary.
1.2 Connection diagram for charge pressure control and vacuum control - ve‐
hicles to 06.02
164 Rep. gr.21 - Turbocharging/supercharging

1 - Mechanical air recirculation

valve
2 - Charge pressure control
solenoid valve - N75-
3 - Pressure control valve for
crankcase breather system
4 - Secondary air pump motor
- V101-
5 - Air cleaner
❑ With air mass meter -
G70-
6 - Non-return valve
❑ Installation position: as
shown in illustration, the
arrow points in direction
of flow
7 - To activated charcoal filter
8 - Activated charcoal filter sol‐
enoid valve 1 - N80-
9 - Turbocharger
10 - Combination valve for sec‐
ondary air system
11 - To brake servo
of flow
shown in illustration, the arrow points in direction of flow
14 - Crankcase breather
15 - Vacuum reservoir
❑ Installation position: as shown in illustration, the arrow points in direction of flow
17 - Secondary air inlet valve - N112-
❑ Fitting location: below intake manifold
18 - To fuel system diagnostic pump - V144-
❑ Only on USA vehicles
❑ respect
with Onlyto on USA vehicles

20 - Charge air cooler
❑ With charge pressure sender - G31-
21 - Turbocharger air recirculation valve - N249-
1. Servicing charge air system with turbocharger 165

22 - Vacuum unit for charge pressure control

❑ When the secondary air combination valve is opened, the mechanical charge pressure regulating valve
in the turbocharger opens as well and the secondary air is delivered directly to the catalytic converter
past the turbocharger
1.3 Connection diagram for charge pressure control and vacuum control - ve‐
hicles from 07.02 onwards
1 - Resonator
valve
- V101-
4 - Charge pressure control
solenoid valve - N75-
5 - Air cleaner
❑ With air mass meter -
G70-
of flow by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
7 - To activated charcoal
with respect filterof information in this document. Copyright by AUDI AG.
to the correctness
8 - Activated charcoal filter sol‐

enoid valve 1 - N80-
9 - Turbocharger
10 - Pressure control valve for
crankcase breather system
ondary air system
of flow
13 - To brake servo
14 - Vacuum booster
16 - Crankcase breather
19 - To fuel system diagnostic pump - V144-
❑ Only on USA vehicles

21 - Secondary air inlet valve - N112-

❑ With charge pressure sender - G31-
23 - Turbocharger air recirculation valve - N249-
24 - Vacuum unit for charge pressure control
❑ When the secondary air combination valve is opened, the mechanical charge pressure regulating valve
in the turbocharger opens as well and the secondary air is delivered directly to the catalytic converter
past the turbocharger
1.4 Checking turbocharger and charge

pressure regulating valve


♦ Turbocharger tester - V.A.G 1397 A-
♦ Vehicle diagnostic, testing and information system - VAS 5051

A-
Test conditions
• All hoses and pipes securely fitted and free of leaks.
• Fault memory interrogated, final control diagnosis performed
⇒ Vehicle diagnostic tester.

Test sequence
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.
– Connect T-piece with test hose of turbocharger tester -

V.A.G 1397 A- to intake manifold (front).
– Route test hose under rear edge of bonnet and through right
window into passenger compartment.
– Switch on turbocharger tester and set measuring range se‐

lector switch to position -I- (absolute pressure).
– Attach test hose to connection -I-.
Note
♦ Hose connections must be completely airtight, otherwise

measurement errors may occur.
♦ Take care not to trap test hose at bonnet and side window.
♦ Pressing memory button “M” on turbocharger tester causes
last measured value to be stored until memory button “M” is
pressed again or tester is switched off.
♦ The decimal point in the display flashes to indicate that the
value is being stored.
♦ If the battery voltage of the turbocharger tester drops below
the minimum level, an arrow will appear at the top left of the
display.
♦ Before performing the test, drive vehicle moderately fast for at
least 3 km (choose a route where traffic lights etc. will not hold
you up).
♦ A second mechanic is required to note the readings on the
tester when the vehicle is moving.

– Connect vehicle diagnostic, testing and information system -

VAS 5051 A- to diagnosis connector with ignition switched off.
– Start engine.
Display on -VAS 5051 A- :

– Press the “Vehicle self-diagnosis” key.

– From list -1- select vehicle system “01 Engine electronics”.
– Wait until next display appears on tester.

– From list -1- select diagnostic function “08 - Read measured
value block”.


1 - Enter display group (highest possible entry = 255)
– Use keypad -2- to enter “Display group number 115” and con‐
firm by touching the Q key.
– Perform test drive.
– Accelerate vehicle in 3rd gear from 2000 rpm at full throttle
and observe rev counter.
– Press PRINT key on -VAS 5051 A- and memory key -M- on -
V.A.G 1397 A- simultaneously at approx. 2500 rpm.
Note
The charge pressureProtected

shouldby be measured
copyright. Copying forusing
private turbocharger
or commercial purposes, in part or in whole, is not
tester - V.A.G 1397 A- . Vehicle
permitted diagnostic,
unless authorised testing
by AUDI AG. AUDI and informa‐
AG does not guarantee or accept any liability
tion system - VAS 5051 withA- is used
respect to checkofwhether
to the correctness information inthe
this charge
document. Copyright by AUDI AG.
pressure is being registered by the control unit.
Display on -V.A.G 1397 A- :

• Specification: 1.500 ... 1.600 bar.

– Check display in zone -4-.
• Specification: 1500 … 1600 mbar.

Fault Possible causes

Charge pres‐ ♦ Charge pressure control solenoid valve - N75- defective. Checking in “Guided Fault Finding”
sure below ⇒ Vehicle diagnostic tester
specification
♦ Hose connections to charge pressure control solenoid valve - N75- defective. Checking
⇒ “1.2 Connection diagram for charge pressure control and vacuum control - vehicles to
06.02”, page 164 and
⇒ “1.3 Connection diagram for charge pressure control and vacuum control - vehicles from
07.02 onwards”, page 166
♦ Charge pressure regulating valve in turbocharger stuck in open position
♦ Leak between turbocharger and intake manifold. Effects ⇒ page 171
♦ Mechanical air recirculation valve defective. Checking ⇒ page 172
♦ Turbocharger air recirculation valve - N249- defective. Checking in “Guided Fault Finding”
⇒ Vehicle diagnostic tester
♦ Turbocharger defective. Renewing ⇒ page 175
Charge pres‐ ♦ Vacuum unit for charge pressure regulating valve defective. Renew turbocharger
sure above ⇒ page 175
specification
32) ♦ Air leaks in hoses or connections to vacuum unit for charge pressure control (via charge
pressure control solenoid valve - N75- ). Checking
⇒ “1.2 Connection diagram for charge pressure control and vacuum control - vehicles to
06.02”, page 164 and
⇒ “1.3 Connection diagram for charge pressure control and vacuum control - vehicles from
07.02 onwards”, page 166
♦ Charge pressure regulating valve in turbocharger sticking in closed position. Renew turbo‐
charger ⇒ page 175
32) If the charge pressure is too high the fuel supply will be interrupted in order to protect the engine. Misfiring will then occur at high engine
speeds.
1.5 Effects of leaks

Leaks after air mass meter
♦ Effect:
Loss of power
♦ Possible causes of trouble:
1 - Hose connecting air mass meter to turbocharger
2 - Connecting hose to crankcase breather
3 - Connecting hose to mechanical turbocharger air recirculation
valve
Leaks after turbocharger
♦ Effect:with respect to the correctness of information in this document. Copyright by AUDI AG.
Inadequate charge pressure
1 - Connection hoses and pipe between turbocharger and charge
air cooler
2 - Hose between charge air coolers and intake manifold
4 - Seal of charge pressure sender - G31- (in charge-air cooler)
5 - Seal between throttle valve module and intake manifold

6 - Gasket between intake manifold and cylinder head

Leak on exhaust side
♦ Effect:
Inadequate charge pressure; possible smell of exhaust gas,
traces of soot in engine compartment
1 - Connection between turbocharger and exhaust manifold
2 - Connection between exhaust manifold and cylinder head
1.6 Checking mechanical air recirculation

valve
Note
♦ The mechanical air recirculation valve is located upstream of

the turbocharger. It is opened by vacuum from the air recircu‐
lation valve for turbocharger - N249- when the engine is on
overrun or under part load or when idling. This dissipates the
charge pressure upstream of the throttle valve and maintains
a higher turbocharger speed.
♦ Check air recirculation valve in the event of loss of power or
load change jolts.
♦ Hand vacuum pump - V.A.G 1390-
Test sequence
– Connect hand vacuum pump - V.A.G 1390- to air recirculation
valve.
– Operate hand vacuum pump.
• Air recirculation valve should open -arrow-
– Operate air vent valve on vacuum pump after about 30 sec‐
onds.
• Air recirculation valve should close -arrow-.
If air recirculation valve does not open/close or if valve plate does
not provide a tight closure when air recirculation valve is closed:
– Renew air recirculation valve and secure hose connections
with hose clips.
1.7 Turbocharger - exploded view

Part 1

1 - 30 Nm
❑ Use only genuine bolts
⇒ Parts catalogue
2 - Gasket
❑ Renew
3 - Catalytic converter
together with front ex‐
haust pipe ⇒ page 197
4 - 30 Nm
❑ Renew
5 - Threaded connection, 30
Nm
6 - Threaded connection, 35
Nm
7 - Oil supply line
❑ Tighten union nut to 23
Nm
❑ From oil filter bracket
8 - 3.5 Nm
9 - Heat shield
10 - 23 Nm
11 - Exhaust manifold
⇒ page 201 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
12 - 35 Nm
❑ Renew
❑ Coat thread and contact
surface of bolt head with
high-temperature paste; ⇒ Parts catalogue
13 - 10 Nm
14 - Banjo bolt - 30 Nm
15 - Gasket
❑ Renew
16 - Coolant return line
❑ Tighten union nut to 30 Nm
17 - 30 Nm
❑ Renew
18 - Gasket
❑ Renew
19 - Banjo bolt, 35 Nm
20 - Coolant supply line
21 - Banjo bolt, 35 Nm
❑ Install using locking fluid; for locking fluid refer to ⇒ Parts catalogue

22 - 10 Nm
❑ Install using locking fluid; for locking fluid refer to ⇒ Parts catalogue
23 - Gasket
❑ Renew
24 - Oil return line
❑ To sump
25 - Gasket
❑ Renew
26 - 10 Nm
27 - 10 Nm
28 - Turbocharger
29 - 25 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
30 - Bracket with respect to the correctness of information in this document. Copyright by AUDI AG.
1 - Vacuum hose
❑ To turbocharger air re‐
circulation valve - N249-
valve
3 - Hose
❑ To turbocharger air re‐
circulation valve
4 - Air hose
❑ To connection on turbo‐
charger
5 - Hose
❑ To activated charcoal fil‐
ter solenoid valve 1 -
N80-
6 - Pipe
❑ To crankcase breather
7 - 10 Nm
8 - Hose
❑ To crankcase breather
pipe
9 - Pressure control valve
❑ For crankcase breather
10 - Hose
❑ To turbocharger
11 - Hose
❑ To vacuum unit for
charge pressure regu‐
lating valve

12 - Charge pressure control solenoid valve - N75-

13 - Elbow
14 - Hose
❑ To turbocharger
1.8 Removing and installing turbocharger

♦ Hose clamps up to Ø 25 mm - 3094-
Removing
Note
All heat insulation sleeves which are removed must be fitted in

the same position when installing.

noise insulation.

– Unscrew bracket -2- for turbocharger.

– Unscrew oil return line -1- at turbocharger and move clear.
– Loosen air intake hoses -4- and -5- at turbocharger.
– Unscrew banjo bolt -3- for pressure pipe.
– Disconnect hose -1- at vacuum unit for charge pressure reg‐

ulating valve from turbocharger.
– Clamp off coolant supply hose at bottom of turbocharger using
a hose clamp - 3094- .

panel.


- N80- at air duct.

– Detach hoses -1-, -4-, -6- and -7-.
– Remove secondary air pipe (detach hoses -arrows- and un‐

screw bolts -1-).
– Remove heat shield -3- from secondary air pipe -1- and from
cylinder head cover.
Note
Disregard -item 2-.


– Unfasten sleeve on coolant return hose.

– Clamp off coolant return hose going to turbocharger using a
hose clamp - 3094- .
– Loosen hose clip -4- and disconnect coolant return hose from
turbocharger connection. The connection remains fitted on the
turbocharger.


– Unscrew oil supply line -5- at turbocharger.
Note
Do not bend the flexible joint (de-coupling element) in the exhaust

system more than 10°, otherwise it could be damaged.
– Unscrew bolts -6- securing catalytic converter to turbocharger.

– Unscrew bolts -2- securing turbocharger to exhaust manifold.
– Move turbocharger to side, loosen retaining bracket and banjo
bolt for coolant supply line on turbocharger.
– Detach turbocharger.
Installing
Note
♦ Always renew gaskets, seals and self-locking nuts.

♦ Fit all heat insulation sleeves in the original position when in‐
stalling.
– Perform the following operations before securing the turbo‐
charger:
– Fit bracket of coolant supply hose loosely to vacuum unit for
charge pressure regulating valve.
– Tighten banjo bolt to 35 Nm, then tighten securing bolt of
bracket to 10 Nm.
Note
Fill turbocharger with engine oil at connection for oil supply line.

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.

Tightening torques
Component Nm
Coolant supply line to turbocharger 35
Coolant supply line bracket to turbocharger 10
Catalytic converter to turbocharger 30
Oil return line to turbocharger 10
Oil supply line to turbocharger 23
Oil supply line bracket to cylinder head 23
Heat shield to: Secondary air pipe 3.5
Cylinder head 3.5
Bracket for turbo‐ Cylinder block 25
charger to: Turbocharger 30
33) Renew bolts.
Parts catalogue
1.9 Charge air cooling - exploded view


1 - Air duct
❑ For charge air cooler
2 - Air hose
❑ To lock carrier and tur‐
bocharger
❑ Must be free of oil and
grease when installing
3 - Hose clip (reinforced), 5.5
Nm
4 - Air hose
❑ To intake manifold
❑ Must be free of oil and
grease when installing
5 - Not fitted
6 - O-ring
❑ Renew
7 - Charge pressure sender -
G31- / intake air temperature
sender - G42-
⇒ page 182
8 - 5 Nm
9 - Mountings
10 - Bracket for charge air cool‐
er
11 - Rubber grommet
12 - 22 Nm
⇒ page 181
14 - Bracket for refrigerant line
15 - 5 Nm
1.10 Removing and installing charge air cool‐

er
Note
Check all hoses and pipes for correct fitting and leakage before
carrying out tests or repairs.
Removing

– Open hose clips -1- and -2- and disconnect air intake hoses.
WARNING
– Disengage refrigerant line -4- at bracket.

– Detach electrical connector -3- at charge pressure sender -
G31- / intake air temperature sender - G42- .
– Detach charge air cooler by pulling upwards.
Installing
Note


nuts -arrows-.
Rep. gr. 63 .
Tightening torques
Component Nmauthorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless
1.11 Removing and installing charge pres‐

sure sender - G31- with intake air tem‐
perature sender - G42-
Removing

– Remove air intake hose -1- from charge air cooler.

– Detach electrical connector -2- at charge pressure sender -
G31- / intake air temperature sender - G42- .
– Remove bolts and pull charge pressure sender - G31- / intake
air temperature sender - G42- out of charge air cooler.
Installing
Note
Renew O-ring.
Tightening torques
Component Nm
Charge pressure sender - G31- / intake air tem‐ 5
perature sender - G42- to charge air cooler

26 – Exhaust system
1 Removing and installing parts of ex‐
haust system
Note
♦ Always 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.
♦ To avoid any damage, the flexible joint in the front exhaust
pipe must not be bent more than 10°.
1.1 Exhaust system on vehicles with front-wheel drive - exploded view
1 - Turbocharger
⇒ page 175
2 - Gasket
❑ Renew
3 - Lambda probe - G39- (be‐
fore catalytic converter)
❑ Black connector
❑ Threads of new Lambda
probes are already
greased with assembly
paste; the paste must
not get into the slots on
the probe body
❑ When re-using the old
lambda probe, grease
thread withunless
permitted high-tem‐
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
perature lubricant;
with respect the
paste must not get into
the slots of the probe
body; High-temperature
lubricant ⇒ Parts cata‐
logue
⇒ Motronic injection
and ignition system (4-
cyl. turbo); Rep. gr. 24
4 - Lambda probe after catalyt‐
ic converter - G130-
❑ Brown connector
probes are already
the probe body
184 Rep. gr.26 - Exhaust system

❑ When re-using the old lambda probe, grease thread with high-temperature lubricant; the paste must not
get into the slots of the probe body; High-temperature lubricant ⇒ Parts catalogue
❑ Removing and installing ⇒ Motronic injection and ignition system (4-cyl. turbo); Rep. gr. 24
❑ Protect against knocks and impact
❑ Removing and installing together with front exhaust pipe ⇒ page 197
❑ Align exhaust system so it is free of stress ⇒ page 188
6 - Gasket
❑ Renew
7 - 25 Nm
8 - Front exhaust pipe
❑ With flexible joint
❑ Do not bend flexible joint more than 10° – otherwise it can be damaged
9 - Clamp (front)
❑ Before tightening, align exhaust system so it is free of stress ⇒ page 188
❑ Installation position of bolts ⇒ page 186
❑ Tighten bolt connections evenly
10 - 40 Nm
11 - Spacer sleeve
12 - Buffer
13 - Bracket
14 - Washer
15 - 25 Nm
16 - Rear silencer (left-side)
❑ Combined in one unit with centre silencer as original equipment. Can be renewed individually for repair
purposes
❑ Cutting point ⇒ page 187
❑ Renewing tailpipe ⇒ page 187
17 - Mounting
❑ Renew if damaged
❑ Check preload
⇒ “1.3 Stress-free alignment of exhaust system - vehicles with front-wheel drive”, page 188
18 - 25 Nm
19 - Rear silencer (right-side)
purposes
20 - 40 Nm
21 - Clamps (rear)
❑ For individual replacement of centre silencer and the two rear silencers
1. Removing and installing parts of exhaust system 185

❑ Installation position ⇒ page 186

22 - Centre silencer
❑ Forms one unit with the two rear silencers as original equipment. Can be renewed individually for repair
purposes
23 - 25 Nm
24 - Mounting
❑ Check preload
⇒ “1.3 Stress-free alignment of exhaust system - vehicles with front-wheel drive”, page 188
25 - 25 Nm
26 - Washer
27 - Compression spring
28 - Spacer sleeve
29 - 25 Nm
❑ Renew
30 - 40 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Renew permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Installation position of front clamp

– Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.
• Bolt connection faces to left
Installation position of rear clamps

– Fit clamps so that ends of bolts do not protrude beyond bottom
of clamp.
• Bolt connections face outwards.

Renewing tailpipe
– Cut through old tailpipe -1- at a right angle at cutting point
-C- using chain-type pipe cutter - VAS 6254- .
– Push new tailpipe -3- onto tailpipe as far as marking -A-. Slot
on tailpipe should align with marking -B-.
– Tighten clamp connection -2- to 25 Nm.
1.2 Disconnecting centre silencer and rear

silencer - vehicles with front-wheel drive
♦ The connecting pipe can be cut through at the cutting point in
order to renew the centre and rear silencers separately.
♦ The cutting point is marked by an indentation on the outside
of the exhaust pipe.
♦ Chain pipe cutter - VAS 6254-
Procedure
– Cut through exhaust pipes at a right angle at cutting point
-arrows- using chain pipe cutter - VAS 6254- .

– When reassembling, position the clamps -1- and -2- centrally

over the cutting point.

of clamp.
– Tighten bolts on clamps evenly to 40 Nm.
1.3 Stress-free alignment of exhaust system

- vehicles with front-wheel drive
Note
The exhaust system must be aligned when it is cool.
Vehicles without clamp between centre silencer and rear silencer

– Loosen bolt connections of front clamp ⇒ Item 9 (page 185) .
– Push exhaust system towards front of vehicle -arrow- so that
rubber mounting (right-side) for centre silencer is preloaded
by -a- = 5 ... 9 mm.
– Tighten bolts on front clamp ⇒ Item 9 (page 185) evenly to
40 Nm.
– Align tailpipes ⇒ page 189 .

Vehicles with clamp between centre silencer and rear silencer
Note
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 185) and rear
clamp ⇒ Item 21 (page 185) .
– Push front section of exhaust system towards front of vehicle
-arrow-, so that mounting for centre silencer is preloaded by
-a- = 5 ... 9 mm.
– Tighten bolts on front clamp ⇒ Item 9 (page 185) evenly to
40 Nm.
– Push rear section of exhaust system towards front of vehicle

-arrow- until rear rubber mountings for rear silencers are pre‐
loaded by -a- = 7 ... 11 mm.
– Align rear silencer horizontally.
– Tighten bolts on rear clamps ⇒ Item 21by(page
Protected 185)
copyright. evenly
Copying to or commercial purposes, in part or in whole, is not
for private
40 Nm. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Aligning tailpipes
– Check clearance between tailpipes and bumper on both sides.
• Dimension -x- (left-side) = dimension -x- (right-side)
If necessary, correct dimension -x- as follows:

– Slacken nut -arrow- on brace between exhaust pipes.
– Adjust the distance between the rear silencers.
– Tighten nut to 23 Nm.

– Check distances -y- and -z- between tailpipes and bumper.

• Dimension -y- = more than 20 mm.
• Dimension -z- = 10 ... 16 mm.
– If necessary, check whether the exhaust system is aligned free
of stress ⇒ page 188 .
1.4 Exhaust system on vehicles with four-wheel drive - exploded view
1 - Turbocharger
⇒ page 175
2 - Gasket
❑ Renew
3 - Lambda probe - G39- (be‐
fore catalytic converter)
❑ Black connector
probes are already
the probe body
❑ When re-using the old
lambda probe, grease
thread with high-tem‐
perature lubricant; the
paste must not get into
the slots of the probe
body; High-temperature
lubricant ⇒ Parts cata‐
logue
⇒ Motronic injection
and ignition system (4-
cyl. turbo); Rep. gr. 24
4 - Lambda probe after catalyt‐
ic converter - G130-
❑ Brown connector
❑ Threadspermitted
of new
with Lambda
probes are already
the probe body
❑ When re-using the old lambda probe, grease thread with high-temperature lubricant; the paste must not
get into the slots of the probe body; High-temperature lubricant ⇒ Parts catalogue
❑ Removing and installing ⇒ Motronic injection and ignition system (4-cyl. turbo); Rep. gr. 24
❑ Protect against knocks and impact

❑ Removing and installing together with front exhaust pipe ⇒ page 197
6 - Gasket
❑ Renew
7 - 25 Nm
8 - Front exhaust pipe
❑ With flexible joint
❑ Do not bend flexible joint more than 10° – otherwise it can be damaged
9 - Clamp (front)
❑ Installation position of bolts ⇒ page 192
10 - 40 Nm
11 - Spacer sleeve
12 - Buffer
13 - Bracket
14 - Washer
15 - 25 Nm
16 - Rear silencer (left-side)
purposes
17 - Mounting
❑ Check preload
⇒ “1.6 Stress-free alignment of exhaust system - vehicles with four-wheel drive”, page 194
18 - 25 Nm
19 - Rear silencer (right-side)
❑ Combined in one unit with centre silencer as original
Protected equipment.
by copyright. Can
Copying for private be renewed
or commercial individually
purposes, for isrepair
in part or in whole, not
purposes permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
20 - 40 Nm
21 - Clamps (rear)
❑ For individual replacement of centre silencer and the two rear silencers
❑ Installation position ⇒ page 192
22 - Centre silencer
❑ Forms one unit with the two rear silencers as original equipment. Can be renewed individually for repair
purposes


23 - 25 Nm
24 - Mounting
❑ Check preload
⇒ “1.6 Stress-free alignment of exhaust system - vehicles with four-wheel drive”, page 194
25 - 25 Nm
26 - Washer
27 - Compression spring
28 - Bracket
29 - Spacer sleeve
30 - 25 Nm
❑ Renew
31 - 40 Nm
❑ Renew
Installation position of front clamp

– Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.
• Bolt connection faces to left.
Installation position of rear clamps

of clamp.
Renewing tailpipe
– Cut through old tailpipe -1- at a right angle at cutting point
-C- using chain-type pipe cutter - VAS 6254- .
– Push new tailpipe -3- onto tailpipe as far as marking -A-. Slot
on tailpipe should align with marking -B-.
– Tighten clamp connection -2- to 25 Nm.

1.5 Disconnecting centre silencer and rear

silencer - vehicles with four-wheel drive
♦ The connecting pipe can be cut through at the cutting point in
order to renew the centre and rear silencers separately.
♦ The cutting point is marked by an indentation on the outside
of the exhaust pipe.
♦ Chain pipe cutter - VAS 6254-
Procedure
– Cut through exhaust pipes at a right angle at cutting point
-arrows- using chain pipe cutter - VAS 6254- .
Note
The middle indentation (of three) on the exhaust pipe is the cutting
point.
– When reassembling, position the clamps -1- and -2- centrally

over the cutting point.


of clamp.
– Tighten bolts on clamps evenly to 40 Nm.
1.6 Stress-free alignment of exhaust system

- vehicles with four-wheel drive
Note
The exhaust system must be aligned when it is cool.
Vehicles without clamp between centre silencer and rear silencer

– Loosen bolt connections of front clamp ⇒ Item 9 (page 191) .
– Push exhaust system towards front of vehicle -arrow- so that
rubber mounting (right-side) for centre silencer is preloaded
by -a- = 5 ... 9 mm.
– Tighten bolts on front clamp ⇒ Item 9 (page 191) evenly to 40
Nm.
Vehicles with clamp between centre silencer and rear silencer
Note
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 191) and rear
clamp ⇒ Item 21 (page 191) .
– Push front section of exhaust system towards front of vehicle
-arrow-, so that mounting for centre silencer is preloaded by
-a- = 5 ... 9 mm.
– TightenProtected
bolts on front clamp
by copyright. Copying⇒
forItem
private9
or(page 191)
commercial evenly
purposes, toor40
in part in whole, is not
Nm. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Push rear section of exhaust system towards front of vehicle

-arrow- until rear rubber mountings for rear silencers are pre‐
loaded by -a- = 7 ... 11 mm.
– Align rear silencer horizontally.
– Tighten bolts on rear clamps ⇒ Item 21 (page 191) evenly to
40 Nm.
Aligning tailpipes
– Check clearance between tailpipes and bumper on both sides.
• Dimension -x- (left-side) = dimension -x- (right-side)
If necessary, correct dimension -x- as follows:

– Slacken nut -arrow- on brace between exhaust pipes.
– Adjust the distance between the rear silencers.
– Tighten nut to 23 Nm.
– Check distances -y- and -z- between tailpipes and bumper.

• Dimension -y- = more than 20 mm.
• Dimension -z- = 10 ... 16 mm.
– If necessary, check whether the exhaust system is aligned free
of stress ⇒ page 194 .

1.7 Removing and installing front exhaust

pipe
Removing
noise insulation.
noise insulation.
Note
must not be bent
unlessmore than 10°.AG. AUDI AG does not guarantee or accept any liability
permitted authorised by AUDI


– Remove bolts -arrows- securing front exhaust pipe to catalytic

converter.
– Detach front exhaust pipe from catalytic converter.
Installing
Note
Renew gaskets and self-locking nuts.
– Align exhaust system free of stress

⇒ “1.3 Stress-free alignment of exhaust system - vehicles with
front-wheel drive”, page 188 and
four-wheel drive”, page 194 .
Tightening torques
Component Nm
Front exhaust pipe to catalytic converter 25
Mounting plate to gearbox 25
1.8 Removing and installing front exhaust

pipe with catalytic converter
Removing
panel.


- N80- at air duct.

– Detach hoses -1-, -4-, -6- and -7-.

– Unplug electrical wire for coolant shortage indicator switch -
F66- at bottom of expansion tank and move expansion tank to
one side with coolant hoses -1- and -2- attached.
– Detach electrical connectors -2- and -5- from retainer at left of

bulkhead.
– Unplug electrical connectors -2- and -5- and move wiring clear
downwards.

– Unscrew nuts securing turbocharger to catalytic converter

-arrows-.

noise insulation.
noise insulation.

Note
must not be bent more than 10°.

– Detach front exhaust pipe with catalytic converter.
Installing
Note
Renew gaskets and self-locking nuts. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Align exhaust system free of stress

front-wheel drive”, page 188 and
four-wheel drive”, page 194 .
Tightening torques
Component Nm
Front exhaust pipe to catalytic converter 25
Catalytic converter to turbocharger 30 35)
Mounting plate to gearbox 25
35) Renew nuts.

1.9 Removing and installing exhaust mani‐

fold
Removing
noise insulation.
– Unscrew bolts -1- and -2- several turns.


panel.
- N80- at air duct.


– Detach hoses -1-, -4-, -6- and -7-.

– Disconnect front hose from pipe -2- for crankcase breather.

– Disconnect front hose from pipe leading to combination valve
for secondary air -1-.
– Remove heat shield -3-.

– Unscrew bolts -3- for turbocharger.
– Remove gasket between turbocharger and exhaust manifold.
– Seal opening in turbocharger with a cleanpermitted

cloth. unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Unscrew all nuts -arrows- on exhaust manifold.

– Remove washers and exhaust manifold.
Installing
Note
♦ Renew gaskets and self-locking nuts.

♦ Check that sealing surface
permitted is clean.
– Keep to the sequence as listed below:

1- Exhaust manifold to cylinder head
2- Turbocharger to exhaust manifold
3- Bracket for turbocharger to cylinder block
4- Bracket for turbocharger to turbocharger
Tightening torques
Tightening torques
Component Nm
Exhaust manifold to cylinder head 25
Bracket for turbo‐ Cylinder block 25
charger to: Turbocharger 30
Oil supply line to cylinder head 20
Crankcase breather pipe to cylinder head 10
36) Renew bolts.
Parts catalogue
1.10 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‐
charger/catalytic converter etc.
– Rectify any leaks that are found.

2 Secondary air system

♦ The secondary air system is designed to enable the catalytic
converter to heat up and reach its operating temperature more
quickly after a cold start.
♦ Because of the over-enrichment of the mixture in the cold start
phase, the proportion of unburned hydrocarbons in the ex‐
haust gas is higher. The secondary air system improves the
afterburning (oxidation) process in the catalytic converter, and
thus reduces toxic emissions. The heat generated by oxidisa‐
tion accelerates the “light off” of the catalytic converter and
significantly improves exhaust gas quality during warm-up.
Operation
2. Secondary air system 205

2.1 Secondary air system - overview

- V101-
❑ Fitting location
⇒ page 207
2 - Air cleaner
ondary air system
⇒ page 207
of flow
5 - Secondary air pump relay -
J299-
⇒ page 207
6 - Motronic control unit - J220-
❑ Fitting location: in front
left wheel housing be‐
neathunless
linerauthorised by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted
8 - Secondary air inlet valve -

N112-
⇒ page 206
9 - Cylinder head
Fitting location of secondary air inlet valve - N112-

♦ Below intake manifold
1- Turbocharger air recirculation valve - N249- (green connec‐
tor)
2- Secondary air inlet valve - N112- (brown connector)
Note
♦ The illustration shows the intake manifold from below and re‐
moved from the engine.
♦ Checking secondary air inlet valve - N112- in “Guided Fault
Finding” ⇒ Vehicle diagnostic tester.

Fitting location of secondary air pump motor - V101-

♦ At front right in engine compartment below longitudinal mem‐
ber
Note
Checking secondary air pump motor - V101- in “Guided Fault

Finding” ⇒ Vehicle diagnostic tester.
Fitting location of secondary air pump
with respect relay - J299-
♦ Located in 3-position relay carrier in electronics box in plenum

chamber
1- Motronic control unit - J220-
2- Secondary air pump relay - J299-
3- Motronic current supply relay - J271-
4- Secondary air pump fuse - S130-
Note
Checking secondary air pump relay - J299- in “Guided Fault Find‐

ing” ⇒ Vehicle diagnostic tester.
Combination valve for secondary air system

♦ On rear right of cylinder head.
Note
Checking combination valve for secondary air system for proper

operation and leakage ⇒ page 207 .
2.2 Checking combination valve for secon‐

dary air system for proper operation and
leakage

♦ Hand vacuum pump - V.A.G 1390-
Test conditions
• Vacuum hoses and hose connections do not leak.
• Vacuum hoses are not clogged.
Test sequence
panel.
– Detach vacuum hose -arrow- at combination valve.
Note
– Connect the hand vacuum pump - V.A.G 1390- to vacuum

connection of combination valve.

noise insulation.
– Detach pressure hose -arrow- from secondary air pump motor

- V101- and blow into it with light pressure (do not use com‐
pressed air).
• The combination valve should be closed; it should not be pos‐
sible to blow through the valve.
– Create vacuum using hand vacuum pump - V.A.G 1390- .
• The combination valve should open; it should now be possible
to blow through the hose.
If the combination valve does not open:
– Renew combination valve for secondary air system
⇒ page 209 .
2.3 Removing and installing combination

valve for secondary air system
Removing
panel.

– Disconnect hoses -1- and -2- from combination valve.
Note
– Unscrew bolts -arrows- and remove combination valve.

Installing
Note
♦ Renew seals and gaskets.

Tightening torque
Component Nm
Combination valve for secondary air system to 10
cylinder head Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2.4 Removing and installing secondary air
pump motor - V101-

- N80- at air duct.


– Detach hoses -1-, -4-, -6- and -7-.
– Unscrew the two bolts (accessible from above) from bracket
for secondary air pump.

noise insulation.


– Detach air hoses -1- and -2-.
– Unscrew the bolts (accessible from below) from bracket for
secondary air pump.
– Detach secondary air pump motor - V101- with bracket.
– If necessary, detach secondary air pump motor - V101- from
bracket.
Installing
Note
Secure all hose connections with the correct type of hose clips
Tightening torques
Component Nm
Secondary air pump motor - V101- to bracket 10
Secondary air pump bracket to body 10

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Service

Service Department. Technical Information

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Copyright © 2015 Audi AG, Ingolstadt A0059007120

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

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

3.4 Renewing inlet camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

1.1 Engine number

1.2 Engine data

10 – Removing and installing engine

1.1 Removing engine

Special tools and workshop

2 Rep. gr.10 - Removing and installing engine

♦ Used oil collection and ex‐

♦ 15 mm socket insert - Matra V/175- for vehicles with automatic

1. Removing and installing engine 3

– Move selector lever to position “N” on vehicles with multitronic/

Observe notes on procedure for disconnecting the battery ⇒

– Detach rubber seal from plenum chamber cover in direction of

– With ignition switched off, disconnect battery earth cable

Hot steam or hot coolant can escape when expansion tank is

– Open filler cap on coolant expansion tank.

– Remove both front wheels.

4 Rep. gr.10 - Removing and installing engine

– Unbolt bracket for noise insulation -arrows-.

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

1. Removing and installing engine 5

The air conditioner refrigerant circuit must not be opened.

– Disengage refrigerant line at bracket -2-.

– Clamp off hydraulic hoses going to cooling pipe for power

6 Rep. gr.10 - Removing and installing engine

Vehicles with automatic gearbox:

Observe rules for cleanliness when working on automatic gear‐

– If fitted, detach cover -1- on right of engine compartment.

– Disengage solenoid valve 1 for activated charcoal filter system

1. Removing and installing engine 7

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

– Disconnect top coolant hose -1- at radiator.

– Unplug electrical connector -arrow- for headlights on both

– Remove electrical connectors -1- and -2- from bracket.

8 Rep. gr.10 - Removing and installing engine

– Unbolt air cowls (left and right) at radiator -arrows-.

– Unclip ambient temperature sensor - G17- -item 2- from brack‐

The air conditioner refrigerant circuit must not be opened.

– Unscrew securing bolts -arrows- for condenser.

To prevent damage to the refrigerant lines, ensure that the pipes

– Pivot condenser downwards with pipes/hoses attached.

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

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

A second mechanic is required for removing the lock carrier.

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

1. Removing and installing engine 9

– Detach vacuum hose -3- leading to brake servo at bulkhead.

– Disconnect coolant hose (left-side) -arrow- from coolant pipe

10 Rep. gr.10 - Removing and installing engine

– Disconnect coolant hose from hose connection for thermostat

– Detach coolant hose -1- from top coolant pipe.

Disregard -item 2-.

– Detach air intake hose -1- at intake manifold.

– If fitted, detach vacuum hose -arrow- leading to vacuum res‐

1. Removing and installing engine 11

Before removing, mark direction of rotation of poly V-belt with