Audi A4 (B9-8W) FSM 2015-2020 Complete

Service
Maintenance
Audi A4 2015 ➤
Edition 10.2019
Service Department. Technical Information

Service
Maintenance
Heading
1. General information
2. Preparations
3. Maintenance
4. Exhaust emissions test
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 © 2019 Audi AG, Ingolstadt D4B806E4CA8

Audi A4 2015 ➤
Maintenance - Edition 10.2019
Contents
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 --- Change history --- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Vehicle: raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Engine cover panel: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Noise insulation: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Window regulators: activating automatic open/close function . . . . . . . . . . . . . . . . . . . . . . 10
2.5 Vehicle diagnostic tester: connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Diesel particulate filter: reading out ash deposit volume . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 ERA-GLONASS: checking emergency call function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Emergency call function: checking status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Event memory: reading out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5 Service interval display: resetting service event . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.6 Diagnostic work: performing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.7 Transport mode: deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.8 Flight mode: deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.9 Transport mode: checking activation and activating if necessary . . . . . . . . . . . . . . . . . . . . 21
3.10 Battery: reading out status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.11 Connecting vehicle diagnostic tester and sending diagnostic log . . . . . . . . . . . . . . . . . . . . 22
3.12 Battery: checking electrolyte level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.13 Battery: connecting stationary battery charging unit (min. 30A, charging voltage max. 14.8 V
on IV characteristic curve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.14 Battery: determining and recording state of charge (SOC) . . . . . . . . . . . . . . . . . . . . . . . . 26
3.15 Mirror hanger indicating defective battery: renewing battery on affected vehicles . . . . . . . . 28
3.16 Data sheet for Radio Equipment Directive: printing and placing in glove compartment . . . . 28
3.17 Connectivity box: checking emergency battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.18 Connected gateway: renewing emergency battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.19 Brake fluid: changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.20 Brake fluid (vehicles older than 12 months): changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.21 Brake fluid: checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.22 Brake system: checking condition of brake hoses, and checking that caps are fitted on bleeder
screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.23 Brake pads: checking thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.24 Brake discs: checking for surface rust and operating brakes to clean if necessary . . . . . . 36
3.25 Parking brake: releasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.26 Tyres: checking condition and wear pattern, and checking and recording tread depth . . . . 37
3.27 Tyres: checking tyre pressures and adjusting if necessary . . . . . . . . . . . . . . . . . . . . . . . . 38
3.28 Tyres (except spare wheel): checking tyre pressures and adjusting to 3.5 bar if necessary
........................................................................ 40
3.29 Tyre Pressure Loss Indicator: storing changed tyre pressures . . . . . . . . . . . . . . . . . . . . . . 40
3.30 Tyre repair kit: checking that set is complete, and checking and recording expiry date . . 40
3.31 Wheel bolts: tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.32 Suspension struts on front and rear axle: removing locking elements and correctly fitting
bump stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.33 Axles (front and rear): checking components for play, secure attachment and damage, and
checking protective boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.34 Engine, gearbox, final drive and steering: checking for leaks and damage . . . . . . . . . . . . 48
3.35 Vehicle (from below): checking for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.36 Underbody: checking trim, wheel housing liners, side members and pipes/wiring for damage,
and checking that they are properly secured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.37 Roof insert: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Contents i
Audi A4 2015 ➤
3.38 Roof insert - sliding/tilting sunroof: cleaning and lubricating . . . . . . . . . . . . . . . . . . . . . . . . 50

3.39 Roof insert - panorama sunroof: checking, cleaning and lubricating . . . . . . . . . . . . . . . . . . 52
3.40 Water drains - sliding panoramic sunroof: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.41 Door hinges with separate door arrester: cleaning and lubricating . . . . . . . . . . . . . . . . . . 57
3.42 Windscreen/rear window washer system: checking spray pattern and adjusting if
necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.43 Wiper blades: checking for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.44 Headlight washer system: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.45 Headlights: checking for correct adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.46 Headlights and reversing lights, side lights, number plate lights, turn signals, hazard warning
lights: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.47 Luggage compartment lighting: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.48 Luggage compartment: removing protective film and felt pieces . . . . . . . . . . . . . . . . . . . . 63
3.49 Glove box light, interior lighting and reading light: checking operation . . . . . . . . . . . . . . . . 63
3.50 Horn: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.51 Passenger airbag: checking key switch on/off and setting to "on" . . . . . . . . . . . . . . . . . . . . 64
3.52 Owner's literature: checking that all documents are present . . . . . . . . . . . . . . . . . . . . . . . . 64
3.53 Service wallet: affixing vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.54 Service Schedule: entering Delivery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.55 Seat belts: checking that retaining rivets are fitted, and checking locking action of automatic
belt retractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3.56 Vehicle interior: removing protective covers for seats and carpet . . . . . . . . . . . . . . . . . . . . 65
3.57 Vehicle interior: checking that it is clean and cleaning if necessary . . . . . . . . . . . . . . . . . . 65
3.58 Vehicle interior: removing any objects other than those protecting interior surfaces . . . . . . 65
3.59 Vehicle interior and exterior: checking for and documenting any damage . . . . . . . . . . . . . . 66
3.60 Instrument cluster: checking warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.61 Warning triangle: checking availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.62 First-aid kit: checking and recording expiry date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.63 Vehicle keys: checking operation and recording number of keys given to customer . . . . . . 66
3.64 Vehicle key: removing from ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.65 Vehicle key(s), wheel covers and owner's literature: checking availability and recording
number present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.66 Static event memory: working through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.67 Sun visors: checking that they are folded up and folding up if necessary . . . . . . . . . . . . . . 68
3.68 Luggage compartment cover and sun blind: checking that they are rolled up and rolling up if
necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.69 Engine oil: draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.70 Engine oil: extracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.71 Engine oil: renewing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.72 Engine oil: filling up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.73 Engine oil: checking oil level and correcting if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.74 Spark plugs: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.75 Coolant level: checking (coolant level must reach at least top marking on coolant expansion
tank) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.76 Air cleaner: renewing filter element and cleaning housing . . . . . . . . . . . . . . . . . . . . . . . . 91
3.77 Dust and pollen filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.78 Water separator (fuel filter): draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.79 Fuel filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.80 Water separator filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.81 Fuel tank: adding fuel additive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.82 Reducing agent (AdBlue®): filling up tank completely . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.83 Natural gas system: checking for damage and leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.84 Service display for checking natural gas system: resetting . . . . . . . . . . . . . . . . . . . . . . . . 118
3.85 Filler connection for natural gas: checking condition and cleaning if necessary . . . . . . . . 119
3.86 Vehicle doors: removing edge protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.87 Vehicle exterior: checking unprotected areas for dirt, and cleaning if necessary . . . . . . . . 119
3.88 Vehicle exterior: removing protective film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
ii Contents
Audi A4 2015 ➤
3.89 Vehicle cover: checking position and correcting if necessary . . . . . . . . . . . . . . . . . . . . . . 119

3.90 Vehicle cover: removing according to manufacturer's instructions . . . . . . . . . . . . . . . . . . 119
3.91 Paintwork, trims, side windows and wiper blades: checking cleanliness . . . . . . . . . . . . . . 120
3.92 Body: checking vehicle paintwork for damage and corrosion from below and with bonnet, rear
lid and doors open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.93 Vehicles parked outdoors: locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.94 Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.95 Stock vehicles: observing measures specified in Maintenance table for stock vehicles (see
“Before handing vehicle over to customer”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.96 Accessories: installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.97 Checklist "Documentation of cleaning and care routine": checking that list is present . . . . 121
3.98 “Stock vehicle maintenance” checklist: signing and placing in vehicle wallet . . . . . . . . . . 121
3.99 Cleaning and care: checking that required measures have been carried out on time . . . . 122
3.100 Stock vehicle care management: deciding and recording date of next check . . . . . . . . . . 122
3.101 Display instruments: setting time and date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.102 Manual gearbox/automatic gearbox: selecting 1st gear/park . . . . . . . . . . . . . . . . . . . . . . . . 122
3.103 Dual clutch gearbox (S tronic): changing ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.104 Interior mirror: calibrating compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.105 Instrument cluster: resetting driver information system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.106 Poly V-belt for ancillaries: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.107 Toothed belt for coolant pump drive: checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.108 Toothed belt for camshaft drive: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.109 Toothed belt for camshaft drive and tensioning roller: renewing . . . . . . . . . . . . . . . . . . . . 123
4 Exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.1 Petrol engines: performing exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4.2 Diesel engines: performing exhaust emissions test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Contents iii
Audi A4 2015 ➤
iv Contents
Audi A4 2015 ➤
1 General information
(AIGG001025; Edition 10.2019)
Change history ⇒ page 1
Engine number ⇒ page 1
Vehicle identification number ⇒ page 3
Vehicle data sticker ⇒ page 3
1.1 --- Change history ---

N Date Chapter Changes made
o.
1 06.07.20 Emergency call function: checking status LED ⇒ page 18 New chapter
0 19
9 15.08.20 Service display for checking natural gas system: resetting New chapter
18 ⇒ page 118
8 05.07.20 Natural gas system: checking for damage and leaks New chapter
18 ⇒ page 109
Note
For greater clarity, only the last three updates to the document
are listed.
1.2 Engine number
Note
The engine number consists of the engine code letters (3 or 4

characters) and the serial number.
1. General information 1
Audi A4 2015 ➤
4-cyl. petrol engine 1.4 TFSI ⇒ page 2

4-cyl. diesel engine 2.0 TDI ⇒ page 3
1.2.1 4-cyl. petrol engine 1.4 TFSI

The engine number is stamped on the left side at the joint between
the engine and the gearbox -arrow-.
The engine number is also given on the sticker on the toothed belt
cover (top).
In addition, the engine code letters are listed on the vehicle data
sticker ⇒ page 3 .

The engine number is also given on the sticker on the timing chain
cover (top).

Engine number
♦ Pull off engine cover panel and heat shield to make engine
number visible.
♦ The engine number is located at the top rear of the cylinder
block.
1- Serial number
2- Engine code
♦ There is also a sticker on the timing chain cover (top) showing
the engine code and the serial number.
♦ In addition, the engine code is listed on the vehicle data stick‐
ers.

The engine number is located at the top rear of the cylinder block.
cover (top).
2 1. General information
Audi A4 2015 ➤
1.2.5 4-cyl. diesel engine 2.0 TDI

cover (top).

The engine number is stamped on the left side under the toothed
belt for the high-pressure pump -arrow-.
The engine number is also printed on the sticker on the intake
manifold.
1.3 Vehicle identification number

Depending on the equipment and country-specific version, the
vehicle identification number is located:
♦ At the bottom left edge of the windscreen
♦ On the vehicle data sticker ⇒ page 3
♦ Optional: In the MMI under »Servicing & checks«
The vehicle identification number consists of the following:

WAU ZZZ 8W Z B A/N 000 234
Manufacturer Filler charac‐ Type Filler charac‐ Model year Production lo‐ Serial number
code ters ters cation
1.4 Vehicle data sticker

The vehicle data sticker is located:
♦ In the Service Schedule or service wallet
♦ In the area of the spare wheel well under the floor covering
Audi A4 2015 ➤
The vehicle data sticker contains the following vehicle data:

1 - Vehicle identification number
2 - Vehicle model, manufacturer's code, engine type and power
output, production month and year
3 - Engine and gearbox code letters (not specified on some export
models)
4 - Paint number, interior equipment number
5 - Numbers for optional extras
6 - Fuel consumption: urban, extra urban, combined, CO2 (not
specified on some export models)
Audi A4 2015 ➤
2 Preparations
Vehicle: raising ⇒ page 5
Engine cover panel: removing and installing ⇒ page 7
Noise insulation: removing and installing ⇒ page 9
Window regulators: activating automatic open/close function
⇒ page 10
Vehicle diagnostic tester: connecting ⇒ page 11
2.1 Vehicle: raising

WARNING
Risk of damage to vehicle due to incorrect use of lifting platform.
♦ Do not exceed the permissible lifting capacity of the lifting
platform.
♦ The vehicle should be lifted only at the points shown in the
illustration.
♦ Position support plates so that they are aligned centrally be‐
low the lifting points.
♦ Ensure sufficient clearance between low-mounted vehicle
components and the lifting platform.
Procedure:
– Front: Position support plates of lifting platform under lifting
point on side member -arrow-.
2. Preparations 5
Audi A4 2015 ➤
– Rear: Position support plates of lifting platform under lifting

Note
♦ The location of the lifting points is indicated by markings stam‐

ped on the side member trim.
♦ Extend all support plates -2- far enough so that the lifting arm
of the lifting platform does not touch the vehicle trim.
6 2. Preparations
Audi A4 2015 ➤
2.2 Engine cover panel: removing and in‐

stalling

Procedure for removing:
– Carefully pull engine cover panel off retaining pins one after
another -arrows-.
Procedure for installing:
– Position engine cover panel on retaining pins and then use
your hands to press it onto retaining pins, one after the other.

another -arrows-.

Removing engine cover panel (version 1)
another -arrows-. Do not jerk engine cover panel away, and
do not try to pull on one side only.
2. Preparations 7
Audi A4 2015 ➤

Removing heat shield

– Remove ball studs and bolts -arrows- and detach heat shield
-1-.
Installing
WARNING
Danger of fire and damage if the heat shield/engine cover panel
is not fitted.
♦ The heat shield and the engine cover panel must always be
fitted before the bonnet is closed.
♦ If the heat shield and engine cover panel are not fitted, it is
not permissible to start the vehicle with the bonnet closed or
drive the vehicle.
– To avoid damage, do not strike the engine cover panel with

your fist or with any kind of tool.
– Position engine cover panel, paying attention to oil filler neck
and dipstick.
– Press engine cover panel into rubber grommets first on left
side, then on right side.

Procedure:
Remove and install engine cover panel according to Workshop
Manual ⇒ Rep. gr. 10 ; Engine cover panel; Removing and in‐
stalling engine cover panel .
Note
Remove the engine cover panel according to the instructions in

the Workshop Manual.
8 2. Preparations
Audi A4 2015 ➤

another -arrows-.

another -arrows-.
2.3 Noise insulation: removing and installing

Noise insulation (front) ⇒ page 9
Noise insulation (rear) ⇒ page 10
2.3.1 Noise insulation (front)

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410- , measuring range 4 to 20 Nm
♦ Or: torque wrench - VAS 6854- , measuring range 5 to 13 Nm
♦ Or: torque wrench - V.A.G 1331- , measuring range 6 to 50
Nm
Table of tightening torques for installation:
Component/fastener [Nm]
Bolt -1- 12
2. Preparations 9
Audi A4 2015 ➤

– Remove bolts -1-.
– Unscrew quick-release fasteners -2-, -4- and -5- from noise
insulation (front).
– Pull noise insulation -3- towards rear out of bottom section of
bumper cover and detach.
Install in reverse sequence. Note tightening torques (see table of
tightening torques for installation ⇒ page 9 ).
Note
♦ Ensure that you feel the quick-release fasteners engage when

installing.
♦ On vehicles with supplementary heater, opening of exhaust
pipe must be routed vertically through grommet in noise insu‐
lation.
2.3.2 Noise insulation (rear)

– Release fasteners -arrows-.
– Release quick-release fasteners -2- and -3-.
– Pull noise insulation panel -4- out towards rear.
Install in reverse sequence.
Note
Ensure that you feel the quick-release fasteners engage when

installing.
2.4 Window regulators: activating automatic

open/close function
If the vehicle battery was disconnected, the automatic open/close
function for the electric windows must be reactivated.
Procedure:
– Pull up on window regulator switch until windows are com‐
pletely closed.
10 2. Preparations
Audi A4 2015 ➤
– Release switch and pull on it again for at least one second.

– Repeat procedure with all window regulators.
2.5 Vehicle diagnostic tester: connecting

♦ Diagnosis system - VAS 6160 A-
♦ Remote diagnosis head - VAS 5054A-

♦ Or: diagnosis interface - VAS 5055-
Procedure:
– Plug connector for remote diagnosis head - VAS 5054A- into
diagnostic connection in vehicle.
– Switch on diagnostic system - VAS 6160 A- .
– Switch on ignition.
– Follow the menu on the screen to start the desired functions.
2. Preparations 11
Audi A4 2015 ➤
12 3. Maintenance
Audi A4 2015 ➤
3 Maintenance
Display instruments: setting time and date ⇒ page 122
Battery: determining and recording state of charge (SOC)
⇒ page 26
Battery: checking electrolyte level ⇒ page 23
Battery: connecting stationary battery charging unit (min. 30A,
charging voltage max. 14.8 V on IV characteristic curve)
⇒ page 25
Battery: reading out status ⇒ page 22
Axles (front and rear): checking components for play, secure at‐
tachment and damage, and checking protective boots
⇒ page 44
Passenger airbag: checking key switch on/off and setting to "on"
⇒ page 64
Tyres: checking tyre pressures and adjusting if necessary
⇒ page 38
Tyres: checking condition and wear pattern, and checking and
recording tread depth ⇒ page 37
Tyres (except spare wheel): checking tyre pressures and adjust‐
ing to 3.5 bar if necessary ⇒ page 40
Service wallet: affixing vehicle data sticker ⇒ page 64
Owner's literature: checking that all documents are present
⇒ page 64
Brake system: checking condition of brake hoses, and checking
that caps are fitted on bleeder screws ⇒ page 34
Brake pads: checking thickness ⇒ page 35
Brake fluid (vehicles older than 12 months): changing
⇒ page 34
Brake fluid: checking fluid level ⇒ page 34
Brake fluid: changing ⇒ page 29
Brake discs: checking for surface rust and operating brakes to
clean if necessary ⇒ page 36
Checklist "Documentation of cleaning and care routine": checking
that list is present ⇒ page 121
“Stock vehicle maintenance” checklist: signing and placing in ve‐
hicle wallet ⇒ page 121
Connected gateway: renewing emergency battery, telematics
⇒ page 29
Connectivity box: checking emergency battery ⇒ page 28
Roof insert - panorama sunroof: checking, cleaning and lubricat‐
ing ⇒ page 52
Roof insert - sliding/tilting sunroof: cleaning and lubricating
⇒ page 50
Roof insert: checking operation ⇒ page 49
Diagnostic work: performing ⇒ page 19
Diesel particulate filter: reading out ash deposit volume
⇒ page 16
Dual clutch gearbox (S tronic): changing ATF ⇒ page 122
3. Maintenance 13
Audi A4 2015 ➤
ERA-GLONASS: checking emergency call function ⇒ page 17

Natural gas system: checking for damage and leaks
⇒ page 109
Filler connection for natural gas: checking condition and cleaning
if necessary ⇒ page 119
Event memory: reading out ⇒ page 18
Headlights and reversing lights, side lights, number plate lights,
turn signals, hazard warning lights: checking operation
⇒ page 61
Connecting vehicle diagnostic tester and sending diagnostic log
⇒ page 22
Vehicle key(s), wheel covers and owner's literature: checking
availability and recording number present ⇒ page 67
Vehicle key: removing from ignition lock ⇒ page 67
Vehicle key(s): checking operation and recording number of keys
given to customer ⇒ page 66
Mirror hanger indicating defective battery: renewing battery on
affected vehicles ⇒ page 28
Vehicle doors: removing edge protection ⇒ page 119
Vehicle exterior: checking unprotected areas for dirt, and cleaning
if necessary ⇒ page 119
Vehicle exterior: removing protective film ⇒ page 119
Vehicle interior and exterior: checking for and documenting any
damage ⇒ page 66
Vehicle interior: checking that it is clean and cleaning if necessary
⇒ page 65
Vehicle interior: removing any objects other than those protecting
interior surfaces ⇒ page 65
Vehicle interior: removing protective covers for seats and carpet
⇒ page 65
Vehicle (from below): checking for damage ⇒ page 49
Vehicle cover: checking position and correcting if necessary
⇒ page 119
Vehicle cover: removing according to manufacturer's instructions
⇒ page 119
Cleaning and care: checking that required measures have been
carried out on time ⇒ page 122
Suspension struts on front and rear axle: removing locking ele‐
ments and correctly fitting bump stops ⇒ page 42
Filter (water separator): renewing ⇒ page 102
Flight mode: deactivating ⇒ page 20
Luggage compartment cover and sun blind: checking that they
are rolled up and rolling up if necessary ⇒ page 68
Glove box light, interior lighting and reading light: checking oper‐
ation ⇒ page 63
Interior mirror: calibrating compass ⇒ page 122
Vehicles parked outdoors: locking ⇒ page 120
Body: checking vehicle paintwork for damage and corrosion from
below and with bonnet, rear lid and doors open ⇒ page 120
14 3. Maintenance
Audi A4 2015 ➤
Poly V-belt for ancillaries: renewing ⇒ page 122

Luggage compartment lighting: checking operation ⇒ page 62
Luggage compartment: removing protective film and felt pieces
⇒ page 63
Instrument cluster: resetting driver information system
⇒ page 122
Instrument cluster: checking warning lamps ⇒ page 66
Fuel tank: adding fuel additive ⇒ page 104
Fuel filter: renewing ⇒ page 101
Coolant level: checking (coolant level must reach at least top
marking on coolant expansion tank) ⇒ page 86
Paintwork, trims, side windows and wiper blades: checking clean‐
liness ⇒ page 120
Air cleaner: renewing filter element and cleaning housing
⇒ page 91
Engine, gearbox, final drive and steering: checking for leaks and
damage ⇒ page 48
Engine oil: draining ⇒ page 68
Engine oil: extracting ⇒ page 70
Engine oil: renewing oil filter ⇒ page 71
Engine oil: filling up ⇒ page 75
Engine oil: checking oil level and correcting if necessary
⇒ page 76
Emergency call function: checking status LED ⇒ page 18
Parking brake: releasing ⇒ page 37
Road test ⇒ page 120
Wheel bolts: tightening to specified torque ⇒ page 41
Reducing agent (AdBlue®): filling up tank completely
⇒ page 104
Tyre Pressure Loss Indicator: storing changed tyre pressures
⇒ page 40
Tyre repair kit: checking that set is complete, and checking and
recording expiry date ⇒ page 40
Manual gearbox/automatic gearbox: selecting 1st gear/park
⇒ page 122
Windscreen washer system: checking spray pattern and adjust‐
ing if necessary ⇒ page 58
Wiper blades: checking for damage ⇒ page 59
Headlights: checking for correct adjustment ⇒ page 60
Headlight washer system: checking operation ⇒ page 60
Service Schedule: entering Delivery Inspection ⇒ page 64
Service display for checking natural gas system: resetting
⇒ page 118
Service interval display: resetting service event ⇒ page 19
Seat belts: checking that retaining rivets are fitted, and checking
locking action of automatic belt retractor ⇒ page 65
Horn: checking operation ⇒ page 63
3. Maintenance 15
Audi A4 2015 ➤
Sun visors: checking that they are folded up and folding up if nec‐
essary ⇒ page 68
Stock vehicles: observing measures specified in Maintenance ta‐
ble for stock vehicles (see “Before handing vehicle over to cus‐
tomer”) ⇒ page 121
Static event memory: working through ⇒ page 67
Dust and pollen filter: renewing ⇒ page 98
Stock vehicle care management: deciding and recording date of
next check ⇒ page 122
Transport mode: checking activation and activating if necessary
⇒ page 21
Transport mode: deactivating ⇒ page 20
Door hinges with separate door arrester: cleaning and lubricating
⇒ page 57
Underbody: checking trim, wheel housing liners, side members
and pipes/wiring for damage, and checking that they are properly
secured ⇒ page 49
First-aid kit: checking and recording expiry date ⇒ page 66
Warning triangle: checking availability ⇒ page 66
Water drains - sliding panoramic sunroof: checking ⇒ page 56
Water separator (fuel filter): draining ⇒ page 100
Toothed belt for coolant pump drive: checking ⇒ page 123
Toothed belt for camshaft drive and tensioning roller: renewing
⇒ page 123
Toothed belt for camshaft drive: renewing ⇒ page 123
Accessories: installing ⇒ page 121
Spark plugs: renewing ⇒ page 77
3.1 Diesel particulate filter: reading out ash

deposit volume
Table of test values and procedure guidelines:
Engine Measured value designation for di‐ Maximum value for ash deposit
agnostic tester
4-cyl. diesel engine 2.0 TDI Particulate filter, oil ash deposit Oil ash deposit mass: 80 g
mass
6-cyl. diesel engine 3.0 TDI Particulate filter, oil ash deposit vol‐ Oil ash deposit volume: 380 ml
ume
Procedure:
– Connect vehicle diagnostic tester ⇒ page 11 .
– Select Diagnosis mode and begin diagnosis.
– Perform vehicle identification.
– De-select “Working with Guided Fault Finding” by removing
v and press Apply .
– Continue to follow instructions on screen.

– Switch to “Control units” tab.
16 3. Maintenance
Audi A4 2015 ➤
– Select control unit “01 — Engine electronics” and carry out

following functions via right mouse button:
♦ Identify control unit
♦ Guided Functions/Control unit self-diagnosis
♦ 01 - Read measured values/Measured values
– Select desired measured value (see table of test values and
procedure guidelines ⇒ page 16 ) by entering v and confirm‐
ing with OK .
– Evaluate measured value and follow further instructions on
screen.
– Perform the following measures according to the measured
value:
Result: Measure:
Measured value < critical Vehicle can be driven for a further 30,000 km (19,000 miles).
value
Measured value ≥ critical Renew diesel particulate filter and reset measured value to zero ⇒ Engine; Rep.
value gr. 26 ; Emission control system; Removing and installing particulate filter .
3.2 ERA-GLONASS: checking emergency

call function
Requirements:
• Applies to: vehicles with ERA-GLONASS emergency call func‐
tion (depends on market).
• The services can only used if there is sufficient mobile network
coverage.
• The test mode can only be started within 20 seconds of the
ignition being switched on.
• Transport mode deactivated.
• The system is designed to allow up to 15 minutes between
deactivating the transport mode and checking the emergency
call function.
• Ensure adequate mobile reception; move vehicle outside if
necessary.
Procedure:
3. Maintenance 17
Audi A4 2015 ➤
– Check if LED -2- is lit in green.

– Run ERA-GLONASS test mode:
– Press emergency call button behind cover in roof module -1-
10 times in succession and follow the voice prompts to perform
the test and the test call.
Note
♦ If the LED lights up in red or if it is not possible to activate the

test mode, connect vehicle diagnostic tester ⇒ page 11 and
perform Guided Fault Finding “19 - Data Bus On Board Diag‐
nostic Interface, functions, Commissioning ERA-GLONASS”.
♦ Due to applicable legislation in certain countries, the vehicle
must not be delivered unless the ERA-GLONASS emergency
call function (red LED) has been successfully activated.
♦ When the Predelivery inspection total program is star‐
ted, the test program is automatically loaded into the test plan.
3.3 Emergency call function: checking sta‐

tus LED
Requirements:
• Applies to: vehicles with private and statutory emergency call
function (Europe)
• The services can only used if there is sufficient mobile network
coverage.
• Flight and transport mode deactivated
• Ensure adequate mobile reception and GPS reception; move
vehicle outside if necessary.
Procedure:
– Deactivate flight and transport mode.
– Check if LED -2- is lit in green.
Note
♦ It may take up to 15 minutes for the emergency call system to

be activated (LED lights up in green) after deactivating flight/
transport mode.
♦ The vehicle must not be delivered to the customer if the emer‐
gency call function has not been successfully activated (LED
lights up in green).
♦ Due to applicable legislation in certain countries, the vehicle
is only approved for road use with a functioning emergency
call system (LED lights up in green).
♦ If the emergency call system has not been activated after the
specified time has elapsed, please refer to TPI 2055311.
3.4 Event memory: reading out

Procedure:
18 3. Maintenance
Audi A4 2015 ➤

– Select “Working with Guided Fault Finding” by entering v and
press Apply .
The control unit is then identified, and the event memory is inter‐
rogated. Observe notes and test conditions.
– Switch to “Control units” tab and call up “Event memory list”
for an overview of all entries stored in event memory.
– Select “Test plan” tab and carry out test plans according to
instructions.
3.5 Service interval display: resetting serv‐

ice event
Note
The test program Predelivery inspection total may also be

used for the Delivery Inspection.
Procedure:
v and press Apply .
– Switch to “Special functions” tab.

– Reset service event via ODIS (select corresponding service
event).
– Start program by selecting Carry out check .
Note
The distance until the next oil service is calculated on the basis
of the customer’s driving profile. When the service interval display
is reset, the distance until the next oil service is recalculated on
the basis of this driving profile. Frequent cold starts or short jour‐
neys make high demands on the engine oil. This can cause the
information about the distance until the next oil service to vary,
depending on the driving profile.
3.6 Diagnostic work: performing

Procedure:
– Connect vehicle diagnostic tester.
– Untick “Working with Guided Fault Finding”.
– Switch to “Special functions” tab and select following program:
♦ Predelivery inspection total
3. Maintenance 19
Audi A4 2015 ➤

– Continue to follow instructions on screen and complete the
process.
– Switch to the “Control units” tab, press the “Guided Fault Find‐
ing” button and launch Guided Fault Finding as far as the test
plan.
– The entries in the static event memory must be evaluated and
dealt with using Guided Fault Finding where necessary.
– Perform diagnosis; diagnostic log for Delivery Inspection is
sent automatically.
3.7 Transport mode: deactivating
Note

Procedure:
v and press Apply .

♦ 19 - Activating / deactivating transport mode
Note
♦ The transport mode serves to maintain the vehicle's ability to

start.
♦ When the vehicle is in transport mode, many functions, e.g.
radio, are restricted or unavailable.
3.8 Flight mode: deactivating

WARNING
Risk of injury as engine of high-voltage vehicle can start unex‐
pectedly!
♦ Observe warnings for high-voltage system:
♦ For work that requires the ignition to be switched on.
Note

20 3. Maintenance
Audi A4 2015 ➤
Procedure:
v and press Apply .

♦ Deactivate flight mode
CAUTION
Flight mode turns the mobile network connection off. A vehicle
with flight mode activated does not have an emergency call
function and must not be handed over to the customer.
3.9 Transport mode: checking activation

and activating if necessary
Checking transport mode ⇒ page 21
Activating transport mode ⇒ page 21
3.9.1 Checking transport mode

Procedure:
– Check whether »Transport mode on« is shown in instrument
cluster.
– If necessary, activate transport mode ⇒ page 21 .
3.9.2 Activating transport mode

Procedure:
v and press Apply .

Note

start.
3. Maintenance 21
Audi A4 2015 ➤
3.10 Battery: reading out status
Note
Alternatively, the test program Predelivery inspection to-

tal may be carried out.
Procedure:
press Apply .
♦ A - Battery, Testing
– Use results of test to determine following measures:
Result on vehicle diagnostic test‐ Measure:
er:
“Battery OK” No further measures necessary.
“Charge battery” Charge battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Charging battery .
“Battery is no longer of the same Renew battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and
quality as when shipped” installing battery .
Note
A working network connection is necessary to send the diagnostic

log file online.
3.11 Connecting vehicle diagnostic tester

and sending diagnostic log
– Carry out test programs according to test plan.
– Switch to Control units tab.
– Press X Diagnosis button and close diagnosis program.
– Send off diagnostic log online.
Note
♦ The event memory is erased automatically when you exit Gui‐

ded Fault Finding.
♦ The diagnostic log is sent automatically when you exit Guided
Fault Finding.
♦ If no network connection is available, the diagnostic log will be
cached for a few days. Complete the online data transfer as
soon as possible.
22 3. Maintenance
Audi A4 2015 ➤
3.12 Battery: checking electrolyte level
Note
Batteries must not be opened.
Battery without magic eye ⇒ page 23

Battery with magic eye ⇒ page 23
3.12.1 Battery without magic eye

The battery is located in the luggage compartment.
Removal steps:
– Lift luggage compartment floor and secure in position.
– Unscrew nut -1- for vehicle tool kit and take out cover with tool
kit -2- or temporary spare wheel.
Procedure:
– Check battery housing for the following:
♦ Battery terminals are not corroded or damaged
♦ Mechanical damage to battery housing and cover, indicated
by electrolyte leakage or crystals at the damaged area
– Damaged batteries must be renewed.
– Check electrolyte level of all battery cells using markings on
housing.
– If electrolyte level of one or more battery cells is below MIN
marking: Renew battery.
Note
♦ A bright hand-held light helps to better see the MIN and MAX
markings on the housing.
♦ If battery is difficult to see: Use a small mirror to check the
electrolyte level (shine a bright hand-held light at a right angle
onto the battery cells).
3.12.2 Battery with magic eye

WARNING
Risk of explosion if magic eye is colourless or light yellow!
♦ Do not attempt to jump-start vehicle.
♦ Do not check or charge battery.
♦ Renew battery.
3. Maintenance 23
Audi A4 2015 ➤
Removal steps:
Procedure:
– Before checking electrolyte level: Tap magic eye -arrow- care‐

fully with handle of a screwdriver.
– Read off battery electrolyte level according to colour display.

Two different results are possible:
Colour of magic eye: Measure:

Black or green Electrolyte level OK: No further measures necessary
Colourless or light yellow Electrolyte level too low: Battery must be renewed
Note
♦ The magic eye is also referred to as an ALI (acid level indica‐

tor).
♦ The magic eye is only for use in determining the electrolyte
level.
♦ During battery charging or vehicle operation, air bubbles can
form underneath the magic eye which could falsify the colour
display. Tap magic eye lightly to release any bubbles.
24 3. Maintenance
Audi A4 2015 ➤
3.13 Battery: connecting stationary battery

charging unit (min. 30A, charging volt‐
age max. 14.8 V on IV characteristic
curve)
WARNING
Risk of injury if battery terminal clamps are connected incor‐
rectly.
♦ Connect positive battery terminal clamp first, then connect
negative battery terminal clamp.

♦ Battery charger - VAS 5906A-
Only applies to vehicles intended for display.

Requirements:
• Ignition switched off.
Removal steps:
– Remove plastic stopper -C- in spare wheel well and store it in
glove box.
Procedure for connecting battery charger:

– Disconnect charger clamps from battery charger - VAS 5906- .
– Working from above, thread connector end of cable for charg‐
er clamps through hole in spare wheel well.
– Open battery terminal cover (+).
– First connect charger clamp (+) to positive battery terminal
-A-.
– Then connect charger clamp (-) to earth point (-) -B- on body.
– Arrange wiring of battery charger - VAS 5906- neatly in spare
wheel well.
– Stow tool kit in spare wheel well and fit cover for tool kit.
– Fit luggage compartment floor cover.
– Under vehicle: Connect cable for charger clamps to battery
charger - VAS 5906- .
– Switch on battery charger - VAS 5906- and adjust settings as
needed.
– Position battery charger - VAS 5906- under vehicle so that it
is hidden from view as well as possible, ensuring that ventila‐
tion grille of charger is unobstructed.
Procedure for disconnecting battery charger:

Remove in reverse sequence.
3. Maintenance 25
Audi A4 2015 ➤
3.14 Battery: determining and recording state

of charge (SOC)
Vehicles with transport mode ON ⇒ page 26
Vehicles with transport mode OFF ⇒ page 26
3.14.1 Vehicles with transport mode ON

Procedure:
– Read off battery charge level on instrument cluster.
State of charge Measure:
(SOC):
“≥ 80% (12.5 V)” No further measures necessary.
“SOC < 80% (12.5 Charge battery ⇒ Electrical system; Rep.
V) and SOC ≥ 10% gr. 27 ; Battery; Charging battery .
(11.6 V)”
“< 10% (11.6 V)” Charge battery ⇒ Electrical system; Rep.
gr. 27 ; Battery; Charging battery , and at‐
tach mirror hanger for “Battery defective”.
– Record charge level in maintenance table.
Note
If if is not possible to read off the state of charge in the instrument

cluster, measure the battery's no load voltage ⇒ page 27 .
3.14.2 Vehicles with transport mode OFF

♦ Battery tester - VAS 6161-
Removal steps:
Procedure:
– Switch on battery tester - VAS 6161- and select “QC check,
new vehicles”.
– Use battery tester - VAS 6161- to measure voltage between
battery clamps.
Battery Measure:
tester
shows:
“Battery No further measures necessary.
good”
“Charge Charge battery ⇒ Electrical system; Rep. gr. 27 ;
fully now” Battery; Charging battery .
“Battery Charge battery ⇒ Electrical system; Rep. gr. 27 ;
Faulty” Battery; Charging battery , and attach mirror hang‐
er for “Battery defective”.
26 3. Maintenance
Audi A4 2015 ➤
Note
♦ When using battery tester - VAS 6161- , ensure that the soft‐
ware is up to date.
♦ If if is not possible to measure the state of charge with battery
tester - VAS 6161- , measure the battery's no load voltage
⇒ page 27 .
3.14.3 Measuring no load voltage of battery

♦ Hand-held multimeter - V.A.G. 1526 C-
♦ Or: digital multimeter - V.A.G. 1715-

Requirements:
• Battery must not be placed under load from connected elec‐
trical equipment for at least 12 hours before test.
• Battery must not have been charged for at least 12 hours be‐
fore test.
• Engine must remain off for at least 2 hours before test.
• Ignition switched off during test.
Removal steps:
Procedure:
– Use hand-held multimeter - V.A.G. 1526 C- to measure volt‐
age between battery clamps -2- and -3-.

(SOC):
“≥ 12.5 V” No further measures necessary.
3. Maintenance 27
Audi A4 2015 ➤

(SOC):
“SOC < 12.5 V and Charge battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Charging battery .
SOC ≥ 11.6 V”
“< 11.6 V” Charge battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Charging battery , and attach
mirror hanger for “Battery defective”.
3.15 Mirror hanger indicating defective bat‐

tery: renewing battery on affected vehi‐
cles
Only for vehicles with mirror hanger for “Battery defective”.
Procedure:
– Wait until shortly before vehicle delivery, then renew battery
according to instructions in workshop manual ⇒ Electrical
system; Rep. gr. 27 ; Battery; Removing and installing battery .
3.16 Data sheet for Radio Equipment Direc‐

tive: printing and placing in glove com‐
partment
As part of the European Union’s Radio Equipment Directive (RED
2014/53/EU), legislation requires that a data sheet be provided
containing information regarding which radio frequencies are
used.
The Radio Equipment Directive data sheet can be downloaded at
www.audi.com/generalinfo.
– Print out data sheet (same language as owner's literature) and

fold it.
– Place data sheet in glove compartment.
Note
♦ Only markets within the EU.

♦ The data sheet applies to all vehicles across Europe; it can
therefore be printed out in advance and kept at hand.
3.17 Connectivity box: checking emergency

battery
Procedure:
press Apply .
♦ A16 - Emergency battery, telematics, check component
28 3. Maintenance
Audi A4 2015 ➤

3.18 Connected gateway: renewing emer‐

gency battery
The emergency battery, telematics - A16- is located in the data
bus diagnostic interface - J533- .
Removing
– Switch off ignition and all electrical equipment, and remove
ignition key.
– Remove seat bench ⇒ General body repairs, interior; Rep. gr.
72 ; Rear seats; Removing and installing seat bench/individual
seats .
It is not necessary to remove data bus diagnostic interface -
J533- .
– Release catches and lift cover off data bus diagnostic interface
- J533- -1- in direction of -arrow-.
– Pivot emergency battery, telematics - A16- -1- out of data bus

diagnostic interface - J533- .
– Release and unplug electrical connector.
Installing
3.19 Brake fluid: changing

WARNING
Risk of accident if the brake pedal has too much free play.
♦ Make sure that the brakes work properly before the vehicle
is driven on the road.
WARNING
Risk of injury due to caustic brake fluid.
♦ Avoid contact with skin.
3. Maintenance 29
Audi A4 2015 ➤
CAUTION
Risk of damage due to improper handling of brake fluid.
♦ Avoid contact with vehicle paint.
♦ Avoid contact with liquids containing mineral oils (oil, petrol,
cleaning agents).

♦ Brake filling and bleeding equipment - VAS 5234-
♦ Tool set for brake bleeding - VAS 6564-

The value given in the table is for one brake caliper, i.e. if there
are two bleeder screws on one caliper, the sum of the quantities
discharged from both bleeder screws must equal the value given
in the table.
Sequence of opening bleeder screws: Quantity of brake fluid to discharge:
Brake calipers
Front axle on driver's side 1. 0.20 ltr.
Front axle on passenger's side 2. 0.20 ltr.
Rear axle on driver's side 3. 0.30 ltr.
Rear axle on passenger's side 4. 0.30 ltr.
Clutch slave cylinder 5. 0.15 ltr.
⇒ Total quantity, automatic gearbox 1.00 ltr.

⇒ Total quantity, manual gearbox 1.15 ltr.
30 3. Maintenance
Audi A4 2015 ➤
Step 1 - connecting brake filling and bleeding equipment:

– Unscrew filler cap -1- from brake fluid reservoir.
– Use extraction hose included in brake filling and bleeding

equipment - VAS 5234- to extract brake fluid from reservoir
(with strainer installed) until fluid is level with bottom edge of
strainer. Make sure that no more fluid flows back into reservoir
from strainer after extracting fluid.
– Screw adapter -1- onto brake fluid reservoir.

– Connect filling hose -2- included with brake filling and bleeding
equipment - VAS 5234- to adapter.
– Set pressure on brake filling and bleeding equipment -
VAS 5234- (see operating instructions).
Step 2 - bleeding and filling brake system:

If there are two bleeder screws on each brake caliper, first bleed
the inner, then the outer bleeder screw.
– Raise vehicle ⇒ page 5 .
Front axle:
– Brake caliper (driver's side): Remove cap(s) -1- from bleeder

screw(s).
3. Maintenance 31
Audi A4 2015 ➤
– Fit bleeder hose -1- attached to collector container onto bleed‐

er screw from inside of rim.
– Open bleeder screw and allow brake fluid to discharge. Refer
to table for correct quantity of brake fluid to discharge
⇒ page 30 .
– Close bleeder screw.
– If there are two bleeder screws on each brake caliper: Repeat
procedure with second bleeder screw.
– Refit cap on bleeder screw(s).
– Repeat procedure on passenger's side.
Rear axle:

screw(s).
– Take reversible ratchet and appropriate socket from tool set
for brake bleeding - VAS 6564- and fit together.
– Run bleeder hose -1- from inside of rim through reversible

ratchet -2- and socket -3- and fit onto bleeder screw.
– Open bleeder screw with ratchet -2- and allow brake fluid to
discharge. Refer to table for correct quantity of brake fluid to
discharge ⇒ page 30 .
32 3. Maintenance
Audi A4 2015 ➤
– If there are two bleeder screws on each brake caliper: Working

from outside of rim, apply reversible ratchet -2- and socket
-3- and repeat procedure.
– Refit cap on bleeder screw(s) on brake caliper.
Step 3 - bleeding clutch slave cylinder

Only for vehicles with manual gearbox
– Remove components necessary for access; refer to ⇒ Manual
gearbox; Rep. gr. 30 ; Clutch mechanism; Bleeding clutch
mechanism .
– Fit bleeder hose attached to collector container -1- onto bleed‐
er screw of clutch slave cylinder.
– Open bleeder screw and allow correct amount of brake fluid
to flow out (see table of test values and procedure guidelines
⇒ page 30 ).
– Close bleeder screw and fit cap.
Step 4 - final steps:

– Close filling lever of brake filling and bleeding equipment -
VAS 5234- .
– Detach filling hose from adapter.
– Unscrew adapter from brake fluid reservoir.
– Check brake fluid level and adjust if necessary (depending on
brake pad wear) ⇒ page 34 .
– Screw cap onto brake fluid reservoir.
– Operate clutch pedal several times.
– Check pedal pressure and free travel: No more than 1/3 of total
pedal travel.
– Make sure that the brakes work properly before the vehicle is
driven on the road.
– If free travel of brake pedal is greater than specified, or if brake
function is impaired: Check brake system for leaks and renew
brake fluid again.
Note
♦ The bleeder hose must fit tightly on the bleeder screw to pre‐
vent air from entering the brake system.
♦ In the case of certain wheel combinations, the wheels may
have to be removed.
♦ With the aid of the tool set for brake bleeding - VAS 6564- ,
the rear brakes or, depending on version, the front and rear
brakes can be bled without having to remove the wheels.
♦ Use genuine Audi brake fluid; see Electronic parts catalogue
(ETKA).
♦ Do not reuse brake fluid.
♦ Always observe the relevant environmental regulations for
disposal of brake fluid.
3. Maintenance 33
Audi A4 2015 ➤
3.20 Brake fluid (vehicles older than 12

months): changing
Only applies to vehicles older than 12 months (from date of man‐
ufacture).
Procedure:
– Change brake fluid ⇒ page 29 .
3.21 Brake fluid: checking fluid level

Type of service: Fluid level specification:
Delivery Inspection Fluid level must be at MAX marking.
Brake fluid change Fluid level must be between MAX marking and MIN marking according to wear
level of brake pads.
Checking the brake system for leaks is a repair measure and

should be charged separately.
Procedure:
– Evaluate brake fluid level according to markings on brake fluid
reservoir -illustration-.
– Perform the following measures according to the results of the

check:
Fluid level: Evaluation/measure:

Above MAX marking Extract brake fluid.
Below specified level Carry out brake system leak test ⇒ Brake system; Rep. gr. 47 ; Hydraulic system;
Leak test .
Note
When the vehicle is in use, the fluid level drops due to wear and
automatic adjustment of the brake pads.
3.22 Brake system: checking condition of

brake hoses, and checking that caps are
fitted on bleeder screws
Requirements:
• Brake hoses must not touch any components when steering
is on full lock.
• Brake hoses must not be twisted.
34 3. Maintenance
Audi A4 2015 ➤
Procedure:
– Check that all brake hoses are secured properly; when doing
so, ensure that the conditions listed are met:
– Check all brake hoses for abrasion, porosity, blistering and
cracking.
– Check that brake connections are seated correctly, and check
for corrosion and leaks.
– If faults are found on brake hoses: Repair/renew relevant com‐
ponent.
– Check that caps are fitted and secured on bleeder screws of
all brake calipers.
– Renew any missing caps.
3.23 Brake pads: checking thickness

♦ Test pin - T40139 - / test pin - T40139A- : Use the side with
the thin probe (brake symbol) to measure brake pad thickness.

Axle Brake pad wear limit including backplate and damper plate
[mm]
Front axle 10
Rear axle 10
Check only the thickness of the outer brake pads.

Procedure:
– Before you begin: Push sliding ring towards tip of test pin as
far as it will go.
– Bring tip of test pin into contact with brake disc.
– Slide test pin towards brake pad until test pin makes contact
with backplate of brake pad.
3. Maintenance 35
Audi A4 2015 ➤
– Remove test pin and read off brake pad wear value -a- from
scale on tool.
– Repeat procedure for all wheels.
– If brake pad thickness has reached wear limit (see table of test
values and procedure guidelines ⇒ page 35 ): Renew brake
pads ⇒ Brake system; Rep. gr. 46 ; Removing and installing
brake pads .
Note
♦ When removing the test gauge, take care not to move the slid‐
ing ring. This would give an incorrect measurement.
♦ Note where the test gauge makes contact on the rear of the
brake pad and include the thickness of the damper plate in the
calculation if necessary.
♦ In the case of certain wheel combinations, the wheels must be
removed.
♦ On S and RS models, the layout may make it necessary to
measure the brake pads from the inside of the wheels.
3.24 Brake discs: checking for surface rust

and operating brakes to clean if neces‐
sary
Checking brake discs ⇒ page 36
Operating brakes to clean brake discs ⇒ page 36
3.24.1 Checking brake discs

Procedure:
– Check outside of all brake discs for surface rust.
– If necessary, operate brakes to clean brake discs
⇒ page 36 .
Note
The brake discs can be damaged irreparably if surface rust is not

removed at the specified intervals.
3.24.2 Operating brakes to clean brake discs

Procedure:
– Accelerate vehicle to 40 km/h, then brake gently to 10 km/h
(do this five times).
– Accelerate vehicle to 40 km/h, then brake sharply to a stand‐
still (do this five times).
Note
The wheels should not spin or lock during acceleration and brak‐
ing.
36 3. Maintenance
Audi A4 2015 ➤
3.25 Parking brake: releasing

Mechanical parking brake ⇒ page 37
Electromechanical parking brake ⇒ page 37
3.25.1 Mechanical parking brake

Procedure:
– Release parking brake.
3.25.2 Electromechanical parking brake

Procedure:
– Press brake pedal, then press switch for electromechanical
parking brake.
3.26 Tyres: checking condition and wear pat‐

tern, and checking and recording tread
depth
♦ Test pin - T40139 - / test pin - T40139A- : Use the side with
the thick probe and shoulder (scale marked with tyre symbol)
to measure tread depth.

Country-specific regulations for minimum tread depth apply; for
countries not listed, evaluate values according to the country's
specifications.
Country Minimum tread depth [mm]
EU countries 1.61)
Brazil 1.6
China 1.6
India 1.6
Japan 1.6
Norway 1.61)
Russia 1.6
Switzerland 1.6
Turkey 1.6
Ukraine 1.61)
USA 1.6
1) Larger values for winter tyres where these are mandatory
3. Maintenance 37
Audi A4 2015 ➤
Performing wheel alignment is a repair measure and should be

charged separately.
Step 1 - checking condition:
– Check for and remove any foreign bodies in tyre tread.
– Check all tyres for following types of damages:
♦ Cuts, cracks, tears
♦ Scuffing or flattened areas on tyre tread
♦ Porous sidewalls
♦ Blisters on sidewalls
– If damage is found: Renew tyres.
Step 2 - checking tyre wear pattern:
– Check tyre wear pattern of front wheels; check for the follow‐
ing:
♦ Feathering on tread indicating possible incorrect toe setting
♦ One-sided tread wear indicating possible incorrect camber
– If the above types of wear are found: Check wheel alignment
to determine the cause.
Step 3 - checking tread depth:
– Measure tread depth on all tyres (including spare tyre) at sev‐
eral points using test pin - T40139- . Uneven tread depth
indicates damage.
– Record average measurement for each tyre in Maintenance
table.
– If minimum tread depth has been reached (as specified for
your country; see table of test values and procedure guidelines
⇒ page 37 ): Renew tyre.
Note
Vehicles with four-wheel drive must be fitted with tyres with the
same tread pattern. Otherwise the centre differential may be
damaged.
3.27 Tyres: checking tyre pressures and ad‐

justing if necessary
Note
The tyre valves must be sealed with valve caps. Otherwise, dirt
could enter the valve, which will then become blocked and will no
longer seal properly.
38 3. Maintenance
Audi A4 2015 ➤
Front and rear axles ⇒ page 39

Spare wheel and temporary spare wheel ⇒ page 39
3.27.1 Front and rear axle

The tyre pressure specifications are listed on the sticker on the
inside of the driver's door.
Tyre sizes not listed: See Wheel/tyre guide for tyre pressure
specification ⇒ Wheel/Tyre Guide; Rep. gr. 44 ; Wheels, tyres,
vehicle geometry; Tyre pressures .
Procedure:
– Check tyre pressure of all tyres.
– If necessary, adjust to correct tyre pressures.
Note
♦ The tyre pressures listed only apply to cold tyres. When the
tyres are warm, the actual pressures will be higher, but must
not be reduced.
♦ Tyre pressures which significantly differ from the specification
may be the result of a defect. If this occurs, check the tyres
and inform the customer if necessary.
♦ Always adjust to max. tyre pressure specified on vehicles with
stickers indicating tyre pressures for speed range >250km/h
(vehicles without speed limiter system; max. tyre pressures
are obligatory).
3.27.2 Spare wheel and temporary spare

wheel
The following parameters apply to the tyre pressure specifica‐
tions:
• Spare wheel with standard-size tyre: Inflate to maximum tyre
pressure indicated on tyre pressure sticker.
• Temporary spare wheel: The correct tyre pressure is indicated
on the sidewall.
Procedure:
– Check tyre pressure of spare wheel/temporary spare wheel.
Note
Depending on equipment version, there may only be a tyre repair

kit supplied; see Maintenance table.
3. Maintenance 39
Audi A4 2015 ➤
3.28 Tyres (except spare wheel): checking

tyre pressures and adjusting to 3.5 bar
if necessary
Note
Procedure:
– If necessary, adjust tyre pressure to 3.5 bar and record pres‐
sure in maintenance table.
3.29 Tyre Pressure Loss Indicator: storing

changed tyre pressures
The Tyre Pressure Loss Indicator must be initialised at every in‐
spection (after the tyre pressures have been checked or
changed).
Requirements:
• The inflation pressures of all tyres must be adjusted to the
correct values before the pressures are stored.
Procedure:
– Switch on ignition and activate MMI.
– Press function selector button MENU .
– Select »Car«.
– Press left control button and navigate through following menu
structure:
♦ Servicing & checks
♦ Tyre pressure monitoring
♦ Store tyre pressures
♦ Yes, store
– Use MMI rotary pushbutton to select option to store tyre pres‐
sures.
3.30 Tyre repair kit: checking that set is com‐

plete, and checking and recording expi‐
ry date
The tyre repair kit is located in the spare wheel well.
Procedure:
– Check that the following components of the tyre repair kit are
present:
♦ Compressor
♦ Tyre filler bottle incl. filler hose
40 3. Maintenance
Audi A4 2015 ➤
– Take out the bottle and check the expiry date (printed on bottle
-arrow-).
– Record expiry date in Maintenance table.
– If expiry date has been exceeded or if bottle has already been
used: Renew tyre filler bottle.
3.31 Wheel bolts: tightening to specified tor‐

que
Nm
♦ Tool to secure wheel bolt caps 8Z0.012.287

Fastener Tightening torque [Nm]
Wheel bolt 120
The adapter for loosening and tightening anti-theft wheel bolts is

included in the vehicle tool kit.
Procedure:
– Remove wheel bolt caps.
– Tighten wheel bolts in a diagonal sequence to specified torque
(see table of test values and procedure guidelines).
– Press wheel bolt caps on using tool 8Z0.012.287 so that they
are correctly seated.
– If adapter for anti-theft wheel bolts was used from tool kit: Put
adapter back in tool kit.
3. Maintenance 41
Audi A4 2015 ➤
3.32 Suspension struts on front and rear axle:

removing locking elements and correctly
fitting bump stops
Note
♦ These vehicles are identified by a coloured tag fixed to the

mirror -arrow-.
♦ It is not necessary to remove the wheels to perform this oper‐
ation.
Suspension struts on front axle ⇒ page 42

Suspension struts on rear axle ⇒ page 43
Pressing in bump stop ⇒ page 43
3.32.1 Suspension struts on front axle

Requirements:
• Vehicle suspension extended
Procedure:
– Push all locking elements -A- off piston rod.
– Press bump stops all the way into shock absorber mountings
(make sure they are straight).
Note
With vehicle suspension extended, check that all bump stops are
firmly seated in shock absorber mountings.
– If necessary, use a suitable tool to press any loose bump stops

into shock absorber mountings ⇒ page 43 .
– When all locking elements have been removed from vehicle:
Remove tag on interior mirror.
42 3. Maintenance
Audi A4 2015 ➤
3.32.2 Suspension struts on rear axle

Requirements:
Procedure:
– Push all locking elements -1- off piston rod.
Note

3.32.3 Pressing in bump stop

♦ T40401 Lever for mounting bump stops
♦ Soap-based lubricant, e.g. tyre assembly paste
3. Maintenance 43
Audi A4 2015 ➤
Procedure:
– Remove coarse dirt from top edge of loose bump stop and coat
with tyre assembly paste.
– Press bump stop firmly into shock absorber mounting by hand
or using lever - T40401- .
Note
Lever - T40401- can only be used on the rear axle.
3.33 Axles (front and rear): checking compo‐

nents for play, secure attachment and
damage, and checking protective boots
The following applies to all components shown below:
• There must not be any noticeable play.
• As a rule you can identify damage to the boots/drive shaft
boots by emerging grease.
• Check that retaining rings and spring-type clips are seated
correctly.
Front axle ⇒ page 44
Rear axle ⇒ page 46
3.33.1 Front axle

Track control links, guide links and coupling rod:
– Check relative movement between wheel bearing housing and
track control link/guide link.
44 3. Maintenance
Audi A4 2015 ➤
– Track control links and guide links: Check boots -arrows- of

swivel joint all around for damage and make sure they are
seated correctly.
– Check swivel joints for play.
– Check all bonded rubber bushes of track control links and

guide links -arrows- for play.
– Check play at coupling rod -1-.
Track rod ball joint:
– Check boot -2- for track rod ball joint all around for damage
and make sure it is seated correctly.
– Check play at track rod ball joint.
Upper links:
– Upper links -2-: Check bushes of swivel joints all around for
damage and make sure they are seated correctly.
– Check the two bonded rubber bushes -1- and -4- of swivel
joints (top) for play.
Anti-roll bar:
3. Maintenance 45
Audi A4 2015 ➤
– Check anti-roll bar bush -3- for damage.
Drive shaft and steering rack:
– With steering turned: Check drive shaft boots -arrows- all

around for damage and make sure they are seated correctly.
– Check boot -arrow- of steering rack all around for damage and
correct seating.
– Repeat checks for components on opposite side of vehicle.

– If faults are found on any of the above components: Renew
relevant component.
3.33.2 Rear axle

Lower transverse links (front and rear):
both transverse links.
– Check all bonded rubber bushes of lower transverse link
(front) -2- for play.
– Check bonded rubber bushes -arrows- of all transverse links

for play.
– Check anti-roll bar bush -arrow- for damage.
Upper transverse links (front and rear):
46 3. Maintenance
Audi A4 2015 ➤
– Check all bonded rubber bushes of upper transverse link

– Check all bonded rubber bushes of upper transverse link (rear)

-2- for play.
Track rod:
– Check play at bonded rubber bushes of track rod -2-.
Coupling rod and anti-roll bar:
3. Maintenance 47
Audi A4 2015 ➤
– Check anti-roll bar bush -arrows- for damage.
Drive shaft:
Only applies to vehicles with four-wheel drive.
– Check drive shaft boots -arrows- for damage and make sure
they are seated correctly.

relevant component.
3.34 Engine, gearbox, final drive and steer‐

ing: checking for leaks and damage
Remove noise insulation for every inspection.
Removal steps:
– Remove noise insulation ⇒ page 9 .
48 3. Maintenance
Audi A4 2015 ➤
Procedure:
– Check engine and engine ancillaries from below for leaks and
damage.
– Check visible area of belt drives for damage.
– Check radiator and cooling circuit for leaks and damage.
– Check refrigerant circuit for damage (check air conditioner
compressor, condenser and refrigerant lines including con‐
nections).
– Check gearbox, final drive and steering for leaks and damage.
– If faults are found: repair or renew relevant component.
3.35 Vehicle (from below): checking for dam‐

age
Procedure:
– Check underbody carefully and thoroughly for damage and
loose fasteners.
– If faults are found: Renew missing fastener or damaged com‐
ponent.
3.36 Underbody: checking trim, wheel hous‐

ing liners, side members and pipes/wir‐
ing for damage, and checking that they
are properly secured
Procedure:
– Check all underbody trim panels and wheel housing liners for
tears and cracks.
– Use your hands to check that all underbody trim panels and
wheel housing liners are secured correctly and check for miss‐
ing fasteners.
– Inspect side members for deformations.
– Check visible area of pipes/wiring and connections for dam‐
age and ensure they are secured correctly.
– Check stone deflector on rear track control links to make sure
it is securely fitted and undamaged.
ponent.
Note
Depending on equipment version, some vehicles may not be fitted

with a stone deflector.
3.37 Roof insert: checking operation

Only applies to equipment version with sliding/tilting sunroof.
Cleaning and lubricating the roof insert is a repair measure and
Procedure:
– Open and close roof system completely and check for unusual
noises and stiffness/sticking.
3. Maintenance 49
Audi A4 2015 ➤
– If there is unusual noise or stiffness/sticking: Clean and lubri‐

cate roof insert ⇒ page 50 .
3.38 Roof insert - sliding/tilting sunroof:

cleaning and lubricating
CAUTION
Risk of breaking cowl panel.
♦ Use care when lifting cowl panel.

♦ Lubricating paste - G 060 751 A2-
♦ Cleaning solution - D 009 401 04-
♦ Industrial vacuum cleaner, e.g. wet/dry vacuum cleaner - VAS
5128-
♦ Commercially available paintbrush: approx. 15 mm wide and
bent by approx. 40° using workshop equipment
♦ Fine-pored sponge (e.g. a piece of household sponge without
a scouring surface)

Protect vehicle interior from becoming dirty.
Step 1 - cleaning and lubricating glass panel seal:
– Tilt open glass panel at rear.
– Remove all accessible grease and dirt residue from glass pan‐
el seal using cleaning solution - D 009 401 04- and a lint-free
cloth.
– Use a fine-pored sponge -1- to lubricate sides and rear of glass
panel seal -arrows- with lubricating paste - G 052 141 A2- .
Make sure that no coarse residue remains visible after apply‐
ing lubricant.
– Open glass panel completely.

– Using cleaning solution - D 009 401 04- and a lint-free cloth,
remove any grease or dirt residue from front of glass panel
seal in area that has not been lubricated yet.
50 3. Maintenance
Audi A4 2015 ➤
– Use a fine-pored sponge -1- to lubricate glass panel seal at

front -arrow- with lubricating paste - G 052 141 A2- . Make sure
that no coarse residue remains visible after applying lubricant.
Step 2 - cleaning and lubricating wind deflector seal:

Glass panel opened completely.
To avoid risk of breakage, lift the wind deflector carefully with your
hand but do not remove it for the following procedure.
– Remove grease and dirt from wind deflector seal using clean‐
ing solution - D 009 401 04- and a lint-free cloth.
– Use a fine-pored sponge -1- to lubricate rubber lip of wind de‐

flector -arrow- along the entire length with lubricating paste -
G 052 141 A2- . Make sure that no coarse residue remains
visible after applying lubricant.
Step 3 - cleaning and lubricating guide rails:

– First use an industrial vacuum cleaner to remove any loose
residue from guide rails.
– Remove grease and dirt from guide rails with a lint-free cloth.
– Use a paintbrush to lubricate inside of guide rail -arrow- with

lubricating paste - G 060 751 A2- .
3. Maintenance 51
Audi A4 2015 ➤
– Use a paintbrush to lubricate outside of guide rail -arrow- with

– Use a paintbrush to lubricate side guide rail of sliding headliner

-arrow- with lubricating paste - G 060 751 A2- .
– Remove surplus lubricant on guide rails with a lint-free cloth.
– Repeat procedure on opposite side of vehicle.
– Open and close roof system completely and check again for
surplus lubricant.
3.39 Roof insert - panorama sunroof: check‐

ing, cleaning and lubricating
52 3. Maintenance
Audi A4 2015 ➤
♦ Grease stone - VAS 6764-
♦ Hand-cartridge gun - V.A.G 1628-

5128-
♦ Measuring cup
a scouring surface)
Note
First carry out a visual check to determine which type of sunroof

is fitted on the vehicle.

– Carry out a visual check to determine which type of grease has
been used in area of guide rails.
♦ White/grey grease G 060 751 A2: Clean and lubricate accord‐
ing to method used to date (description below)
♦ No white/grey grease: Open and close sunroof completely;
this must not produce any vibrations or noises (rattling,
squeaking, clicking) other than those of normal operation.
Note
Please refer to TPI if normal operating sounds are accompanied

by other noises or vibrations on a sunroof version with new spray-
on grease.
3. Maintenance 53
Audi A4 2015 ➤

Only applies to sunroof version with white/grey grease
G 060 751 A2:
– Open sunroof sun blind completely.
residue from guide rail.
– Insert grease stone - VAS 6764- in rear section of guide rail
-1- and turn 90° into contour of rail -2-.
– Then pull tool into centre of guide rail opening -3-, turn through
90° again -4- and remove -5-.
– Clean front section of guide rail as described in previous step.
To do so, insert grease stone in front section of guide rail (near
wind deflector) and move it to centre of guide rail.
– Repeat cleaning procedure several times as required.
– Remove grease and dirt deposits from guide rail with a lint-
free cloth.
– Screw grease stone - VAS 6764- -1- onto thread of lubricant

cartridge -G 060 751 A2- -2- and insert into hand-cartridge gun
- V.A.G 1628- -3-.
54 3. Maintenance
Audi A4 2015 ➤
– Insert grease stone attached to hand-cartridge gun at front end

of guide rail -1- and turn 90° into contour of rails -2-.
– Pull hand-cartridge gun evenly towards rear -3-, operating lev‐
er continuously to apply lubricating paste - G 060 751 A2- to
guide rail.
– Turn hand-cartridge gun through 90°-4- and remove in vicinity
of open glass panel -5-.
– Repeat lubrication procedure on opposite side of vehicle.
Step 2 - cleaning and lubricating slotted guide for glass panel:

– Remove grease and dirt from slotted guide for glass panel with
a lint-free cloth.
– Open and close sunroof and open glass panel again com‐
pletely. Opening and closing the sunroof distributes the lubri‐
cant along the guide rails. Any deposits of excess lubricant can
be used to grease the slotted guide.
– Use a paintbrush to lubricate slotted guide for glass panel

– Remove excess lubricant from slotted guide and guide rail with
a lint-free cloth.
Step 3 - cleaning and lubricating locking hook for sunroof mech‐

anism:
– Move glass panel to first open position.
– Working from vehicle interior, remove grease and dirt from
locking hook for sunroof mechanism with a lint-free cloth.
– Use a paintbrush to lubricate locking hook -arrow- with lubri‐

cating paste - G 060 751 A2- .
– Remove surplus lubricant from locking hook with a lint-free
cloth.
surplus lubricant at all lubricating locations.
Step 4 - cleaning glass panel:

3. Maintenance 55
Audi A4 2015 ➤
– Remove grease and dirt from front and side edges of glass
panel -arrows- using cleaning solution - D 009 401 04- and a
lint-free cloth.
Step 5 - cleaning and lubricating roof frame seal:

– Remove grease and dirt from seal for roof frame using clean‐
– Use a fine-pored sponge to lubricate roof frame seal

-arrows- with lubricating paste - G 052 141 A2- . Make sure
that no coarse residue remains visible.
Step 6 - cleaning wind deflector:

– Clean screen and frame of wind deflector -1- using a sponge

and soap solution.
– Use an industrial vacuum cleaner to remove any loose residue
from wind deflector slot -arrows-.
3.40 Water drains - sliding panoramic sun‐

roof: checking
♦ Measuring cup
♦ Lint-free cloth
56 3. Maintenance
Audi A4 2015 ➤
♦ Industrial vacuum cleaner

Procedure - checking for dirt in water drains:
– Use industrial vacuum cleaner to remove visible dirt in area of
guide rails or clean with a lint-free cloth.
– Use a measuring cup -1- to slowly pour 0.5 ltr. of water into
guide rail on each side close to open glass panel -arrow-. Work
carefully to ensure that the water does not overflow into the
dry area of the vehicle. Make sure that water is distributed in
both directions so that both water drains (front and rear) can
be checked.
– At underside of vehicle, check that water flows out in the area
of both the front and rear wheel housings.
– If no or only a little water flows out of the appropriate drainage
points, clean water drains ⇒ General body repairs, exterior;
Rep. gr. 60 ; Water drain hoses; Cleaning water drain hoses .
Note
♦ Take care when pouring the water into the guide rail (both
sides). If the water drain is blocked, the water can flow into the
vehicle interior (headliner).
♦ The whole quantity of water must drain quickly (within a mi‐
nute) from the water drains (front and rear, both sides) in the
area of the wheel housings.
3.41 Door hinges with separate door arrester:

♦ Universal spray oil - G 000 115 A2- for door arresters and
hinges
Requirements:
• The vehicle must be at least at room temperature.
Procedure:
– First clean all lubricating points with a lint-free cloth.
– Lubricate door hinge (top and bottom) at points marked
-arrows- as well as separate door arrester -arrows- with uni‐
versal oil spray - G 000 115 A2- .
Door hinge:
3. Maintenance 57
Audi A4 2015 ➤
Door arrester:
– Move door several times so that the universal spray oil is able
to penetrate.
– Use cloth to remove surplus lubricant from all door hinges.
– Repeat cleaning and lubricating procedure on all remaining
doors of vehicle.
3.42 Windscreen/rear window washer sys‐

tem: checking spray pattern and adjust‐
ing if necessary
Checking spray pattern on windscreen ⇒ page 58
Checking spray pattern on rear window ⇒ page 58
Adjusting windscreen washer jets ⇒ page 59
Adjusting rear window washer jets ⇒ page 59
3.42.1 Checking spray pattern on windscreen

The spray pattern must meet the following specifications:
• Evenly distributed, symmetrical spray pattern
• Uniform, precise jets of water
• Jet unit (passenger's side): Upper concentrated jet should
make contact near upper edge of wiper area -1-.
• Jet unit (driver's side): Upper concentrated jet should make
contact -2- at same level as jet unit (passenger's side).
Procedure:
– Operate windscreen washer system and check spray pattern.
– If spray pattern is not as specified, adjust windscreen washer
jets ⇒ page 59 .
3.42.2 Checking spray pattern on rear window

• Water from both spray jets makes contact just above wiper
blade
• Water from inner spray jet makes contact within approx. first
quarter of wiper blade length -illustration-
• Water from outer spray jet makes contact approx. at or just
beyond centre of wiper blade length -illustration- (third quarter)
Procedure:
– Operate rear window washer system and check spray pattern.
– If spray pattern is not as specified, adjust rear window washer
jets. ⇒ page 59
58 3. Maintenance
Audi A4 2015 ➤
3.42.3 Adjusting windscreen washer jets

Procedure:
– Using adjuster screw -2-, set washer jet being adjusted ac‐
cording to specified pattern (use a tool with size 9 external Torx
-3-).
– If the spray pattern still does not correspond to the specifica‐
tion, clean appropriate washer jets ⇒ Vehicle electrics; Rep.
gr. 92 ; Windscreen wash/wipe system; Adjusting washer jets .
Note
Only the height of the jets of water of each jet unit can be adjusted,
and all jets must be adjusted together via an adjuster screw. The
jets cannot be adjusted individually or laterally.
3.42.4 Adjusting rear window washer jets

♦ Commercially available adjusting tool (e.g. adjusting tool -
T10127- ) or suitable needle
Procedure:
– Use adjusting tool to align washer jets as required according
to specification.
tion, clean washer jets ⇒ Electrical system; Rep. gr. 92 ; Rear
window wiper system; Adjusting washer jets .
3.43 Wiper blades: checking for damage

Step 1 - service position:
– Switch off ignition.
– Press windscreen wiper lever downwards briefly.
Step 2 - checking:
– Lift windscreen wipers and check each wiper blade for tears,
cuts, abraded areas or other damage.
– Repeat check on rear window.
– If you find damage: Renew relevant wiper blade. Windscreen
wiper system ⇒ Electrical system; Rep. gr. 92 ; Windscreen
wiper system; Removing and installing wiper blade ; rear win‐
dow wiper system ⇒ Electrical system; Rep. gr. 92 ; Rear
window wiper system; Removing and installing wiper blade
WARNING
♦ Depending on the model, it may be possible to activate the
wipe (touch wipe) function by pressing the windscreen wiper
lever even if the ignition is switched off. When working on
the wiper system, the battery should be disconnected.
3. Maintenance 59
Audi A4 2015 ➤
3.44 Headlight washer system: checking op‐

eration
Not all vehicles are equipped with a headlight washer system
(depending on equipment version).
Procedure:
– Operate headlight washer system and check function.
– If water jet does not contact headlight: Renew relevant washer
jets ⇒ Electrical system; Rep. gr. 92 ; Headlight washer sys‐
tem; Removing and installing washer jets .
Note
The headlight washer jets are set by the manufacturer and there‐
fore cannot be adjusted.
3.45 Headlights: checking for correct adjust‐

ment
♦ Headlight adjustment unit - VAS 5209B-
♦ Or: headlight adjustment unit - VAS 621 001-
Note
Other headlight adjustment units (e.g. VAS 5208A, VAS 621 005,
VAS 5046A and VAS 5047A) can also be used to check the
headlight adjustment (except for matrix LED headlights). Check‐
ing matrix LED headlights requires adjustment unit VAS 5209B
or VAS 621 001.
Performed as part of an inspection, this check is merely an ab‐

breviated form of the headlight adjustment check required, for
example, after a repair, and does not take the place of a full head‐
light adjustment check.
Do not adjust the vehicle load or the tyre pressures for this pro‐
cedure.
Do not adjust the headlights to their basic setting using the vehicle
diagnostic tester.
Checking and adjusting the headlights according to the instruc‐
tions in the Workshop Manual is a repair measure and must be
charged separately.
60 3. Maintenance
Audi A4 2015 ➤
Procedure:
– For vehicles with manually adjustable headlight range control:
Use manual adjuster to set to basic setting.
– Activate dipped headlights.
– Align headlight adjustment unit parallel to vehicle and position
it centrally in front of headlight at a distance of 30 to 70 cm
-distance a-; deviation from centre of light emission surface
must not exceed 3 cm -distance b-.
– Adjust dip setting of headlight adjustment unit so that beam of

headlight falls on test screen according to following parameter:
Horizontal light-dark border should coincide with setting line
-1-.
– Read off dip setting of headlight adjuster.
– Repeat procedure on opposite side.
– Compare dip setting on left and right sides.
– If they deviate 2.0% or more from one another: Check and
adjust headlight setting according to procedure specified in
Workshop Manual ⇒ Electrical system; Rep. gr. 94 ; Head‐
lights; Adjusting headlights .
3.46 Headlights and reversing lights, side

lights, number plate lights, turn signals,
hazard warning lights: checking opera‐
tion
Check the lights/signals listed below from the outside to ensure
they function properly.
Procedure:
– Activate side lights and check that the following exterior lights
function properly:
♦ Side lights (front)
♦ Side lights (rear)
♦ If applicable: additional tail light under open rear lid
– Check operation of daytime running lights (front).
– Operate right turn signal, left turn signal and hazard warning
lights, and check that corresponding turn signal lamps at front,
rear and side function properly.
– Activate dipped headlights and check that the following exte‐
rior lights function properly:
♦ Dipped headlights
♦ Tail lights
♦ Number plate lights
3. Maintenance 61
Audi A4 2015 ➤
– Use appropriate switch to activate fog lights and check that

– Check that main beam headlights function properly.
– Operate brakes and check function of all brake lights.
– Engage reverse gear and check that all reversing lights func‐
tion properly.
– Use appropriate switch to activate rear fog lights and check
that they function properly. This model is fitted with one rear
fog light.
– Renew any defective bulbs.
Note
On vehicles from model year 2017 onwards, the reversing light is

only switched on when the engine is running on versions with
bulbs. This does not affect LED versions.
3.47 Luggage compartment lighting: check‐

ing operation
A4 Saloon ⇒ page 62
A4 Avant ⇒ page 63
3.47.1 A4 Saloon
Procedure:
– Check that luggage compartment light shown -arrow- func‐
tions properly.
62 3. Maintenance
Audi A4 2015 ➤
3.47.2 A4 Avant
Procedure:
– Check proper function of luggage compartment lights shown
-arrow-.
3.48 Luggage compartment: removing pro‐

tective film and felt pieces
Procedure:
– Remove protective film and felt pieces carefully and complete‐
ly from luggage compartment.
3.49 Glove box light, interior lighting and

reading light: checking operation
Procedure:
– Open glove box and check that glove box light functions prop‐
erly.
– Use the appropriate switches to activate the following interior
lights and check that the lights function properly:
♦ Interior lights in headliner at front
♦ Interior lights in headliner at rear
Note
Checking the background lighting is NOT part of the inspection.
3.50 Horn: checking operation

Procedure:
– Operate horn and check proper function of treble horn and
bass horn.
Note
Perform this check outdoors, e.g. when driving the vehicle to the
workshop or during a road test.
3. Maintenance 63
Audi A4 2015 ➤
3.51 Passenger airbag: checking key switch

on/off and setting to "on"
Switch for “Airbag ON/OFF” is located in glove box -arrow-.
Procedure:
– Turn switch to “AIRBAG OFF” position.
– Switch ignition on and wait for vehicle to complete initial sys‐
tem check.
– Check that “PASSENGER AIRBAG OFF” display lights up in
instrument cluster.
– Turn switch to “AIRBAG ON” position.
tem check.
– Check that “PASSENGER AIRBAG OFF” disappears.
Note
The amount of time needed for the vehicle system check varies
depending on the model and equipment.
3.52 Owner's literature: checking that all

documents are present
Procedure:
– Check that all parts of owner's literature are present, and pre‐
pare them for handover to customer.
3.53 Service wallet: affixing vehicle data

sticker
The vehicle data sticker can be found in the supplied pack.
Procedure:
– Remove vehicle data sticker from supplied pack.
– Affix vehicle data sticker in service wallet under “Warranty en‐
titlement record”.
Note
Does not apply to vehicles for USA and China.
3.54 Service Schedule: entering Delivery In‐

spection
The field for documenting the Delivery Inspection can be found
on page 2 of the Service Schedule.
Procedure:
– Apply stamp of Audi Workshop.
– Enter date of work carried out.
– Mark relevant field(s).
64 3. Maintenance
Audi A4 2015 ➤
Note
Only for markets not using the Digital Service Schedule.
3.55 Seat belts: checking that retaining rivets

are fitted, and checking locking action of
automatic belt retractor
Procedure:
For all seat belts installed:
– Check that retaining rivets/clips are fitted.
– Check locking action of automatic belt retractors when belt is
unrolled abruptly.
Note
If the seat belt is securing an object (e.g. child seat), do not re‐
lease the seat belt. Only check the locking action when the belt
is buckled; it is not necessary to check the retaining rivet/clip in
this case.
3.56 Vehicle interior: removing protective

covers for seats and carpet
Procedure:
– Remove protective covers for seats and carpet carefully and
completely from vehicle interior.
3.57 Vehicle interior: checking that it is clean

and cleaning if necessary
Procedure:
Check that the following items are clean (clean them if necessa‐
ry):
♦ Front seats
♦ Rear seat bench
♦ Interior trim
♦ Carpets
♦ Floor mats
♦ Windows/windscreen
3.58 Vehicle interior: removing any objects

other than those protecting interior sur‐
faces
Procedure:
– Remove any objects from vehicle other than those which are
protecting interior surfaces.
3. Maintenance 65
Audi A4 2015 ➤
3.59 Vehicle interior and exterior: checking

for and documenting any damage
Procedure:
– Check interior of vehicle for damage and document any dam‐
age found.
– Check exterior of vehicle for damage and document any dam‐
age found.
3.60 Instrument cluster: checking warning

lamps
Reading out the event memory is a repair measure and should
be charged separately.
Procedure:
– Start engine and wait for vehicle to complete initial system
check.
– Check whether warning lamps light up in instrument cluster.
– Switch off engine.
– If relevant warning lamps light up: Read out event memory
⇒ page 18 .
Note
3.61 Warning triangle: checking availability

Procedure:
– Check that warning triangle(s) is/are present.
3.62 First-aid kit: checking and recording ex‐

piry date
The first-aid kit is located behind the storage net (right-side) in the
luggage compartment.
Procedure:
– Take out first-aid kit and check expiry date printed on kit / ex‐
piry date of contents.
– If expiry date has passed: Renew first-aid kit.
3.63 Vehicle keys: checking operation and

recording number of keys given to cus‐
tomer
Procedure:
– Open key ring to check each key individually.
– Start vehicle with each key individually.
– Record number of keys which have been matched and handed
over in Maintenance table.
66 3. Maintenance
Audi A4 2015 ➤
– If a vehicle key has not been matched: Re-match all keys to

vehicle using Guided Function of vehicle diagnostic tester via
online tool GeKo.
– If there is reason to suspect improper use (e.g. missing key):
See current notices from AUDI AG under “Technical informa‐
tion ► Anti-theft protection” on ServiceNet.
Note
♦ Only the key being checked may be inside the vehicle. Place
all other keys out of transmission range.
♦ If the key has not been matched, the engine will turn off after
a few seconds. In addition, the warning lamp for the immobil‐
iser or the display “SAFE” will appear in the instrument cluster,
depending on the vehicle equipment.
3.64 Vehicle key: removing from ignition lock

Only applies to vehicles with ignition lock.
Procedure:
– Remove vehicle key from ignition lock.
3.65 Vehicle key(s), wheel covers and own‐

er's literature: checking availability and
recording number present
Procedure:
– Check whether there are keys for the vehicle and record num‐
ber of keys in maintenance table.
– Check whether there are wheel covers for the vehicle and re‐
cord number of wheel covers in maintenance table.
– Check whether owner's literature is in place and record num‐
ber of copies in maintenance table.
– Wait until shortly before vehicle delivery to renew any missing
components.
3.66 Static event memory: working through

Starting diagnosis via Guided Fault Finding:
– Select Diagnosis mode.
– Perform vehicle identification and follow program up to test
plan.
– Work through test programs for static event memory entries.
Starting diagnosis without Guided Fault Finding:

– Switch to the “Control units” tab, press the “Guided Fault Find‐
ing” button and launch Guided Fault Finding as far as the test
plan.
– Work through test programs for static event memory entries.
3. Maintenance 67
Audi A4 2015 ➤
3.67 Sun visors: checking that they are folded

up and folding up if necessary
Procedure:
– Check that sun visors are folded up, and fold them up if nec‐
essary.
3.68 Luggage compartment cover and sun

blind: checking that they are rolled up
and rolling up if necessary
Procedure:
– If a luggage compartment cover is fitted, check that it is rolled
up (roll it up if necessary).
– Check that sun blinds are folded up (fold them up if necessary).
3.69 Engine oil: draining
Note
♦ Oil should always be changed when engine is warm.

disposal.
♦ Keep components clean.


♦ Used oil collection and extraction unit - V.A.S 6622 A-
Removal steps:
Procedure:
– Place oil drip tray under engine sump.
68 3. Maintenance
Audi A4 2015 ➤
– Unscrew sealing plug -arrow- for sump.

– Drain engine oil from sump.
– Renew seal for sealing plug.
– Tighten sealing plug all the way.
Continue installation in reverse sequence.


♦ Or: torque wrench - VAS 5820- , measuring range 20 to 100
Nm

Oil drain plug on sump 30
Removal steps:
Procedure:
3. Maintenance 69
Audi A4 2015 ➤
– Unscrew oil drain plug of sump -arrow-.

– Renew seal for oil drain plug.
– Screw oil drain plug into sump and tighten to specified torque
(see table of tightening torques for installation ⇒ page 69 ).
3.70 Engine oil: extracting

Procedure:
– Pull oil dipstick/sealing plug out of guide tube.
– Insert extraction probe of oil extraction unit into guide tube.
Use flexible extraction probe with largest possible diameter
and insert without using any significant force. Otherwise the
tip can become diverted on the bottom of the sump and a large
amount of used oil will remain in the engine.
– Extract engine oil completely. Observe operating instructions
for extraction unit.
– Finally, install oil dipstick/sealing plug.
Note

disposal.
70 3. Maintenance
Audi A4 2015 ➤
3.71 Engine oil: renewing oil filter

6-cyl. petrol engine 2.9 TFSI/3.0 TFSI ⇒ page 72

♦ Oil filter tool - 3417-
♦ Hazet strap wrench - 2171-1-

Nm

Oil filter cartridge 20
Requirements:
• Engine oil drained.
Procedure:
– Use Hazet strap wrench - 2171-1- or oil filter tool - 3417- to
slacken oil filter cartridge -arrow- and then remove it.
– Clean sealing surface for oil filter at engine.
– Lubricate rubber seal on new oil filter cartridge with engine oil.
– Fit new oil filter cartridge on engine and tighten to specified
torque (see table of tightening torques for installation
⇒ page 71 ).
3. Maintenance 71
Audi A4 2015 ➤

Nm

Sealing cap 25
Removal steps:
– Remove engine cover panel ⇒ page 7 .
Procedure:
– Loosen sealing cap -arrow- of oil filter using socket (32 mm) .
This causes a valve to open.
– Wait a few minutes to allow engine oil to drain from filter hous‐
ing into crankcase.
– Fully unscrew sealing cap -arrow- and pull it off straight up‐
wards. Make sure that no engine oil drips onto engine.
– Pull oil filter element -3- and O-ring -4- out of sealing cap -5-.
– Pull oil drain connection -6- out fully and check for damage.
– Clean sealing surfaces of sealing cap.
– Lightly lubricate new O-ring -4- with engine oil and insert O-
ring.
– Fit new oil filter element -3- in sealing cap.
– Fit oil drain connection in new oil filter element.
– Screw sealing cap into oil filter housing and tighten it to speci‐
fied torque using socket (32 mm) (see table of tightening
torques for installation ⇒ page 72 ).
3.71.3 6-cyl. petrol engine 2.9 TFSI/3.0 TFSI

72 3. Maintenance
Audi A4 2015 ➤

Nm

Oil filter 25
Removal steps:
Procedure:
– Loosen sealing cap -13- of oil filter using socket (32 mm) . This
causes a valve to open.
ing into crankcase.
– Completely remove sealing cap. Make sure that no engine oil
drips onto engine.
– Pull oil filter element -11- and O-ring -12- out of sealing cap
-13-.
– Clean sealing surfaces of sealing cap -13-.
ring.
– Screw sealing cap -13- into oil filter housing -5- and tighten it
to specified torque using socket (32 mm) (see table of tight‐
ening torques for installation ⇒ page 73 ).

Nm

Sealing cap 25
3. Maintenance 73
Audi A4 2015 ➤
Removal steps:
– Unscrew bolt -2- on coolant expansion tank.
– Unplug electrical connector for coolant shortage indicator
switch - F66- on coolant expansion tank (bottom).
– Move coolant expansion tank to one side with coolant hoses
attached.
Note
In addition to the removal work described, it may also be neces‐

sary to loosen the engine control unit to access the oil filter.
Procedure:
– Loosen sealing cap of oil filter using socket (32 mm) . This
ing into crankcase.
– Completely remove sealing cap -5-. Make sure that no engine
oil drips onto engine.
ring.
– Screw sealing cap -5- into oil filter housing -2- and tighten it to
specified torque using socket (32 mm) (see table of tightening

Sealing cap 35
74 3. Maintenance
Audi A4 2015 ➤
Procedure:
ing into crankcase.
drips onto engine.
– Pull oil filter element -5- and seal -6- out of sealing cap -7-.
– Lightly lubricate new seal -6- with engine oil and fit it.
3.72 Engine oil: filling up

CAUTION
Risk of engine damage if the engine is revved too soon after
changing the oil!
♦ The engine must only run at idling speed as long as the oil
pressure warning lamp in the instrument cluster is on.
♦ Increase the engine speed only after the warning lamp has
gone out.

♦ Oil filler funnel - VAS 6842-
3. Maintenance 75
Audi A4 2015 ➤
Refer to ELSA maintenance table for engine-specific oil capaci‐

ties and oil grades.
Procedure:
– Fill up engine oil using oil filler funnel - VAS 6842- .
– Then check oil level and adjust if necessary ⇒ page 76 .
– For all 4-cylinder 2.0 TFSI petrol engines with oil filler neck on
timing chain cover: Clean sealing surface -arrow- on inside of
oil filler neck with a lint-free cloth before screwing on filler cap.
Note
The quantity of oil specified in the maintenance table refers to the

oil change; it is not identical to the quantity required for the initial
filling.
3.73 Engine oil: checking oil level and cor‐

recting if necessary
CAUTION
Risk of damage to catalytic converter if engine oil level is too
high!
♦ Drain engine oil until level meets specification.
Requirements for all engines except V6 diesel engines:

• Engine oil temperature at least 60 °C
• Wait a few minutes after switching off the engine to allow the
oil to flow back into the sump.
• Vehicle must be level (horizontal).
Requirements for V6 diesel engines:
• The engine must be at operating temperature (90 °C oil tem‐
perature).
• Wait approx. two minutes after switching off the engine to allow
the oil to drain back into the sump.
Checking oil level on MMI ⇒ page 76
3.73.1 Checking oil level on MMI

Procedure:
– If necessary, close bonnet.
– Select »Car«.
structure:
♦ Fluid level
76 3. Maintenance
Audi A4 2015 ➤
– Read off and evaluate oil level on display.
– If necessary, correct oil level:
Fluid level Evaluation/measure

At or just under “max” Optimum oil level.
Significantly under “max” Fill up engine oil to optimum level (close bonnet to refresh oil level display).
Note
♦ The oil level display on the MMI is not refreshed when the
bonnet is open.
♦ A warning lamp in the driver information system indicates that
the level is too low.
3.74 Spark plugs: renewing

Lubricating ignition coils with output stages ⇒ page 85

♦ Spark plug spanner - 3122B-
3. Maintenance 77
Audi A4 2015 ➤
♦ Puller - T 10530-
♦ Torque wrench - VAS 6583- , measuring range 3 to 60 Nm

Spark plugs with M12 thread 20+5
Bolt for ignition coil 8
Nut for earth wire 8
Bolt for fuel line 4
Bolt for crankshaft breather 9
Removal steps:
– Disconnect crankcase breather hose -1-.
– Unplug electrical connectors -1- and -2- and move clear.
78 3. Maintenance
Audi A4 2015 ➤
– Unscrew bolt -2- and move fuel line clear.

– Move hose -4- for activated charcoal filter system and coolant
hose -6- clear.
– Unplug electrical connector -5- from charge pressure sender
- G31- .
– Release catches -arrows- and detach air pipe -3-.
– Press release tabs and disconnect hose -2-.

– Unscrew bolts -arrows- and disconnect crankcase breather
hose -1- towards rear.
Step 1 - removing spark plugs:

– Unscrew nuts for earth wires and move earth wires clear.
– Push ignition coil connector -2- towards ignition coil, release

retainer and detach connector from ignition coil.
– Move connector -2- slightly to one side. Make sure that wiring
is not kinked or damaged.
– Unscrew bolts -1- for ignition coils.
– Insert puller - T10530- into hole -1- of ignition coil and turn
knurled nut -2- clockwise until puller is secured in place.
3. Maintenance 79
Audi A4 2015 ➤
– Carefully pull ignition coils out upwards using puller - T10530- .

– Repeat removal procedure with all other ignition coils.
– Unscrew spark plugs using spark plug socket and extension -
VAS 3122B- .
Step 2 - installing spark plugs:

– Install new spark plugs using spark plug socket and extension
- VAS 3122B- and tighten to specified torque (see table of
– Lubricating ignition coils ⇒ page 85
– Fit all ignition coils loosely into spark plug apertures and align
with connectors of connector rail.
– Press ignition coils onto spark plugs by hand evenly (do NOT
knock in with tools).
– Tighten bolts -1- for ignition coils to specified torque (see table
of tightening torques for installation ⇒ page 78 ).
– Plug in connector -2- on each ignition coil until it engages.
Continue installation in reverse sequence. Note tightening tor‐
ques (see table of tightening torques for installation ⇒ page 78 ).

80 3. Maintenance
Audi A4 2015 ➤
♦ Puller - T10530-


Removal steps:
– Unplug electrical connector -1- for Lambda probe - G39- .
3. Maintenance 81
Audi A4 2015 ➤
– Unscrew nut -2- for earth wire and move earth wire -1- clear.
– Push ignition coil connector towards ignition coil, release re‐
tainer and detach connector from ignition coil in direction of
-arrow-.
– Place electrical connectors slightly to one side. Make sure that
wiring is not kinked or damaged.

VAS 3122B- .

– Tighten bolts -arrows- for ignition coils to specified torque (see
table of tightening torques for installation ⇒ page 81 ).

♦ Spark plug spanner - VAS 6919-
82 3. Maintenance
Audi A4 2015 ➤
♦ Puller - T10530-


Removal steps:
Step 1 - removing spark plugs, cylinder bank (right-side):
– Remove air cleaner housing ⇒ Rep. gr. 24 ; Air cleaner; Re‐
moving and installing air cleaner housing .
– Unplug connectors -1- and -2- for Lambda probe - G39- and
move wiring clear.
– Release and unplug electrical connectors -arrows- from ac‐
tuators for camshaft adjustment.
– Unplug connectors -3- for ignition coils.
– Remove bolts -4- and move earth wire clear.
– Detach wiring duct -2- from ball studs and press to one side.
3. Maintenance 83
Audi A4 2015 ➤
– Unscrew bolt -arrow- for ignition coil.

VAS 6919- .
Step 2 - removing spark plugs, cylinder bank (left-side):

– Take engine control unit - J623- out of bracket and move to
one side ⇒ Rep. gr. 24 ; Engine control unit .
– Release retainer -arrow-, detach wiring duct -1- from ball studs
and press to one side. If necessary, move electrical wiring
harness clear.
– Unplug connectors -2- for ignition coils.
84 3. Maintenance
Audi A4 2015 ➤
– Unscrew bolt -arrow- for ignition coil.

VAS 6919- .

- VAS 6919- and tighten to specified torque (see table of tight‐
ening torques for installation ⇒ page 83 ).
– Tighten bolts for ignition coils to specified torque (see table of
– Plug in connector on each ignition coil until it engages.
3.74.4 Lubricating ignition coils with output

stages
♦ Silicone paste
3. Maintenance 85
Audi A4 2015 ➤
Procedure:
– Grease all around sealing hose -arrow- of ignition coils with
silicone paste. The bead of grease should be 1-2 mm thick.
Note
♦ For the silicone paste to be used, refer to Electronic parts

catalogue (ETKA).
♦ New ignition coils are already lubricated when they are deliv‐
ered; it is not necessary to lubricate them again when instal‐
ling.
CAUTION
Ignition coils can be damaged irreparably if the wrong lubricant
is used.
– Use only the approved silicone paste.
3.75 Coolant level: checking (coolant level

must reach at least top marking on cool‐
ant expansion tank)
WARNING
Coolant expansion tank under pressure - risk of injuries!
♦ Only open coolant expansion tank when engine is cold.
CAUTION
Incorrect coolant additives can cause serious damage to vehi‐
cle components.
♦ The coolant additive G12EVO is not approved for engines
based on EA288 (A4 2.0 TDI).
86 3. Maintenance
Audi A4 2015 ➤
Note
♦ Specification for coolant level is top marking on coolant ex‐

pansion tank.
♦ Coolant additives may only be mixed with distilled water, as
the effectiveness of the coolant and the corrosion protection it
provides are greatly influenced by the quality of the water with
which the coolant is mixed. To ensure an adequate water
quality, the coolant additive should be mixed with distilled wa‐
ter.
♦ Only use approved coolant additives; refer to Electronic parts
catalogue (ETKA).
♦ Coolant additives G12EVO, G13 and G12++ may be mixed
together.
♦ G12EVO, G13 and G12++ may be mixed with coolant addi‐
tives G11, G12 and G12+.
♦ G12 and G11 must NOT be mixed together.
♦ Do not reuse coolant.
♦ Only use water/coolant additive as a lubricant for coolant ho‐
ses.
♦ It is permissible to operate the vehicle if the coolant level is
above the MAX marking on the coolant expansion tank (this is
by technical design). Do NOT extract coolant.
Checking coolant level and anti-freeze: all vehicles except 6-cyl.

diesel engine 3.0 TDI ⇒ page 87
Checking coolant level and anti-freeze: 6-cyl. diesel engine 3.0
TDI ⇒ page 89
Filling up coolant ⇒ page 91
3.75.1 Checking coolant level and anti-freeze:

all vehicles except 6-cyl. diesel engine
3.0 TDI
♦ Refractometer - T10007 A-
♦ Refractometer - VAS 531 005-

Type of service: Coolant level specification:
Delivery Inspection Coolant at least at level of MAX marking.
3. Maintenance 87
Audi A4 2015 ➤

Inspection Coolant at level of MAX marking.
Checking the cooling system for leaks is a repair measure and

Requirements:
• Anti-freeze protection must be guaranteed to -25 °C (in coun‐
tries with an arctic climate to -36 ℃); note specification in
Maintenance table.
• The proportion of coolant additive must not exceed 55 %
(gives anti-freeze protection down to -48 °C); beyond this con‐
centration the frost protection and the cooling efficiency are
reduced again.
• The vehicle must be parked on a level surface.
Step 1 - checking coolant level:
– Check coolant level (according to marking -illustration-) in
coolant expansion tank with engine cold.
– If coolant level is too low: Add required amount (using correct
mixture ratio) ⇒ page 91 .
– If fluid losses are greater than can be reasonably expected:
First use a leak test to determine the cause ⇒ Engine; Rep.
gr. 19 ; Cooling system/coolant; Checking cooling system for
leaks .
Step 2 - checking anti-freeze:

– Use a pipette to place a drop of coolant on glass of refractom‐
eter - T10007 A- . Light-dark border will now be clearly visible
through refractometer.
– Check level of anti-freeze protection using corresponding
scale on refractometer; to do so, read off value on light-dark
border.
– If anti-freeze protection level does not meet specification in
Maintenance table: Perform following measures:
Anti-freeze protection level: Evaluation/measure:

> Specification Depending on deviation from specification, remove a small amount of coolant
and replace it with distilled water. Repeat procedure until coolant mixture meets
correct specification.
< Specification Depending on deviation from specification, remove a small amount of coolant
and replace it with coolant additive. Repeat procedure until coolant mixture
meets correct specification.
– Check coolant additive concentration once more following

road test.
88 3. Maintenance
Audi A4 2015 ➤
Note
♦ The refractometer - T10007 A- must be used to determine the

current anti-freeze concentration.
♦ Scale -1- on the refractometer applies to coolant additives
G11, G12, G12+ and G12++.
♦ Scale -2- refers only to coolant additive G13.
♦ If more than one type of coolant additive has been used: Al‐
ways use the scale for G13 to determine the anti-freeze pro‐
tection.
♦ The temperature indicated on the refractometer - T10007 A-
corresponds to the temperature at which the first ice crystals
can form in the coolant.
♦ It is essential that anti-freeze be used in the cooling system all
year round. In the correct concentration, coolant additives pre‐
vent scaling and frost and corrosion damage, and also raise
the boiling point of the coolant.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads in countries with tropical climates.

6-cyl. diesel engine 3.0 TDI

Delivery Inspection Top edge of floater flush with opening in coolant expansion tank
Inspection Top edge of floater between MIN marking and opening in coolant expansion tank
Checking the cooling system for leaks is a repair measure and

Requirements:
Maintenance table.
3. Maintenance 89
Audi A4 2015 ➤

reduced again.
leaks .

border.


road test.
90 3. Maintenance
Audi A4 2015 ➤
Note

G11, G12, G12+ and G12++.
tection.
3.75.3 Filling cooling system

Frost protection to: Coolant additive: Water:
-25 °C approx. 40 % approx. 60 %
-36 °C approx. 50 % approx. 50 %
Procedure:
– Add required amount (using mixture ratio according to anti-
freeze protection specification in Maintenance table). Use the
table as a reference for the coolant mixture ratio.
Note
Small quantities of coolant can simply be topped up. Use the

cooling system charge unit - VAS 6096- to add larger quantities
of coolant.
3.76 Air cleaner: renewing filter element and

cleaning housing
Note
♦ Use only silicone-free lubricants when installing intake hoses.

♦ Secure all hose connections with hose clips (same as original
equipment); see Electronic parts catalogue (ETKA).
3. Maintenance 91
Audi A4 2015 ➤
Air cleaner housing: cleaning ⇒ page 98

4-cyl. petrol engine 1.4 TFSI/2.0 TFSI (version 1) ⇒ page 92
4-cyl. petrol engine 2.0 TFSI (version 2) ⇒ page 93

(version 1)
♦ Torque screwdriver - V.A.G 1624- , measuring range 1 to 5
Nm
Nm
Component/fastener: [Nm]
Securing bolts for air cleaner (top section) 3.5
Step 1 - removing air filter element:

– Release hose clip and detach air pipe.
– Remove securing bolts and detach air cleaner (top section)
-1-.
– Turn filter element in anti-clockwise direction -arrow A- and

remove it.
Step 2 - installing air filter element:

– Check for dirt in housing and water drains and clean if neces‐
sary ⇒ page 98 .
92 3. Maintenance
Audi A4 2015 ➤
– Fit new filter element in air cleaner (top section) and turn it in
clockwise direction -arrow B- until it engages.
– Place top section of air cleaner onto bottom section of air
cleaner without applying any significant force. Ensure that top
and bottom sections of air cleaner are flush.
– Fit securing bolts in air cleaner (top section) and tighten to
specified torque (see table of tightening torques for installation
⇒ page 92 ).
– Attach air pipe to air cleaner (top section) and fit hose clip.
Note
There is more than one version of the air cleaner for the 4-cylinder
2.0 TFSI petrol engine ⇒ page 93 .
3.76.2 4-cyl. petrol engine 2.0 TFSI (version 2)

Nm
Nm

– Unplug electrical connector -2- for air mass meter - G70- .
-1-.
3. Maintenance 93
Audi A4 2015 ➤
– Press release tab, turn filter element in anti-clockwise direction

-arrow A- and remove it.

sary ⇒ page 98 .
⇒ page 93 ).
Note
2.0 TFSI petrol engine ⇒ page 92 .

Nm
Securing bolts for air filter element 1.5
Removal steps:
– Remove lock carrier cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front) .
94 3. Maintenance
Audi A4 2015 ➤

– Remove bolts -arrows- and detach air duct -2-.
– Release hose clip -2- and detach air pipe.

– Remove securing bolts and detach air cleaner (top section).
– Remove filter element from air cleaner (top section) by un‐

screwing both bolts -arrows-.

– Check for dirt in housing and water drains -arrow- and clean if
necessary ⇒ page 98 .
– Insert new air filter element centrally in mounting in air cleaner

(top section). Tab of air filter element -1- must rest against tab
of air cleaner (top section) -2-.
⇒ page 94 ).

Nm
3. Maintenance 95
Audi A4 2015 ➤

Nm

– Release hose clips -arrows- and detach air pipe -1-.

– Move fuel hoses -3- clear and push to one side.
-1-.


sary ⇒ page 98 .
96 3. Maintenance
Audi A4 2015 ➤
⇒ page 96 ).

Nm
Nm


-1-.
3. Maintenance 97
Audi A4 2015 ➤


sary ⇒ page 98 .
⇒ page 97 ).
3.76.6 Cleaning air cleaner housing

Procedure:
– Remove any loose dirt or leaves out of air cleaner housing (top
and bottom sections).
– Check whether water drain hose in air cleaner (bottom section)
is dirty or blocked and clean if necessary.
Note
♦ When cleaning air cleaner housing with compressed air: Cov‐

er air mass meter with a clean cloth.
♦ On vehicles for cold countries, the snow screen in the intake
section must also be cleaned; see specification in ELSA Main‐
tenance table.
3.77 Dust and pollen filter: renewing

The dust and pollen filter is fitted under the glove box.
Removal steps:
– On vehicles with special equipment used by driving schools:
Remove pedal cluster if necessary; see installation instruc‐
tions for equipment for driving schools.
Step 1 - removing filter element:
– Cover footwell beneath dust and pollen filter with paper.
98 3. Maintenance
Audi A4 2015 ➤
– Remove screw fasteners -A- and detach insulating mat -B-.
– Release retaining tabs -A-, swivel cover -B- for aperture down
and detach.
– Pull filter element -E- out of aperture in direction of -arrow-.
Step 2 - installing filter element:

– Clean aperture with a vacuum cleaner before fitting new filter
element.
– Fit new filter element -E- correctly: arrow -D- points towards
fresh air blower.
Note
If the retainers -A- for the cover -B- are broken off on the heating
and air conditioning unit or on the service cover, the service cover
can also be secured to the heating and air conditioning unit using
four self-tapping screws -C- (e.g. 3.5 x 16 mm or 4.9 x 16 mm;
see Electronic parts catalogue ETKA). To do so, drill holes (4.5
mm diameter) in the cover -B- at attaching points marked -C-.
3. Maintenance 99
Audi A4 2015 ➤
3.78 Water separator (fuel filter): draining

WARNING
Fuel is hot and under pressure - risk of injuries!
♦ Put on protective gloves.
♦ Put on safety goggles.
♦ Loosen draining valve carefully.

♦ Diesel extractor - VAS 5226-

Nm
Fastener Tightening torque
[Nm]
Bolts for cover of filter housing 4
The water separator filter is located in the engine compartment.
100 3. Maintenance
Audi A4 2015 ➤
Procedure:
– Attach hose to water drain plug -5- on cover of filter housing.
Place opposite end of hose in appropriate container.
– Start engine. System pressure is necessary for draining fuel
filter.
– Open water drain plug slowly until water begins to drain.
– When diesel fuel begins to drain: Screw water drain plug back
in.
– Turn off engine and disconnect hose from water drain plug.
– Tighten water drain plug -5- to specified torque (see table of
3.79 Fuel filter: renewing

WARNING
♦ Allow connections of fuel lines to cool down.
♦ Place cloths around connections and loosen them carefully.

♦ Hose clip pliers - VAS 6362-

Nm
♦ Reservoir
3. Maintenance 101
Audi A4 2015 ➤

[Nm]
Nuts for bracket 8
The fuel filter is located on the underbody.

Removal steps:
– Remove underbody trim (right-side) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody trim; Removing and instal‐
ling underbody trim .
Step 1 - removing fuel filter:
– Observe the safety precautions when working on the fuel sys‐
tem ⇒ Fuel supply system, diesel engines; Rep. gr. 00 ; Safety
precautions; Safety precautions when working on the fuel sys‐
tem .
– Unscrew nut -1-.
– Swivel bracket -2- downwards, disengage it from mounting
points -arrows- and detach it.
– Place drip tray under fuel filter cartridge.
– Using hose clip pliers, disconnect fuel supply hoses -1- and
-3- at T-piece and leading to aluminium pipe, and remove fuel
filter -2- along with fuel supply hoses.
Step 2 - installing fuel filter:

Flow direction for fuel filter cartridge is indicated by arrows on filter
housing.
– Then bleed fuel system ⇒ Engine; Rep. gr. 23 ; Injection sys‐
tem; Filling/bleeding fuel system .
Note
♦ Do not loosen spring-type clips on fuel filter.

♦ Renew spring-type clips on T-piece and leading to aluminium
pipe.
3.80 Water separator filter: renewing

102 3. Maintenance
Audi A4 2015 ➤
♦ Diesel extractor - VAS 5226-

Nm
[Nm]
Bolts for cover of filter housing 4
The water separator filter is located in the engine compartment.

Step 1 - removing:
– Fit hose of diesel extractor - VAS 5226- together with suitable
adapter onto water drain plug -11-.
– Open water drain plug -11-.
– Operate diesel extractor - VAS 5226- until no more diesel
emerges.
– Hand-tighten water drain plug -11-.
– Unscrew bolts -12- and lift cover of filter housing to one side
(fuel hoses remain connected).
– Remove filter element -5- and seals from filter housing -2-.
– Use diesel extractor - VAS 5226- to draw off remaining diesel
fuel.
– Clean filter housing -2-.
Step 2 - installing:
– Insert new filter element in filter housing so that it is centred.
– Fit new seals.
– Fit and align cover of filter housing.
– Fit bolts for cover of filter housing and tighten to specified tor‐
que (see table of tightening torques for installation
⇒ page 103 ).
– Finally, bleed fuel system ⇒ Rep. gr. 23 ; Injection system;
Filling/bleeding fuel system .
3. Maintenance 103
Audi A4 2015 ➤
3.81 Fuel tank: adding fuel additive

♦ Or: multi-purpose additive for petrol fuels - G 001 780 M3-

China, Middle East Russia India
VW 507 53 B: Applies to all petrol VW 507 53 B: Applies to all petrol VW 507 53 B: Applies to all petrol
engines engines engines
VW 507 53 A: Applies to all petrol VW 507 53 A: Applies to all petrol
engines except g-tron and E85 flex‐ engines except g-tron and E85 flex‐
ible fuel ible fuel
Multi-purpose additive for petrol Multi-purpose additive for petrol Multi-purpose additive for petrol
fuels - G 001 780 M3- fuels - G 001 780 M3- fuels - G 001 780 M3-
This maintenance item only applies to certain countries: Note

specification in Maintenance table.
Procedure:
– Follow measuring guidelines on fuel additive container and
add fuel additive to fuel tank according to current fuel tank
level.
Note
♦ Use only fuel additives that correspond to the standard VW

507 53 A or VW 507 53 B.
♦ After adding fuel additive, it is very important to tell the cus‐
tomer to fill up the fuel tank.
3.82 Reducing agent (AdBlue®): filling up

tank completely
WARNING
Risk of injury due to contact with reducing agent!
♦ Do not kink lines of filling device/refuelling system.
♦ If you come into contact with this liquid: Rinse it off immedi‐
ately with plenty of water and contact a medical professional.
CAUTION
Risk of damage to trim and body components due to contact
with reducing agent!
♦ Clean the affected areas with clean water and a cotton cloth.
♦ Remove any crystallised reducing agent using warm water
and a sponge.
104 3. Maintenance
Audi A4 2015 ➤
Note
♦ The reducing agent is statutory for vehicles with SCR system.

♦ The reducing agent is used for the after-treatment of exhaust
gases of diesel-engined vehicles, i.e. to reduce the level of
nitrogen oxides.
♦ The reducing agent is not a diesel additive and must not be
filled into the diesel fuel tank.
♦ Do not add any additives to the reducing agent, and do not
dilute it with water.
♦ Only use the reducing agent as supplied in its original con‐
tainer.
♦ In addition, please observe the reducing agent manufacturer's
notices on usage and storage.
♦ Both filling device for AdBlue - VAS 6542- and AdBlue refuel‐
ling system - VAS 6960- can be used to fill up the reducing
agent.
Filling up reducing agent (AdBlue®) using filling device for AdBlue

- VAS 6542- ⇒ page 105
Filling up reducing agent (AdBlue®) using AdBlue refuelling sys‐
tem - VAS 6960- ⇒ page 108
3.82.1 Filling up reducing agent (AdBlue®) us‐

ing filling device for AdBlue - VAS 6542-
♦ Filling device for AdBlue - VAS 6542-
♦ Engine and gearbox jack - VAS 6931-
3. Maintenance 105
Audi A4 2015 ➤
♦ Mounting plate - V.A.G 1383A/1-
Components of filling device -VAS 6542-
1 - Breather connection for re‐

ducing agent container
2 - Union nut for reducing
agent container
3 - Cut-off valve for breather
line
4 - Quick-release coupling on
breather line
5 - Filler line
6 - Cut-off valve for filler line
7 - Union nut for tank filler neck
8 - Breather line
106 3. Maintenance
Audi A4 2015 ➤
Procedure:
– Open tank flap and unscrew cap of reducing agent tank.
– Clean filler neck of tank for reducing agent with a lint-free cot‐
ton cloth soaked with water.
– Close cut-off valves of breather and filler lines of filling device
for AdBlue - VAS 6542- .
– Apply filling device for AdBlue - VAS 6542- to reducing agent
container (see Electronic parts catalogue, ETKA) and screw it
on as far as stop.
– Position reducing agent container on engine and gearbox jack
- VAS 6931- with mounting plate - V.A.G 1383A/1- . The dif‐
ference in height of the reducing agent container and the filler
neck of the tank for reducing agent must be between
60 - 80 cm -dimension A-.
3. Maintenance 107
Audi A4 2015 ➤
– Position filling device for AdBlue - VAS 6542- on filler neck on

vehicle and screw it on as far as stop.
– Open cut-off valve for breather line.
– Open cut-off valve for filler line and fill reducing agent tank of
vehicle completely. Tank is completely full when container
contracts and bleeder line fills with liquid.
– Close cut-off valve for filler line.
– Close cut-off valve for breather line.
– Disconnect quick-release coupling on breather line and let any
excess liquid flow into a suitable container.
– Unscrew filling device for AdBlue - VAS 6542- from tank filler
neck.
– Clean filler neck of reducing agent tank and filler cap with a
lint-free cotton cloth soaked with water.
– Screw filler cap onto reducing agent tank.
– Take container off mounting plate and put it on the floor.
– Open cut-off valve on filler line and let remaining liquid drain
back into container.
– Unscrew filling device for AdBlue - VAS 6542- from container.
Note
It is possible to overfill the reducing agent tank when using a filling

device which operates using gravity. When filling the tank using
VAS 6542 (or other filling device which operates in the same way),
disconnect it from the vehicle immediately once filling is comple‐
ted.

ing AdBlue refuelling system - VAS
6960-
♦ AdBlue refuelling system - VAS 6960-
Procedure:
– Open tank flap and unscrew filler cap for reducing agent tank.
– Insert nozzle of AdBlue refuelling system - VAS 6960- into filler
neck of reducing agent tank.
108 3. Maintenance
Audi A4 2015 ➤
– Operate nozzle to fill up reducing agent completely.

– Remove nozzle from filler neck of reducing agent tank.
Note
♦ Observe operating instructions for AdBlue refuelling system -

VAS 6960- .
♦ Nozzle of AdBlue refuelling system - VAS 6960- switches off
automatically when maximum fill level is reached.
3.83 Natural gas system: checking for dam‐

age and leaks
DANGER
Risk of explosion due to escaped natural gas!
♦ Keep any ignition sources away from the vicinity of the nat‐
ural gas system.
♦ If you suspect a leak, follow the steps described immediately
⇒ page 117 .
♦ Service and repairs on the natural gas system may only be
performed by specially trained staff ⇒ Natural gas engines
- General information; Rep. gr. 00 ; Safety briefing/employ‐
ee qualification .
WARNING
Risk of suffocation due to escaped natural gas!
♦ If you suspect a leak, follow the steps described immediately
⇒ page 117 .
♦ Service and repairs on the natural gas system may only be
performed by specially trained staff

♦ Gas leak detector - VAS 6227-
3. Maintenance 109
Audi A4 2015 ➤
♦ Hand wheel - T50026-
♦ Socket wrench -T40333-

♦ Explosion-proof LED battery lamp - VAS 6901-
♦ Adapters - T40173/2-
110 3. Maintenance
Audi A4 2015 ➤
♦ Gearbox support - T40173-
♦ Support elements - T40173/3-
♦ Bracket - T10351-
♦ Endoscope - VAS 6785A- , VAS 6748A or VAS 6748B (probe

head diameter max. 4 mm)
♦ Extension - T40333-
♦ Hand mirror
3. Maintenance 111
Audi A4 2015 ➤
Note
♦ Work on the natural gas system itself may only be carried out
by specially trained staff at a work station for natural gas ve‐
hicles!
♦ When checking the natural gas system, also observe any legal
requirements valid in your market regarding the qualification
of employees, documentation or additional checks.
♦ When working on the natural gas tanks, take care not to dam‐
age the surface of the tanks. If necessary, protect the tank
surface using suitable workshop materials.
♦ For general notes on working on a natural gas system, refer
to the Workshop Manual under Power unit -> Natural gas en‐
gines - General information.
Natural gas can escape from pressurised natural gas tanks.

Natural gas is highly flammable and forms flammable air-vapour
mixtures.
Natural gas is NOT odourless: it has been mixed with strong-
smelling additives.
Natural gas can cause drowsiness and respiratory damage if in‐
haled. In high concentrations there is a danger of suffocation due
to lack of oxygen.
Requirements:
• All areas of natural gas system that require testing must be
accessible.
• Exhaust emissions warning lamp must not light up in dash
panel insert.
• Natural gas tank must be at least 80% full.
• Ensure that the work area is free of draughts when performing
the leak test with the gas leak detector. A draught over 1.8 km/
h (slow gust of air) will cause incorrect measurement results.
Removal steps:
– Remove engine cover panel.
– Remove underbody trim for natural gas tanks ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody trim .
– Remove heat shields for natural gas tanks ⇒ General body
repairs, exterior; Rep. gr. 66 ; Heat shields .
Step 1 - checking for damage:
– Check components of natural gas system in engine compart‐
ment for damage.
– In addition, check that rubber plug of pressure relief valve
-arrow- is fitted on gas pressure regulator -A20-12001-.
112 3. Maintenance
Audi A4 2015 ➤
– Check condition of natural gas filler connection -9- and clean

it if necessary.
– Raise vehicle.
3. Maintenance 113
Audi A4 2015 ➤
– Detach underbody trim (centre left) -A66-11781 no. 4- so that

natural gas line is visible underneath -A20-11859 no. 11- ⇒
General body repairs, exterior; Rep. gr. 66 ; Underbody trim .
– Check natural gas line for damage.
Checking natural gas tanks:
– Remove tank 1 -A20-11859 no. 8- ⇒ Fuel supply system - g-
tron; Rep. gr. 20 ; Fuel tanks; Removing and installing fuel
tanks .
– Check tank 1 all over for damage ⇒ Natural gas engines -
General information; Rep. gr. 20 ; Fuel tanks .
– Read factory label of natural gas tank to check expiry date.
– If expiry date is past: Renew natural gas tank ⇒ Rep. gr. 20 ;
Fuel tanks; Removing and installing natural gas fuel tanks .
– Check tanks 2, 3, 4 -A20-11859 nos. 4, 6, 7- for damage. Use
endoscope - VAS 6785A- to check upper area of tank and
hand mirror to check more accessible areas.
– In the event of irregularities, assess them with the help of the
damage examples given in ⇒ Natural gas engines - General
information; Rep. gr. 20 ; Fuel tanks .
– Read factory label of natural gas tank to check expiry date.
– If expiry date is past: Renew natural gas tank ⇒ Rep. gr. 20 ;
Fuel tanks; Removing and installing natural gas fuel tanks .
– Damaged tanks or components must be renewed and then
checked as part of a gas system inspection.
Note
♦ If you are unsure of the damage situation in relation to the

damage catalogue when performing the test procedure speci‐
fied above, remove the corresponding tanks and perform suf‐
ficient tests.
♦ A gas system inspection according to the regulations in the
relevant country must be performed after a tank has been re‐
moved and installed.
Step 2 - setting gas system to operating status:

The system must be at least 80 % filled with natural gas in order
to check for leaks.
114 3. Maintenance
Audi A4 2015 ➤
– Using hand wheel - T50026- and extension - T40333- , ensure

that all four mechanical shut-off valves N361, N362, N363 and
N429 are fully open.
– Start engine to set pressure levels in gas system to operating
status.
– Check whether green CNG light appears in the instrument
cluster to ensure that vehicle has been started in natural gas
mode.
– Switch engine off again.
Step 3 - checking for leaks:

When performing the leak test with the gas leak detector - VAS
6227- :
♦ Check for leaks all around all threaded connections of the gas
system several times (from each 90° angle) and at all joints
-arrows-.
♦ The tester head must be no further than 5 mm from the area/
component being checked. Measurements are not possible at
distances greater than 5 mm.
♦ Gas leak detector can only detect whether there is natural gas
in the ambient air.
♦ The results of the test using the gas leak detector are only
satisfactory if the green LED for »O.K.« lights up.
♦ If a yellow or red LED lights up, a leak detector spray must be
used to verify definitively whether gas is actually escaping
from the vehicle system. When using the leak detector spray,
bubbles must not emerge from the sprayed area during a test
period of three minutes.
– Check natural gas filler connection for leaks in area of opening

-arrow- with filler cap removed.
3. Maintenance 115
Audi A4 2015 ➤
– Check for leaks at connecting piece adjoining non-return valve

-arrow- and at all threaded connections -arrows- to gas lines.
– Check for leaks at threaded connections -arrow- for fuel tank

shut-off valve 1 - N361- , fuel tank shut-off valve 2 - N362- ,
fuel tank shut-off valve 3 - N363- and fuel tank shut-off valve
4 - N429- on respective natural gas tank.
– At each fuel tank shut-off valve, check for leaks at threaded

connections for mechanical shut-off valve -arrow- and for ther‐
mal fuse -arrow-, as well as at threaded connections for elec‐
tromagnetic valve and for natural gas line -arrows-.
– Check for leaks at gas pressure regulator (in left of engine

compartment at wheel housing) in area of high-pressure pipe
and low-pressure pipe connections -arrows-, at threaded con‐
nection of high-pressure valve for gas mode - N372- -arrow-
and at threaded connection and electrical connector for sensor
module -GX23- -arrows-.
116 3. Maintenance
Audi A4 2015 ➤
– Check for leaks at gas rail in area of connection for flexible

low-pressure pipe -3-, at threaded connection and electrical
connector for temperature and pressure sensor -GX21- -2-
and at all four gas injection valves N366 to N369 -1-.
– Any leaking components must be renewed and then checked
as part of a gas system inspection.
Note
♦ Maintain order and cleanliness when working on the natural

gas system.
♦ Further information on the natural gas system and fuel tanks
can be found in ⇒ Natural gas engines - General information;
Rep. gr. 20 ; Fuel tanks .
3.83.1 If you suspect a leak, take the following

steps immediately
♦ Hand wheel - T50026-
♦ Extension -T40333-
3. Maintenance 117
Audi A4 2015 ➤
Procedure:
– Close all four fuel tank shut-off valves -1- and -2- manually
using extension -T40333- and hand wheel - T50026- .
– Ventilate the work area.
– Immediately inform staff with special gas system training to
determine how to proceed.
Note
If natural gas continues to escape (noticeable odour) after the fuel

tank shut-off valves have been closed, the vehicle must be moved
outdoors and marked accordingly.
3.84 Service display for checking natural gas

system: resetting
Note
♦ Applies for vehicles with natural gas drive from model year
2019 onwards
♦ The test program Predelivery inspection total may also
be used for the Delivery Inspection.
♦ Check natural gas system before resetting specific interval
display for vehicles with natural gas system (observe country-
specific legal requirements for checking gas systems).
Procedure:
v and press Apply .

– “ ”Select “17 - Service display for checking CNG system: Re‐
set”.
118 3. Maintenance
Audi A4 2015 ➤
3.85 Filler connection for natural gas: check‐

ing condition and cleaning if necessary
Procedure:
– Open tank flap and check condition of cap -1-.
– Remove cap in direction of -arrow-.
– Ensure that seal -2- is present and check its condition.
– If damage is found: Renew seal.
– Check filler connection for natural gas on outside and inside
for dirt and damage.
– If filler connection is dirty: clean with compressed air and/or a
dry cloth. This will not damage filler connection.
3.86 Vehicle doors: removing edge protec‐

tion
Procedure:
– Carefully remove edge protection from all vehicle doors.
3.87 Vehicle exterior: checking unprotected

areas for dirt, and cleaning if necessary
Procedure:
– Check unprotected areas of vehicle exterior not covered by
car cover or protective transport film for dirt/soiling.
– Clean any dirty areas.
3.88 Vehicle exterior: removing protective

film
Procedure:
– Remove protective film carefully and completely.
3.89 Vehicle cover: checking position and

correcting if necessary
Procedure:
– Check, and if necessary, correct position of vehicle cover on
vehicle body.
– Check, and if necessary, correct position of protective trans‐
port film.
3.90 Vehicle cover: removing according to

manufacturer's instructions
Procedure:
– Vehicle cover: Remove according to manufacturer's instruc‐
tions.
3. Maintenance 119
Audi A4 2015 ➤
3.91 Paintwork, trims, side windows and wip‐

er blades: checking cleanliness
Procedure:
– Check that exterior paintwork, trims, side windows and wiper
blades are clean.
– Clean any dirty components.
3.92 Body: checking vehicle paintwork for

damage and corrosion from below and
with bonnet, rear lid and doors open
Procedure:
– Open all vehicle doors, bonnet and rear lid.
– Check vehicle paintwork on inside and outside of body for
damage and corrosion.
– Rectify defects of any kind (repair measure).
3.93 Vehicles parked outdoors: locking

Procedure:
– Use vehicle key to lock vehicle if it is parked outdoors.
3.94 Road test

Procedure:
– The following points must be checked during the road test:
♦ Engine: performance, misfiring, idling speed, acceleration,
starting behaviour (engine cold and warm), engine noise
♦ Clutch: pulling away, pedal pressure, odours, noise due to
load change
♦ Manual gearbox: ease of operation, gear lever position, gear‐
box noise
♦ Automatic gearbox: selector lever position, shift lock / ignition
key lock, gearbox noise, kickdown, shift behaviour, instrument
cluster display
♦ Brake pedal and handbrake: operation, travel and effective‐
ness, pulling to one side, response (delayed braking), judder‐
ing, squeal
♦ ABS function: pulsing must be felt at brake pedal when per‐
forming ABS-controlled braking.
♦ Steering: operation, steering free play, steering wheel central‐
ised when wheels are in straight-ahead position, moving off
line when travelling straight
♦ Imbalance: wheels, drive shafts
♦ Wheel bearings: noises
♦ Roof insert: unusual noise during operation
♦ Horn: checking
Note
To what extent all of these can be checked depends on vehicle

equipment and local conditions (urban/country).
120 3. Maintenance
Audi A4 2015 ➤
3.95 Stock vehicles: observing measures

specified in Maintenance table for stock
vehicles (see “Before handing vehicle
over to customer”)
This maintenance item only applies to stock vehicles.
Procedure:
– Before handing vehicle over to customer: Check whether the
following three measures for stock vehicles (as specified in the
Maintenance table) are due, and carry them out as necessary:
♦ For vehicles older than 12 months (from date of manufacture):
Renew brake fluid ⇒ page 29 .
♦ For vehicles with defective battery: Renew battery ⇒ Rep. gr.
27 ; Battery; Removing and installing battery .
♦ Check brake discs for surface rust; if necessary, operate
brakes to remove rust according to manufacturer's instruc‐
tions.
– Record measures performed in maintenance table for stock
vehicles.
3.96 Accessories: installing

Procedure:
– Place any accessories included with the vehicle in the vehicle
tool kit.
Note
♦ The available accessories may vary according to model,

equipment and market.
♦ Depending on the vehicle model, the accessories may be
found in the luggage compartment, glove box or supplied
pack.
3.97 Checklist "Documentation of cleaning

and care routine": checking that list is
present
Procedure:
– Check that checklist “Documentation of cleaning and care rou‐
tine” is in glove box or front passenger footwell. This checklist
is only present in vehicles which remained with the importer or
manufacturer longer than 14 days without being transported
further; it documents all cleaning and care work carried out
there.
– If missing, place checklist “Documentation of cleaning and
care routine” in glove box.
3.98 “Stock vehicle maintenance” checklist:

signing and placing in vehicle wallet
Procedure:
– Sign “Stock vehicle maintenance” checklist and place it in ve‐
hicle wallet.
3. Maintenance 121
Audi A4 2015 ➤
3.99 Cleaning and care: checking that re‐

quired measures have been carried out
on time
Procedure:
– Check that all cleaning and care measures due previously
were carried out on time.
– Carry out and document any cleaning and care which is due.
3.100 Stock vehicle care management: decid‐

ing and recording date of next check
Procedure:
– Decide date of next check with person in charge of stock ve‐
hicle care management.
– Record chosen date in maintenance table.
3.101 Display instruments: setting time and

date
Procedure:
– Change settings of display instruments: Refer to Operating
Manual for radio/sound system/MMI system.
3.102 Manual gearbox/automatic gearbox: se‐

lecting 1st gear/park
Procedure:
Vehicles with manual gearbox: Select 1st gear.
Vehicles with automatic gearbox: Select park position.
3.103 Dual clutch gearbox (S tronic): changing

ATF
Procedure:
– Change ATF according to instructions in Workshop Manual ⇒
7-speed dual clutch gearbox 0CJ, 0CK, 0CL, 0DN; Rep. gr.
34 ; ATF; Draining and filling ATF .
3.104 Interior mirror: calibrating compass

Procedure:
– Calibrate compass according to Workshop Manual ⇒ General
body repairs, interior; Rep. gr. 68 ; Interior mirror; Calibrating
digital compass .
3.105 Instrument cluster: resetting driver infor‐

mation system
Procedure:
– Reset single journey memory and total journey memory of
driver information system; refer to vehicle Owner's Manual.
3.106 Poly V-belt for ancillaries: renewing

Procedure:
– Renew poly V-belt for ancillaries according to specifications in
Workshop Manual ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve
122 3. Maintenance
Audi A4 2015 ➤
common rail (EA 288 Gen. I); Rep. gr. 13 ; Cylinder block
(pulley end); Removing and installing poly V-belt .
3.107 Toothed belt for coolant pump drive:

checking
Checking condition of toothed belt - 1.4 TFSI engines:
– Remove toothed belt cover ⇒ 4-cylinder direct injection engine

(1.4 ltr. 4-valve TFSI EA211); Rep. gr. 19 ; Coolant pump/
thermostat assembly; Removing and installing coolant pump .
– Turn bolt securing pulley to turn crankshaft in direction of nor‐
mal engine rotation; check entire length of toothed belt for the
following:
♦ Cracks, cross-sectional fractures, tears (on toothed belt cover
side) -arrow-
♦ Wear along edges
♦ Fraying of cord strands
♦ Tears (on toothed side) -arrow-
♦ Layer separation (toothed belt body, cord strands)
♦ Surface cracks (synthetic coating)
♦ Traces of oil and grease
Note
It is essential to renew the toothed belt if faults are found. This will
prevent failures and malfunctions. Renewing the toothed belt is a
repair measure.
3.108 Toothed belt for camshaft drive: renew‐

ing
Procedure:
– Renew toothed belt for camshaft drive according to specifica‐
tions in Workshop Manual ⇒ ; Rep. gr. 15 ; Toothed belt drive;
Removing and installing toothed belt .
3.109 Toothed belt for camshaft drive and ten‐

sioning roller: renewing
Procedure:
– Renew tensioning roller according to Workshop Manual ⇒ ;
Rep. gr. 15 ; Toothed belt drive; Exploded view - toothed belt .
3. Maintenance 123
Audi A4 2015 ➤
4 Exhaust emissions test
Note
♦ Please observe the statutory regulations applicable to your

country.
♦ The exhaust emissions test described below conforms to the
statutory regulations applicable in Germany.
Petrol engines: performing exhaust emissions test ⇒ page 124

Diesel engines: performing exhaust emissions test ⇒ page 131
4.1 Petrol engines: performing exhaust

emissions test
Note
♦ The following description refers to vehicles equipped with on-

board diagnosis (OBD) with a closed-loop catalytic converter.
♦ The OBD monitors all components and (sub)systems which
affect the exhaust gas quality.

♦ Emissions test station - VAS 6300-
♦ Adapter wire, OBD communication - VAS 5052/16-1-
Note
♦ In order for the exhaust emissions test to be carried out, all

components of the emissions test station - VAS 6300- must
be properly plugged in and connected to one another as speci‐
fied in the operating instructions.
♦ All the required steps are displayed on the emissions test sta‐
tion - VAS 6300- .
Test requirements
• All test requirements and data for the exhaust emissions test
are stated on the exhaust emissions test data sheet for the
required engine.
• If the specifications for the exhaust emissions test will be
scanned in using a bar code, the data sheet must be available
as a printout.
124 4. Exhaust emissions test

Audi A4 2015 ➤
• Automatic gearbox: selector lever in position “P” or “N”

• Manual gearbox: gear lever in neutral
• Handbrake applied
– Follow instructions shown on display.
Start screen
– Select “Emissions test” button -arrow-.
An overview of exhaust emissions test types will appear.
– Select “Emissions test, petrol” -arrow-.

A display for the warm-up period will be shown.
– Continue exhaust emissions test according to the instructions

on the display.
– When the options for the exhaust emissions test specifications

are shown, select the option required -arrow-:
♦ Either “Standard specifications” (for an initial exhaust emis‐
sions test)
♦ Or “Last vehicle” (to repeat a previous exhaust emissions test)
– Confirm Next -item 1- on display.
4. Exhaust emissions test 125

Audi A4 2015 ➤
Entering vehicle data

The input menu for vehicle data will be shown.
– Enter the following data from the registration document (part
1):
♦ -1- Vehicle manufacturer, e.g. Audi
♦ -2- Vehicle model, e.g. A6 / 4G
♦ -3- Code for 14.1, e.g. 0572
♦ -4- Code for 2.1, e.g. 0588
♦ -5- Code for 2.2, e.g. 846
♦ -6- Engine code: e.g. CHVA
♦ -7- Number plate: e.g. IN-MV 1234
♦ -8- Vehicle identification number, e.g.
WAUZZZ4GZAN001234
– Enter mileage (km), e.g. 33350, at -item 9-.
Note
♦ Additional functions can be selected using the Go to button.

♦ The Go to button can be used to cancel the test.
– Select “With OBD” -arrow-.

Audi A4 2015 ➤
Entering exhaust emissions test specifications
Note
♦ The specifications must be entered manually if they are not

available as a bar code.
♦ Refer to ⇒ Data sheets for exhaust emissions test (for required
engine) for all test requirements and data for the exhaust
emissions test.
Entering exhaust emissions test specifications manually

– Follow instructions on display to enter data manually.
– Enter data listed on emissions test data sheet under “Test val‐
ues for exhaust emissions test” on display in following order:
1- Test engine speed (idling speed)
2- Warm-up period of catalytic converter
3- Engine temperature
4- Increased idling speed
5- CO content at increased idling speed
6- Lambda at increased idling speed
7- Idling speed
8- Select control probe type: either »two-state probe« or
»broad-band probe« -item 1-.
9- Lambda probe value
– Once you have entered all data correctly, confirm your entry
with Next button -arrow-.
Entering exhaust emissions test specifications with a bar code

– If exhaust emissions test specifications are available as a bar
code, use scanner pen to scan bar code on data sheet.
All required data will be shown on display.
– Press ► button -arrow- to continue procedure.
Visual inspection
– Inspect all components relevant to exhaust emissions.
– Check that all components of exhaust system are fitted, com‐
plete and free of leaks and damage.
– If results of inspection are OK, press button for “OK” -arrow-.
Note
Pressing the button for “Not OK” will start a test.

Audi A4 2015 ➤
Plugging in diagnostic connector

The screen for the visual inspection must be shown with prompts
to plug in the diagnostic connector -arrow A- and to check exhaust
emissions warning lamp -arrow B-.
– Follow instructions shown on display -arrow A- and

-arrow B-.
– Plug connector of diagnosis cable into EOBD connection.
Visual check of exhaust emissions warning lamp with engine off

– Check exhaust emissions warning lamp.
– If lamp lights up, press button for “Lamp on” -arrow C-.
Note
The exhaust emissions test is failed if the exhaust emissions

warning lamp does not light up during the visual check.

Audi A4 2015 ➤
Visual check of exhaust emissions warning lamp with engine on

– Start engine and confirm that it is running by selecting “Yes”
on display.
– Check exhaust emissions warning lamp; it must not light up or
flash.
– Insert emission probe into exhaust pipe.
Note
Do not continue the exhaust emissions test until the test probe is
in the exhaust pipe.
The system will automatically switch over to a test readiness

check.
This checks that all test readiness checks supported by the con‐
trol unit have been carried out.
– Confirm status of exhaust emissions warning lamp -arrow-.
Note
♦ If all the display values are set to zero, a control probe test will
not be performed.
♦ If not all the display values are set to zero, a control probe test
will be performed in a later step.
Catalytic converter temperature conditioning

The system will automatically switch over to the warm-up phase
of the catalytic converter.
The measurement starts when the engine has reached the re‐
quired speed.
– Keep engine speed within required range.
The remaining time for carrying out the warm-up phase will be
shown -arrow A-.
Warm-up period
The system will automatically switch over to the screen for meas‐
uring the engine temperature.
Note
This screen is only shown if the engine temperature has not yet
reached 80 degrees Celsius.
– Bring engine up to required temperature.

Audi A4 2015 ➤
Measurement at increased idling speed

uring at increased idling speed.
quired speed.
Note
♦ You can skip the measurement by pressing the ► button (the

emissions test will be failed).
♦ You can reset the test values with the ← button and repeat the
test.

The remaining time for carrying out the measurement will be
shown -arrow A-.
Measuring idling speed and CO content

The system will automatically switch over to the screen for idling
speed and CO content.
quired speed.
shown -arrow A-.
Control probe test
Note
The control probe test cannot be carried out unless all values dis‐
played from the test readiness check are NOT set to zero.
The system will automatically switch over to the screen for the
control probe test.
Note
The control probe test is carried out individually for each Lambda
probe.
quired speed.
shown -arrow A-.

Audi A4 2015 ➤
Evaluation
Once the exhaust emissions test is completed, the test log is dis‐
played on the screen.
The result of the test will be shown.
You can enter remarks on the exhaust emissions test here
-arrow A-. These will be added to the test log.
– If emissions test is passed, select date and “Emissions test
seal granted” from drop-down menu -arrow B-.
– Confirm with “Yes” -arrow C-.
Printing
Following confirmation, two test certificates will be printed auto‐
matically.
– If additional certificates are required, press button for “Print”
-arrow A-.
– Remove emission probe from exhaust pipe.
– Then press ► button -arrow B-.
The exhaust emissions test is completed; a new test can now be
performed.
4.2 Diesel engines: performing exhaust

emissions test
Note
♦ The following description refers to vehicles equipped with on-

board diagnosis (OBD).
♦ The OBD monitors all components and (sub)systems which
affect the exhaust gas quality.

♦ Emissions test station - VAS 6300-
♦ Adapter wire, OBD communication - VAS 5052/16-1-

Audi A4 2015 ➤
Note
♦ In order for the exhaust emissions test to be carried out, all

components of the emissions test station - VAS 6300- must
be properly plugged in and connected to one another as speci‐
fied in the operating instructions.
♦ All the required steps are displayed on the emissions test sta‐
tion - VAS 6300- .
Test requirements
• All test requirements and data for the exhaust emissions test
are stated on the exhaust emissions test data sheet for the
required engine.
• If the specifications for the exhaust emissions test will be
scanned in using a bar code, the data sheet must be available
as a printout.
• Automatic gearbox: selector lever in position “P” or “N”
• Manual gearbox: gear lever in neutral
• Handbrake applied
Start screen
– Select “Emissions test” button -arrow-.
An overview of exhaust emissions test types will appear.
– Select “Emissions test, diesel” -arrow-.

A display for the warm-up period will be shown.

Audi A4 2015 ➤
– Continue exhaust emissions test according to the instructions

on the display.
– When the options for the exhaust emissions test specifications

are shown, select the option required -arrow-:
♦ Either “Standard specifications” (for an initial exhaust emis‐
sions test)
♦ Or “Last vehicle” (to repeat a previous exhaust emissions test)
– Confirm Next -item 1- on display.
Entering vehicle data

The input menu for vehicle data will be shown.
– Enter the following data from the registration document (part
1):
♦ -1- Vehicle manufacturer, e.g. Audi
♦ -2- Vehicle model, e.g. A6 / 4G
♦ -3- Code for 14.1, e.g. 0572
♦ -4- Code for 2.1, e.g. 0588
♦ -5- Code for 2.2, e.g. 846
♦ -6- Engine code: e.g. CHVA
♦ -7- Number plate: e.g. IN-MV 1234
♦ -8- Vehicle identification number, e.g.
WAUZZZ4GZAN001234
– Enter mileage (km), e.g. 33350, at -item 9-.
Note
♦ Additional functions can be selected using the Go to button.

♦ The Go to button can be used to cancel the test.

Audi A4 2015 ➤
– Select “Diesel OBD” -arrow-.

Entering exhaust emissions test specifications
There are various ways of entering the specifications:
♦ 1. Manually
♦ 2. By scanning the bar code from the emissions test data sheet
♦ 3. Via the ELSA web service
Note
♦ To use the ELSA web service, the vehicle diagnostic tester

being used to perform the exhaust emissions test must be in‐
tegrated in the workshop network.
♦ When using the ELSA web service, the vehicle specifications
are entered on the corresponding screen automatically via the
network.
Entering exhaust emissions test specifications manually
Note
Refer to ⇒ Data sheets for exhaust emissions test (for required

engine) for all test requirements and data for the exhaust emis‐
sions test.
– Follow instructions on display to enter data manually.

– Enter data listed on emissions test data sheet under “Test val‐
ues for exhaust emissions test” on display in following order:
1- Engine speed for temperature conditioning
2- Number of times engine revved up for temperature condi‐
tioning
3- Engine oil temperature (minimum value)
4- Select method for measuring engine oil temperature
5- Idling speed
6- Governed speed
7- Governed speed measuring time (to nearest second)
8- Turbidity value (arithmetic mean)
9- Select probe type (probe number)
10 - Select measurement mode
11 - Time required for measurement
– Once you have entered all data correctly, confirm your entry
with → button -arrow-.
Entering exhaust emissions test specifications with a bar code
– If exhaust emissions test specifications are available as a bar
code, use scanner pen to scan bar code on data sheet.

Audi A4 2015 ➤
All required data will be shown on display -1-.

– Press → button -arrow- to continue procedure.
Visual inspection
– Inspect all components relevant to exhaust emissions.
– Check that all components of exhaust system are fitted, com‐
plete and free of leaks and damage.
– If results of inspection are OK, press button for “OK” -arrow-.
Note
Pressing the button for “Not OK” will start a test.
Plugging in diagnostic connector

• Ignition is switched off.
The screen for the visual inspection must be shown with prompts
to plug in the diagnostic connector -arrow A- and to check exhaust
emissions warning lamp -arrow B-.
– Plug connector of diagnosis cable into EOBD connection.
Visual check of exhaust emissions warning lamp with engine off

– Check exhaust emissions warning lamp.

Audi A4 2015 ➤
– If lamp lights up, press button for “Lamp on” -arrow C-.
Note
The exhaust emissions test is failed if the exhaust emissions

warning lamp does not light up during the visual check.
Visual check of exhaust emissions warning lamp with engine on

– Start engine and confirm that it is running by selecting “Yes”
on display.
– Check exhaust emissions warning lamp; it must not light up or
flash.
– Confirm status of exhaust emissions warning lamp -arrow-.
The system will automatically switch over to a test readiness
check.
This checks that all test readiness checks supported by the con‐
trol unit have been carried out.
Temperature conditioning
In the temperature conditioning phase, the engine and any emis‐
sion control systems are brought up to operating temperature by
revving up the engine several times; this makes them ready for
the exhaust emissions test.
If you are certain that no temperature conditioning is necessary,
press → button -arrow- to proceed to next measurement.
Reading out the engine temperature
The engine temperature is read out from the engine control unit
via the diagnostic connector.
After the required engine temperature has been reached, the
system will automatically switch over to the screen for measuring
the idling speed.

Audi A4 2015 ➤
Measuring the idling speed

quired speed.
Note
♦ Do not insert emission probe into exhaust pipe yet.

♦ You can skip the measurement by pressing the → button (the
♦ The ← button can be used to repeat the test.

shown -arrow-.
Measuring the governed speed

uring the governed speed.
quired speed.
– Press the accelerator pedal down without delay and hold until
measurement has been completed.
Note
♦ If the rev limiter is activated, deactivate it before performing

the exhaust emissions test:
♦ Switch on the ignition and then press and hold the ESP button
until the corresponding symbol flashes in the instrument clus‐
ter.

shown -arrow-.
Note
♦ Do not insert emission probe into exhaust pipe yet.


Audi A4 2015 ➤
Air quality check

An air quality check is started before the free acceleration proce‐
dure is performed. The emission probe must NOT be in the
exhaust pipe at this stage. Otherwise, measurement errors or er‐
ror messages may occur during the subsequent measurement
procedures.
– After air quality check is completed, insert emission probe in
exhaust pipe.
Free acceleration
The system will automatically switch over to the screen for the
free acceleration procedure.
In the free acceleration procedure, the engine is accelerated as
quickly as possible (without load) until the governed speed is
reached.
The free acceleration test consists of at least four individual ac‐
celerations.
Free acceleration - phase 1

– Follow instructions shown on display -arrow A- and
-arrow C-.
– Keep idling speed in specified speed range -arrow D-.
shown -arrow B-.
Note
♦ The emission probe must be in the exhaust pipe.

♦ If the engine speed is not within the specified speed range, the
measurement procedure is re-started.

Audi A4 2015 ➤

– Follow instructions shown on display -arrow B-.
– Press accelerator pedal down fully when prompted to do so
and hold it until display prompts you to let engine idle.
– Take your foot off accelerator pedal as soon as display shows
prompt for engine idling speed -arrow B-, and let engine idle.
The result of the measurement procedure and information about
the most recently performed free acceleration procedure will ap‐
pear on the display -arrow A-. If the measured values are not OK,
you will be informed at this stage about the reasons why the free
acceleration test was failed.
Note
♦ If the field is white, the measured value is within the tolerated

range.
♦ If the field is red, the measured value is outside the tolerated
range.
♦ If the field is yellow, the measured value is outside the toler‐
ated range but is subject to the judgement of the person
performing the test.
Further individual accelerations

The next individual acceleration is now performed, beginning with
phase 1 of the free acceleration procedure.
It is possible to perform as many free acceleration procedures as
desired until:
♦ Three free acceleration procedures in a row have been
passed, and the acceleration range is OK.
♦ All values are OK with the exception of the acceleration range,
and the → button -arrow C- has been pressed to continue the
test procedure (in this case, the person performing the test
judges whether or not the value is OK).
♦ The values are not OK, and the → button -arrow C- has been
pressed to end/skip the measurement.
If all measured values are OK after the engine has been revved
up three times (i.e. all fields are white), the exhaust emissions test
has been passed.
If all measured values are OK after the engine has been revved
up three times, the exhaust emissions test has been passed.
Evaluation
Once the exhaust emissions test is completed, the test log is dis‐
played on the screen.
The result of the test will be shown.
You can enter remarks on the exhaust emissions test here
-arrow A-. These will be added to the test log.
– If emissions test has been passed, select date and “Emissions
test seal granted” from drop-down menu -arrow B-.
– Confirm with “Yes” -arrow C-.

Audi A4 2015 ➤
The emissions test log appears on the screen and can be printed
out as often as desired using the “Print” button -arrow A- in the
“Print preview” menu.
– You can close the “Print preview” menu by using the “Close”
button -arrow B-.
– Remove emission probe from exhaust pipe.
– Then press → button -arrow B-.

The exhaust emissions test is completed; a new test can now be
performed.

Service
Maintenance
Audi A4 2015 ➤
Edition 01.2016
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
Maintenance
Heading
1. General information
2. Preparations
3. Maintenance

Copyright © 2016 Audi AG, Ingolstadt D4B8058F4E5

Audi A4 2015 ➤
Contents
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 --- Change history --- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Vehicle: raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Engine cover panel: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Noise insulation: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Window regulators: activating automatic open/close function . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Vehicle diagnostic tester: connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 Diesel particulate filter: reading out ash deposit volume . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Event memory: reading out and erasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Service interval display: resetting service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 Transport mode: deactivating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5 Transport mode: checking activation and activating if necessary . . . . . . . . . . . . . . . . . . . . 17
3.6 Battery: reading out status and sending diagnostic log . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.7 Battery: checking that battery and battery cables are securely fitted . . . . . . . . . . . . . . . . . . 18
3.8 Battery: checking electrolyte level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.9 Battery: connecting stationary battery charging unit (min. 30A, charging voltage max. 14.8 V
on IV characteristic curve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.10 Battery: determining and recording state of charge (SOC) . . . . . . . . . . . . . . . . . . . . . . . . 23
3.11 Mirror hanger indicating defective battery: renewing battery on affected vehicles . . . . . . . . 25
3.12 Connected gateway: renewing emergency battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.13 Brake fluid: changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.14 Brake fluid (vehicles older than 12 months): changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.15 Brake fluid: checking fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.16 Brake system: checking condition of brake hoses, and checking that caps are fitted on bleeder
screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.17 Brake pads: checking thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.18 Brake discs: checking for surface rust and operating brakes to clean if necessary . . . . . . 33
3.19 Parking brake: releasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.20 Tyres: checking condition and wear pattern, and checking and recording tread depth . . . . 34
3.21 Tyres: checking tyre pressures and adjusting if necessary . . . . . . . . . . . . . . . . . . . . . . . . 35
3.22 Tyres (except spare wheel): checkingProtected tyre pressures and adjusting
by copyright. Copying to 3.5 bar
for private or commercial if necessary
purposes, in part or in whole, is not
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . permitted
. . . . . unless
. . . . authorised
. . . . . .by. .AUDI
. . .AG.
. .AUDI
. . . AG
. . does
. . .not
. .guarantee
. . . . . .or.accept
. . . .any liability
36
3.23 Tyre Pressure Loss Indicator: storing changed tyre pressures . . . . . . . . . . . . . . . . . . . . . . 37
3.24 Tyre repair kit: checking that set is complete, and checking and recording expiry date . . 37
3.25 Wheel bolts: tightening to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.26 Suspension struts on front and rear axle: removing locking elements . . . . . . . . . . . . . . . . 38
3.27 Components of front and rear axles: checking play, secure attachment and protective
boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.28 Engine, gearbox, final drive and steering: checking for leaks and damage . . . . . . . . . . . . 44
3.29 Vehicle (from below): checking for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.30 Underbody: checking trim, wheel housing liners, side members and pipes/wiring for damage,
and checking that they are properly secured . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.31 Roof insert: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.32 Roof insert - sliding/tilting sunroof: cleaning and lubricating . . . . . . . . . . . . . . . . . . . . . . . . 46
3.33 Roof insert - panorama sunroof: cleaning and lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.34 Windscreen/rear window washer system: checking spray pattern and adjusting if
necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.35 Wiper blades: checking for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.36 Headlight washer system: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.37 Headlights: checking for correct adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Contents i
Audi A4 2015 ➤
3.38 Headlights and reversing lights, side lights, number plate lights, turn signals, hazard warning
lights: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.39 Luggage compartment lighting: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.40 Luggage compartment: removing protective film and felt pieces . . . . . . . . . . . . . . . . . . . . 57
3.41 Glove box light, interior lighting and reading light: checking operation . . . . . . . . . . . . . . . . 57
3.42 Horn: checking operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.43 Front passenger airbag: checking key switch on / off and setting to "on" . . . . . . . . . . . . . . 58
3.44 Owner's literature: checking that all documents are present . . . . . . . . . . . . . . . . . . . . . . . . 58
3.45 Service Schedule: affixing vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.46 Service Schedule: entering Delivery Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.47 Seat belts: checking that retaining rivets are fitted, and checking locking action of automatic
belt retractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.48 Vehicle interior: removing protective covers for seats and carpet . . . . . . . . . . . . . . . . . . . . 59
3.49 Vehicle interior: checking that it is clean and cleaning if necessary . . . . . . . . . . . . . . . . . . 59
3.50 Vehicle interior: removing any objects other than those protecting interior surfaces . . . . . . 60
3.51 Vehicle interior and exterior: checking for and documenting any damage . . . . . . . . . . . . . . 60
3.52 Instrument cluster: checking warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.53 Warning triangle: checking availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.54 First-aid kit: checking and recording expiry date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.55 Vehicle keys: checking operation and recording number of keys given to customer . . . . . . 61
3.56 Vehicle key: removing from ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.57 Vehicle key(s), wheel covers and owner's literature: checking availability and recording
number present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.58 Sun visors: checking that they are folded up and folding up if necessary . . . . . . . . . . . . . . 61
3.59 Luggage compartment cover and sun blind: checking that they are rolled up and rolling up if
necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.60 Engine oil: draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.61 Engine oil: extracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.62 Engine oil: renewing oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.63 Engine oil: filling up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.64 Engine oil: checking oil level and correcting if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.65 Spark plugs: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.66 Cooling system: checking anti-freeze and coolant level, and correcting if necessary . . . . 75
3.67 Air cleaner: renewing filter element and cleaning housing . . . . . . . . . . . . . . . . . . . . . . . . 79
3.68 Dust and pollen filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.69 Fuel filter: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.70 Fuel tank: adding fuel additive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.71 Reducing agent (AdBlue®): filling up tank completely . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.72 Vehicle doors: removing edge protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.73 Vehicle exterior: checking unprotected areas for dirt, and cleaning if necessary . . . . . . . . 93
3.74 Vehicle exterior: removing protective film . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.75 Protective transport film and car cover: checking position and correcting if necessary . . . . 94
3.76 Protective transport film: renewing according to manufacturer's instructions . . . . . . . . . . 94
3.77 Car cover: renewing according to manufacturer's instructions . . . . . . . . . . . . . . . . . . . . . . 94
3.78 Paintwork, trims, side windows and wiper blades: checking cleanliness . . . . . . . . . . . . . . 94
3.79 Body: checking vehicle paintwork for damage and corrosion from below and with bonnet, rear
lid and doors open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.80 Vehicles parked outdoors: locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.81 Vehicles parked outdoors: covering unprotected vehicles with protective transport film and
car cover (not for vehicles with control number 5K0 on data sticker on windscreen) . . . . . . 95
3.82 Road test . .Protected
. . . . . by. .copyright.
. . . . .Copying
. . . . for
. . private
. . . .or. commercial
. . . . . . purposes,
. . . . . .in.part
. . or. .in.whole,
. . . is. .not. . . . . . . . . . . . . . 95
3.83 Stock vehicles: observing measures specified in Maintenance table any
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept forliability
stock vehicles (see
“Before handingwith vehicle over to customer”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
respect to the correctness of information in this document. Copyright by AUDI AG.
96
3.84 Accessories: installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.85 Check list "Documentation of cleaning and care routine": checking availability . . . . . . . . . . 96
3.86 Check list "Documentation of cleaning and care routine": signing and placing in vehicle
wallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.87 Cleaning and care: checking that required measures have been carried out on time . . . . 97
ii Contents
Audi A4 2015 ➤
3.88 Stock vehicle care management: deciding and recording date of next check . . . . . . . . . . 97
3.89 Display instruments: setting time and date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.90 Manual gearbox/automatic gearbox: selecting 1st gear/park . . . . . . . . . . . . . . . . . . . . . . . . 97
3.91 Dual clutch gearbox (S tronic): changing ATF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.92 Dual clutch gearbox (S tronic): changing ATF and renewing exchangeable ATF filter . . . . 97
3.93 Dual clutch gearbox (S tronic): changing ATF and renewing exchangeable ATF filter (if
fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.94 Interior mirror: calibrating compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.95 Instrument cluster: resetting driver information system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.96 Toothed belt for camshaft drive: renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.97 Toothed belt for camshaft drive and tensioning roller: renewing . . . . . . . . . . . . . . . . . . . . 98
Contents iii
Audi A4 2015 ➤
iv Contents
Audi A4 2015 ➤
1 General information
(AIGG00073; Edition 01.2016)
Change history ⇒ page 1
Engine number ⇒ page 1
Vehicle identification number ⇒ page 3
Vehicle data sticker ⇒ page 3
1.1 --- Change history ---

N Date Chapter Changes made
o.
2 02.11.20 Various chapters on stock vehicles New chapter
15
Various chapters on Delivery Inspection New chapter
Overview of engines Chapter deleted. An overview of
engines (including adjustment
values of tester for oil level indi‐
cator T40178) can be found in
the Workshop Manual under ⇒
Power unit; Rep. gr. 00 ; Tech‐
nical data
Reducing agent (AdBlue®): filling up tank completely
permitted unless authorised by AUDI AG. AUDI AG does not guarantee AdBlue
or acceptrefuelling
any liability system VAS
⇒ page 89 6960byadded
with respect to the correctness of information in this document. Copyright AUDI AG.as alternative filling
device
Fuel tank: adding fuel additive ⇒ page 88 Chapter updated
1 14.09.20 All New document
15
Note
For greater clarity, only the last three updates to the document
are listed.
1.2 Engine number
Note
The engine number consists of the engine code letters (3 or 4

characters) and the serial number.
Audi A4 2015 ➤
4-cyl. petrol engine 1.4 ltr. TFSI ⇒ page 2

4-cyl. diesel engine 2.0 ltr. TDI ⇒ page 2
1.2.1 4-cyl. petrol engine 1.4 ltr. TFSI

cover (top).
sticker ⇒ page 3 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

cover (top).
1.2.3 4-cyl. diesel engine 2.0 ltr. TDI

cover (top).
Audi A4 2015 ➤

The engine number is stamped on the left side under the toothed
belt for the high-pressure pump -arrow-.
The engine number is also printed on the sticker on the intake
manifold.
1.3 Vehicle identification number

Depending on the equipment and country-specific version, the
vehicle identification number is located:
♦ At the bottom left edge of the windscreen
♦ On the vehicle data sticker ⇒ page 3
♦ Optional: In the MMI under »Servicing & checks«
The vehicle identification number consists of the following:

WAU ZZZ 8W Z B A/N 000 234
Manufactur‐ Filler charac‐ Type Filler charac‐ Model year Production lo‐ Serial number
er's mark ters ters cation
1.4 Vehicle data sticker

The vehicle dataProtected
sticker is located:
by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ In the Service Schedule
♦ In the area of the spare wheel well under the floor covering
-arrow-
Audi A4 2015 ➤
The vehicle data sticker contains the following vehicle data:

1 - Vehicle identification number
2 - Vehicle model, manufacturer's code, engine type and power
output, production month and year
3 - Engine and gearbox code letters (not specified on some export
models)
4 - Paint number, interior equipment number
5 - Numbers for optional extras
6 - Fuel consumption: urban, extra urban, combined, CO2 (not
specified on some export models)
Audi A4 2015 ➤
2 Preparations
Vehicle: raising ⇒ page 5
Engine cover panel: removing and installing ⇒ page 6
Noise insulation: removing and installing ⇒ page 7
Window regulators: activating automatic open/close function
⇒ page 9
Vehicle diagnostic tester: connecting ⇒ page 9
2.1 Vehicle: raising
Caution
Risk of damage to vehicle due to incorrect use of lifting plat‐

form.
♦ Do not exceed the permissible lifting capacity of the lifting
platform.
♦ The vehicle should be lifted only at the points shown in the
illustration.
♦ Position support plates so that they are aligned centrally
below the lifting points.
♦ Ensure sufficient clearance between low-mounted vehicle
components and the lifting platform.
Procedure:
– Front: Position support plates of lifting platform under lifting
2. Preparations 5
Audi A4 2015 ➤
– Rear: Position support plates of lifting platform under lifting

Note
♦ The location of the lifting points is indicated by markings stam‐

ped on the side member trim.
♦ Extend all support plates -2- far enough so that the lifting arm
of the lifting platform does not touch the vehicle trim.
2.2 Engine cover panel: removing and in‐

stalling
6-cyl. diesel engine 3.0 ltr. TDI ⇒ page 7 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

another -arrows-.
6 2. Preparations
Audi A4 2015 ➤

another -arrows-.

another -arrows-.

another -arrows-.
2.3 Noise insulation: removing and installing

Noise insulation (front) ⇒ page 7
Noise insulation (rear) ⇒ page 9
2.3.1 Noise insulation (front)

2. Preparations 7
Audi A4 2015 ➤

Nm
Bolt -1- 12

– Unscrew bolts -1-.
– Unscrew quick-release fasteners -2-, -4- and -5- from noise
insulation (front).
– Pull noise insulation -3- towards rear out of bottom section of
bumper cover and detach.
Note
♦ Ensure that you feel the quick-release fasteners engage when

installing.
♦ On vehicles with supplementary heater, opening of exhaust
pipe must be routed vertically through grommet in noisebyinsu‐
permitted unless authorised AUDI AG. AUDI AG does not guarantee or accept any liability
lation. with respect to the correctness of information in this document. Copyright by AUDI AG.
8 2. Preparations
Audi A4 2015 ➤
2.3.2 Noise insulation (rear)

– Release spreader clips -arrows-.
– Release quick-release fasteners -2- and -3-.
– Pull noise insulation panel -4- out towards rear.
Note
Ensure that you feel the quick-release fasteners engage when

installing.
2.4 Window regulators: activating automatic

open/close function
If the vehicle battery was disconnected, the automatic open/close
function for the electric windows must be reactivated.
Procedure:
– Pull up on window regulator switch until windows are com‐
pletely closed.
– Release switch and pull on it again for at least one second.
– Repeat procedure with all window regulators.
2.5 Vehicle diagnostic tester: connecting

♦ Diagnosis system - VAS 6160 A-
♦ Remote diagnosis head - VAS 5054A-

♦ Or: Diagnosis interface - VAS 5055-
2. Preparations 9
Audi A4 2015 ➤
Procedure:
– Plug connector for remote diagnosis head - VAS 5054A- into
diagnostic connection in vehicle.
– Switch on diagnostic system - VAS 6160 A- .
– Follow the menu on the screen to start the desired functions.
10 2. Preparations
Audi A4 2015 ➤
3. Maintenance 11
Audi A4 2015 ➤
3 Maintenance
Display instruments: setting time and date ⇒ page 97
Battery: checking that battery and battery cables are securely fit‐
ted ⇒ page 18
Battery: determining and recording state of charge (SOC)
⇒ page 23
Battery: checking electrolyte level ⇒ page 19
Battery: connecting stationary battery charging unit (min. 30A,
charging voltage max. 14.8 V on IV characteristic curve)
⇒ page 21
Battery: reading out status and sending diagnostic log
⇒ page 18
Axles (front and rear): checking components for play Protected
and secureby copyright. Copying for private or commercial purposes, in part or in whole, is not
attachment, and checking protective boots ⇒ page 40permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Front passenger airbag: checking key switch on / off and setting
to "on" ⇒ page 58
Tyres: checking tyre pressures and adjusting if necessary
⇒ page 35
Tyres: checking condition and wear pattern, and checking and
recording tread depth ⇒ page 34
Tyres (except spare wheel): checking tyre pressures and adjust‐
ing to 3.5 bar if necessary ⇒ page 36
Owner's literature: checking that all documents are present
⇒ page 58
Brake system: checking condition of brake hoses, and checking
that caps are fitted on bleeder screws ⇒ page 31
Brake pads: checking thickness ⇒ page 32
Brake fluid (vehicles older than 12 months): changing
⇒ page 31
Brake fluid: checking fluid level ⇒ page 31
Brake fluid: changing ⇒ page 26
Brake discs: checking for surface rust and operating brakes to
clean if necessary ⇒ page 33
Checklist "Documentation of cleaning and care routine": checking
availability ⇒ page 96
Checklist "Documentation of cleaning and care routine": signing
and placing in vehicle wallet ⇒ page 97
Connected gateway: renewing emergency battery, telematics
⇒ page 25
Roof insert - panorama sunroof: cleaning and lubricating
⇒ page 48
Roof insert - sliding/tilting sunroof: cleaning and lubricating
⇒ page 46
Roof insert: checking operation ⇒ page 45
Diesel particulate filter: reading out ash deposit volume
⇒ page 15
Dual clutch gearbox (S tronic): changing ATF fluid ⇒ page 97
Dual clutch gearbox (S tronic): changing ATF and renewing ex‐
changeable ATF filter ⇒ page 97
12 3. Maintenance
Audi A4 2015 ➤
Dual clutch gearbox (S tronic): changing ATF and renewing ex‐

changeable ATF filter (if fitted) ⇒ page 98
Event memory: reading out and erasing ⇒ page 16
Headlights and reversing lights, side lights, number plate lights,
turn signals, hazard warning lights: checking operation
⇒ page 56
Vehicle key(s), wheel covers and owner's literature: checking
availability and recording number present ⇒ page 61
Vehicle key: removing from ignition lock ⇒ page 61
Vehicle key(s): checking operation and recording number of keys
given to customer ⇒ page 61
Mirror hanger indicating defective battery: renewing battery on
affected vehicles ⇒ page 25
Vehicle doors: removing edge protection ⇒ page 93
Vehicle
Protected exterior:
by copyright. checking
Copying unprotected
for private or areas
commercial purposes, for ordirt,
in part andiscleaning
in whole, not
if necessary
permitted ⇒ page
unless authorised 93AG. AUDI AG does not guarantee or accept any liability
by AUDI
Vehicle exterior: removing protective film ⇒ page 93
Vehicle interior and exterior: checking for and documenting any
damage ⇒ page 60
Vehicle interior: checking that it is clean and cleaning if necessary
⇒ page 59
Vehicle interior: removing any objects other than those protecting
interior surfaces ⇒ page 60
Vehicle interior: removing protective covers for seats and carpet
⇒ page 59
Vehicle (from below): checking for damage ⇒ page 45
Cleaning and care: checking that required measures have been
carried out on time ⇒ page 97
Suspension struts on front and rear axle: removing locking ele‐
ments ⇒ page 38
Car cover: renewing according to manufacturer's instructions
⇒ page 94
Luggage compartment cover and sun blind: checking that they
are rolled up and rolling up if necessary ⇒ page 62
Glove box light, interior lighting and reading light: checking oper‐
ation ⇒ page 57
Interior mirror: calibrating compass ⇒ page 98
Vehicles parked outdoors: covering unprotected vehicles with
protective transport film and car cover (not for vehicles with con‐
trol number 5K0 on data sticker on windscreen) ⇒ page 95
Vehicles parked outdoors: locking ⇒ page 95
Body: checking vehicle paintwork for damage and corrosion from
below and with bonnet, rear lid and doors open ⇒ page 95
Luggage compartment lighting: checking operation ⇒ page 57
Luggage compartment: removing protective film and felt pieces
⇒ page 57
Instrument cluster: resetting driver information system
⇒ page 98
Instrument cluster: checking warning lamps ⇒ page 60
Fuel tank: adding fuel additive ⇒ page 88
3. Maintenance 13
Audi A4 2015 ➤
Fuel filter: renewing ⇒ page 86

Cooling system: checking anti-freeze and coolant level, and cor‐
recting if necessary ⇒ page 75
Paintwork, trims, side windows and wiper blades: checking clean‐
liness ⇒ page 94
Air cleaner: renewing filter element and cleaning housing
⇒ page 79
Engine, gearbox, final drive and steering: checking for leaks and
damage ⇒ page 44
Engine oil: draining ⇒ page 62
Engine oil: extracting ⇒ page 63
Engine oil: renewing oil filter ⇒ page 63
Engine oil: filling up ⇒ page 67
Engine oil: checking oil level and correcting if necessary
⇒ page 68
Parking brake: releasing ⇒ page 34
Road test ⇒ page 95
Wheel bolts: tightening
Protected to specified
by copyright. torque
Copying for private ⇒ pagepurposes,
or commercial 37 in part or in whole, is not
Reducing agent (AdBlue®):
with respect filling ofup
to the correctness tank completely
information in this document. Copyright by AUDI AG.
⇒ page 89
Tyre Pressure Loss Indicator: storing changed tyre pressures
⇒ page 37
Tyre repair kit: checking that set is complete, and checking and
recording expiry date ⇒ page 37
Manual gearbox/automatic gearbox: selecting 1st gear/park
⇒ page 97
Windscreen/rear window washer system: checking spray pattern
and adjusting if necessary ⇒ page 53
Wiper blades: checking for damage ⇒ page 54
Headlights: checking for correct adjustment ⇒ page 55
Headlight washer system: checking operation ⇒ page 54
Service Schedule: affixing vehicle data sticker ⇒ page 59
Service Schedule: entering Delivery Inspection ⇒ page 59
Service interval display: resetting service ⇒ page 16
Seat belts: checking that retaining rivets are fitted, and checking
locking action of automatic belt retractor ⇒ page 59
Horn: checking operation ⇒ page 58
Sun visors: checking that they are folded up and folding up if nec‐
essary ⇒ page 61
Stock vehicles: observing measures specified in Maintenance ta‐
ble for stock vehicles (see “Before handing vehicle over to cus‐
tomer”) ⇒ page 96
Dust and pollen filter: renewing ⇒ page 85
Stock vehicle care management: deciding and recording date of
next check ⇒ page 97
Transport mode: checking activation and activating if necessary
⇒ page 17
Transport mode: deactivating ⇒ page 16
14 3. Maintenance
Audi A4 2015 ➤
Protective transport film and car cover: checking position and

correcting if necessary ⇒ page 94
Protective transport film: renewing according to manufacturer's
instructions ⇒ page 94
Underbody: checking trim, wheel housing liners, side members
and pipes/wiring for damage, and checking that they are properly
secured ⇒ page 45
First-aid kit: checking and recording expiry date ⇒ page 60
Warning triangle: checking availability ⇒ page 60
Toothed belt for camshaft drive and tensioning roller: renewing
⇒ page 98
Toothed belt for camshaft drive: renewing ⇒ page 98
Accessories: installing ⇒ page 96
Spark plugs: renewing ⇒ page 69
3.1 Diesel particulate filter: reading out ash

deposit volume
Engine Measured value designation for di‐ Maximum value for ash deposit
agnostic tester
4-cyl. diesel engine 2.0 ltr. TDI Particulate filter, oil ash deposit Oil ash deposit mass: 80 g
mass
6-cyl. diesel engine 3.0 ltr. TDI Particulate filter, oil ash deposit vol‐ Oil ash deposit volume: 380 ml
ume
Procedure:
v and press Apply .

– Switch to “Control units” tab.
– Select control unit “01 — Engine electronics” and carry out
following functions via right mouse button:
♦ Identify control unit
♦ Guided Functions/Control unit self-diagnosis
♦ 01 - Read measured values/Measured values
– Select desired measured value (see table of test values and
procedure guidelines ⇒ page 15 ) by entering v and confirm‐
ing with OK .
– Evaluate measured value and follow further instructions on
screen.
– Perform the following measures according to the measured
value:
Result: Measure:
Measured value < critical Vehicle can be driven for a further 30,000 km (19,000 miles).
value
3. Maintenance 15
Audi A4 2015 ➤
Result: Measure:
Measured value ≥ critical Renew diesel particulate filter and reset measured value to zero ⇒ Engine; Rep.
value gr. 26 ; Emission control system; Removing and installing particulate filter .
3.2 Event memory: reading out and erasing

Procedure:
press Apply .
The control unit
permitted is then
unless identified,
authorised by AUDI AG. and
AUDIthe event
AG does memory
not guarantee is inter‐
or accept any liability
rogated. Observe
with respect tonotes and test
the correctness conditions.
of information in this document. Copyright by AUDI AG.
– Switch to “Control units” tab and call up “Event memory list”

for an overview of all entries stored in event memory.
– Correct relevant faults and erase event memory.
Note
The event memory is erased automatically if the Guided Fault

Finding is closed correctly.
3.3 Service interval display: resetting serv‐

ice
Procedure:
v and press Apply .

– Select service setting to be reset (e.g. “17 — Inspection”).
Note
Please refer to the relevant Maintenance table for information on

which service channel to reset and what data to enter.
3.4 Transport mode: deactivating

Procedure:
16 3. Maintenance
Audi A4 2015 ➤

v and press Apply .

Note

start.
3.5 Transport mode: checking activation

and activating if necessary
Checking transport mode ⇒ page 17
Activating transport mode ⇒ page 17
3.5.1 Checking transport mode

Procedure:
– Check whether »Transport mode on« is shown in instrument
cluster.
– If necessary, activate transport mode ⇒ page 17 .
3.5.2 Activating transport mode

Procedure:
v and press Apply .

– Start program
permitted by selecting
unless authorised Carry
by AUDI AG. AUDI AGout check
does not . or accept any liability
guarantee
Note

start.
3. Maintenance 17
Audi A4 2015 ➤
3.6 Battery: reading out status and sending

diagnostic log
Procedure:
press Apply .
♦ A - Battery check
Result on vehicle diagnostic test‐ Measure:
er:
“Battery OK” No further measures necessary.
“Charge battery” Charge battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Charging battery .
“Battery is no longer of the same Renew battery after consulting with customer ⇒ Electrical system; Rep. gr.
quality as when shipped” 27 ; Battery; Removing and installing battery .
– Switch to Control units tab.

– Press X Diagnosis button and close diagnosis program.
– Send off diagnosis log online.
Note
♦ A working network connection is necessary to send the diag‐

nostic log file online.
♦ After the diagnosis is complete, you will receive confirmation
that the test log was sent successfully.
3.7 Battery: checking that battery and bat‐

tery cables are securely fitted
WARNING
Risk of injury due to loose battery clamp on positive terminal.

♦ Disconnect battery clamp from negative terminal
Protected and Copying
by copyright. then for private or commercial purposes, in part or in whole, is not
tighten battery clamp on positive terminal.

18 3. Maintenance
Audi A4 2015 ➤

Nut on battery clamp 4
Bolt on retainer plate 18

Requirements:
Removal steps:
– Open battery terminal covers.
Procedure:
– Check by hand that battery terminal clamps are securely seat‐

ed. If necessary tighten nuts -2- and -4- for battery terminal
clamps to specified torque (see table of tightening torques for
installation ⇒ page 19 ).
– Check by hand that battery -1- is securely installed. If neces‐
sary tighten bolt -6- on retainer plate -7- to specified torque
(see table of tightening torques for installation ⇒ page 19 ).
3.8 Battery: checking electrolyte level
Note
Batteries must not be opened.
Battery without magic eye ⇒ page 19

Battery with magic eye ⇒ page 20
3.8.1 Battery without magic eye

Removal steps:
3. Maintenance 19
Audi A4 2015 ➤
Procedure:
– Check electrolyte level of all battery cells using markings on
housing.
– If electrolyte level of one or more battery cells is below MIN
marking: Renew battery.
Note
♦ A bright hand-held light helps to better see the MIN and MAX
markings on the housing.
♦ If battery is difficult to see: Use a small mirror to check the
electrolyte level (shine a bright hand-held light at a right angle
onto the battery cells).
3.8.2 Battery with magic eye
WARNING
Risk of explosion if magic eye is colourless or light yellow!

♦ Do not attempt to jump-start vehicle.
♦ Do not check or charge battery.
♦ Renew battery.

Removal steps:
Procedure:
20 3. Maintenance
Audi A4 2015 ➤
– Before checking electrolyte level: Tap magic eye -arrow- care‐

fully with handle of a screwdriver.
– Read off battery electrolyte level according to colour display.

Two different results are possible:
Colour of magic eye: Measure:

Black or green Electrolyte level OK: No further measures necessary
Colourless or light yellow Electrolyte level too low: Battery must be renewed
Note
♦ The magic eye is also referred to as an ALI (acid level indica‐

tor).
♦ The magic eye is only for use in determining the electrolyte
level.
♦ During battery charging or vehicle operation, air bubbles can
form underneath the magic eye which could falsify the colour
display. Tap magic eye lightly to release any bubbles.
3.9 Battery: connecting stationary battery

charging unit (min. 30A, charging volt‐

age max. 14.8 V on IV characteristic

curve)
WARNING
Risk of injury if battery terminal clamps are connected incor‐

rectly.
♦ Connect positive battery terminal clamp first, then connect
negative battery terminal clamp.
3. Maintenance 21
Audi A4 2015 ➤
♦ Battery charger - VAS 5906-
Only applies to vehicles intended for display.

Requirements:
Removal steps:
– Remove plastic stopper -C- in spare wheel well and store it in
glove box.
Procedure for connecting battery

Protected charger:
– Disconnect charger clamps from
with respect battery
to the charger
correctness - VAS
of information 5906-
in this . Copyright by AUDI AG.
document.
– Working from above, thread connector end of cable for charg‐

er clamps through hole in spare wheel well.
– Open battery terminal cover (+).
– First connect charger clamp (+) to positive battery terminal
-A-.
– Then connect charger clamp (-) to earth point (-) -B- on body.
– Arrange wiring of battery charger - VAS 5906- neatly in spare
wheel well.
– Stow tool kit in spare wheel well and fit cover for tool kit.
– Fit luggage compartment floor cover.
– Under vehicle: Connect cable for charger clamps to battery
charger - VAS 5906- .
– Switch on battery charger - VAS 5906- and adjust settings as
needed.
– Position battery charger - VAS 5906- under vehicle so that it
is hidden from view as well as possible, ensuring that ventila‐
tion grille of charger is unobstructed.
Procedure for disconnecting battery charger:

Remove in reverse sequence.
22 3. Maintenance
Audi A4 2015 ➤
3.10 Battery: determining and recording state

of charge (SOC)
Vehicles with transport mode ON ⇒ page 23
Vehicles with transport mode OFF ⇒ page 23
3.10.1 Vehicles with transport mode ON

Procedure:
– Read off battery charge level on instrument cluster.
(SOC):
“≥ 80% (12.5 V)” No further measures necessary.
“SOC < 80% (12.5 Charge battery ⇒ Electrical system; Rep.
V) und SOC ≥ 10% gr. 27 ; Battery; Charging battery .
(11.6 V)”
“< 10% (11.6 V)” Charge battery ⇒ Electrical system; Rep.
gr. 27 ; Battery; Charging battery , and at‐
tach mirror hanger for “Battery defective”.
Note
If if is not possible to read off the state of charge in the instrument

cluster, measure the battery's no load voltage ⇒ page 24 .
3.10.2 Vehicles with transport mode OFF

♦ Battery tester - VAS 6161-
The battery is located in the luggage compartment.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Removal steps: with respect to the correctness of information in this document. Copyright by AUDI AG.

Procedure:
– Switch on battery tester - VAS 6161- and select “QC check,
new vehicles”.
– Use battery tester - VAS 6161- to measure voltage between
battery clamps.
Battery Measure:
tester
shows:
“Battery No further measures necessary.
Good”
“Charge Charge battery ⇒ Electrical system; Rep. gr. 27 ;
fully now” Battery; Charging battery .
“Battery Charge battery ⇒ Electrical system; Rep. gr. 27 ;
Faulty” Battery; Charging battery , and attach mirror hang‐
er for “Battery defective”.
3. Maintenance 23
Audi A4 2015 ➤
Note
♦ When using battery tester - VAS 6161- , ensure that the soft‐
ware is up to date.
♦ If if is not possible to measure the state of charge with battery
tester - VAS 6161- , measure the battery's no load voltage
⇒ page 24 .
3.10.3 Measuring no load voltage of battery

♦ Hand-held multimeter - V.A.G. 1526 C-
♦ Or: digital multimeter - V.A.G. 1715-

Requirements: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
• Battery must not be placed under load from connected elec‐
trical equipment for at least 12 hours before test.
• Battery must not have been charged for at least 12 hours be‐
fore test.
• Engine must remain off for at least 2 hours before test.
Removal steps:
Procedure:
– Use hand-held multimeter - V.A.G. 1526 C- to measure volt‐
age between battery clamps -2- and -3-.

(SOC):
“≥ 12.5 V” No further measures necessary.
24 3. Maintenance
Audi A4 2015 ➤

(SOC):
“SOC < 12.5 V und Charge battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Charging battery .
SOC ≥ 11.6 V”
“< 11.6 V” Charge battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Charging battery , and attach
mirror hanger for “Battery defective”.
3.11 Mirror hanger indicating defective bat‐

tery: renewing battery on affected vehi‐
cles
Only for vehicles with mirror hanger for “Battery defective”.
Procedure:
– Wait until shortly before vehicle delivery, then renew battery
according to instructions in workshop manual ⇒ Electrical
system; Rep. gr. 27 ; Battery; Removing and installing battery .
3.12 Connected gateway: renewing emer‐

gency battery
The emergency battery, telematics - A16- is located in the data
bus diagnostic interface - J533- .
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Switch off ignition and all electrical equipment,
with respect and
to the correctness removein this document. Copyright by AUDI AG.
of information
ignition key.
– Remove rear seat bench ⇒ General body repairs, interior;
Rep. gr. 72 ; Rear seats; Removing and installing seat bench/
individual seats .
It is not necessary to remove data bus diagnostic interface -
J533- .
– Release catches and lift cover off data bus diagnostic interface
- J533- -1- in direction of -arrow-.
3. Maintenance 25
Audi A4 2015 ➤
– Pivot emergency battery, telematics - A16- -1- out of data bus

diagnostic interface - J533- .
– Release and unplug electrical connector.
Installing
3.13 Brake fluid: changing
WARNING
Risk of accident if the brake pedal has too much free play.
♦ Make sure that the brakes work properly before the vehicle
is driven on the road.
WARNING
Risk of injury due to caustic brake fluid.

♦ Avoid contact with skin.
Caution with respect to the correctness of information in this document. Copyright by AUDI AG.
Risk of damage due to improper handling of brake fluid.

♦ Avoid contact with vehicle paint.
♦ Avoid contact with liquids containing mineral oils (oil, pet‐
rol, cleaning agents).

♦ Brake filling and bleeding equipment - VAS 5234-
26 3. Maintenance
Audi A4 2015 ➤
♦ Tool set for brake bleeding - VAS 6564-

The value given in the table is for one brake caliper, i.e. if there
are two bleeder screws on one caliper, the sum of the quantities
discharged from both bleeder screws must equal the value given
in the table.
Sequence of opening bleeder screws: Quantity of brake fluid to discharge:
Brake calipers
Front axle on driver's side 1. 0.20 ltr.
Front axle on front passenger's side 2. 0.20 ltr.
Rear axle Protected
on driver's side Copying
by copyright. 3. for0.30
privateltr.
or commercial purposes, in part or in whole, is not
Rear axle on front passenger's side 4. 0.30 ltr.
Clutch slave cylinder 5. 0.15 ltr.
⇒ Total quantity, automatic gearbox 1.00 ltr.

⇒ Total quantity, manual gearbox 1.15 ltr.
Step 1 - connecting brake filling and bleeding equipment:

– Unscrew filler cap -1- from brake fluid reservoir.
3. Maintenance 27
Audi A4 2015 ➤
– Use extraction hose included in brake filling and bleeding

equipment - VAS 5234- to extract brake fluid from reservoir
(with strainer installed) until fluid is level with bottom edge of
strainer. Make sure that no more fluid flows back into reservoir
from strainer after extracting fluid.
– Screw adapter -1- onto brake fluid reservoir.

– Connect filling hose -2- included with brake filling and bleeding
equipment - VAS 5234- to adapter.
– Set pressure on brake filling and bleeding equipment -
VAS 5234- (see operating instructions).
Step 2 - bleeding and filling brake system:

If there are two bleeder screws on each brake caliper, first bleed
the inner, then the outer bleeder screw.
– Raise vehicle ⇒ page 5 .
Front axle:

screw(s).
28 3. Maintenance
Audi A4 2015 ➤
– Fit bleeder hose -1- attached to collector container onto bleed‐

er screw from inside of rim.
– Open bleeder screw and allow brake fluid to discharge. Refer
to table for correct quantity of brake fluid to discharge
⇒ page 27 .
– If there are two bleeder screws on each brake caliper: Repeat
procedure with second bleeder screw.
– Refit cap on bleeder screw(s).
Rear axle:

screw(s).
– Take reversible ratchet and appropriate socket from tool set
for brake bleeding - VAS 6564- and fit together.
– Run bleeder hose -1- from inside of rim through reversible

ratchet -2- and socket -3- and fit onto bleeder screw.
– Open bleeder screw with ratchet -2- and allow brake fluid to
discharge. Refer to table for correct quantity of brake fluid to
discharge ⇒ page 27 .
3. Maintenance 29
Audi A4 2015 ➤
– If there are two bleeder screws on each brake caliper: Working

from outside of rim, apply reversible ratchet -2- and socket
-3- and repeat procedure.
– Refit cap on bleeder screw(s) on brake caliper.
Step 3 - bleeding clutch slave cylinder

Only for vehicles with manual gearbox
– Remove components necessary for access; refer to ⇒ Manual
gearbox; Rep. gr. 30 ; Clutch mechanism; Bleeding clutch
mechanism .
– Fit bleeder hose attached to collector container -1- onto bleed‐
er screw of clutch slave cylinder. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Open bleeder screw and allow correct amountwith ofrespect
brake fluid
to the correctness of information in this document. Copyright by AUDI AG.
to flow out (see table of test values and procedure guidelines
⇒ page 27 ).
– Close bleeder screw and fit cap.
Step 4 - final steps:

– Close filling lever of brake filling and bleeding equipment -
VAS 5234- .
– Detach filling hose from adapter.
– Unscrew adapter from brake fluid reservoir.
– Check brake fluid level and adjust if necessary (depending on
brake pad wear) ⇒ page 31 .
– Screw cap onto brake fluid reservoir.
– Operate clutch pedal several times.
– Check pedal pressure and free travel: No more than 1/3 of total
pedal travel.
– Make sure that the brakes work properly before the vehicle is
driven on the road.
– If free travel of brake pedal is greater than specified, or if brake
function is impaired: Check brake system for leaks and renew
brake fluid again.
Note
♦ The bleeder hose must fit tightly on the bleeder screw to pre‐
vent air from entering the brake system.
♦ In the case of certain wheel combinations, the wheels may
have to be removed.
♦ With the aid of the tool set for brake bleeding - VAS 6564- ,
the rear brakes or, depending on version, the front and rear
brakes can be bled without having to remove the wheels.
♦ Use genuine Audi brake fluid; see Electronic parts catalogue
(ETKA).
♦ Do not reuse brake fluid.
disposal of brake fluid.
30 3. Maintenance
Audi A4 2015 ➤
3.14 Brake fluid (vehicles older than 12

months): changing
Only applies to vehicles older than 12 months (from date of man‐
ufacture).
Procedure:
– Change brake fluid ⇒ page 26 .
3.15 Brake fluid: checking fluid level

Type of service: Fluid level specification:
Delivery Inspection Fluid level must be at MAX marking.
Brake fluid change Fluid level must be between MAX marking and MIN marking according to wear
level of brake pads.
Checking the brake system for leaks is a repair measure and

Procedure:
– Evaluate brake fluid level according to markings on brake fluid
reservoir -illustration-.
– Perform the following measures according to the results of the

check:
Fluid level: Evaluation/measure:
Above MAX marking Extract brake fluid.

Below specified level Carry out brake system leak test ⇒ Brake system; Rep. gr. 47 ; Hydraulic system;
Leak test .
Note
When the vehicle is in use, the fluid level drops due to wear and
automatic adjustment of the brake pads.
3.16 Brake system: checking condition of

brake hoses, and checking that caps are
fitted on bleeder screws
Requirements:
• Brake hoses must not touch any components when steering
is on full lock.
• Brake hoses must not be twisted.
3. Maintenance 31
Audi A4 2015 ➤
Procedure:
– Check that all brake hoses are secured properly; when doing
so, ensure that the conditions listed are met:
– Check all brake hoses for abrasion, porosity, blistering and
cracking.
– Check that brake connections are seated correctly, and check
for corrosion and leaks.
– If faults are found on brake hoses: Repair/renew relevant com‐
ponent.
– Check that caps are fitted and secured on bleeder screws of
all brake calipers.
– Renew any missing caps.
3.17 Brake pads: checking thickness

♦ Test pin - T40139- : Use the side with the thin probe (brake
symbol) to measure brake pad thickness.

Axle Brake pad wear limit including backplate and damper plate
[mm]
Front axle 10
Rear axle 7
Check only the thickness of the outer brake pads.

Procedure:
– Before you begin: Push sliding ring towards tip of test pin as
far as it will go.
– Bring tip of test pin into contact with brake disc.
– Slide test pin towards brake pad until test pin makes contact
with backplate of brake pad.
32 3. Maintenance
Audi A4 2015 ➤
– Remove test pin and read off brake pad wear value -a- from
scale on tool.
– Repeat procedure for all wheels.
– If brake pad thickness has reached wear limit (see table of test
values and procedure guidelines ⇒ page 32 ): Renew brake
pads ⇒ Brake system; Rep. gr. 46 ; Removing and installing
brake pads .
Note with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ When removing the test gauge, take care not to move the slid‐
ing ring. This would give an incorrect measurement.
♦ Note where the test gauge makes contact on the rear of the
brake pad and include the thickness of the damper plate in the
calculation if necessary.
♦ In the case of certain wheel combinations, the wheels must be
removed.
3.18 Brake discs: checking for surface rust

and operating brakes to clean if neces‐
sary
Checking brake discs ⇒ page 33
Operating brakes to clean brake discs ⇒ page 33
3.18.1 Checking brake discs

Procedure:
– Check outside of all brake discs for surface rust.
– If necessary, operate brakes to clean brake discs
⇒ page 33 .
Note
The brake discs can be damaged irreparably if surface rust is not

removed at the specified intervals.
3.18.2 Operating brakes to clean brake discs

Procedure:
– Accelerate vehicle to 40 km/h, then brake gently to 10 km/h
(do this five times).
– Accelerate vehicle to 40 km/h, then brake sharply to a stand‐
still (do this five times).
Note
The wheels should not spin or lock during acceleration and brak‐
ing.
3. Maintenance 33
Audi A4 2015 ➤
3.19 Parking brake: releasing

Mechanical parking brake ⇒ page 34
Electromechanical parking brake ⇒ page 34
3.19.1 Mechanical parking brake

Procedure:
– Release parking brake.
3.19.2 Electromechanical parking brake

Procedure:
– Press brake pedal, then press switch for electromechanical
parking brake.
3.20 Tyres: checking condition and wear pat‐

tern, and checking and recording tread
depth
♦ Test pin - T40139- : Use the side with the thick probe and
shoulder (scale marked with tyre symbol) to measure tread
depth.

Country-specific regulations for minimum tread depth apply; for
countries not listed, evaluate values according to the country's
specifications.
Country Minimum tread depth [mm]
EU countries 1.61)
Brazil 1.6
China 1.6
India 1.6
Japan 1.6
Norway 1.61)
Russia 1.6
Switzerland 1.6
Turkey 1.6
Ukraine 1.61)
USA 1.6
1) Larger values for winter tyres where these are mandatory
34 3. Maintenance
Audi A4 2015 ➤
Performing wheel alignment is a repair measure and should be

charged separately.
Step 1 - checking condition:
– Check for and remove any foreign bodies in tyre tread.
– Check all tyres for following types of damages:
♦ Cuts, cracks, tears
♦ Scuffing or flattened areas on tyre tread
♦ Porous sidewalls
♦ Blisters on sidewalls
– If damage is found: Renew tyres.
Step 2 - checking tyre wear pattern:
– Check tyre wear pattern of front wheels; check for the follow‐
ing:
♦ Feathering on tread indicating possible incorrect toe setting
♦ One-sided tread wear indicating possible incorrect camber
– If the above types of wear are found: Check wheel alignment
to determine the cause.
Step 3 - checking tread depth:
– Measure tread depth on all tyres (including spare tyre) at sev‐
eral points using test pin - T40139- . Uneven tread depth
indicates damage.
– Record average measurement for each tyre in Maintenance
table.
– If minimum tread depth has been reached (as specified for
your country; see table of test values and procedure guidelines
⇒ page 34 ): Renew tyre.
Note
Vehicles with four-wheel drive must be fitted with tyres with the
same tread pattern. Otherwise the centre differential may be
damaged.
3.21 Tyres: checking tyre pressures and ad‐

justing if necessary
Note
3. Maintenance 35
Audi A4 2015 ➤
Front and rear axles ⇒ page 36

Spare wheel and temporary spare wheel ⇒ page 36
3.21.1 Front and rear axle

The tyre pressure specifications are listed on the sticker on the
inside of the driver's door.
Tyre sizes not listed: See Wheel/tyre guide for tyre pressure
specification ⇒ Wheel/Tyre Guide; Rep. gr. 44 ; Wheels, tyres,
vehicle geometry; Tyre pressures .
Procedure:
Note
The tyre pressures listed only apply to cold tyres. When the tyres
are warm, the actual pressures will be higher, but must not be
reduced.
3.21.2 Spare wheel and

Protected temporary
by copyright. spare
Copying for private or commercial purposes, in part or in whole, is not
wheel permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
The following parameters apply to the tyre pressure specifica‐

tions:
• Spare wheel with standard-size tyre: Inflate to maximum tyre
pressure indicated on tyre pressure sticker.
• Temporary spare wheel: The correct tyre pressure is indicated
on the sidewall.
Procedure:
– Check tyre pressure of spare wheel/temporary spare wheel.
Note
Depending on equipment version, there may only be a tyre repair

kit supplied; see Maintenance table.
3.22 Tyres (except spare wheel): checking

tyre pressures and adjusting to 3.5 bar
if necessary
Note
Procedure:
36 3. Maintenance
Audi A4 2015 ➤
– If necessary, adjust tyre pressure to 3.5 bar and record pres‐

sure in maintenance table.
3.23 Tyre Pressure Loss Indicator: storing

changed tyre pressures
The Tyre Pressure Loss Indicator must be initialised after every
time the tyre pressures are changed or the tyres are renewed.
Requirements:
• The inflation pressures of all tyres must be adjusted to the
correct values before the pressures are stored.
Procedure: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Switch on ignition and activate MMI.to the correctness of information in this document. Copyright by AUDI AG.
with respect

– Select »Car«.
structure:
♦ Tyre pressure monitoring
♦ Store tyre pressures
♦ Yes, store
– Use MMI rotary pushbutton to select option to store tyre pres‐
sures.
3.24 Tyre repair kit: checking that set is com‐

plete, and checking and recording expi‐
ry date
The tyre repair kit is located in the spare wheel well.
Procedure:
– Check that the following components of the tyre repair kit are
present:
♦ Compressor
♦ Tyre filler bottle incl. filler hose
– Take out the bottle and check the expiry date (printed on bottle
-arrow-).
– If expiry date has been exceeded or if bottle has already been
used: Renew tyre filler bottle.
3.25 Wheel bolts: tightening to specified tor‐

que
3. Maintenance 37
Audi A4 2015 ➤

Nm

Fastener Tightening torque [Nm]
Wheel bolt 120
The adapter for loosening and tightening anti-theft wheel bolts is

included in the vehicle tool kit.
Procedure:
– Tighten wheel bolts in a diagonal sequence to specified torque
(see table of test values and procedure guidelines
⇒ page 38 ).
– If adapter for anti-theft wheel bolts was used: Put adapter back
in tool kit.
3.26 Suspension struts on front and rear axle:

removing locking elements
Note
♦ These vehicles are identified by a coloured tag fixed to the

mirror -arrow-.
♦ It is not necessary to remove the wheels to perform this oper‐
ation.
Suspension struts on front axle ⇒ page 38

Suspension struts on rear axle ⇒ page 39
Pressing in bump stop ⇒ page 40
3.26.1 Suspension struts on front axle

Requirements:
Procedure:
– Push all locking elements -A- off piston rod.
Note

38 3. Maintenance
Audi A4 2015 ➤

3.26.2 Suspension struts on rear axle

Requirements:
with• respect
Vehicle suspension
to the correctness extended
of information in this document. Copyright by AUDI AG.
Procedure:
– Push all locking elements -1- off piston rod.
Note


3. Maintenance 39
Audi A4 2015 ➤
3.26.3 Pressing in bump stop

♦ Soap-based lubricant, e.g. tyre assembly paste
Procedure:
– Remove coarse dirt from top edge of loose bump stop and coat
with tyre assembly paste.
– Press loose bump stop firmly into shock absorber mounting by
hand.
3.27 Components of front and rear axles:

checking play, secure attachment and
protective boots
The following applies to all components shown below:
• There must be no noticeable or visual play.
• As a rule you can identify damage to the boots/drive shaft
boots by emerging grease.
• Check that retaining rings and spring-type clips are seated
correctly.
Front axle ⇒ page 40
Rear axle ⇒ page 42
3.27.1 Front axle

Track control links, guide links and coupling rod:
track control link/guide link.
40 3. Maintenance
Audi A4 2015 ➤
– Track control links and guide links: Check boots -arrows- of

swivel joint all around for damage and make sure they are
seated correctly.
– Check all bonded rubber bushes of track control links and

guide links -arrows- for play.
Track rod ball joint:

– Check boot -2- for track rod ball joint all around for damage
and make sure it is seated correctly.
– Check play at track rod ball joint.
Upper links:
– Upper links -2-: Check bushes of swivel joints all around for
damage and make sure they are seated correctly.
– Check the two bonded rubber bushes -1- and -4- of swivel
joints (top) for play.
Anti-roll bar:
3. Maintenance 41
Audi A4 2015 ➤
– Check anti-roll bar bush -3- for damage.
Drive shaft and steering rack:
– With steering turned: Check drive shaft boots -arrows- all

around for damage and make sure they are seated correctly.
– Check boot -arrow- of steering rack all around for damage and
correct seating.
relevant component.
3.27.2 Rear axle

Lower transverse links (front and rear):
both transverse links.
– Check all bonded rubber bushes of lower transverse link
– Check bonded rubber bushes -arrows- of all transverse links

for play.
– Check anti-roll bar bush -arrow- for damage.
Upper transverse links (front and rear):
42 3. Maintenance
Audi A4 2015 ➤
– Check all bonded rubber bushes of upper transverse link

– Check all bonded rubber bushes of upper transverse link (rear)

-2- for play.
Track rod:
– Check play at bonded rubber bushes of track rod -2-.
Coupling rod and anti-roll bar:
3. Maintenance 43
Audi A4 2015 ➤
– Check anti-roll bar bush -arrows- for damage.
Drive shaft:
Only applies to vehicles with four-wheel drive.
– Check drive shaft boots -arrows- for damage and make sure
they are seated correctly.
– Repeat checks for components
withon opposite
respect side ofof vehicle.
to the correctness information in this document. Copyright by AUDI AG.

relevant component.
3.28 Engine, gearbox, final drive and steer‐

ing: checking for leaks and damage
Remove noise insulation for every inspection.
Removal steps:
44 3. Maintenance
Audi A4 2015 ➤
Procedure:
– Check engine and engine ancillaries from below for leaks and
damage.
– Check radiator and cooling circuit for leaks and damage.
– Check refrigerant circuit for damage (check air conditioner
compressor, condenser and refrigerant lines including con‐
nections).
– Check gearbox, final drive and steering for leaks and damage.
– If faults are found: repair or renew relevant component.
3.29 Vehicle (from below): checking for dam‐

age
Procedure:
– Check underbody carefully and thoroughly for damage and
loose fasteners.
ponent. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3.30 Underbody: checking
with respect to the correctness trim,
of information in thiswheel hous‐by AUDI AG.
document. Copyright
ing liners, side members and pipes/wir‐

ing for damage, and checking that they
are properly secured
Procedure:
– Check all underbody trim panels and wheel housing liners for
tears and cracks.
– Use your hands to check that all underbody trim panels and
wheel housing liners are secured correctly and check for miss‐
ing fasteners.
– Inspect side members for deformations.
– Check visible area of pipes/wiring and connections for dam‐
age and ensure they are secured correctly.
– Check stone deflector on rear track control links to make sure
it is securely fitted and undamaged.
ponent.
3.31 Roof insert: checking operation

Only applies to equipment version with sliding/tilting sunroof.
Procedure:
– Open and close roof system completely and check for unusual
noises and stiffness/sticking.
– If there is unusual noise or stiffness/sticking: Clean and lubri‐
cate roof insert ⇒ page 46 .
3. Maintenance 45
Audi A4 2015 ➤
3.32 Roof insert - sliding/tilting sunroof:

Caution
Risk of breaking cowl panel.

♦ Use care when lifting cowl panel.

♦ Krytox lubricating paste - G 052 141 A2-
5128-
a scouring surface)

Step 1 - cleaning and lubricating glass panel seal:
– Tilt open glass panel at rear.
– Remove all accessible grease and dirt residuepermitted
from glass pan‐ by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
el seal using cleaning solution - D 009 401 04-with
and a lint-free
cloth.
– Use a fine-pored sponge -1- to lubricate sides and rear of glass
panel seal -arrows- with Krytox lubricating paste - G 052 141
A2- . Make sure that no coarse residue remains visible after
applying lubricant.

– Using cleaning solution - D 009 401 04- and a lint-free cloth,
remove any grease or dirt residue from front of glass panel
seal in area that has not been lubricated yet.
46 3. Maintenance
Audi A4 2015 ➤
– Use a fine-pored sponge -1- to lubricate glass panel seal at

front -arrow- with Krytox lubricating paste - G 052 141 A2- .
Make sure that no coarse residue remains visible after apply‐
ing lubricant.
Step 2 - cleaning and lubricating wind deflector seal:

To avoid risk of breakage, lift the wind deflector carefully with your
hand but do not remove it for the following procedure.
– Remove grease and dirt from wind deflector seal using clean‐
– Use a fine-pored sponge -1- to lubricate rubber lip of wind de‐

flector -arrow- along the entire length with Krytox lubricating
paste - G 052 141 A2- . Make sure that no coarse residue
remains visible after applying lubricant.

residue from guide rails.
– Remove grease and dirt from guide rails with a lint-free cloth.
– Use a paintbrush to lubricate inside of guide rail -arrow- with

3. Maintenance 47
Audi A4 2015 ➤
– Use a paintbrush to lubricate outside of guide rail -arrow- with

– Use a paintbrush to lubricate side guide rail of sliding headliner

– Remove surplus lubricant on guide rails with a lint-free cloth.
surplus lubricant.
3.33 Roof insert - panorama sunroof: clean‐

ing and lubricating
♦ Krytox lubricating paste - G 052 141 A2-
48 3. Maintenance
Audi A4 2015 ➤
♦ Grease stone - VAS 6764-
♦ Hand-cartridge gun - V.A.G 1628-

5128-
♦ Measuring cup
a scouring surface)

– Open sunroof sun blind completely.
residue from guide rail.
3. Maintenance 49
Audi A4 2015 ➤
– Insert grease stone - VAS 6764- in rear section of guide rail

-1- and turn 90° into contour of rail -2-.
– Then pull tool into centre of guide rail opening -3-, turn through
90° again -4- and remove -5-.
– Clean front section of guide rail as described in previous step.
To do so, insert grease stone in front section of guide rail (near
wind deflector) and move it to centre of guide rail.
– Repeat cleaning procedure several times as required.
– Remove grease and dirt deposits from guide rail with a lint-
free cloth.
– Screw grease stone - VAS 6764- -1- onto thread of lubricant

cartridge -G 060 751 A2- -2- and insert into hand-cartridge gun
- V.A.G 1628- -3-.
– Insert grease stone attached to hand-cartridge gun at front end

of guide rail -1- and turn 90° into contour of rails -2-.
– Pull hand-cartridge gun evenly towards rear -3-, operating lev‐
er continuously to apply lubricating paste - G 060 751 A2- to
guide rail.
– Turn hand-cartridge gun through 90°-4- and remove in vicinity
of open glass panel -5-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Repeat lubrication procedure on opposite side of vehicle.
Step 2 - cleaning and lubricating slotted guide for glass panel:

– Remove grease and dirt from slotted guide for glass panel with
a lint-free cloth.
– Open and close sunroof and open glass panel again com‐
pletely. Opening and closing the sunroof distributes the lubri‐
cant along the guide rails. Any deposits of excess lubricant can
be used to grease the slotted guide.
50 3. Maintenance
Audi A4 2015 ➤
– Use a paintbrush to lubricate slotted guide for glass panel

– Remove excess lubricant from slotted guide and guide rail with
a lint-free cloth.
Step 3 - cleaning and lubricating locking hook for sunroof mech‐

anism:
– Tilt open glass panel.
– Working from vehicle interior, remove grease
permitted unless and dirtbyfrom
authorised AUDI AG. AUDI AG does not guarantee or accept any liability
locking hook for sunroof mechanismwithwith a lint-free cloth.
– Use a paintbrush to lubricate locking hook -arrow- with lubri‐

cating paste - G 060 751 A2- .
– Remove surplus lubricant from locking hook with a lint-free
cloth.
surplus lubricant at all lubricating locations.
Step 4 - cleaning glass panel:

– Remove grease and dirt from front and side edges of glass
panel -arrows- using cleaning solution - D 009 401 04- and a
lint-free cloth.
Step 5 - cleaning and lubricating roof frame seal:

– Remove grease and dirt from seal for roof frame using clean‐
3. Maintenance 51
Audi A4 2015 ➤
– Use a fine-pored sponge to lubricate roof frame seal

-arrows- with Krytox lubricating paste - G 052 141 A2- . Make
sure that no coarse residue remains visible.
Step 6 - cleaning wind deflector:

– Clean screen and frame of wind deflector -1- using a sponge

and soap solution.
– Use an industrial vacuum cleaner to remove any loose residue
from wind deflector slot -arrows-.
Step 7 - checking water drains for dirt:

– Use a measuring cup -1- to pour water into guide rail close to
open glass panel -arrow-. Work carefully to ensure that the
water does not overflow into the vehicle interior. Make sure
that water is distributed in both directions so that both water
drains can be checked.
– At underside of vehicle, check that water flows out in the area
of both the front and rear wheel housings.
– If water does not flow out of the appropriate drainage points,
clean water drain ⇒ General body repairs, exterior; Rep. gr.
60 ; Water drain hoses; Cleaning water drain hoses .
52 3. Maintenance
Audi A4 2015 ➤
3.34 Windscreen/rear window washer sys‐

tem: checking spray pattern and adjust‐
ing if necessary
Checking spray pattern on windscreen ⇒ page 53
Checking spray pattern on rear window ⇒ page 53
Adjusting windscreen washer jets ⇒ page 54
Adjusting rear window washer jets ⇒ page 54
3.34.1 Checking spray pattern on windscreen

• Evenly distributed, symmetrical spray pattern
• Jet unit (passenger's side): Upper concentrated jet should
make contact near upper edge of wiper area -1-.
• Jet unit (driver's side): Upper concentrated jet should make
contact -2- at same level as jet unit (passenger's side).
Procedure:
– Operate windscreen washer system and check spray pattern.
– If spray pattern is not as specified, adjust windscreen washer
jets ⇒ page 54 .
3.34.2 Checking spray pattern on rear window

• Water from both spray jets makes contact just above wiper
blade
• Water from inner spray jet makes contact within approx. first
quarter of wiper blade length -illustration-
• Water from outer spray jet makes contact approx. at or just
beyond centre of wiper blade length -illustration- (third quarter)
Procedure:
– Operate rear window washer system and check spray pattern.
– If spray pattern is not as specified, adjust rear window washer
jets ⇒ page 54 .
3. Maintenance 53
Audi A4 2015 ➤
3.34.3 Adjusting windscreen washer jets

Procedure:
– Using adjuster screw -2-, set washer jet being adjusted ac‐
cording to specified pattern (use a tool with size 9 external Torx
-3-).
tion, clean appropriate washer jets ⇒ Vehicle electrics; Rep.
gr. 92 ; Windscreen wash/wipe system; Adjusting washer jets .
Note
Only the height of the jets of water of each jet unit can be adjusted,
and all jets must be adjusted together via an adjuster screw. The
jets cannot be adjusted individually or laterally.
3.34.4 Adjusting rear window washer jets

♦ Commercially available adjusting tool (e.g. adjusting tool -
T10127- ) or suitable needle
Procedure:
– Use adjusting tool to align washer jets as required according
to specification.
tion, clean washer jets ⇒ Electrical system; Rep. gr. 92 ; Rear
window wiper system; Adjusting washer jets .
3.35 Wiper blades: checking for damage

Step 1 - service position:
– Press windscreen wiper lever downwards briefly.
Step 2 - checking:
– Lift windscreen wipers and check each wiper blade for tears,
cuts, abraded areas or other damage.
– Repeat check on rear window.
– If you find damage: Renew relevant wiper blade. Windscreen
wiper system ⇒ Electrical system; Rep. gr. 92 ; Windscreen
wiper system; Removing and installing wiper blade ; rear win‐
dow wiper system ⇒ Electrical system; Rep. gr. 92 ; Rear
window wiper system; Removing
Protected and
by copyright. installing
Copying for private wiper blade
or commercial purposes, in part or in whole, is not
3.36 Headlight washer system: checking op‐

eration
Not all vehicles are equipped with a headlight washer system
(depending on equipment version).
Procedure:
– Operate headlight washer system and check function.
54 3. Maintenance
Audi A4 2015 ➤
– If water jet does not contact headlight: Renew relevant washer

jets ⇒ Electrical system; Rep. gr. 92 ; Headlight washer sys‐
tem; Removing and installing washer jets .
Note
The headlight washer jets are set by the manufacturer and there‐
fore cannot be adjusted.
3.37 Headlights: checking for correct adjust‐

ment
♦ Headlight adjustment unit - VAS 5209B-
♦ Or: headlight adjustment unit - VAS 621 001-
Performed as partProtected
of an inspection, this for
by copyright. Copying check
private is merely an
or commercial ab‐ in part or in whole, is not
purposes,
breviated form of the headlight
permitted adjustment
unless authorised by AUDI check
AG. AUDIrequired, for
AG does not guarantee or accept any liability
example, after a repair, and does
with respect not takeofthe
to the correctness placeinofthisadocument.
information full head‐Copyright by AUDI AG.
light adjustment check.
Do not adjust the vehicle load or the tyre pressures for this pro‐
cedure.
Do not adjust the headlights to their basic setting using the vehicle
diagnostic tester.
Checking and adjusting the headlights according to the instruc‐
tions in the Workshop Manual is a repair measure and must be
charged separately.
Procedure:
– For vehicles with manually adjustable headlight range control:
Use manual adjuster to set to basic setting.
– Activate dipped headlights.
– Align headlight adjustment unit parallel to vehicle and position
it centrally in front of headlight at a distance of 30 to 70 cm
-distance a-; deviation from centre of light emission surface
must not exceed 3 cm -distance b-.
3. Maintenance 55
Audi A4 2015 ➤
– Adjust dip setting of headlight adjustment unit so that beam of

headlight falls on test screen according to following parameter:
Horizontal light-dark border should coincide with setting line
-1-.
– Read off dip setting of headlight adjuster.
– Repeat procedure on opposite side.
– Compare dip setting on left and right sides.
– If they deviate 2.0% or more from one another: Check and
adjust headlight setting according to procedure specified in
Workshop Manual ⇒ Electrical system; Rep. gr. 94 ; Head‐
lights; Adjusting headlights .
3.38 Headlights and reversing lights, side

lights, number plate lights, turn signals,
hazard warning lights: checking opera‐
tion
Check the lights/signals listed below from the outside to ensure
Procedure:
– Activate side lights and check that the following exterior lights
function properly:
♦ Side lights (front)
♦ Side lights (rear)
♦ If applicable: additional tail light under open rear lid
– Check operation of daytime running lights (front).
– Operate right turn signal, left turn signal and hazard
permitted warning
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
lights, and check that corresponding turn signal lamps at front,
rear and side function properly.

– Activate dipped headlights and check that the following exte‐
rior lights function properly:
♦ Dipped headlights
♦ Taillights
♦ Number plate lights
– Use appropriate switch to activate fog lights and check that
– Check that main beam headlights function properly.
– Operate brakes and check function of all brake lights.
– Engage reverse gear and check that all reversing lights func‐
tion properly. This model is fitted with two reversing lights.
– Use appropriate switch to activate rear fog lights and check
that they function properly. This model is fitted with one rear
fog light.
– Renew any defective bulbs.
56 3. Maintenance
Audi A4 2015 ➤
3.39 Luggage compartment lighting: check‐

ing operation
A4 Saloon ⇒ page 57
A4 Avant ⇒ page 57
3.39.1 A4 Saloon
Procedure:
– Check that luggage compartment light shown -arrow- func‐
tions properly.
3.39.2 A4 Avant
Procedure:
– Check proper function of luggage compartment lights shown
-arrow-.
3.40 Luggage compartment: removing pro‐

tective film and felt pieces
Procedure:
– Remove protective film and felt pieces carefully and complete‐
ly from luggage compartment.
3.41 Glove box light, interior lighting and

reading light: checking operation
Procedure:
– Open glove box and check that glove box light functions prop‐
erly.
3. Maintenance 57
Audi A4 2015 ➤
– Use the appropriate switches to activate the following interior

lights and check that the lights function properly:
♦ Interior lights in headliner at front
♦ Interior lights in headliner at rear
Note
Checking the ambient lighting is NOT part of the inspection.
3.42 Horn: checking operation

Procedure:
– Operate horn and check proper function of treble horn and
bass horn.
Note
Perform this check outdoors, e.g. when driving the vehicle to the
workshop or during a permitted
road test.
3.43 Front passenger airbag: checking key

switch on / off and setting to "on"
Switch for “Airbag ON/OFF” is located in glove box -arrow-.
Procedure:
– Turn switch to “AIRBAG OFF” position.
tem check.
– Check that “PASSENGER AIRBAG OFF” display lights up in
instrument cluster.
– Turn switch to “AIRBAG ON” position.
tem check.
– Check that “PASSENGER AIRBAG OFF” disappears.
Note
3.44 Owner's literature: checking that all

documents are present
Procedure:
– Check that all parts of owner's literature are present, and pre‐
pare them for handover to customer.
58 3. Maintenance
Audi A4 2015 ➤
3.45 Service Schedule: affixing vehicle data

sticker
The vehicle data sticker can be found in the supplied pack.
Procedure:
– Remove vehicle data sticker from supplied pack.
– Affix vehicle data sticker in Service Schedule under “Warranty
entitlement record”.
3.46 Service Schedule: entering Delivery In‐

spection
The field for documenting the Delivery Inspection can be found
on page 2 of the Service Schedule.
Procedure:
– Apply stamp of Audi Workshop.
– Enter date of work carried out.
– Mark relevant field(s).
Note
Only for markets not using the Digital Service Schedule.
3.47 Seat belts: checking that retaining rivets

are fitted, and checking locking action of
automatic belt retractor
Procedure:
For all seat belts installed:
– Check that retaining rivets/clips are fitted.
– Check locking action of automatic belt retractors when belt is
unrolled abruptly.
Note
If the seatpermitted
belt isunless
securing an object (e.g. child seat), do not re‐
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
lease the seat belt. Only check the locking action when the belt
is buckled; it is not necessary to check the retaining rivet/clip in

this case.
3.48 Vehicle interior: removing protective

covers for seats and carpet
Procedure:
– Remove protective covers for seats and carpet carefully and
completely from vehicle interior.
3.49 Vehicle interior: checking that it is clean

and cleaning if necessary
Procedure:
Check that the following items are clean (clean them if necessa‐
ry):
3. Maintenance 59
Audi A4 2015 ➤
♦ Front seats
♦ Rear seat bench
♦ Interior trim
♦ Carpets
♦ Floor mats
♦ Windows/windscreen
3.50 Vehicle interior: removing any objects

other than those protecting interior sur‐
faces
Procedure:
– Remove any objects from vehicle other than those which are
protecting interior surfaces.
3.51 Vehicle interior and exterior: checking

for andProtected
documenting any
by copyright. Copying damage
for private or commercial purposes, in part or in whole, is not
Procedure: with respect to the correctness of information in this document. Copyright by AUDI AG.
– Check interior of vehicle for damage and document any dam‐

age found.
– Check exterior of vehicle for damage and document any dam‐
age found.
3.52 Instrument cluster: checking warning

lamps
Reading out the event memory is a repair measure and should
be charged separately.
Procedure:
– Start engine and wait for vehicle to complete initial system
check.
– Check whether warning lamps light up in instrument cluster.
– If relevant warning lamps light up: Read out event memory
⇒ page 16 .
Note
3.53 Warning triangle: checking availability

Procedure:
– Check that warning triangle(s) is/are present.
3.54 First-aid kit: checking and recording ex‐

piry date
The first-aid kit is located behind the storage net (right-side) in the
luggage compartment.
Procedure:
– Take out first-aid kit and check expiry date printed on kit.
60 3. Maintenance
Audi A4 2015 ➤

– If expiry date has passed: Renew first-aid kit.
3.55 Vehicle keys: checking operation and

recording number of keys given to cus‐
tomer
Procedure:
– Open key ring to check each key individually.
– Start engine with each key individually.
– Record number of keys which have been matched and handed
over in Maintenance table.
– If a vehicle key has not been matched: Re-match all keys to
vehicle using Guided Function of vehicle diagnostic tester via
online tool GeKo.
– If there is reason to suspect improper use (e.g. missing key):
See current notices from AUDI AG under “Technical informa‐
tion ► Anti-theft protection” on ServiceNet.
Note
♦ Only the key being checked may be inside the vehicle. Place
all other keys out of transmission range.
♦ If the key has not been matched, the engine will turn off after
a few seconds. In addition, the warning lamp for the immobil‐
iser or the display “SAFE” will appear in the instrument cluster,
depending on the vehicle equipment.
3.56 Vehicle key: removing from ignition lock

Only applies to vehicles with ignition lock.
Procedure:
– Remove vehicle key from ignition lock.
3.57 Vehicle key(s), wheel covers and own‐

er's literature: checking availability and
recording number present
Procedure:
– Check whether there are keys for the vehicle and record num‐
ber of keys in maintenance table.
– Check whether there are wheel covers for the vehicle and re‐
cord number of wheel covers in maintenance table.
– Check whether owner's literature is in place and record num‐
ber of copies in maintenance table.
– Wait until shortly before vehicle delivery to renew any missing
components.
3.58 Sun visors: checking that they are folded

up and folding up if necessary
Procedure:
– Check that sun visors are folded up, and fold them up if nec‐
essary.
3. Maintenance 61
Audi A4 2015 ➤
3.59 Luggage compartment cover and sun

blind: checking that they are rolled up
and rolling up if necessary
Procedure:
– If a luggage compartment cover is fitted, check that it is rolled
up (roll it up if necessary).
– Check that sun blinds are folded up (fold them up if necessary).
3.60 Engine oil: draining
Note

disposal.
4-cyl. diesel engine 1.4 ltr. TFSI ⇒ page 62
3.60.1 4-cyl. diesel engine 1.4 ltr. TFSI

Removal steps:
Procedure:
– Unscrew sealing plug -arrow- for sump.
– Renew seal for sealing plug.
– Tighten sealing plug all the way.
62 3. Maintenance
Audi A4 2015 ➤
3.61 Engine oil: extracting

Procedure:
– Pull oil dipstick/sealing plug out of guide tube.
– Insert extraction probe of oil extraction unit into guide tube.
Use flexible extraction probe with largest possible diameter
and insert without using any significant force. Otherwise the
tip can become diverted on the bottom of the sump and a large
amount of used oil will remain in the engine.
– Extract engine oil completely. Observe operating instructions
for extraction unit.
– Finally, install oil dipstick/sealing plug.
Note

disposal.
3.62 Engine oil: renewing oil filter


3. Maintenance 63
Audi A4 2015 ➤
♦ Oil filter tool - 3417-
♦ Hazet strap wrench - 2171-1-

Nm

Oil filter cartridge 20
Removal steps:
Procedure:
– Use Hazet strap wrench - 2171-1- or oil filter tool - 3417- to
slacken oil filter cartridge -arrow- and then remove it.
– Clean sealing surface for oil filter at engine.
– Lubricate rubber seal on new oil filter cartridge with engine oil.
– Fit new oil filter cartridge on engine and tighten to specified
torque (see table of tightening torques for installation
⇒ page 64 ).

Nm
64 3. Maintenance
Audi A4 2015 ➤

Sealing cap 25
Removal steps:
Procedure:
ing into crankcase.
– Completely remove sealing cap -arrow-. Make sure that no
engine oil drips onto engine.
– Clean sealing surfaces of sealing cap.
ring.
– Screw sealing cap into oil filter housing and tighten it to speci‐
fied torque using socket (32 mm) (see table of tightening

Nm

Sealing cap 25
3. Maintenance 65
Audi A4 2015 ➤
Removal steps:
Procedure:
– Loosen sealing cap of oil filter using socket (32 mm) . This
ing into crankcase.
drips onto engine.
ring.
– Screw sealing cap -5- into oil filter housing and tighten it to

Sealing cap 35
66 3. Maintenance
Audi A4 2015 ➤
Procedure:
ing into crankcase.
drips onto engine.
– Pull oil filter element -5- and seal -6- out of sealing cap -7-.
– Lightly lubricate new seal -6- with engine oil and fit it.
3.63 Engine oil: filling up Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Caution
Risk of engine damage if the engine is revved too soon after

changing the oil!
♦ The engine must only run at idling speed as long as the
oil pressure warning lamp in the instrument cluster is on.
♦ Increase the engine speed only after the warning lamp has
gone out.

♦ Oil filler funnel - VAS 6842-
3. Maintenance 67
Audi A4 2015 ➤
Refer to ELSA maintenance table for engine-specific oil capaci‐

ties and oil grades.
Procedure:
– Fill up engine oil using oil filler funnel - VAS 6842- .
– Then check oil level and adjust if necessary ⇒ page 68 .
– For all 4-cylinder 2.0 ltr. TFSI petrol engines with oil filler neck
on timing chain cover: Clean sealing surface -arrow- on inside
of oil filler neck with a lint-free cloth before screwing on filler
cap.
3.64 Engine oil: checking oil level and cor‐

recting if necessary
Caution
Risk of damage to catalytic converter if engine oil level is too

high!
♦ Drain engine oil until level meets specification.
Requirements for all engines except V6 diesel engines:

• Engine oil temperature at least 60 ℃.
• Wait a few minutes after switching off the engine to allow the
oil to flow back into the sump.
Requirements for V6 diesel engines:
• The engine must be at operating temperature (90 °C oil tem‐
perature).
• Wait approx. two minutes after switching off the engine to allow
the oil to drain back into the sump.
Checking oil level on MMI ⇒ page 68
3.64.1 Checking oil level on MMI

Procedure:
– If necessary, close bonnet.
– Press function selector button MENU . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Select »Car«. with respect to the correctness of information in this document. Copyright by AUDI AG.

structure:
68 3. Maintenance
Audi A4 2015 ➤
♦ Oil level
– Read off and evaluate oil level on display.
– If necessary, correct oil level:
Oil level Evaluation/measure

At “max” Drain engine oil until level meets optimum level.
Just under “max” Optimum oil level.
Significantly under “max” Fill up engine oil to optimum level (close bonnet to refresh oil level display).
Note
♦ The oil level display on the MMI is not refreshed when the
bonnet is open.
♦ A warning lamp in the driver information system indicates that
the level is too low.
3.65 Spark plugs: renewing


♦ Spark plug socket and extension - 3122B-
3. Maintenance 69
Audi A4 2015 ➤
♦ Puller - T 10530-
♦ Torque wrench - VAS 6583- , measuring range 3 to 60 Nm

Spark plugs 30
Bolt for fuel line 4
Bolt for crankshaft breather 9
Removal steps:
– Disconnect crankcase breather
Protected by copyright. hose
Copying for -1-.
private or commercial purposes, in part or in whole, is not
– Unplug electrical connectors -1- and -2- and move clear.
70 3. Maintenance
Audi A4 2015 ➤
– Unscrew bolt -2- and move fuel line clear.

– Move hose -4- for activated charcoal filter and coolant hose
-6- clear.
- G31- .
– Press release tabs and disconnect hose -2-.

– Unscrew bolts -arrows- and disconnect crankcase breather
hose -1- towards rear.
Step 1 - removing spark plugs: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Unscrew nuts for earth wires and move earthpermitted
wires clear.
– Push ignition coil connector -2- towards ignition coil, release

retainer and detach connector from ignition coil.
– Move connector -2- slightly to one side. Make sure that wiring
is not kinked or damaged.
3. Maintenance 71
Audi A4 2015 ➤
– Carefully pull ignition coil out upwards using puller - T10530- .

VAS 3122B- .

– Push ignition coils evenly onto spark plugs by hand (do not
attempt to knock in coils with any kind of tool).
– Tighten bolts -1- for ignition coils to specified torque (see table
of tightening torques for installation ⇒ page 70 ).
– Plug in connector -2- on each ignition coil until it engages.

♦ Spark plug socket and extension - 3122B-
72 3. Maintenance
Audi A4 2015 ➤
♦ Puller - T10530-


Spark plugs 30
Removal steps:
– Unplug electrical connectorProtected
-1- forbyLambda probefor- private
copyright. Copying G39-or.commercial purposes, in part or in whole, is not
3. Maintenance 73
Audi A4 2015 ➤
– Unscrew nut -2- for earth wire and move earth wire -1- clear.
– Push ignition coil connector towards ignition coil, release re‐
tainer and detach connector from ignition coil in direction of
-arrow-.
– Place electrical connector slightly to one side. Make sure that
wiring is not kinked or damaged.
– Carefully pull ignition coil out upwards using puller - T10530- .

VAS 3122B- .

– Push ignition coils evenly onto spark plugs by hand (do not
attempt to knock in coils with any kind of tool).
– Tighten bolts -arrows- for ignition coils to specified torque (see
table of tightening torques for installation ⇒ page 73 ).
74 3. Maintenance
Audi A4 2015 ➤
3.66 Cooling system: checking anti-freeze

and coolant level, and correcting if nec‐
essary
WARNING
Coolant expansion tank under pressure - risk of injuries!

♦ Only open coolant expansion tank when engine is cold.
Note
♦ Coolant additives may only be mixed with distilled water, as

the effectiveness of the coolant and the corrosion protection it
provides are greatly influenced by the quality of the water with
which the coolant is mixed. To ensure an adequate water
quality, the coolant additive should be mixed with distilled wa‐
ter.
♦ For approved coolant additives, refer to Electronic parts cata‐
logue (ETKA).
♦ G13 and G12++ may be mixed together.
♦ Coolant additives G13 and G12++ may be mixed with coolant
additives G11, G12 and G12+, though this may result in de‐
creased corrosion protection.
♦ G12 and G11 may NOT be mixed together.
♦ Only water/coolant additive may be used as lubricant for cool‐
ant hoses.
♦ It is permissible to operate the vehicle if the coolant level is
above the MAX marking on the coolant expansion tank (this is
by technical design). Do NOT extract coolant.
Checking coolant level and anti-freeze: all vehicles except 6-cyl.

diesel engine 3.0 ltr. TDI ⇒ page 75
Checking coolant level and anti-freeze: 6-cyl. diesel engine 3.0 ltr.
TDI ⇒ page 77
Filling up coolant ⇒ page 79

all vehicles except 6-cyl. diesel engine
3.0 ltr. TDI
3. Maintenance 75
Audi A4 2015 ➤

Delivery Inspection Coolant at level of MAX marking.
Inspection Coolant level between MIN and MAXtomarkings.
with respect the correctness of information in this document. Copyright by AUDI AG.
Checking the coolant system for leaks is a repair measure and

Requirements:
Maintenance table.
reduced again.
leaks .

border.
76 3. Maintenance
Audi A4 2015 ➤


road test.
Note

G11, G12, G12+ and G12++.
tection.

6-cyl. diesel engine 3.0 ltr. TDI

Delivery Inspection Top edge of floater flush with opening in coolant expansion tank
Inspection Top edge of floater between MIN marking and opening in coolant expansion tank
3. Maintenance 77
Audi A4 2015 ➤
Checking the coolant system for leaks is a repair measure and

Requirements:
Maintenance table.
reduced again.

leaks .

border.


road test.
78 3. Maintenance
Audi A4 2015 ➤
Note

G11, G12, G12+ and G12++.
tection.
♦ BecauseProtected
of its high boiling
by copyright. point,
Copying the coolant
for private improves
or commercial purposes, inengine
part or in whole, is not
reliabilitypermitted
under heavy
unless loadsbyinAUDI
authorised countries
AG. AUDIwith
AG doestropical climates.
not guarantee or accept any liability
3.66.3 Filling up coolant

Frost protection to: Coolant additive: Water:
-25 ℃ approx. 40 % approx. 60 %
-36 ℃ approx. 50 % approx. 50 %
Procedure:
– Add required amount (using mixture ratio according to anti-
freeze protection specification in Maintenance table). Use the
table as a reference for the coolant mixture ratio.
Note
Small quantities of coolant can simply be topped up. Use the

cooling system charge unit - VAS 6096- to add larger quantities
of coolant.
3.67 Air cleaner: renewing filter element and

cleaning housing
Note
♦ Use only silicone-free lubricants when installing intake hoses.

♦ Secure all hose connections with hose clips (same as original
equipment); see Electronic parts catalogue (ETKA).
3. Maintenance 79
Audi A4 2015 ➤
Air cleaner housing: cleaning ⇒ page 85

4-cyl. petrol engine 1.4 ltr. TFSI/2.0 ltr. TFSI (version 1)
⇒ page 80
4-cyl. petrol engine 2.0 ltr. TFSI (version 2) ⇒ page 81
3.67.1 4-cyl. petrol engine 1.4 ltr. TFSI/2.0 ltr.

TFSI (version 1)
Nm
Nm

-1-.
– Turn filter element in anti-clockwise direction -arrow A- and

remove it.

sary ⇒ page 85 .
80 3. Maintenance
Audi A4 2015 ➤
⇒ page 80 ).
Note
2.0 ltr. TFSI petrol engine ⇒ page 81 .
3.67.2 4-cyl. petrol engine 2.0 ltr. TFSI (version

2)
Nm
Nm

-1-.
3. Maintenance 81
Audi A4 2015 ➤


sary ⇒ page 85 .
⇒ page 81 ).
Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2.0 ltr. TFSI petrol engine ⇒ page 80 .

Nm
Nm
82 3. Maintenance
Audi A4 2015 ➤


-1-.


sary ⇒ page 85 .
⇒ page 82 ).

Nm
3. Maintenance 83
Audi A4 2015 ➤

Nm


– Remove securing bolts and detach air cleanerProtected
(top section)
-1-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability


sary ⇒ page 85 .
84 3. Maintenance
Audi A4 2015 ➤
⇒ page 84 ).
3.67.5 Cleaning air cleaner housing

Procedure:
– Remove any loose dirt or leaves out of air cleaner housing (top
and bottom sections).
– Check whether water drain hose in air cleaner (bottom section)
is dirty or blocked and clean if necessary.
Note
♦ When cleaning air cleaner housing with compressed air: Cov‐

er air mass meter with a clean cloth.
♦ On vehicles for cold countries, the snow screen in the intake
section must also be cleaned; see specification in ELSA Main‐
tenance table.
3.68 Dust and pollen filter: renewing

The dust and pollen filter is fitted under the glove box.
Removal steps:
– On vehicles with special equipment used by driving schools:
Remove pedal cluster if necessary; see installation instruc‐
tions for equipment for driving schools.
Step 1 - removing filter element:
– Cover footwell beneath dust and pollen filter with paper.
– Remove screw fasteners -A- and detach insulating mat -B-.
3. Maintenance 85
Audi A4 2015 ➤
– Release retaining tabs -A-, swivel cover -B- for aperture down
and detach.
– Pull filter element -E- out of aperture in direction of -arrow-.
Step 2 - installing filter element:

– Clean aperture with a vacuum cleaner before fitting new filter
element.
– Fit new filter element -E- correctly: arrow -D- points towards
fresh air blower.
Note
If the retainers -A- for the cover -B- are broken off on the heating
and air conditioning unit or on the service cover, the service cover
can also be secured to the heating and air conditioning unit using
four self-tapping screws -C- (e.g. 3.5 x 16 mm or 4.9 x 16 mm;
see Electronic parts catalogue ETKA). To do so, drill holes (4.5
mm diameter) in the cover -B- at attaching points marked -C-.
3.69 Fuel filter: renewing
WARNING

♦ Wear protective gloves.
♦ Wear safety goggles.
♦ Allow connections of fuel lines to cool down.
♦ Place cloths around connections and loosen them care‐
fully.
86 3. Maintenance
Audi A4 2015 ➤
♦ Torque wrench
Protected - V.A.G
by copyright. Copying1783- , measuring
for private rangein2part
or commercial purposes, toor10 Nm is not
in whole,
♦ Or: torque wrench - V.A.Gof1410- , measuring

in this document.range 4 by
toAUDI
20 AG.
with respect to the correctness information Copyright
Nm
♦ Container for collecting fluid

[Nm]
Nuts for bracket 8
The fuel filter is located on the underbody.

Removal steps:
– Remove underbody trim (right-side) ⇒ General body repairs,
Step 1 - removing fuel filter:
– Observe the safety precautions when working on the fuel sys‐
tem ⇒ Fuel supply system, diesel engines; Rep. gr. 00 ; Safety
precautions; Safety precautions when working on the fuel sys‐
tem .
– Swivel bracket -2- downwards, disengage it from mounting
points -arrows- and detach it.
– Place drip tray under fuel filter cartridge.
3. Maintenance 87
Audi A4 2015 ➤
– Use hose clip pliers to disconnect fuel supply hoses -1- and
-3- and detach fuel filter -2-.
Step 2 - installing fuel filter:

Flow direction for fuel filter cartridge is indicated by arrows on filter
housing.
– Then bleed fuel system ⇒ Engine; Rep. gr. 23 ; Injection sys‐
tem; Filling/bleeding fuel system .
3.70 Fuel tank: adding fuel additive

♦ Multi-purpose additive for petrol fuels - G 001 770 A2-
♦ Or: Multi-purpose
unless authorisedadditive for petrol fuel
not -guarantee
G 001or780 M3-
permitted by AUDI AG. AUDI AG does accept any liability

China, Middle East Russia India
VW 507 53 B: Applies to all petrol VW 507 53 B: Applies to all petrol VW 507 53 B: Applies to all petrol
engines engines engines
VW 507 53 A: Applies to all petrol VW 507 53 A: Applies to all petrol
engines except g-tron and E85 flex‐ engines except g-tron and E85 flex‐
ible fuel ible fuel
Multi-purpose additive for petrol Multi-purpose additive for petrol Multi-purpose additive for petrol
fuels - G 001 780 M3- fuels - G 001 780 M3- fuels - G 001 780 M3-
Multi-purpose additive for petrol Multi-purpose additive for petrol
fuels - G 001 770 A2- fuels - G 001 770 A2-
This maintenance item only applies to certain countries: Note

specification in Maintenance table.
Procedure:
– Follow measuring guidelines on fuel additive container and
add fuel additive to fuel tank according to current fuel tank
level.
Note
♦ Use only fuel additives that correspond to the standard VW

507 53 A or VW 507 53 B.
♦ After adding fuel additive, it is very important to tell the cus‐
tomer to fill up the fuel tank.
88 3. Maintenance
Audi A4 2015 ➤
3.71 Reducing agent (AdBlue®): filling up

tank completely
WARNING
Risk of injury due to contact with reducing agent!

♦ If you come into contact with this liquid: Rinse it off imme‐
diately with plenty of water and contact a medical profes‐
sional.
Caution
Risk of damage to trim and body components due to contact

with reducing agent!
♦ Clean the affected areas with clean water and a cotton
cloth.
♦ Remove any crystallised reducing agent using warm wa‐
ter and a sponge.
Note
♦ The reducing agent is statutory for vehicles with SCR system.

♦ The reducing agent is used for the after-treatment of exhaust
gases of diesel-engined vehicles, i.e. to reduce the level of
nitrogen oxides.
♦ The reducing agent is not a diesel additive and
Protected by must
copyright. not be
Copying for private or commercial purposes, in part or in whole, is not
filled into the diesel fuel tank. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Do not add any additives to the reducing agent, and do not
dilute it with water.
♦ Only use the reducing agent as supplied in its original con‐
tainer.
♦ In addition, please observe the reducing agent manufacturer's
notices on usage and storage.
♦ Both filling device for AdBlue - VAS 6542- and AdBlue refuel‐
ling system - VAS 6960- can be used to fill up the reducing
agent.
Filling up reducing agent (AdBlue®) using filling device for AdBlue

- VAS 6542- ⇒ page 89
Filling up reducing agent (AdBlue®) using AdBlue refuelling sys‐
tem - VAS 6960- ⇒ page 92

ing filling device for AdBlue - VAS 6542-
3. Maintenance 89
Audi A4 2015 ➤
♦ Filling device for AdBlue - VAS 6542-
♦ Mounting plate - V.A.G 1383A/1-
Components of filling device -VAS 6542-
90 3. Maintenance
Audi A4 2015 ➤
1 - Breather connection for re‐

ducing agent container
2 - Union nut for reducing
agent container
3 - Cut-off valve for breather
line
4 - Quick-release coupling on
breather line
5 - Filler line
6 - Cut-off valve for filler line
7 - Union nut for tank filler neck
8 - Breather line
– Open tank flap and unscrew with
caprespect
of reducing agent
to the correctness tank. in this document. Copyright by AUDI AG.
of information
– Close cut-off valves of breather and filler lines of filling device
for AdBlue - VAS 6542- .
– Apply filling device for AdBlue - VAS 6542- to reducing agent
container (see Electronic parts catalogue, ETKA) and screw it
on as far as stop.
3. Maintenance 91
Audi A4 2015 ➤
– Position reducing agent container on engine and gearbox jack

- VAS 6931- with mounting plate - V.A.G 1383A/1- . The dif‐
ference in height of the reducing agent container and the filler
neck of the tank for reducing agent must be between
60 - 80 cm -dimension A-.
– Position filling device for AdBlue - VAS 6542- on filler neck on

vehicle and screw it on as far as stop.
– Open cut-off valve for breather line.
– Open cut-off valve for filler line and fill reducing agent tank of
vehicle completely. Tank is completely full when container
contracts and bleeder line fills with liquid.
– Close cut-off valve for filler line.
– Close cut-off valve for breather line.
– Disconnect quick-release coupling on breather line and let any
excess liquid flow into a suitable container.
– Unscrew filling device for AdBlue - VAS 6542- from tank filler
neck.
– Take container off mounting plate and put it on the floor.
– Open cut-off valve on filler line and let remaining liquid drain
back into container.
– Unscrew filling device for AdBlue - VAS 6542- from container.

ing AdBlue refuelling system - VAS
6960-
92 3. Maintenance
Audi A4 2015 ➤
♦ AdBlue refuelling system - VAS 6960-
Procedure:
– Open tank flap and unscrew filler cap for reducing agent tank.
– Insert nozzle of AdBlue refuelling system - VAS 6960- into filler
neck of reducing agent tank.
– Operate nozzle to fill up reducing agent completely.
– Remove nozzle from filler neck of reducing agent tank.
Note
♦ Observe operating instructions for AdBlue refuelling system -

VAS 6960- .
♦ Nozzle of AdBlue refuelling system - VAS 6960- switches off
automatically when maximum fill level is reached.
3.72 Vehicle doors: removing edge protec‐

tion
Procedure:
– Carefully remove edge protection from all vehicle doors.
3.73 Vehicle exterior: checking unprotected

areas for dirt, and cleaning if necessary
Procedure:
– Check unprotected areas of vehicle exterior not covered by
car cover or protective transport film for dirt/soiling.
– Clean any dirty areas.
3.74 Vehicle exterior: removing protective

film
Procedure:
– Remove protective film carefully and completely.
3. Maintenance 93
Audi A4 2015 ➤
3.75 Protective transport film and car cover:

checking position and correcting if nec‐
essary
Procedure:
– Check, and if necessary, correct position of car cover on ve‐
hicle body.
– Check, and if necessary, correct position of protective trans‐
port film.
3.76 Protective transport film: renewing ac‐

cording to manufacturer's instructions
Procedure:
– Go to “http://www.tesa.com/extranet” and log in using the fol‐
lowing details:
♦ Login / E-mail: Bodyguard 50530
♦ Password: PflegeVW
– Order protective transport film, adding the following note:
♦ For Audi vehicles
♦ Ordering number: APS 277 140 (1400 mm)
– Apply new protective transport film according to manufactur‐
er's instructions.
Note
♦ Do not apply protective transport film to vehicles with PR num‐

ber “5K0” on the windscreen; these have been ordered inten‐
tionally without film.
♦ On vehicles with a fabric convertible roof, do not remove the
protective transport covering put in place at the factory.
3.77 Car cover: renewing according to man‐

ufacturer's instructions
Procedure:
– Remove car cover.
– Cover vehicle with a new car cover according to manufactur‐
er's instructions.
3.78 Paintwork, trims, side windows and wip‐

er blades: checking cleanliness
Procedure:
– Check that exterior paintwork, trims, side windows and wiper
blades are clean.
– Clean any dirty components.
94 3. Maintenance
Audi A4 2015 ➤
3.79 Body: checking vehicle paintwork for

damage and corrosion from below and
with bonnet, rear lid and doors open
Procedure:
– Open all vehicle doors, bonnet and rear lid.
– Check vehicle paintwork on inside and outside of body for
damage and corrosion.
– Rectify defects of any kind (repair measure).
3.80 Vehicles parked outdoors: locking

Procedure:
– Use vehicle key to lock vehicle if it is parked outdoors.
3.81 Vehicles parked outdoors: covering un‐

protected vehicles with protective trans‐
port film and car cover (not for vehicles
with control number 5K0 on data sticker
on windscreen)
Procedure:
– Apply protective transport film ⇒ page 94 .
– Cover vehicle with car cover ⇒ page 94 .
3.82 Road test

Procedure:
– The following points must be checked during the road test:
♦ Engine: performance, misfiring, idling speed, acceleration,
starting behaviour (engine cold and warm), engine noise
♦ Clutch: pulling away, pedal pressure, odours, noise due to
load change
♦ Manual gearbox: ease of operation, gear lever position, gear‐
box noise
♦ Automatic gearbox: selector lever position, shift lock / ignition
key lock, gearbox noise, kickdown, shift behaviour, instrument
cluster display
♦ Brake pedal and handbrake: operation, travel and effective‐
ness, pulling to one side, response (delayed braking), judder‐
ing, squeal
♦ ABS function: pulsing must be felt at the brake pedal when
performing ABS-controlled braking.
♦ Steering: operation, steering free play, steering wheel central‐
ised when wheels are in straight-ahead position, moving off
line when travelling straight
♦ Imbalance: wheels, drive shafts
♦ Wheel bearings: noises
♦ Roof insert: unusual noise during operation
♦ Horn: checking with respect to the correctness of information in this document. Copyright by AUDI AG.
3. Maintenance 95
Audi A4 2015 ➤
Note
To what extent all of these can be checked depends on vehicle

equipment and local conditions (urban/country).
3.83 Stock vehicles: observing measures

specified in Maintenance table for stock
vehicles (see “Before handing vehicle
over toProtected
customer”)
This maintenance item only applies
with respect to stock ofvehicles.
to the correctness information in this document. Copyright by AUDI AG.
Procedure:
– Before handing vehicle over to customer: Check whether the
following three measures for stock vehicles (as specified in the
Maintenance table) are due, and carry them out as necessary:
♦ For vehicles older than 12 months (from date of manufacture):
Renew brake fluid ⇒ page 26 .
♦ For vehicles with defective battery: Renew battery ⇒ Rep. gr.
27 ; Battery; Removing and installing battery .
♦ Check brake discs for surface rust; if necessary, operate
brakes to remove rust according to manufacturer's instruc‐
tions.
– Record measures performed in maintenance table for stock
vehicles.
3.84 Accessories: installing

Procedure:
– If included with vehicle, place the following accessories in ve‐
hicle tool kit:
♦ Adapter for anti-theft wheel bolts
♦ Puller
♦ Plastic clip
Note
♦ The available accessories may vary according to model,

equipment and market.
♦ Depending on the vehicle model, the accessories may be
found in the luggage compartment, glove box or supplied
pack.
3.85 Check list "Documentation of cleaning

and care routine": checking availability
Procedure:
– Check that checklist “Documentation of cleaning and care rou‐
tine” is in glove box.
– If missing, place checklist “Documentation of cleaning and
care routine” in glove box.
96 3. Maintenance
Audi A4 2015 ➤
3.86 Check list "Documentation of cleaning

and care routine": signing and placing in
vehicle wallet
Procedure:
– Sign checklist “Documentation of cleaning and care routine”
and place it in vehicle wallet.
3.87 Cleaning and care: checking that re‐

quired measures have been carried out
on time
Procedure:
– Check that all cleaning and care measures due previously
were carried out on time.
– Carry out and document any cleaning and care which is due.
3.88 Stock vehicle care management: decid‐

ing and recording dateauthorised
of next check
permitted unless by AUDI AG. AUDI AG does not guarantee or accept any liability
Procedure:
– Decide date of next check with person in charge of stock ve‐
hicle care management.
– Record chosen date in maintenance table.
3.89 Display instruments: setting time and

date
Procedure:
– Change settings of display instruments: Refer to Operating
Manual for radio/sound system/MMI system.
3.90 Manual gearbox/automatic gearbox: se‐

lecting 1st gear/park
Procedure:
Vehicles with manual gearbox: Select 1st gear.
Vehicles with automatic gearbox: Select park.

ATF
Procedure:
– Change ATF according to Workshop Manual ⇒ ; Rep. gr. 37 ;
ATF; Draining and filling ATF .

ATF and renewing exchangeable ATF
filter
Procedure:
– Change ATF according to Workshop Manual ⇒ Rep. gr. 34 ;
– Change exchangeable ATF filter according to Workshop Man‐
ual ⇒ Rep. gr. 34 ; Mechatronic unit; Removing and installing
ATF filter .
3. Maintenance 97
Audi A4 2015 ➤

ATF and renewing exchangeable ATF
filter (if fitted)
Procedure:
– Change ATF according to Workshop Manual ⇒ Rep. gr. 34 ;
– Change exchangeable ATF filter according to Workshop Man‐
ual ⇒ Rep. gr. 34 ; Mechatronic unit; Removing and installing
ATF filter .
3.94 Interior mirror: calibrating compass

Procedure:
– Calibrate compass according to Workshop Manual ⇒ General
body repairs, interior; Rep. gr. 68 ; Interior mirror; Calibrating
digital compass .
3.95 Instrument cluster: resetting driver infor‐

mation system
– Reset single journey memory and total journey inmemory of Copyright by AUDI AG.
with respect to the correctness of information this document.
driver information system; refer to vehicle Owner's Manual.
3.96 Toothed belt for camshaft drive: renew‐

ing
Procedure:
3.97 Toothed belt for camshaft drive and ten‐

sioning roller: renewing
Procedure:
– Renew tensioning roller according to Workshop Manual ⇒ ;
Rep. gr. 15 ; Toothed belt drive; Exploded view - toothed belt .
98 3. Maintenance
Service
Workshop Manual
Audi A4 2015 ➤
Technical data for engines
Engine ID
CWN CWP CWG CVK DEU DET DEU DEU CYR
A B D B B A A C C
DFV CSW CRT CYM CVN CYR DBP DES CZH
A B C C A B A A A
DET DEM DCP DDW CVLA DHD DEC DKN DLVB
B A C A A A A
DKY DEZ DEZ DMT DLVA
A B E A
Edition 04.2019

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data

Copyright © 2019 Audi AG, Ingolstadt D4B805AB65B

Audi A4 2015 ➤
Technical data for engines - Edition 04.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Overview of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Overview of engines with adjustment values (oil gauge tester T40178) . . . . . . . . . . . . . . 1
Contents i
Audi A4 2015 ➤
ii Contents
Audi A4 2015 ➤
00 – Technical data
1 Overview of engines
(ARL006414; Edition 04.2019)
⇒ “1.1 Overview of engines with adjustment values (oil gauge
tester T40178)”, page 1
1.1 Overview of engines with adjustment

values (oil gauge tester T40178)
Audi A4 - vehicle model code 8W ⇒ page 1
1) Not available at time of publication.
1.1.1 Audi A4 - vehicle model code 8W

Petrol engines
En‐ En‐ Ca‐ Injec‐ Power Tor‐ Cam‐ Stroke Bore Com‐ Ad‐ Min. Max.
gine gine pacity tion output que shaft [mm] [mm] press‐ just‐ oil lev‐ oil lev‐
code type/ [ltr.] sys‐ [kW] [Nm] drive ion ra‐ ment el el
num‐ tem (rpm) (rpm) tio value
ber of [:1] for ad‐
cylin‐ juster
ders ring
CVKB R4 2.0 FSI 140 320 Tim‐ 92.8 82.5 11.65 60 0 16
4200- 1350- ing
6000 4100 chain
CVLA R4 2.0 FSI 125 270 Tim‐ 92.8 82.5 12.6 55 0 18
5000- 1600- ing
5500 4000 chain
CVNA R4 1.4 FSI 110 250 Tooth‐ 80 74.5 10 31 0 22
5000 1500- ed
3500 belt
CWG V6 3.0 FSI 260 500 Tim‐ 89 84.5 11.2 76 0 16
D 5300 1500- ing
5300 chain
CWN R4 2.0 FSI 140 320 Tim‐ 92.8 82.5 11.65 60 0 16
A 4200- 1450- ing
6000 4200 chain
CWP R4 2.0 FSI 185 370 Tim‐ 92.8 82.5 9.60 60 0 16
B 5000- 1600- ing
6000 4500 chain
CYM R4 2.0 FSI 185 370 Tim‐ 92.8 82.5 9.6 60 0 16
C 4900- 1600- ing
5900 4700 chain
CYRB R4 2.0 FSI 185 370 Tim‐ 92.8 82.5 9.6 60 0 16
5000- 1600- ing
6000 4500 chain
CYRC R4 2.0 FSI 183 370 Tim‐ 92.8 82.5 9.6 60 0 16
5000- 1600- ing
6000 4500 chain
DBPA R4 2.0 FSI 140 320 Tim‐ 92.8 82.5 11.65 60 0 16
4200- 1350- ing
6000 4100 chain
1. Overview of engines 1
Audi A4 2015 ➤
cylin‐ juster
ders ring
DDW R4 2.0 FSI 185 370 Tim‐ 92.8 82.5 9.60 60 0 16
A 5000- 1600- ing
6000 4500 chain
DECA V6 2.9 FSI 331 600 Tim‐ 86.0 84.5 10.0 76 0 14
5700- 1700- ing
6700 5000 chain
DEMA R4 2.0 FSI 140 320 Tim‐ 92.8 82.5 11.65 60 0 16
4200- 1450- ing
6000 4200 chain
DHDA R4 2.0 FSI 140 320 Tim‐ 92.8 82.5 11.65 60 0 16
4200- 1450- ing
6000 4200 chain
DKNA R4 2.0 FSI 180 370 Tim‐ 92.8 82.5 9.60 60 0 16
5000- 1600- ing
6000 4500 chain
DLVA R4 2.0 FSI 140 320 Tim‐ 92.8 82.5 11.65 60 0 16
4200- 1450- ing
6000 4200 chain
DLVB R4 2.0 FSI 110 270 Tim‐ 92.8 82.5 11.65 60 0 16
3900- 1250- ing
6000 3900 chain
Diesel engines
cylin‐ juster
ders ring
CRTC V6 3.0 TDI 200 600 Tim‐ 91.4 83 16 99 0 13
com‐ 4000 1700- ing
mon 2750 chain
rail
CSW V6 3.0 TDI 160 400 Tim‐ 91.4 83 16 99 0 13
B com‐ 4000 1250- ing
mon 3200 chain
rail
CZHA R4 2.0 TDI 110 320 Tooth‐ 95.5 81 15.5 13 0 18
com‐ 3250- 1500- ed
mon 4200 3250 belt
rail
DCPC V6 3.0 TDI 210 620 Tim‐ 91.4 83 15.50 99 0 13
com‐ 4000 1750- ing
mon 3000 chain
rail
DESA R4 2.0 TDI 140 400 Tooth‐ 95.5 81 15.5 13 0 18
com‐ 3800- 1750- ed
mon 4200 3000 belt
rail
2 Rep. gr.00 - Technical data

Audi A4 2015 ➤
cylin‐ juster
ders ring
DETA R4 2.0 TDI 140 400 Tooth‐ 95.5 81 15.5 13 0 18
com‐ 3800- 1750- ed
mon 4200 3000 belt
rail
DETB R4 2.0 TDI 120 400 Tooth‐ 95.5 81 15.5 13 0 18
com‐ 3000- 1750- ed
mon 4200 2750 belt
rail
DEUA R4 2.0 TDI 110 320 Tooth‐ 95.5 81 16.2 13 0 18
com‐ 3250- 1500- ed
mon 4200 3250 belt
rail
DEUB R4 2.0 TDI 100 320 Tooth‐ 95.5 81 16.2 13 0 18
com‐ 3000- 1500- ed
mon 4400 3000 belt
rail
DEUC R4 2.0 TDI 90 270 Tooth‐ 95.5 81 16.2 13 0 18
com‐ 4200 1750- ed
mon 2500 belt
rail
DFVA R4 2.0 TDI 140 400 Tooth‐ 95.5 81 16.2 13 0 18
com‐ 3500- 2000- ed
mon 4000 3250 belt
rail
1. Overview of engines 3
Service
Workshop Manual
Audi A3 2013 ➤
Audi A4 2015 ➤
Audi A5 2016 ➤
Natural gas engines - General information
Engine ID
CPW CVLA DHF
A A
Edition 04.2019

Service
Repair Group
00 - Technical data
20 - Fuel supply system

Copyright © 2019 Audi AG, Ingolstadt D4B806FF7C8

Audi A3 2013 ➤ , Audi A4 2015 ➤ , Audi A5 2016 ➤
Natural gas engines - General information - Edition 04.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on the natural gas system . . . . . . . . . . . . . . . . . . . . . . 1
2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 General information on natural gas engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Controlled gas release and uncontrolled gas escape . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Safety briefing/employee qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Reception of vehicles with natural gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5 Laws and regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.1 Legal regulations and guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Requirements for the work station for vehicles with natural gas system . . . . . . . . . . . . . . 7
6 Basic technical and physical principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1 Physical properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7.2 Painting work on vehicles with natural gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8 Checking natural gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8.1 Test requirements for gas systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8.2 Checking natural gas system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8.3 Leak test with gas leak detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8.4 Leak test with leak detection spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1 Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.1 Handling natural gas fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2 Assessing damage to fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3 Storing natural gas fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.4 Handling unpressurised natural gas fuel tanks made of composite fibre materials . . . . . . 30
1.5 Setting up and marking a protected area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.6 Discharging natural gas fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.7 Determining residual pressure in natural gas fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.8 Rendering natural gas fuel tanks inert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.9 Disposing of natural gas fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Contents i
ii Contents
1 Safety precautions
(ARL006345; Edition 04.2019)
⇒ “1.1 Safety precautions when working on the natural gas sys‐
tem”, page 1
1.1 Safety precautions when working on the natural gas system

Risk of explosion due to uncontrolled gas escape in connection
with ignition sources and electrostatic discharge - risk of death!
Danger of severe or fatal injuries due to explosion.
– Never drive a vehicle with a natural gas system into the work‐
shop if you can clearly hear gas escaping. Instead, park the
vehicle outside and set up a protected area ⇒ Natural gas
engines - General information; Rep. gr. 20 ; Fuel tanks; Set‐
ting up and marking a protected area .
– Work on natural gas systems may only be performed by spe‐
cially trained persons ⇒ Natural gas engines - General infor‐
mation; Rep. gr. 00 ; Safety briefing/employee qualification .
– Gas tank must be closed manually on vehicles with natural gas
systems if gas can be heard escaping and smelt ⇒ Fuel supply
system - g-tron; Rep. gr. 20 ; Fuel tanks; Closing fuel tank
shut-off valves mechanically .
Risk of explosion due to ignition sources - risk of death!

Risk of explosion due to ignition sources near natural gas systems
- risk of death! Escaping natural gas may ignite and cause an
explosion. Danger of severe or fatal injuries due to explosion.
– Keep any ignition sources away from the vicinity of natural gas
systems.
Risk of explosion due to flammable natural gas - risk of death!

Risk of explosion due to static discharge near natural gas systems
– Wear protective clothing consisting of at least 35% cotton.
– Wear protective gloves consisting of at least 35% cotton.
– Wear safety shoes with ESD protection.
Risk of injury due to high pressure

Uncontrolled gas escape may occur under high pressure. Danger
of frostbite to hands and other parts of the body.
– Dissipate high pressure in natural gas system before perform‐
ing work on natural gas system ⇒ Fuel supply system - g-tron;
1. Safety precautions 1
Rep. gr. 20 ; Fuel tanks; Dissipating pressure in natural gas

high-pressure pipe .
– Check for leaks after performing work on the natural gas sys‐
tem.

2 General notes
⇒ “2.1 General information on natural gas engines”, page 3
⇒ “2.2 Controlled gas release and uncontrolled gas escape”, page
3
2.1 General information on natural gas en‐

gines
♦ A3: Self-study programme no. 621 ⇒ Self-study programme
No. 621 ;
♦ A4, A5: Self-study programme no. 659 ⇒ Self-study pro‐
gramme No. 659 ;
2.2 Controlled gas release and uncontrolled

gas escape
Controlled gas release
Controlled gas release refers, for example, to opening the me‐
chanical tank shut-off valve on a repaired and closed gas system
briefly with the hand wheel and then closing it again in order to
subsequently perform a leak test. In this case, the largest amount
of gas that could escape from a leaking gas system would, at
most, be the amount of gas in the pipe. This procedure is per‐
missible at the work station for natural gas vehicles.
– Switch ignition off again after controlled gas release.
Uncontrolled gas escape
Uncontrolled gas escape refers to gas continuing to escape from
the fuel tank even though the ignition has been switched off or the
tank shut-off valves have been closed, or to a leak where the
tanks are not closed electrically or manually.
DANGER
– Never bring vehicles with uncontrolled gas escape into the
workshop.
– Leave vehicles with uncontrolled gas escape outdoors.
– Set up a protected area of 10x10 m.
– The protected area must be kept under permanent supervi‐
sion.
– Never bring ignition sources into the protected area.
– Set up a protected area ⇒ page 31 .
2. General notes 3
3 Safety briefing/employee qualifica‐

tion
Which qualifications are required?
Work Qualifications/requirements
General work on the vehicle ♦ Instruction at dealership
♦ Country-specific requirements
Work on natural gas system ♦ Training by Audi

Leak test, approving or starting up system ♦ Training by Audi

♦ Legal provisions
Note
The information in ELSA and the Offboard Diagnosis Information

System (ODIS) must be observed and followed when working on
vehicles with natural gas system.
Who must receive a safety briefing?

♦ All employees of dealerships/workshops who come into con‐
tact with vehicles with natural gas system must be appropri‐
ately instructed on how to work safely with natural gas
vehicles.
♦ The safety briefing must be repeated at least once a year.
Why is a safety briefing necessary?
♦ In some countries, every employer is obliged to inform and
instruct their employees about dangers in the workshop as
part of their duty of care.
♦ Audi requests employers to provide a safety briefing even if
this obligation does not apply in their country.
♦ Note country-specific regulations.
♦ The safety briefing must be updated if necessary, e.g. when
new vehicle technologies are introduced or when new legal
requirements come into force.
Content of the safety briefing
♦ How do I recognise a natural gas vehicle?
♦ Which components contain gas?
♦ Which repairs/tasks on components on the vehicle which do
not contain gas am I permitted to perform as an instructed
person?
♦ How do I recognise a vehicle with a leak?
♦ How should I behave around a vehicle with a leak?
♦ What safety regulations need to be adhered to? For example,
avoiding ignition sources or covering components.
♦ How do I recognise a vehicle with a leak?

♦ How can I secure a vehicle with a leak? For example, by clos‐

ing the tank shut-off valves with the hand wheel.
♦ Which training course do I need to take to be permitted to work
on components containing gas?
♦ What is controlled gas release and uncontrolled gas escape
⇒ page 3 ?
Who can perform the safety briefing?
♦ Anyone in the dealership who is qualified to work on the natural
gas system can instruct the other dealership employees.
Documentation of safety briefing
♦ The documentation must specify (in writing) who was instruc‐
ted, what content was presented and when the briefing took
place. The documentation of the safety briefing must be ad‐
ministered in the dealership documentation by the responsible
senior staff member.
3. Safety briefing/employee qualification 5

4 Reception of vehicles with natural

gas system
Note
The information in ELSA and the Offboard Diagnosis Information

System (ODIS) must be observed and followed when working on
vehicles with natural gas system.
Identifying a natural gas vehicle

A reliable method of identifying a vehicle with natural gas system
is to check for the additional filler neck for gas -1- behind the tank
flap next to the filler neck for petrol -2-.
Reception of vehicles with natural gas system
• When vehicles are taken in for repair, check for any indications
of leaks in the gas system.
• If there is reason to suspect leaks in the gas system, any fur‐
ther measures or repairs must be performed outdoors or at the
work station for vehicles with natural gas system.
• If the leak CANNOT be stopped by switching off the ignition or
closing the tank shut-off valves, the vehicle must remain out‐
doors and be kept under observation.
DANGER
– Never bring vehicles with uncontrolled gas escape into the
workshop.
– Leave vehicles with uncontrolled gas escape outdoors.
sion.
• If the leak can be stopped by switching off the ignition or clos‐

ing the tank shut-off valves, all further work can be performed
at the work station for vehicles with natural gas system.
• The vehicle can also be worked on at a normal work station if
there is no reason to suspect leaks and if work on the gas
system is not necessary.

5 Laws and regulations

⇒ “5.1 Legal regulations and guidelines ”, page 7
⇒ “5.2 Requirements for the work station for vehicles with natural
gas system”, page 7
5.1 Legal regulations and guidelines

Country-specific laws, regulations and guidelines apply to work
with natural gas and natural gas systems.
Some examples of the regulations which apply in Germany are:
♦ Technical regulations for technical gases (pressurised gases)
= TRG
♦ Technical Rules for Hazardous Substances = TRGS
♦ Technical workplace safety regulations = TRBS
5.2 Requirements for the work station for

vehicles with natural gas system
♦ Sufficient natural or technical ventilation of the work station for
vehicles with natural gas system means that air exchange
must be guaranteed at least three times an hour for the dura‐
tion of controlled gas release. Definition of controlled gas
release ⇒ page 3
♦ It is advisable to locate the work station near doors, windows
and/or skylights if the work station is to be ventilated naturally.
♦ It is advisable to install a gas detector at the work station for
vehicles with natural gas system. The gas detector (which is
fitted on the ceiling) ensures that a warning is given before the
lower explosive limit is reached.
♦ Always follow country-specific regulations.
5. Laws and regulations 7

6 Basic technical and physical princi‐

ples
⇒ “6.1 Physical properties”, page 8
6.1 Physical properties

Physical data of dry natural gas
Note
Dry natural gas does not form methane hydrates. Methane hy‐
drates can lead to deposits in the components.
Chemical formula CH4

Methane content 79-99 %
Properties Colourless
Odour Odourless but can be odorised (odorant mixed in)
Boiling point at 1 bar -161 °C
Ignition temperature Approx. 575 °C to 625 °C
Ignition threshold Lower explosive limit (LEL): 4 vol.-%
Upper explosive limit (UEL): 17 vol.-%
Relative density (air = 1) 0.55 to 0.75 (therefore lighter than air)
RON 130-140
Energy content 1 kg: approx. 13.5 kWh
Colour Natural gas is invisible
Reaction with metals Gas impurities can lead to certain metals and plastics corroding. This can
cause blockages, leaks and deposits on springs and valves
Water content Only very small amounts of water are soluble in liquid gas
Combustibility Natural gas is a highly flammable gas. It can form explosive/flammable va‐
pour/air mixtures

7 Repair instructions
⇒ “7.1 Rules for cleanliness”, page 9
⇒ “7.2 Painting work on vehicles with natural gas system”,
page 9
7.1 Rules for cleanliness

Even small quantities of dirt can lead to defects. For this reason,
please observe the following rules when working on the fuel sup‐
ply system and injection system:
♦ Clean connections and surrounding areas thoroughly with
cleaning agent - D 009 401 04- before loosening; commercially
available brake cleaner can damage the surfaces. Dry cleaned
area thoroughly.
♦ Seal off open pipes and connections immediately with clean
plugs, e.g. from engine bung set - VAS 6122- .
♦ After removal, place parts on a clean surface and cover them.
Only use lint-free cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use any
parts that have been unpacked previously and stored away
loosely (e.g. in a tool box).
♦ Do not work with compressed air when the system is open.
♦ Do not move vehicle.
♦ Immediately seal open lines and unions with clean plugs, for
example from engine bung set - VAS 6122- .
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
7.2 Painting work on vehicles with natural

gas system
• When performing paintwork repairs, object temperatures of 60
°C (80 °C in a painting oven) must not be exceeded in drying
ovens or their preheating zones. Do not expose vehicles to
high temperatures for more than one hour.
• The vehicle must only be placed in the drying oven once it has
cooled down from its operating temperature.
• The vehicle’s natural gas fuel tanks must be a maximum of 7/
8 full when the vehicle is put in the drying oven. The fill level
indicator must have already gone down by one segment.
7. Repair instructions 9
8 Checking natural gas system

⇒ “8.1 Test requirements for gas systems”, page 10
⇒ “8.2 Checking natural gas system for leaks”, page 10
⇒ “8.3 Leak test with gas leak detector”, page 15
⇒ “8.4 Leak test with leak detection spray”, page 16
8.1 Test requirements for gas systems

• At least 160 bar of pressure in the natural gas fuel tanks (i.e.
filled to at least 80%).
• The exhaust emissions warning lamp in the dash panel insert
must not light up.
• There must not be any entries in the event memory of the en‐
gine control unit relating to the natural gas system ⇒ Vehicle
diagnostic tester.
• No cut-off criteria for the gas system in Measured values in
“Guided Fault Finding” ⇒ Vehicle diagnostic tester.
• All areas of gas system that require testing must be accessi‐
ble.
• A draught over 0.5 m/s (slow gust of air) will cause incorrect
measurement results. It is therefore very important to ensure
that the work area is free of draughts.
8.2 Checking natural gas system for leaks

⇒ “8.2.1 Checking natural gas system for leaks”, page 10
⇒ “8.2.2 Checking natural gas system for leaks after working on
high-pressure section”, page 12
⇒ “8.2.3 Checking natural gas system for leaks after working on
low-pressure section”, page 13
8.2.1 Checking natural gas system for leaks

♦ This Workshop Manual describes different methods of check‐
ing for leaks in the gas system. These methods have been
tested and, when applied correctly for particular problems,
lead to reliable results under various operating conditions.
♦ Minor leaks can be detected with an electronic leak detector
or leak detection spray, for example.
♦ There are numerous methods available on the open market
for the detection of leaks. They do not always deliver clear
results and may also cause various components of the gas
system to be identified as leaking when they are not. In addi‐
tion, certain procedures may damage or cause excessive
wear to gas system components.
DANGER
– Never repair components on which a leak has been found.
– Never fill a leaking gas system with gas.
– Check pressure of natural gas system ⇒ page 14 .

Test requirements
• Natural gas fuel tanks must be filled to min. 80% if the natural
gas fuel supply system is to be checked for leaks.
• The vehicle must be filled up at a filling station to achieve this.
• The vehicle must not be driven in natural gas mode without
successfully passing the leak test.
• To make sure that no uncontrolled escape of natural gas oc‐
curs after refilling and before the leak test, the relay for gas
shut-off valves - J908- must be removed from the relay carrier.
Note
♦ Pulling out the relay for gas shut-off valves - J908- closes the
gas shut-off valves electrically. It is still possible to refill the
tank.
♦ The natural gas system is deactivated and it is no longer pos‐
sible for larger amounts of gas to escape at locations where
there are leaks.
– Drive to filling station in petrol mode.

After refilling
– Drive back to workshop (vehicle must be in petrol mode).
– Before driving into the workshop, re-activate natural gas mode
by inserting relay for gas shut-off valves - J908- .
♦ Fuel tank shut-off valves are only actuated for approx. 2 sec‐
onds when the ignition is switched on.
♦ A mechanical »clicking« noise can be heard.
♦ While the fuel tank shut-off valves are being actuated, you
must listen for the sound of gas escaping at the area being
worked on.
♦ If the valves are not actuated, an adaption drive must be per‐
formed to activate the natural gas system.
♦ The adaption drive can only be performed successfully by en‐
tering the engine's part-load zone several times.
♦ You can check that the natural gas system has been activated
by examining the natural gas system’s fuel level display.
– Before driving the vehicle into the workshop, check whether
you can hear the sound of gas escaping.
If you can hear sound of gas escaping:
DANGER
Risk of explosion due to escaping natural gas - risk of death!
The sound of gas escaping indicates that there are leaks in the
natural gas system. Leaks in the natural gas system can cause
uncontrolled escape of natural gas.
– Never work on a natural gas system if you can hear gas es‐
caping.
– Never drive the vehicle into the workshop if you can hear gas
escaping.
– Park the vehicle outside and set up a protected area.
8. Checking natural gas system 11

– Set up a protected area (observe safety measures

⇒ “1.1 Safety precautions when working on the natural gas
system”, page 1 ).
– Activate petrol mode using the following adaption : Switch
mode ⇒ Vehicle diagnostic tester.
– Wait until sound of gas escaping can no longer be heard.

If sound of gas escaping can no longer be heard:
– Drive vehicle into workshop.
– Loosen all bolted connections which were previously loosened
during repair work and then tighten to specified torque.
– Drive vehicle out of workshop.
– Deactivate petrol mode using the following adaption :
Switch mode ⇒ Vehicle diagnostic tester.
– Check whether you can hear sound of gas escaping.

If sound of gas escaping cannot be heard:
– Drive vehicle into workshop.
– Perform leak test after working on high-pressure section
⇒ “8.2.2 Checking natural gas system for leaks after working
on high-pressure section”, page 12 , or after working on low-
pressure section
on low-pressure section”, page 13 .

after working on high-pressure section
DANGER
caping.
escaping.
– Perform gas system inspection:

♦ A3 ⇒ Maintenance ; Booklet 821 ; Maintenance; Natural gas
system: checking for damage and leaks .
♦ A4, A5 ⇒ Maintenance ; Booklet 830 ; Maintenance; Natural
gas system: checking for damage and leaks .
• Natural gas fuel tanks must be filled to min. 80% if the natural
gas fuel supply system is to be checked for leaks.
DANGER
Leaks in the natural gas system can cause uncontrolled escape
of natural gas. Danger of severe or fatal injuries due to explo‐
sion.
– Check natural gas system for leaks.

The vehicle must only be handed over to the customer after the
leak test has been passed successfully.

after working on low-pressure section
• Checking the natural gas system for leaks after working on the
low-pressure section does not replace the necessity to check
for leaks as part of maintenance work.
• Only specially trained staff may perform work and check for
leaks on natural gas systems.
• The natural gas system must be checked for leaks if gas-con‐
veying components are loosened or renewed in the low-pres‐
sure section.
♦ Gas leak detector - VAS 523 003-
♦ Leak detection spray (commercially available)

Test requirements
• Test pressure: low-pressure section approx. 5 bar, transition
between low-pressure section and high-pressure section 160
… 200 bar
on high-pressure section”, page 12
• As soon as the system is activated, it can be expected that the
required minimum pressure of 5 … 12 bar will be reached.
• If the system is not activated, it is not possible to perform a
reliable test. Fill natural gas system.
• All bolted connections must be tightened to specified torque.
If the fuel tank shut-off valves were previously closed electrically
or mechanically:
– Re-install relay for gas shut-off valves - J908- .
– Open all fuel tank shut-off valves.
– Activate natural gas mode using the following adaption :
Switch mode ⇒ Vehicle diagnostic tester.

DANGER
caping.
escaping.
– Observe safety precautions

⇒ “1 Safety precautions”, page 1 .
• Gas leak detector - VAS 523 003- can only detect whether
there is natural gas in the ambient air.
• The results of the test using the gas leak detector are only
satisfactory if the green LED for “O.K.” lights up.
• If a yellow or red LED lights up, a leak detector spray must be
used to verify definitively whether gas is actually escaping
from the vehicle’s natural gas system.
• When using the leak detector spray, bubbles must not emerge
from the sprayed area during a test period of three minutes.
• If any leaks appear, a repair measure must be carried out to
rectify the problem, and the leak test must then be repeated.
Procedure
– Determine pressure of natural gas system via Read measured
values function by reading off current pressure of tank pres‐
sure sensor ⇒ Vehicle diagnostic tester.
– All connections and components which have been opened or
renewed must be checked using the gas leak detector - VAS
523 003- and a leak detector spray.
DANGER
Leaks in the natural gas system can cause uncontrolled escape
of natural gas. Danger of severe or fatal injuries due to explo‐
sion.
– Check natural gas system for leaks.
– Move gas leak detector around the location being checked for
leaks by 90°, keeping it at each point for at least 5 seconds.
If leaks are found using gas leak detector - VAS 523 003- :
– Spray connection or component with leak detector spray and
observe for approx. 3 minutes. No bubbles must form.
• If no natural gas concentration and therefore no losses of gas
are found in the leak test, the vehicle can be made ready for
operation.
• If any losses of gas are determined in the leak test, the cause
of the fault must be determined and eliminated. Once this has
been done, a new leak test must be performed.
• The vehicle must only be handed over to the customer after
the leak test has been passed successfully.

8.3 Leak test with gas leak detector

♦ Gas leak detector - VAS 523 003-
♦ Explosion-proof LED battery lamp - VAS 6901-
♦ Mirror
Detecting leaks
Note
♦ The gas leak detector - VAS 6227- can only detect whether
there is gas in the ambient air in its immediate vicinity.
♦ If the green LED does not light up, the leak detection spray
must be used to confirm the location of the leak
⇒ page 16 .
– Observe safety precautions ⇒ page 1 .

– Test requirements for gas systems ⇒ page 10 .
– Start gas leak detector ⇒ operating instructions .
– Hold probe tip above the suspected leak for 5 seconds in sev‐
eral different locations.
The leak has been found when the following occurs (depending
on gas leak detector version) ⇒ operating instructions :
♦ the frequency of the acoustic signal increases,
♦ a warning tone sounds,
♦ or LEDs light up.
Locations where the gas system must be checked for leaks:
♦ A3 ⇒ Maintenance ; Booklet 821 ; Maintenance; Natural gas
system: checking for damage and leaks .

♦ A4, A5 ⇒ Maintenance ; Booklet 830 ; Maintenance; Natural

gas system: checking for damage and leaks .
8.4 Leak test with leak detection spray

– Observe safety precautions ⇒ page 1 .
– Test requirements for gas systems ⇒ page 10 .
– Spray leak detection spray around connections and observe
for three minutes.
• In the three minute checking time, no bubbles whatsoever
must emerge from the sprayed area.

20 – Fuel supply system

1 Fuel tanks
⇒ “1.1 Handling natural gas fuel tanks”, page 17
⇒ “1.2 Assessing damage to fuel tanks”, page 18
⇒ “1.3 Storing natural gas fuel tanks”, page 29
⇒ “1.4 Handling unpressurised natural gas fuel tanks made of
composite fibre materials”, page 30
⇒ “1.6 Discharging natural gas fuel tanks”, page 33
⇒ “1.7 Determining residual pressure in natural gas fuel tank”,
page 33
⇒ “1.8 Rendering natural gas fuel tanks inert”, page 41
⇒ “1.9 Disposing of natural gas fuel tanks”, page 43
1.1 Handling natural gas fuel tanks

DANGER
Natural gas fuel tanks may explode if handled improperly - risk
of death!
– Secure tanks to prevent them from falling or tipping.
– Store unsecured tanks in horizontal position and ensure that
they cannot roll away.
– Never throw tanks.
– Protect tanks before heating them to more than 60 °C. Ob‐
ject temperatures of 60 °C (80 °C in a painting oven) must
not be exceeded for periods of more than 1 hour. It may be
necessary to cover the tanks or put them in the shade.
– Only transport tanks when they are secured with tensioning
straps. This protects the tank shut-off valves.
• Tanks that have tipped over or fallen may be so severely dam‐

aged that they burst. Pressure releases suddenly, releasing
substantial force. Debris from a burst tank can cause serious
injuries.
1. Fuel tanks 17
1.2 Assessing damage to fuel tanks

⇒ “1.2.1 Assessing damage to fuel tanks after accident damage”,
page 18
⇒ “1.2.2 Assessing damage to fuel tanks made of steel”,
page 18
⇒ “1.2.3 Assessing damage to fuel tanks made of composite fibre
materials”, page 18
⇒ “1.2.4 Assessing damage to fuel tanks - A3”, page 19
⇒ “1.2.5 Assessing damage to fuel tanks - A4/A5”, page 21
1.2.1 Assessing damage to fuel tanks after

accident damage
Note
Note country-specific regulations.
• If the vehicle structure (e.g. longitudinal member) is not dam‐

aged, it is sufficient to perform a visual check on the gas
system/fuel tanks according to the damage assessment and
a leak test ⇒ Maintenance ; Booklet 821 ; Maintenance; Nat‐
ural gas system: checking for damage and leaks or ⇒ Main‐
tenance ; Booklet 830 ; Maintenance; Natural gas system:
checking for damage and leaks . If result is OK; no compo‐
nents of the gas system need to be renewed.
• If the vehicle structure (e.g. longitudinal member) is damaged,
the fuel tanks must be removed, checked and, if necessary,
renewed.
• If load-bearing gas system components (mounting, securing
straps) have become deformed, the fuel tanks must be re‐
newed.
• If the stainless steel pipe system is bent/damaged, the corre‐
sponding components must be renewed.
1.2.2 Assessing damage to fuel tanks made

of steel
♦ The fuel tank must be renewed at the first signs of damage or
rust. The fuel tank must not be repaired.
♦ The fuel tank will be irreparably damaged if salt and water en‐
ters it.
♦ For fuel tanks made of steel, there must be a layer of wax
between the fuel tank and the tank shut-off valve to protect
against corrosion.
1.2.3 Assessing damage to fuel tanks made

of composite fibre materials
Note
Note country-specific regulations.
♦ The following images should be used to assess whether dam‐

age to a fuel tank requires it to be renewed. The fuel tank must
not be repaired.
18 Rep. gr.20 - Fuel supply system

♦ Thermal influences can negatively affect the structure of the

fuel tank.
♦ The fuel tank will be irreparably damaged if salt and water en‐
ters it.
The following criteria are used in the damage guide:
Green Red
Fuel tank is OK until next inspection, unless further Fuel tank is not OK and must be renewed
damage occurs
⇒ “1.2.4 Assessing damage to fuel tanks - A3”, page 19

⇒ “1.2.5 Assessing damage to fuel tanks - A4/A5”, page 21
1.2.4 Assessing damage to fuel tanks - A3

Scratch
Has no effect if no fibres are damaged
• Evaluation: Green
Minor storage marks on the surface

Has no effect.
Deep cut
Has an effect.
• Evaluation: Red
1. Fuel tanks 19
Tear in fibres
Has an effect.
• Evaluation: Red
Abrasion
Has an effect.
• Evaluation: Red
Impact
Has an effect.
• Evaluation: Red
Temperature
Has an effect.
• Evaluation: Red

Infiltration, e.g. of air, water

Has an effect.
• Evaluation: Red
1.2.5 Assessing damage to fuel tanks - A4/A5

Marking, stamps, stickers and tags
The necessary information is present and readable. The sticker
and the matrix code on the valve mounting can be read easily.

The necessary information is present and readable. The sticker
and the matrix code on the valve mounting can be read easily.

The necessary information is not readable/traceability is not guar‐
anteed.
The serial number, matrix code and tank sticker are no longer
readable. Repairs are not permitted.
• Evaluation: Red
1. Fuel tanks 21

The necessary information is not readable/traceability is not guar‐
anteed.
The serial number, matrix code and tank sticker are no longer
readable. Repairs are not permitted.
• Evaluation: Red
Cuts, scratches, grooves

Surface is slightly damaged, but fibres have not been exposed or
cut through.

cut through.

cut through.


Fibres have been exposed and/or cut through. It cannot be de‐
finitively ruled out that the fibres have been damaged/exposed.
• Evaluation: Red

• Evaluation: Red

• Evaluation: Red

Dimension -a- = 1 mm
• Evaluation: Red
1. Fuel tanks 23
Abrasion
cut through.
Abrasion
cut through.
Abrasion
cut through.
Abrasion
• Evaluation: Red

Charring/soot
No noticeable discolouration or browning. Deposits or dirt can be
washed off.
Discolouration or darkened areas are present locally or over large
surfaces; they cannot be washed/wiped off. The surface shows
the effects of heat.
• Evaluation: Red
Charring/soot
• Evaluation: Red
Charring/soot
• Evaluation: Red
Effect of chemicals
The surface can be cleaned; no residue remains on the surface.
The chemical can definitely not have had an effect on the cylinder
material.
Effect of chemicals
The chemical cannot be identified or it cannot be ruled out that
the cylinder has been adversely affected. There is visible disco‐
louration/roughness on the surface, fibres are exposed, surface
shows signs of delamination.
• Evaluation: Red
1. Fuel tanks 25
Effect of chemicals
• Evaluation: Red
Effect of chemicals
• Evaluation: Red
Effect of chemicals
• Evaluation: Red
Disintegration
The tank shows an even disintegration. It has a slight loss of shine
or may appear chalky. The surface is not similar to other damage
images.
Disintegration
The surface shows cracks; the material can be scratched off with‐
out significant force. The fibres are exposed, the surface is no
longer sealed. There is a noticeable discolouration/browning of
the surface.
• Evaluation: Red

Impact, e.g. due to collision or accident
Note
♦ Tank material was hit by something and grazed.

♦ The resin may appear broken.
The damage is only on the surface. It can be ruled out that the
damage has reached the fibres. The area affected does not show
any discolouration at the point of impact.
Note

The surface has been penetrated as far as the fibres; the fibres
are exposed and/or damaged. There is discolouration (delami‐
nation) around the point of impact.
• Evaluation: Red
Note

• Evaluation: Red
Note

• Evaluation: Red
1. Fuel tanks 27
Note

• Evaluation: Red
Tensioning crack with or without corrosion

There are noticeable surface cracks; the fibres are not damaged
or exposed.

There are noticeable surface cracks; the fibres are not damaged
or exposed.

The fibres have been damaged; blow-outs are noticeable in the
surface; fibres have been exposed.
• Evaluation: Red


The fibres have been damaged; blow-outs are noticeable in the
surface; fibres have been exposed.
• Evaluation: Red
Corrosion, hole
Signs of surface corrosion present; deeper corrosion cannot be
ruled out. Surface may also have blown out.
• Evaluation: Red
1.3 Storing natural gas fuel tanks

DANGER
Filled natural gas fuel tanks constitute an explosion risk - risk of
death!
– In the event of a fire, remove filled natural gas fuel tanks from
the burning area or spray them with water.
– Inform the fire brigade of any stored, filled natural gas fuel
tanks.
Where to store
• Filled natural gas fuel tanks must only be stored in well venti‐
lated areas which are protected from unauthorised access.
• They should preferably be stored outdoors, e.g. in a wire-mesh
cage. The gas must be able to escape upwards unobstructed.
• Locate the wire-mesh cage so that no object temperatures
greater than 60 °C in the shade can occur.
Applies to Germany:
• Filled and non-leaking natural gas fuel tanks which have been
removed from a vehicle and which will be reinstalled in the
vehicle on the same day (8 hours) may be stored next to the
vehicle for this period.
Note
If, in exceptional cases, it is necessary to store tanks inside, tech‐

nical measures must be taken to ensure that an explosive atmos‐
phere cannot under any circumstances form.
1. Fuel tanks 29
How to store
• Removed natural gas fuel tanks must be secured to prevent
them from falling or tipping.
• Store the tanks in such a way that they cannot be damaged.
Signs for storage area
The storage area (e.g. wire-mesh cage) must be marked as fol‐
lows:
♦ GHS “flame” pictogram
♦ GHS “gas cylinder” pictogram

The following safety notices must be displayed at the storage
area:
♦ F+: R12.
♦ Highly flammable
♦ May cause suffocation in high concentrations
♦ Compressed gas
Signs for natural gas fuel tanks
The following information must be clearly displayed on removed
fuel tanks and fuel tanks that have not been discharged/rendered
inert (e.g. by hanging signs on them).
♦ Fuel tank (natural gas/CNG)
♦ Fill level of fuel tank
♦ Vehicle number plate or vehicle identification number
1.4 Handling unpressurised natural gas fuel

tanks made of composite fibre materials
NOTICE
Natural gas fuel tanks made of composite fibre materials can be
damaged irreparably if they are unpressurised when stored.
– Never store natural gas fuel tanks unpressurised.
1.5 Setting up and marking a protected area

Always follow country-specific laws, regulations and guidelines
⇒ “5 Laws and regulations”, page 7 .

DANGER
Risk of explosion due to gas escape in connection with ignition
sources and electrostatic discharge - risk of death!
– Never discharge natural gas fuel tanks in enclosed areas.
– Never discharge natural gas fuel tanks if a thunderstorm is
approaching.
sion.
– Equalise potential between mechanic and natural gas fuel
tank.
Setting up a protected area

– A protected area of 10x10 m must be set up around the dis‐
charge opening. Requirements:
• No buildings in the protected area.
• No mobile phones switched on in the protected area.
• No active ignition sources (e.g. open fire, hot surfaces or elec‐
trostatically charged objects) in the protected area.
• No persons in the protected area who are not actively per‐
forming work.
• The gas must not be able to enter cellars, neighbouring build‐
ings, open doors, open windows, or any other openings.
Signs for protected area
1. Fuel tanks 31
♦ Sign for area with explosion risk

♦ Gas cylinder
♦ Sign prohibiting unauthorised entry
♦ Sign prohibiting mobile phones
♦ Sign prohibiting fire and naked flames
♦ Sign prohibiting smoking
Precautions against electrostatic charging
• Do not change your work clothing or protective clothing in the
protected area and do not take anything off or put anything on.
• The mechanic must wear dissipative shoes and gloves.
• Equalise potential between mechanic and natural gas fuel
tank before fitting exhaust -VAS 523 001- .

1.6 Discharging natural gas fuel tanks

DANGER
– Never discharge natural gas fuel tanks in enclosed areas.
– Never discharge natural gas fuel tanks if a thunderstorm is
approaching.
sion.
tank.
Setting up and marking a protected area

– Set up and mark a protected area
⇒ “1.5 Setting up and marking a protected area”, page 30 .
Requirements for discharging
• Discharging must be performed outdoors.
• Permitted outside temperature: -10 … 40 °C
• Permitted wind speed: less than 15 m/s
• Gas must only be discharged from natural gas fuel tanks using
the prescribed gas discharge tube - VAS 523 001- .
• The discharge opening must be at least 3 metres above
ground level.
• After discharging is complete, determine the residual pressure
in the natural gas fuel tank to ensure that the fuel tank has
been discharged to a non-hazardous residual pressure
⇒ page 38 .
All further procedures are described in ⇒ Fuel supply system - g-
tron; Rep. gr. 20 ; Fuel tanks; Discharging natural gas fuel tanks .
1.7 Determining residual pressure in natural

gas fuel tank
⇒ “1.7.1 Procedure for determining residual pressure in natural
gas fuel tank”, page 33
⇒ “1.7.2 Checking and modifying adapter for checking residual
pressure in natural gas tank”, page 34
⇒ “1.7.3 Self-test for cooling system tester V.A.G 1274 B ”, page
36
⇒ “1.7.4 Self-test for adapter V.A.G 1274B/12 A ”, page 36
⇒ “1.7.5 Determining residual pressure in natural gas fuel tank”,
page 38
1.7.1 Procedure for determining residual

pressure in natural gas fuel tank
1. Fuel tanks 33
♦ Cooling system tester - V.A.G 1274 B-
♦ Adapter - V.A.G 1274B/12 A- (not illustrated)

Procedure
• Natural gas fuel tank discharged
⇒ “1.6 Discharging natural gas fuel tanks”, page 33 .
The residual pressure of the natural gas fuel tank must be deter‐
mined after the tank has been discharged to ensure that there is
no residual pressure remaining. A counter-pressure test is used
to determine the residual pressure in the natural gas fuel tank.
This involves attempting to force air into the natural gas fuel tank
using the cooling system tester and a suitable adapter
⇒ page 34 .
♦ If air can be forced in, the residual pressure in the natural gas
fuel tank has been dissipated.
♦ If air cannot be forced in, there is still residual pressure in the
natural gas fuel tank.
To ensure that the test is reliable, a self-test must be performed
first to check the cooling system tester and the adapter
⇒ page 36 and ⇒ page 36 . The residual pressure can then
be determined ⇒ page 38 .
1.7.2 Checking and modifying adapter for

checking residual pressure in natural
gas tank
DANGER
Risk of explosion due to gas escape from natural gas fuel tanks
that have not been sufficiently discharged in connection with
ignition sources and electrostatic discharge - risk of death!
– Only used approved adapters to determine residual pres‐
sure in natural gas fuel tank.

• Before using the adapter for checking residual pressure in

natural gas tank, it is important to check that you have the
correct version of this tool ⇒ page 35 .
• Only the adapter - V.A.G 1274B/12 A- may be used.
• The older adapter - V.A.G 1274B/12- may also be used if an
adapter with pressure relief valve has been retrofitted
⇒ page 35 .
Identifying different versions
A - Non-approved old version: Adapter - V.A.G 1274B/12-
-item 1- without pressure relief valve in connection -2-
♦ The old version -A- does not have a pressure relief valve and
must only be used if it has been fitted with an adapter with
pressure relief valve.
B - Adapter - V.A.G 1274B/12 A- with pressure relief valve in con‐
nection piece -2-
♦ The new version -B- is significantly longer in area -2-. The
pressure relief valve is located in this area.
Modifying adapter -V.A.G 1274B/12- to correspond to new ver‐

sion
Adapter - V.A.G 1274B/12A-1- is required for the modification; it
consists of:
1- Cap
2- Screw-type connection to fuel tank shut-off valve
3- Connection piece
4- Pressure relief valve
5- Seal
Procedure
– Observe safety precautions when working on the natural gas
system ⇒ page 1 .
– Observe rules for cleanliness ⇒ page 9 .
– Counterhold at connection -1- and unscrew union nut -2- on

adapter - V.A.G 1274B/12- .
– Detach spacer ring from connection -1-.
1. Fuel tanks 35
– Fit filter strainer -2- in adapter - V.A.G 1274B/12A-1- -item 1-.

– Fit seal -3- in adapter - V.A.G 1274B/12A-1- -item 1-.
– Push spacer ring -4- onto threaded piece of adapter -V.A.G
1274B/12- -item 5-.
– Screw adapter - V.A.G 1274B/12 A-1- -item 1- onto adapter -
V.A.G 1274B/12- -item 5- and tighten to 20 Nm (counterhold
at connection -5-).
– Perform self-test on modified adapter for checking residual
pressure in natural gas tank ⇒ page 36 .
1.7.3 Self-test for cooling system tester -

V.A.G 1274 B-
Procedure
– Disconnect any adapter lines connected to cooling system
tester - V.A.G 1274 B- .
– Operate cooling system tester - V.A.G 1274 B- several times.
– Build up a pressure of 3.0 bar on cooling system tester - V.A.G

1274 B- .
– Monitor pressure on pressure gauge of cooling system tester
- V.A.G 1274 B- for 30 seconds.
If pressure does not build up, or if pressure dissipates again:
• Cooling system tester - V.A.G 1274 B- is not OK and must not
be used to check residual pressure.
If pressure builds up and does not dissipate:
• Cooling system tester - V.A.G 1274 B- is OK and may be used.
1.7.4 Self-test for adapter - V.A.G 1274B/12

A-
Procedure
• Different types of fuel tank shut-off valve may be fitted.
• Depending on the version, the fuel tank shut-off valve may
have one or two pipe connections.
• On fuel tank shut-off valves with two connections, both con‐
nections must be closed off using the adapter for checking
residual pressure in natural gas tank and the additional sealing
cap.

– Check that mechanical shut-off valve on fuel tank shut-off

valve -1- is closed.
– If necessary, close it with hand wheel - T50026- -arrow-.
– If fitted, detach magnetic release tool - T10349- .
– Connect adapter - V.A.G 1274B/12 A- -item 2- to cooling sys‐

tem tester - V.A.G 1274 B- -item 1-.
– Connect adapter - V.A.G 1274B/12 A- -item 2- to gas tank

shut-off valve -1-.
– Open cut-off valve -arrow- on adapter - V.A.G 1274B/12 A- .
• Lever points in direction of flow.
1. Fuel tanks 37

1274 B- by operating it repeatedly.
– Check connection between tank shut-off valve, adapter -
V.A.G 1274B/12 A- and, if necessary, cap. Tighten if neces‐
sary.
– Perform check (self-test) again.
If pressure still does not build up, or if pressure dissipates again:
• Adapter - V.A.G 1274B/12 A- is not OK and must not be used
to check residual pressure.
If pressure builds up and does not dissipate:
• Cooling system tester - V.A.G 1274 B- and adapter - V.A.G
1274B/12 A- are OK and can be used to check residual pres‐
sure.
– Press the button for pressure equalisation on the cooling sys‐
tem tester - V.A.G 1274 B- . This will dissipate the pressure in
the cooling system tester - V.A.G 1274 B- and the adapter -
V.A.G 1274B/12 A- .
1.7.5 Determining residual pressure in natural

gas fuel tank
Test requirements

• Self-test performed for cooling system tester - V.A.G 1274 B-

⇒ page 36 .
• Self-test performed for adapter - V.A.G 1274B/12 A-
⇒ page 36 .
• Cooling system tester - V.A.G 1274 B- and adapter - V.A.G
1274B/12 A- -item 2- connected to tank shut-off valve -1-.
• Magnetic release tool - T10349- detached.
• On tank shut-off valves with two connections, the second con‐
nection must be sealed with cap -arrow- from adapter - V.A.G
1274B/12 A- .
Procedure
– Using hand wheel - T50026- -item 2-, carefully open -arrow-
mechanical shut-off valve on tank shut-off valve -1-.
– Close cut-off valve -arrow- on adapter - V.A.G 1274B/12 A-

-item 2-.
• The lever should point perpendicular to direction of flow.

1274 B- by operating it repeatedly.
1. Fuel tanks 39
– Open cut-off valve -arrow- on adapter - V.A.G 1274B/12 A-

-item 2-.
• Lever points in direction of flow.
If pressure does not drop below 1.0 bar immediately:
• The pressure in the fuel tank is too high.
• The fuel tank has not been sufficiently discharged.
DANGER
– Never work on natural gas fuel tanks that have not been
sufficiently discharged and are still under pressure.
– Repeat discharging procedure for fuel tank ⇒ Fuel supply

system - g-tron; Rep. gr. 20 ; Fuel tank; Discharging natural
gas fuel tanks .
– Determine residual pressure in natural gas fuel tank
⇒ page 39 .
If pressure drops below 1.0 bar immediately:
– To ensure that the test was performed correctly, determine the
residual pressure in the natural gas fuel tank again
⇒ page 39 .
– Operate cooling system tester - V.A.G 1274 B- again several
times after checking residual pressure.
• Air will be pumped audibly into the tank.
• Pressure should not build up when doing so.
• If pressure builds up, determine the residual pressure in the
natural gas fuel tank again ⇒ page 39 .
If pressure continues to build up:
DANGER
– Never perform further work on a natural gas fuel tank if it was
not possible to reduce the residual pressure to 1.0 bar or
below.
– In this case, the fuel tank with tank shut-off valve must be dis‐
posed of by a specialist company.
Note:
♦ Ask your distribution centre or Importer which company is re‐
sponsible for doing this.
♦ In Germany, the company responsible is a bomb disposal or‐
ganisation.

DANGER
– Further work may only be performed after the residual pres‐
sure in the natural gas fuel tank has been successfully
reduced to 1.0 bar or below.
• Natural gas fuel tank is discharged sufficiently and pressure is

dissipated.
DANGER
– Never dispose of a natural gas fuel tank which has not been
fully discharged.
– Render discharged natural gas fuel tanks inert before dis‐
posal.
– Render natural gas fuel tanks inert ⇒ page 41 .
1.8 Rendering natural gas fuel tanks inert

♦ Key - T50025-
• Residual pressure in natural gas fuel tank determined

⇒ page 38 .
•
• Only render natural gas fuel tanks inert for disposal.
1. Fuel tanks 41
DANGER
– Residual pressure in natural gas fuel tank must not exceed
1.0 bar.
– Never render natural gas fuel tanks inert in enclosed areas.
– Never render natural gas fuel tanks inert if a thunderstorm
is approaching.
sion.
tank.
– Apply key - T50025- at mechanical tank shut-off valve -1-, as

shown.
– Ensure that guide of key -T50025- is seated correctly on me‐
chanical tank shut-off valve.
– Using key - T50025- , loosen mechanical tank shut-off valve
-1- carefully.
Note:
Depending on the residual pressure, you may hear some noise
when releasing the seal from the sealing area.
– Unscrew tank shut-off valve slowly in stages of 360° by no
more than six turns.
– Because natural gas escapes during the inertisation process,
the same precautions must be taken as when natural gas is
discharged ⇒ page 1 .
Rendering tanks inert with nitrogen
– Place fuel tank in vertical position and insert a hose or an in‐
jection lance in the fuel tank opening so that it reaches the
bottom.
– Fill fuel tank with nitrogen.
• The gas will be displaced upwards out of the fuel tank opening.
– Allow the natural gas fuel tank to stand for 12 hours.
Rendering tanks inert with water
– Place fuel tank in vertical position and fill it with water (it must
be completely full).
• The gas will be displaced upwards out of the fuel tank opening.
• Ensure that no pockets of gas form in the fuel tank.
– Allow the natural gas fuel tank to stand for 12 hours.

1.9 Disposing of natural gas fuel tanks

DANGER
– Never dispose of a natural gas fuel tank which has not been
fully discharged.
– Render discharged natural gas fuel tanks inert before dis‐
posal.
• Any natural gas fuel tanks which are to be disposed of must

be discharged fully.
• Full discharge must be performed by rendering the tank inert
(filling with nitrogen or water) ⇒ page 41 .
• The fuel tank can then be discharged and disposed of.
• A 10 mm hole must be made in fuel tanks made of composite
fibre materials after discharge.
1. Fuel tanks 43
Service
Workshop Manual
Audi A4 2015 ➤
Audi A4 Avant 2015 ➤
Audi A5 2016 ➤
4-cylinder TDI engine, 2.0 ltr. 4-valve common rail (EA
288 Gen. I)
Engine ID
DET DEU DEU DES CZH DEU DET
A A B A A C B
Edition 05.2019

Service
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
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system

Copyright © 2019 Audi AG, Ingolstadt D4B8058D90C

Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤
4-cylinder TDI engine, 2.0 ltr. 4-valve common rail (EA 288 Gen. I) - Edition 05.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3 Removing and installing engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.4 Removing and installing gearbox mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 Exploded view - cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2 Exploded view - sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.7 Removing and installing engine support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.8 Removing and installing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.1 Exploded view - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.2 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.3 Removing and installing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.1 Exploded view - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 46
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3 Oil filter/oil pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Contents i
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.3 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.1 Exploded view - coolant pump/thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.2 Exploded view - electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.3 Exploded view - coolant temperature senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.4 Removing and installing electric coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.6 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.7 Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.8 Removing and installing coolant valve for cylinder head N489 . . . . . . . . . . . . . . . . . . . . . . 65
2.9 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 66
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1 Exploded view - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.2 Removing and installing coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.3 Removing and installing coolant pipes for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4 Radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.1 Exploded view - radiators/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.3 Removing and installing radiator blind (top) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.4 Removing and installing radiator blind (bottom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.5 Removing and installing radiator blind control motor (top) . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.6 Removing and installing radiator blind control motor (bottom) . . . . . . . . . . . . . . . . . . . . . . 97
4.7 Removing and installing water radiator for charge air cooling circuit . . . . . . . . . . . . . . . . . . 99
4.8 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.9 Removing and installing radiator fan V7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.1 Overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.2 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
1.3 Filling and bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.4 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.1 Connection diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.2 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.1 Exploded view - air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.2 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5 Injectors/high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
7 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.1 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.2 Removing and installing fuel temperature sender G81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.3 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.4 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.5 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 124
ii Contents
7.6 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 124

8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
9.1 Exploded view - engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
9.2 Removing and installing engine/motor control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . 126
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.1 Exploded view - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
1.2 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1.3 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.4 Removing and installing silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
1.5 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
2 Emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3 SCR (selective catalytic reduction) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.1 Exploded view - reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.2 Exploded view - reducing agent supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.3 Draining reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.4 Removing and installing reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.5 Removing and installing injector for reducing agent N474 . . . . . . . . . . . . . . . . . . . . . . . . 147
3.6 Removing and installing control unit for reducing agent metering system J880 . . . . . . . . 147
3.7 Removing and installing reducing agent quality sensor G849 . . . . . . . . . . . . . . . . . . . . . . 148
4 Exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
5 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.1 Exploded view - glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.2 Removing and installing glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.3 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 152
1.4 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.5 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Contents iii
iv Contents
1 Identification
(ARL006409; Edition 05.2019)
All information can be found in ⇒ Servicing 4-cylinder TDI engine,
common rail; Rep. gr. 00 ; Identification .
1. Identification 1
common rail; Rep. gr. 00 ; Safety precautions .

common rail; Rep. gr. 00 ; Repair instructions .
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 4
⇒ “1.2 Securing engine to engine and gearbox support”,
page 19
⇒ “1.3 Installing engine”, page 19
1.1 Removing engine

♦ Support bracket - 10-222A-
♦ Removal lever - 80-200-
♦ Lifting tackle - 2024A-
4 Rep. gr.10 - Removing and installing engine

♦ Gearbox support - 3147-
♦ Ring spanner insert AF 16 - V.A.G 1332/14-
♦ Workshop hoist - VAS 6100-
♦ Lift arm extension/workshop hoist - VAS 6101-
1. Removing and installing engine 5

♦ Engine bung set - VAS 6122-
♦ Coolant collecting system - VAS 5014- or drip tray for work‐

shop hoist - VAS 6208-
♦ Adapter - VAS 6948-

♦ Tool set - T10395A- with suitable tool insert
♦ Safety goggles
♦ Protective gloves
Procedure
• The engine is removed upwards without gearbox.
• Re-install all cable ties in original positions.
– Disconnect earth wire from battery terminal ⇒ Electrical sys‐
tem; Rep. gr. 27 ; Battery; Disconnecting and connecting
battery .
CAUTION
The cooling system is under pressure when the power unit is
hot. Risk of scalding due to hot steam and hot coolant.
Danger of scalding skin and other parts of the body.
– Put on protective gloves.
– Put on safety goggles.
– Cover filler cap on expansion tank with a cloth and open
carefully to release pressure.
– Release fastener -arrow- and open filler cap -1- on coolant

expansion tank.
– Remove front wheels ⇒ Running gear, axles, steering; Rep.
gr. 44 ; Wheels, tyres .
– Remove wheel spoilers (left and right) and wheel housing liner
(front right) ⇒ General body repairs, exterior; Rep. gr. 66 ;
Wheel housing liners; Removing and installing wheel housing
liner (front) .
– Unfasten front section of wheel housing liner (front left) and
press slightly towards rear ⇒ General body repairs, exterior;
Rep. gr. 66 ; Wheel housing liners; Removing and installing
wheel housing liner (front) .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .

Air cleaner housing with secondary air intake:

– Unplug electrical connector -2- for air filter bypass flap valve -
N275- .
– Detach water drain -1- downwards -arrow-.
All vehicles (continued):

– Move retaining clip -2- clear with fuel hoses.


– Lift off air cleaner housing -1- and detach.

– Unscrew nut -1-. (Nuts -2- do not have to be removed at this

stage.)
– Unscrew exhaust gas temperature sender 4 - G648- -arrow-

using a tool from tool set - T10395A- .
– Release catch -arrow B- and open electronics box -1-

-arrow A-.
– Remove nut -2- and move B+ wire clear.
– Move wiring duct (top) clear.
– Place collector tank from coolant collecting system -VAS

5014- or drip tray for workshop hoist - VAS 6208- underneath.
– Remove drain plug -1- and drain off coolant.
– Lift retaining clip -2- and detach coolant hose from radiator.

– Move electrical wiring harness clear.

– Lift retaining clip -arrow-, disconnect coolant hose and drain
off coolant.

– Lift retaining clips -arrows-, disconnect coolant hoses and
move them clear.
– Unplug electrical connector -1- for coolant shortage indicator
switch - F66- .
– Unscrew bolt -2- and detach coolant expansion tank -3-.
– Vehicles with dual clutch gearbox: Release hose clips

-arrows-, disconnect coolant hoses from coolant pipes for
gearbox and drain off coolant.
– Unplug electrical connector -3- for auxiliary pump for heating

- V488- and move electrical wiring clear.
– Release hose clip -arrow-, disconnect coolant hose and drain
off coolant.
– Remove nut -2- and move earth wire clear.
– Remove bolt -1- for support mounting (both sides).

– Detach electrical connector -2- from bracket and unplug.

– Release fasteners -arrows- and move wiring duct -1- clear.
– Unscrew nuts -1, 3- and remove cover -2- for drive shaft (right-
side).
– Unscrew bolted connections -arrows- and press subframe

shield (right-side) -1- to the side (illustration shows shield on
left side).
– Remove bolts -arrows- and detach heat shield for drive shaft
(right-side).

– Remove remaining nuts -2-.
– Remove bolt -1- and turn retaining tab downwards.

– Bring subframe shield (right-side) back into installation posi‐
tion.
Risk of damage to flexible joint

The flexible joint can be damaged or develop leaks if it is handled
incorrectly.
– Do not bend flexible joint more than 10°.
– Install flexible joint so that it is not under tension.
– Remove nuts -2- and bolts -1- and detach front exhaust pipe.

– Detach bottom cover -1- from gearbox -arrow-.
– Detach cap from vibration damper.

– Counterhold crankshaft on central bolt for vibration damper
using angled ring spanner -1- when loosening bolts for fly‐
wheel.
– Then turn crankshaft in steps of 120° in direction of engine
rotation -arrow-.
– Remove 3 bolts -arrow- for flywheel -1-.
Vehicles with manual gearbox:

– Unscrew bolt -1- using ring spanner insert, 16 mm - V.A.G
1332/14- and adapter - VAS 6948- .
– Remove bolts -6 ... 10- securing gearbox to engine.

Vehicles with dual clutch gearbox:

– Remove bolt -1- using ring spanner insert, 16 mm - V.A.G
1332/14- and adapter - VAS 6948- .

– Remove bolt -2- for engine mounting (left-side).
– Remove support mounting (right-side) ⇒ page 32 .
– Remove engine support (right-side)

⇒ “1.7.2 Removing and installing engine support (right-side)”,
page 36 .
– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .
– Re-install engine mounting (right-side) and engine support.

– Unplug electrical connector -1-.

– Disconnect SCR supply line -2- and move it clear ⇒ Servicing
4-cylinder TDI engine, common rail; Rep. gr. 26 ; SCR (se‐
lective catalytic reduction) system; Exploded view - reducing
agent supply line .
– Remove nuts -arrows- and move bracket clear.
NOTICE
Risk of irreparable damage due to running a used belt in the
opposite direction when it is refitted.
– Mark running direction before removing.
– Pay attention to running direction when reinstalling.
– To slacken poly V-belt turn tensioner in anti-clockwise direc‐

tion -arrow- using ring spanner.
– Lock tensioner with locking tool - T40098- .
– Take off poly V-belt.
– Remove air conditioner compressor from bracket ⇒ Heating,
air conditioning; Rep. gr. 87 ; Air conditioner compressor; De‐
taching and attaching air conditioner compressor at bracket .
– Unbolt drive shaft (left and right) from gearbox ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and
installing drive shaft .
– Disconnect fuel hose -1- ⇒ Fuel supply system; Rep. gr. 20 ;

Plug-in connectors; Disconnecting plug-in connectors .
– Release hose clips:
2 - For blue fuel hose
3 - For white fuel hose
– Move coolant hoses clear and tie to right side.
– Seal off open lines and connections with plugs (thoroughly
cleaned) from engine bung set - VAS 6122- .

Vehicles with water separator:

– Unplug electrical connector -1- for water level sender - G120- .
– Release fastener -arrow-, lift water separator -2- off bracket
and place it on engine.

– Lift retaining clips -1- and disconnect coolant hose and coolant
line.
– Release the two hose clips -2- and disconnect coolant hoses.

– Release catch -arrow- and detach control unit for NOx sender
- J583- -item 1-; move control unit clear and place it on engine.
– Take electrical connectors -2, 3, 4- out of bracket, unplug con‐

nectors and move wiring harness clear.

– Detach electrical connectors -2 and 3- from bracket and un‐

plug.
– Unplug electrical connector -1- for engine control unit - J623- .
– Move electrical wiring harness clear and place on engine.
– Remove plenum chamber partition panel ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Bulkhead; Removing and instal‐
ling plenum chamber partition panel .

– Remove bolts -2 ... 5- (accessible from above) securing engine
to gearbox.
– Separate starter slightly from gearbox and leave in position.

– Remove bolts -3, 4, 5- securing gearbox to engine.
– Separate starter from gearbox and leave in position.

Note:
Bolt -2- secures the starter to the gearbox and is provided with a
spacer sleeve -arrow-.

– Set up support bracket - 10-222A- with adapters -10-222A/22-

on bolted flanges of wing panels (left and right) as illustrated.
– Use gearbox support - 10-222A/11- to hook spindle - 3147-
onto gearbox. (Engine has been removed in illustration).
– Take up weight of gearbox with spindle.
– Unplug electrical connectors -1, 2-.
NOTICE
Risk of damage to pressure differential sender if connection
breaks off.
– Carefully disconnect hose from connection, taking care to
keep hose straight.
– Remove bolt -3- and move bracket with exhaust gas pressure
sensor 1 - G450- and pressure differential sender - G505-
carefully to one side.

– Remove lifting eye of lifting tackle - 2024A- (pull out split pin
and press out pin).
– Reinsert lifting eye in 4th hole from front on lifting tackle.
– Secure pin with split pin again.
– Attach lifting tackle - 2024A- to engine and workshop hoist -
VAS 6100- with lift arm extension/workshop hoist - VAS 6101-
as shown in illustration.
CAUTION
Accident risk from loose components of lifting tackle.
– The support hooks and retaining pins on the lifting tackle
must be secured with locking pins.
– Raise engine until engine mountings are clear.

– Tighten spindle - 10-222A/11- further.
NOTICE
Risk of damage to lines/pipes, hoses and engine compartment
when lowering engine/gearbox assembly.
– Check that all connections between engine, gearbox, sub‐
frame and body have been detached.
– Carefully guide out engine/gearbox assembly with subframe
from engine compartment when lowering.
– Separate engine from gearbox and lift engine out of engine

compartment.
1.2 Securing engine to engine and gearbox

support
All procedures are described in ⇒ Servicing 4-cylinder TDI en‐
gine, common rail; Rep. gr. 10 ; Removing and installing engine;
Securing engine to engine and gearbox support .
1.3 Installing engine

When installing a new base engine, you must check whether
there is a sticker on the cylinder head cover.
If a sticker is attached which states Spannpratzen auf vor-
geschriebenes Drehmoment angezogen (clamping pieces tight‐
ened to specified torque), the clamping pieces have already been
tightened to the specified final torque at the factory.
If no sticker is attached, it is essential that the clamping pieces for
the injectors are tightened to the specified torque after installing
the high-pressure pipes. If these instructions are not observed,
the engine could be damaged.

♦ Assembly aid - T40169-
♦ Transportation lock - T40170-
♦ All special tools listed under "Removing engine"

Procedure
• After removing, renew bolts tightened with specified tightening
angle.
• Renew self-locking nuts and bolts as well as seals, gaskets
and O-rings after removal.
• Do not remove plugs or protective caps until you are ready to
fit the relevant line.
• Secure all hose connections with correct type of hose clips (as
original equipment) ⇒ Electronic parts catalogue .
• Do not reuse coolant.

– The following preparations are required before joining engine

and gearbox:
– Insert assembly aid - T40169- into gearbox housing between
flywheel/torque converter and gearbox housing from below, as
illustrated.
• The assembly aid must engage in the semi-circular recess
-1- and in the inspection hole -2-.
Note:
There is only one inspection hole on the circumference; turn the
flywheel accordingly.
– Insert pin of assembly aid into hole on gearbox housing.
– Insert transportation lock - T40170- into gearbox housing from

below and clamp onto flange shaft -1-.
– Check whether aluminium bolts securing engine to gearbox
can be reused; if so, apply marking ⇒ Gearbox; Rep. gr. 34 ;
Removing and installing gearbox; Tightening torques for gear‐
box .
– Check whether dowel sleeves -A- for centring engine and

gearbox are fitted in cylinder block (illustration shows manual
gearbox).
– Bring engine into position on gearbox, guiding starter as nec‐
essary.
– Fit and tighten bolts -3 ... 5-.

– Slacken spindle - 10-222A/11- .

– Lower workshop hoist and place engine/gearbox assembly
onto engine mounting.
– Secure engine mounting ⇒ page 26 .
– Detach workshop hoist - VAS 6100- and lifting tackle - 2024
A- .
– Tighten bolts -6 … 9- or -6 … 10- to secure engine to gearbox

(illustration shows manual gearbox).
– Remove transport lock - T40170- and assembly aid - T40169- .
• The following step is necessary to ensure that the flywheel is

straight and that it makes even contact with the drive plate.
– Using assembly lever -1-, press flywheel -2- slightly against
drive plate -3- -arrow-.
– Bolt flywheel onto drive plate as follows:

Note:
Use ring spanner insert AF 16 - V.A.G 1332/14- to tighten bolts.
– Tighten first bolt -arrow- to 10 Nm and loosen again; then
tighten to 2 Nm (hand-tight).

– Turn crankshaft via vibration damper 120° further in normal

direction of engine rotation -arrow- with an angled ring spanner
-1-.
– Tighten bolt accessible in this crankshaft position to specified
torque ⇒ Rep. gr. 30 ; Clutch; Exploded view - flywheel and
dual clutch .
• When performing the next step, turn the crankshaft only in the
normal direction of rotation -arrow-.
– Turn crankshaft by 120° each time and tighten remaining 2
bolts to specified torque.
Remaining installation steps are carried out in reverse sequence;
note the following:

Note:
• The spacer sleeve must be fitted between the starter and the
gearbox.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
moving and installing starter .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Install bracket for pressure sensors ⇒ Servicing 4-cylinder TDI
engine, common rail; Rep. gr. 23 ; Lambda probe; Exploded
view - Lambda probe .
– Install plenum chamber partition panel ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Bulkhead; Exploded view - plenum
chamber partition panel .
– Connect fuel hoses ⇒ Fuel supply system; Rep. gr. 20 ; Plug-
in connectors; Disconnecting plug-in connectors .
– Secure drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Exploded view - drive shaft .
– Install heat shield for drive shaft ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Drive shaft; Removing and installing heat
shield for drive shaft .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Exploded view - air
conditioner compressor drive unit .
– Install poly V-belt ⇒ Servicing 4-cylinder TDI engine, common
rail; Rep. gr. 13 ; Cylinder block (pulley end); Removing and
installing poly V-belt .
– Connect SCR supply line ⇒ Servicing 4-cylinder TDI engine,
common rail; Rep. gr. 26 ; SCR (selective catalytic reduction)
system; Exploded view - reducing agent supply line .
– Install front exhaust pipe
⇒ “1.2 Removing and installing front exhaust pipe”,
page 133 .
– Install subframe shield ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Subframe; Exploded view - subframe .
– Install exhaust gas temperature sender 4 - G648- ⇒ Servicing
4-cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas
temperature control; Removing and installing exhaust gas
temperature sender 4 - G648- .
– Install air cleaner housing
⇒ “3.2 Removing and installing air cleaner housing”,
page 117 .
– Install lock carrier cover ⇒ General body repairs, exterior;
– Connect coolant hoses with plug-in connector ⇒ page 87 .
– Fill with engine oil and check oil level ⇒ Maintenance ; Booklet
830 .
– Fill up with coolant
⇒ “1.3 Draining and filling cooling system”, page 52 .
– Observe steps required after re-connecting battery ⇒ Electri‐
cal system; Rep. gr. 27 ; Battery; Disconnecting and connect‐
ing battery .

NOTICE
Risk of irreparable damage to control units because of exces‐
sive voltage.
– Do not use a battery charger to boost starting.
– Install wheel housing liners and wheel spoilers ⇒ General

body repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Re‐
moving and installing wheel housing liner (front) .
– Fit front wheels ⇒ Running gear, axles, steering; Rep. gr. 44 ;
Wheels, tyres .
– Install noise insulation panels ⇒ General body repairs, exte‐
rior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .
– If engine has been renewed, perform adaptions listed in Gui-
ded Function 01 - Functions component replacement
⇒ Vehicle diagnostic tester.
Tightening torques
♦ Tightening torques apply only to lightly greased, oiled,
phosphated or black-finished nuts and bolts.
♦ Additional lubricants such as engine or gear oil may be used,
but do not use lubricants containing graphite.
♦ Do not use degreased parts.
♦ Tolerance for tightening torques: ± 15 %
Component Nm
Bolts/nuts M6 10
M7 15
M8 20
M10 40
M12 65
♦ ⇒ “2.1 Exploded view - assembly mountings”, page 26
♦ Bolts securing engine to gearbox ⇒ Gearbox; Rep. gr. 34 ;
box

2 Assembly mountings
⇒ “2.1 Exploded view - assembly mountings”, page 26
⇒ “2.2 Supporting engine in installation position”, page 29
⇒ “2.3 Removing and installing engine mountings”, page 30
⇒ “2.4 Removing and installing gearbox mounting”, page 32
2.1 Exploded view - assembly mountings

Engine mounting
1 - Subframe
2 - Bolt
❑ 20 Nm
3 - Bolt
❑ 10 Nm
4 - Support mounting
❑ Removing and installing
⇒ page 32
❑ Installation position
⇒ page 27
5 - Bolt
❑ 55 Nm
6 - Engine support
⇒ page 35
7 - Heat shield
8 - Bolt
❑ 10 Nm
9 - Bolt
❑ 55 Nm
10 - Engine mounting
❑ with
♦ Left electrohydraulic en‐
gine mounting solenoid
valve - N144-
♦ Right electrohydraulic en‐
valve - N145-
⇒ page 30
11 - Bolt
❑ Renew after removing
❑ 90 Nm +90°
12 - Bolt
❑ 30 Nm

Installation position of support mounting

♦ Projection -2- on engine support must engage in recess -1- on
support mounting.
Gearbox mounting for manual gearbox
1 - Nut
❑ Only remove if detach‐
ing gearbox mounting
from gearbox support
❑ Tightening torques ⇒ 6-
speed manual gearbox;
Rep. gr. 34 ; Assembly
mountings; Exploded
view - assembly mount‐
ings
2 - Bolt
mountings; Exploded
ings
3 - Tunnel cross member
⇒ 6-speed manual
gearbox; Rep. gr. 34 ;
Assembly mountings;
Exploded view - assem‐
bly mountings
4 - Stop plate
❑ For gearbox mounting
5 - Gearbox mounting
⇒ page 32
6 - Bolt
mountings; Exploded
ings
7 - Final drive
8 - Nut
❑ Only remove if detaching gearbox mounting from gearbox support
❑ Tightening torques ⇒ 6-speed manual gearbox; Rep. gr. 34 ; Assembly mountings; Exploded view -
assembly mountings
2. Assembly mountings 27
9 - Gearbox support
❑ Removing and installing ⇒ page 32
10 - Bolt
assembly mountings
11 - Bolt
❑ 9 Nm
12 - Bracket
❑ For electrical connector
Gearbox mounting for dual clutch gearbox
1 - Bolt
speed dual clutch gear‐
box; Rep. gr. 34 ; As‐
sembly mountings; Ex‐
ploded view - assembly
mountings
⇒ 7-speed dual clutch
Assembly mountings;
bly mountings
3 - Stop plate
⇒ page 32
5 - Final drive
6 - Nut
mountings
7 - Gearbox support
⇒ “2.4 Removing and in‐
stalling gearbox mount‐
ing”, page 32
8 - Bolt
❑ Tightening torques ⇒ 7-speed dual clutch gearbox; Rep. gr. 34 ; Assembly mountings; Exploded view
- assembly mountings
9 - Bolt

10 - Nut
2.2 Supporting engine in installation posi‐

tion
Procedure
– Remove engine cover panel ⇒ Servicing 4-cylinder TDI en‐
gine, common rail; Rep. gr. 10 ; Engine cover panel; Remov‐
ing and installing engine cover panel .
NOTICE
breaks off.
keep hose straight.
– Remove bolt -3- and move bracket with exhaust gas pressure
sensor 1 - G450- and pressure differential sender - G505-
carefully to one side.
– Set up support bracket - 10-222A- on wing mounting flanges

(left and right) as illustrated.
– Attach spindles -10-222A/11- to engine lifting eyes.
– Partly take up weight of engine with spindles.
Assembling
Assembly is performed in reverse sequence; note the following:
– Install engine cover panel ⇒ Servicing 4-cylinder TDI engine,
common rail; Rep. gr. 10 ; Engine cover panel; Removing and
installing engine cover panel .
Tightening torques
♦ Bracket for exhaust gas pressure sensor 1 - G450- and pres‐
sure differential sender - G505- ⇒ Servicing 4-cylinder TDI
engine, common rail; Rep. gr. 23 ; Lambda probe; Exploded
view - Lambda probe
2.3 Removing and installing engine mount‐

ings
⇒ “2.3.1 Removing and installing engine mountings”, page 30
⇒ “2.3.2 Removing and installing support mounting”, page 32
2.3.1 Removing and installing engine mount‐

ings
Removing
– Remove front noise insulation ⇒ General body repairs, exte‐
insulation .
– Remove wheel spoiler (front) ⇒ General body repairs, exteri‐
or; Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
housing liner (front) .
– Remove corresponding front wheel (left or right).
Engine mounting (left-side):
– Unplug electrical connector -2- for electrohydraulic engine
mounting solenoid valve.
– Remove bolt -1- for support mounting.

Engine mounting (right-side):

– Remove nut -arrow- and move earth wire clear.
– Remove bolt -arrow- and move bracket -1- clear with electrical
wiring harness.
Both sides (continued):

– Support engine in installation position ⇒ page 29 and take up
weight with spindle - 10-222A/11- until load on engine mount‐
ing is relieved.
– Remove bolts -arrows- and detach engine mounting.
Installing
Installation is carried out in reverse order; note the following:
angle.
– Fit corresponding front wheel (left or right) ⇒ Running gear,
axles, steering; Rep. gr. 44 ; Wheels, tyres .
Tightening torques
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
2.3.2 Removing and installing support mount‐

ing
Removing
insulation .
– Unscrew bolts -1, 3- and detach support mounting -2-.
Installing
angle.
– Observe correct installation position ⇒ page 27 .
Tightening torques
2.4 Removing and installing gearbox

mounting
Removing gearbox support with gearbox mounting
– Remove tunnel cross member ⇒ 6-speed manual gearbox;
Rep. gr. 34 ; Assembly mountings; Exploded view - assembly
mountings , or ⇒ 7-speed dual clutch gearbox; Rep. gr. 34 ;
Assembly mountings; Exploded view - assembly mountings .
– Remove bolts -arrows- and detach gearbox support and gear‐
box mounting from gearbox.
Removing gearbox mounting

– Unscrew bolts -1- and detach stop -2- for gearbox mounting.
– Remove nut -5- and detach gearbox mounting -3- from gear‐
box support -4-.
Installing
– Tighten nut -5- hand-tight initially.
– Tighten bolts -1- and then nut -5-.
The remaining installation steps are carried out in the reverse se‐
quence.
Tightening torques
♦ ⇒ 6-speed manual gearbox; Rep. gr. 34 ; Assembly mount‐
ings; Exploded view - assembly mountings
♦ ⇒ 7-speed dual clutch gearbox; Rep. gr. 34 ; Assembly
mountings; Exploded view - assembly mountings

3 Engine cover panel

gine, common rail; Rep. gr. 10 ; Engine cover panel .
3. Engine cover panel 33

13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Exploded view - cylinder block (pulley end)”, page 34
⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 34
⇒ “1.3 Removing and installing poly V-belt”, page 34
⇒ “1.4 Removing and installing tensioner for poly V-belt”,
page 34
⇒ “1.5 Removing and installing vibration damper”, page 34
⇒ “1.6 Removing and installing bracket for ancillaries”,
page 34
⇒ “1.7 Removing and installing engine support”, page 35
⇒ “1.8 Removing and installing sealing flange (pulley end)”, page
38
1.1 Exploded view - cylinder block (pulley

end)
All components are described in ⇒ Servicing 4-cylinder TDI en‐
gine, common rail; Rep. gr. 13 ; Cylinder block (pulley end);
Exploded view - cylinder block (pulley end) .
1.2 Exploded view - sealing flange (pulley

end)
Exploded view - sealing flange (pulley end) .
1.3 Removing and installing poly V-belt

Removing and installing poly V-belt .
1.4 Removing and installing tensioner for

poly V-belt
Removing and installing tensioner for poly V-belt .
1.5 Removing and installing vibration damp‐

er
Removing and installing vibration damper .
1.6 Removing and installing bracket for an‐

cillaries
Removing and installing bracket for ancillaries .
34 Rep. gr.13 - Crankshaft group

1.7 Removing and installing engine support

⇒ “1.7.1 Removing and installing engine support (left-side)”, page
35
page 36
1.7.1 Removing and installing engine support

(left-side)
Removing
– Remove engine mounting (left-side)
⇒ “2.3.1 Removing and installing engine mountings”,
page 30 .
– Remove poly V-belt ⇒ Servicing 4-cylinder TDI engine, com‐
mon rail; Rep. gr. 13 ; Cylinder block (pulley end); Removing
and installing poly V-belt .
– Remove air conditioner compressor from bracket with refrig‐
erant lines still attached and tie up to left side ⇒ Heating, air
conditioning; Rep. gr. 87 ; Air conditioner compressor; De‐
Vehicles with water separator:

– Remove bolts -arrows- and press coolant pipe (bottom left) to
the side.
1. Cylinder block (pulley end) 35

– Move electrical wiring -1- clear.

– Remove bolts -arrows- and detach engine support (left-side)
-2-.
Installing
angle.
Rep. gr. 87 ; Air conditioner compressor; Detaching and at‐
taching air conditioner compressor at bracket .
Tightening torques
♦ ⇒ “3.1 Exploded view - coolant pipes”, page 67

(right-side)
Removing
Risk of irreparable damage to electronic components
When disconnecting the battery there is a risk of irreparable dam‐
age to electronic components.
– Always switch off the ignition before disconnecting the battery.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and connecting battery .
– Release catch -arrow- and disconnect vacuum hose -1-.

– Remove nut -4- and move bracket with electrical connectors

-1, 2, 3- to one side.
– Remove bolt -1- and centre hex stud -2-.

– Remove nut -2- and bolts -1, 4- and push coolant pipe (rear)
slightly to one side.
– Remove engine mounting (right-side)
page 30 .
– Remove nut -3- and bolt -1- and push bracket -2- with auxiliary
pump for heating - V488- clear to one side.

– Remove bolts -arrows- and detach engine support -1- (right-

side).
Installing
angle.
ing battery .
Tightening torques
♦ ⇒ page 26
♦ ⇒ Servicing 4-cylinder TDI engine, common rail; Rep. gr. 21 ;
Charge air system; Exploded view - charge air system
Charge air system; Exploded view - hose connections for
charge air system
1.8 Removing and installing sealing flange

(pulley end)
Removing and installing sealing flange (pulley end) .

2 Cylinder block (gearbox end)

All procedures and components are described in ⇒ Servicing 4-
cylinder TDI engine, common rail; Rep. gr. 13 ; Cylinder block
(gearbox end) .
2. Cylinder block (gearbox end) 39

3 Crankshaft
cylinder TDI engine, common rail; Rep. gr. 13 ; Crankshaft .

4 Pistons and conrods

cylinder TDI engine, common rail; Rep. gr. 13 ; Pistons and
conrods .
4. Pistons and conrods 41

15 – Cylinder head, valve gear

1 Toothed belt drive
cylinder TDI engine, common rail; Rep. gr. 15 ; Toothed belt
drive .
42 Rep. gr.15 - Cylinder head, valve gear

2 Cylinder head
cylinder TDI engine, common rail; Rep. gr. 15 ; Cylinder head .
2. Cylinder head 43
3 Valve gear
⇒ “3.1 Exploded view - valve gear”, page 44
⇒ “3.2 Removing and installing camshaft oil seal”, page 44
⇒ “3.3 Removing and installing valve stem oil seals”, page 44
3.1 Exploded view - valve gear

gine, common rail; Rep. gr. 15 ; Valve gear; Exploded view - valve
gear .
3.2 Removing and installing camshaft oil

seal
Removing
Note:
The following steps enable you to fit the special tool correctly.
– Remove noise insulation (front) ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .
– Support engine in installation position ⇒ page 29 .
All further procedures are described in ⇒ Servicing 4-cylinder TDI
engine, common rail; Rep. gr. 15 ; Valve gear; Removing and
installing camshaft oil seal .
Installing
– Detach support bracket
⇒ “2.2 Supporting engine in installation position”, page 29 .
Tightening torques
♦ ⇒ page 26
3.3 Removing and installing valve stem oil

seals
gine, common rail; Rep. gr. 15 ; Valve gear; Removing and
installing valve stem oil seals .

4 Inlet and exhaust valves

gine, common rail; Rep. gr. 15 ; Inlet and exhaust valves .
4. Inlet and exhaust valves 45

17 – Lubrication
1 Sump/oil pump
⇒ “1.1 Exploded view - sump/oil pump”, page 46
⇒ “1.2 Engine oil”, page 46
⇒ “1.3 Removing and installing sump”, page 46
⇒ “1.4 Removing and installing oil pump”, page 46
⇒ “1.5 Removing and installing oil level and oil temperature send‐
er G266 ”, page 46
1.1 Exploded view - sump/oil pump

gine, common rail; Rep. gr. 17 ; Sump/oil pump; Exploded view
- sump/oil pump .
1.2 Engine oil

♦ Refer to ⇒ Maintenance ; Booklet 830 for instructions on
draining and filling up engine oil, checking oil level, removing
and installing oil filter element.
♦ Oil capacities, oil specifications and viscosity grades ⇒ Main‐
tenance tables .
1.3 Removing and installing sump

Removing
• Engine oil drained ⇒ Maintenance ; Booklet 830
– Lower subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Lowering subframe .
– Remove engine support (left-side)
⇒ “1.7.1 Removing and installing engine support (left-side)”,
page 35 .
engine, common rail; Rep. gr. 17 ; Sump/oil pump; Removing and
installing sump .
Installing
Additional work:
– Install engine support (left-side)
page 35 .
– Install subframe ⇒ Running gear, axles, steering; Rep. gr.
1.4 Removing and installing oil pump

gine, common rail; Rep. gr. 17 ; Sump/oil pump; Removing and
installing oil pump .
1.5 Removing and installing oil level and oil

temperature sender - G266-
installing oil level and oil temperature sender -G266- .
46 Rep. gr.17 - Lubrication

2 Engine oil cooler

Engine oil cooler must not be separated from oil filter housing. In
the event of a fault, the engine oil cooler must be renewed with
the oil filter housing ⇒ Servicing 4-cylinder TDI engine, common
rail; Rep. gr. 17 ; Oil filter/oil pressure switches; Removing and
installing oil filter housing .
2. Engine oil cooler 47

3 Oil filter/oil pressure switches

cylinder TDI engine, common rail; Rep. gr. 17 ; Oil filter/oil
pressure switches .

19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 49
⇒ “1.2 Checking cooling system for leaks”, page 52
⇒ “1.3 Draining and filling cooling system”, page 52
1.1 Connection diagram - coolant hoses

⇒ “1.1.1 Connection diagram - coolant hoses, vehicles without
auxiliary heater”, page 49
⇒ “1.1.2 Connection diagram - coolant hoses, vehicles with aux‐
iliary heater”, page 51
1.1.1 Connection diagram - coolant hoses,

vehicles without auxiliary heater
♦ Blue = Large coolant circuit
♦ Red = Small coolant circuit
♦ Violet = Coolant circuit for charge air cooler.
♦ Brown = Heating circuit
♦ Green = Coolant circuit for gearbox
♦ Arrows = Direction of coolant flow
1. Cooling system/coolant 49
1 - Water radiator for charge air

cooling circuit
2 - Radiator
3 - Coolant pump
4 - Non-return valve
5 - Cylinder head/cylinder
block
6 - Auxiliary pump for heating -
V488-
7 - Turbocharger
8 - Coolant temperature send‐
er - G62-
10 - Exhaust gas recirculation
cooler
11 - Bleeder hole
12 - Heat exchanger for heater
14 - ATF cooler
❑ For equipment version
with dual clutch gearbox
15 - Thermostat
❑ For coolant circuit for
gearbox
16 - Thermostat
17 - Throttle valve module -
J338-
18 - Exhaust gas recirculation control motor - V338-
19 - Injector for reducing agent - N474-
20 - Filler cap
❑ For coolant expansion tank
❑ Checking pressure relief valve ⇒ page 52
21 - Coolant expansion tank
22 - Charge air cooler
23 - Restrictor
25 - Restrictor
26 - Charge air cooling pump - V188-
28 - Engine oil cooler
50 Rep. gr.19 - Cooling


vehicles with auxiliary heater

cooling circuit
2 - Radiator
3 - Coolant pump
V488-
6 - Auxiliary heater
❑ With circulation pump -
V55-
7 - Turbocharger
block
er - G62-
12 - Heater coolant shut-off
valve - N279-
13 - Bleeder hole
cooler
17 - ATF cooler
18 - Thermostat
❑ For coolant circuit for gearbox
❑ For equipment version with dual clutch gearbox
19 - Thermostat
20 - Throttle valve module - J338-
23 - Filler cap

26 - Restrictor
28 - Restrictor
1.2 Checking cooling system for leaks

gine, common rail; Rep. gr. 19 ; Cooling system/coolant; Check‐
ing cooling system for leaks .
1.3 Draining and filling cooling system

Drain coolant ⇒ page 54 .
Fill and bleed coolant circuit ⇒ page 55 .
Bleed cooling system ⇒ page 59 .
♦ Vehicle diagnostic tester
♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Pipe for cooling system tester - V.A.G 1274/10-

♦ Cooling system charge unit - VAS 6096-

♦ Refractometer - T10007A-
♦ Safety goggles
Draining coolant
CAUTION

expansion tank.
noise insulation .
– Lift retaining clip -2-, disconnect coolant hose and drain off
coolant.

off coolant.


-arrows-, disconnect coolant hoses from ATF cooler and drain
off coolant.

off coolant.
– Tighten drain plug and connect coolant hoses.
– Connect coolant hose with plug-in connector ⇒ page 87 .
Filling and bleeding coolant circuit:
NOTICE
Risk of damage to engine if cooling system is insufficiently filled/
bled.
– After it is filled, the cooling system must be bled using the
Note
♦ The effectiveness of the coolant is greatly influenced by the

quality of the water with which it is mixed. Because water may
contain different substances depending on the country or even
the region, the water quality to be used for cooling systems
has been specified. Distilled water meets all the requirements
and is therefore recommended for use when topping up or fill‐
ing up with coolant.
♦ Use only coolant additives listed in the ⇒ Electronic parts
catalogue (ETKA) . If you use other coolant additives, this can
significantly impair in particular the corrosion protection effect.
The resulting damage could lead to loss of coolant and con‐
sequently to serious engine damage.
♦ Coolant with the recommended mixture ratio prevents frost
and corrosion damage and stops scaling. At the same time it
raises the boiling point of the fluid in the system. For this rea‐
son the cooling system must be filled all year round with the
correct coolant additive.
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ Refractometer - T10007A- or refractometer - T10007B- MUST
be used to determine the current level of frost protection.
♦ Scale -1- on the refractometer applies to coolant additives G12
++ and G12evo.
♦ Scale -2- on the refractometer applies to coolant additive G13.
tection.
♦ The mixture must guarantee frost protection down to at least
-25 ℃ (in countries with arctic climate: down to -36 ℃). The
amount of antifreeze should only be increased if greater frost
protection is required in very cold climates. This must only be
down to -48 ℃, however, as otherwise the cooling efficiency
of the coolant is impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be provided to at least -25 ℃.
♦ The temperature indicated on the refractometer corresponds
to the temperature at which the first ice crystals can form in
the coolant.
ses.
Recommended mixture ratio for coolant

• Coolant (40 %) and distilled water (60 %) for frost protection
to -25 °C
to -36 °C
• Coolant ⇒ Electronic parts catalogue (ETKA)

To fill up with coolant:

– Fill reservoir of cooling system charge unit -VAS 6096- with at
least 8 litres of premixed coolant (according to recommended
ratio):
– To simplify filling procedure, place reservoir on as high a sur‐
face as possible, e.g. on a workshop trolley or the engine and
gearbox jack.
– Fit adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank.
– Attach cooling system charge unit - VAS 6096- to adapter -
V.A.G 1274/8- .
– Run vent hose -2- into a small container -3-.
Note:
The vented air draws along a small amount of coolant, which
should be collected.
– Close both valves -A- and -B- (turn lever at right angles to di‐
rection of flow).
– Connect hose -4- to compressed air supply.
• Pressure: 7 ... 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 reservoir of -VAS 6096- can fill with coolant.
– Close valve -A- again.
– Leave valve -B- open for another 2 minutes.
• The suction jet pump continues to generate a partial vacuum
in the cooling system; the needle on the gauge should remain
in the green zone.
– Close valve -B-.
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
• If the needle does not reach the green zone, repeat the proc‐
ess.
• Check cooling system for leaks if the vacuum is not main‐
tained.
– Detach compressed air hose.
– Open valve -A-.
• The vacuum in the cooling system causes the coolant to be
drawn out of the reservoir of -VAS 6096- ; the cooling system
is then filled.
– Detach cooling system charge unit - VAS 6096- from adapter
-V.A.G 1274/8- on coolant expansion tank.
– Attach pipe -V.A.G 1274/10- onto adapter -V.A.G 1274/8- .

– Fill up with coolant until pipe for cooling system tester is filled.
If required, add further coolant when performing bleeding pro‐
cedure.
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Release hose clip on coolant hose going to heat exchanger

for heater and pull back hose until bleeder hole -arrow- in hose
is no longer blocked by connection.
– Fill up with coolant until it flows out at bleeder hole in coolant
hose.
– Push coolant hose back onto connection and secure with
spring-type hose clip.
– Close filler cap -1- on coolant expansion tank (make sure it

engages).

Bleeding cooling system:

– Coolant must be topped up to “max” mark.
– Start engine.
– Set temperature to “HI”.
– Switch off air conditioner compressor (press AC button).
• LED in button should not light up.
– Set fresh air blower to lowest setting.
– Connect ⇒ Vehicle diagnostic tester.
– Switch on ignition and select following menu options:
– Start Guided Fault Finding.
– Choose Select own test tab and select following options
one after the other:
♦ Drive train
♦ Select engine code and engine
♦ 01 - Self-diagnosis compatible systems
♦ 01 - Engine electronics J623
♦ 01 - Engine electronics, functions
♦ 01 - Coolant circuit charge
– Follow instructions shown on ⇒ Vehicle diagnostic tester.
– Switch off ignition and allow engine to cool down.
Checking coolant level:
CAUTION
• 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.
– Top up with coolant again if necessary.
– Fill up coolant to approx. 5 mm above max. marking when en‐
gine is cold.
– Install engine cover panel.
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Erase event memory ⇒ Vehicle diagnostic tester.
Tightening torques
♦ ⇒ “4.1 Exploded view - radiators/radiator fan”, page 85

2 Coolant pump/thermostat assembly

⇒ “2.1 Exploded view - coolant pump/thermostat”, page 61
⇒ “2.2 Exploded view - electric coolant pump”, page 61
⇒ “2.3 Exploded view - coolant temperature senders”,
page 62
⇒ “2.4 Removing and installing electric coolant pump”,
page 62
⇒ “2.5 Removing and installing coolant pump”, page 65
⇒ “2.6 Removing and installing thermostat”, page 65
⇒ “2.7 Checking thermostat”, page 65
⇒ “2.8 Removing and installing coolant valve for cylinder head
N489 ”, page 65
⇒ “2.9 Removing and installing coolant temperature sender G62
”, page 66
2.1 Exploded view - coolant pump/thermo‐

stat
gine, common rail; Rep. gr. 19 ; Coolant pump/thermostat as‐
sembly; Exploded view - coolant pump/thermostat .
2.2 Exploded view - electric coolant pump
2. Coolant pump/thermostat assembly 61

1 - Bolt
❑ 40 Nm
2 - Bracket
❑ For auxiliary pump for
heating - V488-
3 - Nut
❑ 9 Nm
4 - Grommet
5 - Bolt
❑ 2.7 Nm
6 - Spacer bush
7 - Charge air cooling pump -
V188-
⇒ page 62
8 - Bracket
❑ For charge air cooling
pump - V188-
9 - Nut
❑ 9 Nm
10 - Nut
❑ 9 Nm
11 - Retaining bracket
12 - Auxiliary pump for heating
- V488-
⇒ page 64
2.3 Exploded view - coolant temperature

senders
sembly; Exploded view - coolant temperature senders .
2.4 Removing and installing electric coolant

pump
⇒ “2.4.1 Removing and installing charge air cooling pump V188
”, page 62
⇒ “2.4.2 Removing and installing auxiliary pump for heating V488
”, page 64
2.4.1 Removing and installing charge air cool‐

ing pump - V188-

♦ Hose clamps up to 25 mm - 3094-
Removing
• Engine cold.
– Relieve residual pressure in cooling system by releasing fas‐
tener -arrow- and briefly opening filler cap -1- on coolant
expansion tank (cover filler cap with a cloth beforehand and
open carefully).
– Close filler cap -arrow- again.


– Place a cloth underneath to catch escaping coolant.
– Clamp off coolant hoses using hose clamps up to 25 mm -
3094- , release hose clips -2- and disconnect hoses.
– Clamp off coolant hose with hose clamps up to 25 mm - 3094-
and detach coolant hose.
– Remove nut -3-, release retaining bracket and detach charge
air cooling pump - V188- .
Installing
– Bleed cooling system ⇒ page 59 .
Tightening torques
♦ ⇒ “2.2 Exploded view - electric coolant pump”, page 61
2.4.2 Removing and installing auxiliary pump

for heating - V488-
Removing
• Engine cold.


tener -arrow- and opening filler cap -1- on coolant expansion
tank.

insulation .
– Clamp off coolant hoses with hose clamps up to 25 mm -
3094- .
– Release hose clips -1- and disconnect coolant hoses.
– Unscrew nut -3- and bolt -5- and disengage auxiliary pump for
heating - V488- with bracket.
– Remove bolts -4- to detach auxiliary pump for heating from
bracket.
Installing
– Bleed cooling system ⇒ page 59 .
Tightening torques
♦ Noise insulation ⇒ General body repairs, exterior; Rep. gr.
66 ; Noise insulation; Exploded view - noise insulation
2.5 Removing and installing coolant pump

sembly; Removing and installing coolant pump .
2.6 Removing and installing thermostat

sembly; Removing and installing thermostat .
2.7 Checking thermostat

sembly; Checking thermostat .
2.8 Removing and installing coolant valve

for cylinder head - N489-

sembly; Removing and installing coolant valve for cylinder head

- N489- .
2.9 Removing and installing coolant temper‐

ature sender - G62-
sembly; Removing and installing coolant temperature sender -
G62- .

3 Coolant pipes
⇒ “3.1 Exploded view - coolant pipes”, page 67
⇒ “3.2 Removing and installing coolant pipes”, page 69
⇒ “3.3 Removing and installing coolant pipes for gearbox”,
page 83
3.1 Exploded view - coolant pipes

• The arrow markings on coolant pipes and on ends of hoses
must align.
Coolant pipes on engine
1 - Bolt
❑ 20 Nm
2 - Coolant pipe (right-side)
⇒ “3.2.6 Removing and
installing coolant pipe
(right-side)”, page 76
3 - Bolt
❑ 10 Nm
4 - O-ring
❑ Lubricate with coolant
5 - Bolt
❑ 10 Nm
6 - Coolant pipe (rear)
⇒ page 81
7 - Coolant pipe (rear right)
⇒ page 78
8 - Bolt
❑ 10 Nm
9 - Bolt
❑ 10 Nm
10 - Nut
❑ 10 Nm
11 - Bolt
❑ 10 Nm
12 - Coolant pipes (rear left)
13 - Bolt
❑ 10 Nm
14 - Bolt
❑ 10 Nm
15 - Bolt
❑ 10 Nm
3. Coolant pipes 67
16 - Coolant pipe (top left)

17 - Bolt
❑ 10 Nm
18 - Bolt
❑ 10 Nm
19 - Coolant pipe (bottom left)
Coolant pipes for gearbox
1 - Coolant hoses
2 - Coolant hoses
3 - Bolt
❑ 9 Nm
4 - Coolant pipes for gearbox
⇒ page 83
5 - Bolt
❑ 9 Nm

3.2 Removing and installing coolant pipes

⇒ “3.2.1 Installing coolant hoses with pre-tensioned spring-type
clips”, page 69
⇒ “3.2.2 Removing and installing coolant pipe (left-side)”,
page 70
⇒ “3.2.3 Removing and installing coolant pipes (rear left)”,
page 71
⇒ “3.2.4 Removing and installing coolant pipe (top left)”,
page 73
⇒ “3.2.5 Removing and installing coolant pipe (bottom left)”, page
74
⇒ “3.2.6 Removing and installing coolant pipe (right-side)”,
page 76
⇒ “3.2.7 Removing and installing coolant pipe (rear right)”,
page 78
⇒ “3.2.8 Removing and installing coolant pipe (rear)”, page 81
3.2.1 Installing coolant hoses with pre-ten‐

sioned spring-type clips
♦ Release tool - VAS 531 001-
Opening clip:
– Use hose clip pliers to compress spring-type clips until clip
engages.
– This opens clip, and coolant hose can be detached.
– Clip cannot be removed from coolant hose.
3. Coolant pipes 69
Closing clip:
– Fit coolant hose.
– Release pre-tensioned spring-type clip by inserting release
tool - VAS 531 001- into spring-type clip -1-, as shown. Re‐
lease catch.
– Depending on space, use a suitable hook for releasing clip.
3.2.2 Removing and installing coolant pipe

(left-side)
Removing
– Remove oil filter housing ⇒ Servicing 4-cylinder TDI engine,
common rail; Rep. gr. 17 ; Oil filter/oil pressure switches; Re‐
moving and installing oil filter housing .
– Remove throttle valve module - J338- ⇒ Servicing 4-cylinder
TDI engine, common rail; Rep. gr. 23 ; Intake manifold; Re‐
moving and installing throttle valve module - J338- .
– Remove bolts -arrows-.

– Release hose clip -1- and disconnect coolant hose.

– Remove bolt -4-.
– Release retainer for vacuum line -2-.
– Detach and remove coolant pipe (left-side) -3-, taking care not
to damage vacuum line -2-.
Installing
• Renew gaskets and O-rings after removal.
• Before fitting, check vacuum line for damage and renew if
necessary.
– Clean and smoothen sealing surfaces for seals and O-rings.
– Lubricate seals and O-rings with coolant.
– Install throttle valve module - J338- ⇒ Servicing 4-cylinder TDI
engine, common rail; Rep. gr. 23 ; Intake manifold; Removing
and installing throttle valve module - J338- .
– Install oil filter housing ⇒ Servicing 4-cylinder TDI engine,
common rail; Rep. gr. 17 ; Oil filter/oil pressure switches; Re‐
moving and installing oil filter housing .
– Fill and bleed coolant circuit ⇒ page 55 .
Tightening torques
3.2.3 Removing and installing coolant pipes

(rear left)
3. Coolant pipes 71
Removing
– Remove coolant pipe (top left)
⇒ “3.2.4 Removing and installing coolant pipe (top left)”, page
73 .
– Remove bolts -1- and press charge pressure sender - G31- to
side.
Version with water level sender - G120- :



move them clear.
switch - F66- .
– Unscrew bolt -2- and detach coolant expansion tank.
– Move electrical wiring clear.
– Release hose clips -arrows- and disconnect coolant hoses.
Note
Take care not to damage coolant hoses when disconnecting.
– Remove bolts -1 and 2- and detach coolant pipes (rear left).

Installing
– Install coolant pipe (top left)
⇒ “3.2.4 Removing and installing coolant pipe (top left)”, page
73 .
Tightening torques

(top left)
Removing
– Drain coolant ⇒ page 52 .
3. Coolant pipes 73


move them clear.
switch - F66- .
– Move coolant line clear at retaining clip -2-.

– Lift retaining clip -1- and disconnect coolant hose.
– Remove bolt -arrow-, lift retaining clip -3- and detach coolant
pipe (top left).
Installing
• Renew O-ring after removal.
Tightening torques

(bottom left)


Removing
3. Coolant pipes 75


3094- .
– Lift retaining clip -1-, release hose clip -2- and disconnect
coolant hoses.
– Remove bolts -arrows- and detach coolant pipe (bottom left).
Installing
Tightening torques
♦ ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Exploded view - air conditioner compressor drive unit

(right-side)


♦ U/J extension adapter with socket insert (commercially avail‐

able)
Removing
– Remove wheel housing liner (front right) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (front) .
– Remove air cleaner housing
page 117 .
insulation .
– Remove nut -arrow-, move cable duct -1- clear and push it to
one side.
3. Coolant pipes 77

– Remove bolt -1- using U/J extension adapter with socket insert
(commercially available).
– Unscrew centre hex stud -3- and remove coolant pipe (right-
side).
Installing
– Install air cleaner housing ⇒ page 117 .
Tightening torques

(rear right)

Removing
page 117 .
– Remove exhaust gas temperature sender 4 - G648- ⇒ Serv‐
icing 4-cylinder TDI engine, common rail; Rep. gr. 26 ; Ex‐
haust gas temperature control; Removing and installing
exhaust gas temperature sender 4 - G648- .
-1, 2- to one side.
3. Coolant pipes 79
– Remove bolts -1- and centre hex stud -2-.

– Disconnect fuel hoses -1- ⇒ Fuel supply system; Rep. gr. 20 ;

– Release hose clips:
2 - For blue fuel hose
3 - For white fuel hose
– Press release tabs -arrows- on both sides and disconnect

crankcase breather hose -1-.

– Move electrical wiring harness clear and unplug electrical con‐

nector -2-.
– Loosen hose clip -3- and detach coolant pipe (rear right).
• It is difficult to access the bolt -top arrow-; for this reason, use
a small ratchet with a short bit to unscrew it.
Installing
page 117 .
Tightening torques
charge air system
♦ ⇒ General body repairs, exterior; Rep. gr. 50 ; Bulkhead;
Exploded view - plenum chamber partition panel

(rear)
3. Coolant pipes 81
Removing
– Remove front exhaust pipe
page 133 .
-1, 2- to one side.



– Remove nut -2- and bolts -1 and 4-.
– Release hose clips -3- and -arrows- and disconnect coolant
hoses.
– Detach rear coolant pipe.
Installing
page 133 .
– Install support mounting (right-side) ⇒ page 32 .
Tightening torques
charge air system

for gearbox
3. Coolant pipes 83

Removing
– Remove noise insulation (rear) ⇒ General body repairs, ex‐
noise insulation .
– Loosen hose clips -2- and detach coolant pipes.
Installing
Tightening torques

4 Radiator/radiator fan
⇒ “4.1 Exploded view - radiators/radiator fan”, page 85
⇒ “4.2 Removing and installing radiator”, page 90
⇒ “4.3 Removing and installing radiator blind (top)”, page 95
⇒ “4.4 Removing and installing radiator blind (bottom)”,
page 95
⇒ “4.5 Removing and installing radiator blind control motor (top)”,
page 96
⇒ “4.6 Removing and installing radiator blind control motor (bot‐
tom)”, page 97
⇒ “4.7 Removing and installing water radiator for charge air cool‐
ing circuit”, page 99
⇒ “4.8 Removing and installing radiator cowl”, page 101
⇒ “4.9 Removing and installing radiator fan V7 ”, page 103
4.1 Exploded view - radiators/radiator fan

⇒ page 85
⇒ page 87
⇒ page 87
⇒ page 88
⇒ page 89
Radiator
4. Radiator/radiator fan 85
1 - Radiator
⇒ page 90
❑ If there are slight im‐
pressions on the fins, re‐
fer to ⇒ Servicing 4-
cylinder TDI engine,
common rail; Rep. gr.
00 ; Repair instructions;
Installing radiators and
condensers
❑ If renewed, change
coolant in entire system
2 - Drain plug
❑ 1.5 … 3 Nm
3 - O-ring
4 - Coolant hose
❑ Lift retaining clip to de‐
tach
❑ Connecting
⇒ page 87
5 - O-rings
❑ Renew if damaged
6 - Coolant hose
tach
❑ Connecting
⇒ page 87
7 - Coolant pipe
❑ To coolant expansion
tank
❑ Press release ring to detach
❑ Connecting ⇒ page 87
8 - O-ring
9 - Rubber bush
❑ For radiator
10 - Sleeve
11 - Retaining pin
❑ Use screwdriver to release and pull off
12 - Coolant hoses
13 - Water radiator for charge air cooling circuit
❑ If there are slight impressions on the fins, refer to ⇒ Servicing 4-cylinder TDI engine, common rail; Rep.
gr. 00 ; Repair instructions; Installing radiators and condensers
❑ If renewed, change coolant in entire system

14 - Air duct
15 - Rubber bush
❑ For radiator
16 - Radiator bracket
17 - Bolt
❑ 5 Nm
18 - Support
19 - Bolt
❑ 4.5 Nm
Connecting coolant hose with plug-in connector

• If damaged, renew retaining clip -4-.
– If damaged, renew O-ring. To do so, remove O-ring -2- from
plug-in connector -3- using a suitable tool (do not use a sharp
tool). Take care not to damage the plug-in connector or the
surface on which the O-ring is seated.
– Lightly lubricate new O-ring with coolant and fit O-ring in cool‐
ant hose.
– Press coolant hose onto connection -1- until it engages audi‐
bly.
– Press coolant hose in again and then pull to check that plug-
in connector is correctly engaged.
Radiator cowl and radiator fan
1 - Radiator cowl
⇒ page 101
2 - Bolt
❑ 5 Nm
3 - Radiator fan - V7-
❑ With radiator fan control
unit - J293-
⇒ page 103
4 - Air flow flap
❑ Different versions avail‐
able ⇒ Electronic parts
catalogue
Radiator blind (top)

1 - Air duct
2 - Radiator blind (top)
⇒ page 95
3 - Bolt
❑ 5 Nm
4 - Fin
5 - Bracket
6 - Bolt
❑ 8 Nm
7 - Carrier
8 - Bolt
❑ 2.5 Nm
9 - Connecting piece
10 - Radiator blind control mo‐
tor - V544-
⇒ page 96
11 - Speed nut
12 - Air duct
13 - Spring element
14 - Bolt
❑ 8 Nm
Radiator blind (bottom)
1 - Air duct
2 - Radiator blind (bottom)
⇒ page 95
3 - Bolt
❑ 2.5 Nm
4 - Steel angle
5 - Bracket
6 - Bolt
❑ 1.5 Nm
7 - Radiator blind control motor
2 - V550-
⇒ page 97
8 - Fin
10 - Air duct
11 - Bolt
❑ 1.5 Nm
12 - Pop rivet
13 - Mounting bracket
❑ For impact bar
14 - Support
15 - Bracket
❑ For radiator blind
16 - Bolt
❑ 2.5 Nm
17 - Bolt
❑ 2.5 Nm
4.2 Removing and installing radiator

The radiator must be removed and installed together with the ra‐
diator cowl.
♦ Pop rivet pliers - VAS 5072A-


♦ Assembly tool - T10118-
♦ Electric drill
♦ Pop rivets ⇒ Electronic parts catalogue
Removing
CAUTION
Risk of injury as the radiator fan may start up automatically.
– When working in the vicinity of the radiator, keep a safe dis‐
tance from the radiator fan.

noise insulation .
The following step is required on A4 vehicles with LED headlights
or matrix LED headlights:
– Remove headlight (left-side) ⇒ Electrical system; Rep. gr. 94 ;
Headlights; Removing and installing headlights .
Vehicles without radiator blind:
– Remove bracket for bumper cover together with impact bar ⇒
General body repairs, exterior; Rep. gr. 50 ; Lock carrier; Ex‐
ploded view - lock carrier .
Vehicles with radiator blind:

– Remove impact bar together with radiator blind (top)
⇒ page 95 .
– Remove radiator blind (bottom) ⇒ page 95 .
– Drill off rivet heads -arrows-, drive out rivet stems and remove
any remaining rivet pieces.
– Detach bracket (left-side) -1- for radiator blind (bottom).

– Lift retaining clip -2- and disconnect coolant hose from radiator
(bottom right).
– Unplug electrical connector -arrow- for radiator fan.
– Release catches -arrow- and detach air ducts -1, 3-.

– Unclip air duct -2-.

– Detach air duct (top) -arrow-.

– Remove water radiator for charge air cooling circuit
⇒ page 99 .
– Unplug electrical connector -2- for high-pressure sender -

G65- .
– Release fasteners -arrows- on both sides, disengage con‐
denser -1- from radiator and tie up to one side.
– Lift retaining clips -1, 2-, detach coolant connection from radi‐
ator and move connection clear.
– Remove bolt -2- on both sides and press radiator bracket -1-
with radiator towards front -arrow-.
– Release fasteners -arrows- on both sides and pull retaining

pins -1- for radiator out upwards.
– Detach radiator.
– Press locking tabs on left and right sides of radiator cowl to‐
gether -arrow- and lift radiator cowl off radiator.
Installing
• If there are slight impressions on the fins, refer to ⇒ Servicing
4-cylinder TDI engine, common rail; Rep. gr. 00 ; Repair in‐
structions; Installing radiators and condensers .
– Install water radiator for charge air cooling circuit
⇒ page 99 .
– Install headlight ⇒ Electrical system; Rep. gr. 94 ; Headlights;
Removing and installing headlights .
Tightening torques
♦ ⇒ “3.2 Removing and installing air cleaner housing”,
page 117
♦ ⇒ General body repairs, exterior; Rep. gr. 50 ; Lock carrier;
Exploded view - lock carrier

4.3 Removing and installing radiator blind

(top)
Removing
– Remove impact bar ⇒ General body repairs, exterior; Rep.
gr. 63 ; Bumper (front); Removing and installing impact bar .
– Vehicles with pedestrian protection: Unplug electrical connec‐

tor -1- at crash sensor for pedestrian protection and move
electrical wiring harness -2- clear.
– Unplug electrical connector -3- and move clear.

– Remove bolts -arrows- (left and right).
– Slide mounting bracket -2- with Bowden cable for operating
lever for arrester towards lock carrier.
– Detach radiator blind (top) -1- towards front.
Installing
– Install impact bar ⇒ General body repairs, exterior; Rep. gr.
63 ; Bumper (front); Removing and installing impact bar .
Tightening torques
♦ ⇒ General body repairs, exterior; Rep. gr. 55 ; Bonnet; Ex‐
ploded view - Bowden cable

(bottom)
Removing
– Detach water radiator for charge air cooling circuit from radi‐
ator with coolant hoses connected, and tie it up to one side
⇒ page 99 .
– Unplug electrical connector -1- at ambient temperature sensor

- G17- and move electrical wiring harness clear. (Shown with‐
out the bumper cover.)
– Detach radiator blind (bottom) -2-.
Installing
⇒ page 99 .
Tightening torques

control motor (top)
♦ Spreader tool (commercially available)
Removing
– Remove radiator blind (top) ⇒ page 95 .
– Press connecting piece -2- off fins using spreader tool -1-.

– Unplug electrical connector -1- for radiator blind control motor
- V544- .


– Carefully unclip actuator -2- and pull slightly upwards.
– Swivel radiator blind control motor - V544- -1- downwards and
detach.
Installing
– To press on connecting piece, bring all fins into closed position
as shown.
– Press on connecting piece -arrows- in the sequence -1, 2-.
– Install radiator blind (top) ⇒ page 95 .
Tightening torques

control motor (bottom)
♦ Spreader tool (commercially available)
Removing
– Remove radiator blind (bottom) ⇒ page 95 .
– Press connecting piece -2- off fins using spreader tool -1-.

– Carefully lift motor -1- with fins.
– Unplug electrical connector -2- at radiator blind control motor
2 - V550- .
– Carefully lift out radiator blind control motor 2 - V550- -1- with
fins.
– Pull fin -1- off motor -arrow-.
– Remove bolt -arrow-.
– Pull radiator blind control motor 2 - V550- in direction of

-arrow- and remove from mounting.

Installing
– To press on connecting piece, bring all fins into closed position
as shown.
– Press on connecting piece -arrows- in the sequence -1, 2, 3-.
– Install radiator blind (bottom) ⇒ page 95 .
Tightening torques
4.7 Removing and installing water radiator

for charge air cooling circuit

Removing
– Remove closure plate for bumper cover ⇒ General body re‐
pairs, exterior; Rep. gr. 63 ; Bumper (front) .
– Remove air intake grille on both sides ⇒ General body repairs,

exterior; Rep. gr. 63 ; Bumper (front) .
– Move air guides -1, 3- (left and right) clear at water radiator for
charge air cooling circuit.

– Release fasteners on both sides and detach water radiator for
charge air cooling circuit -1-.
Installing
– Install closure plate at bumper cover and air intake grille (left
and right) ⇒ General body repairs, exterior; Rep. gr. 63 ;
Bumper (front) .

4.8 Removing and installing radiator cowl

Removing
– Remove closure plate for bumper cover ⇒ General body re‐
pairs, exterior; Rep. gr. 63 ; Bumper (front) .
– Remove air intake grille on both sides ⇒ General body repairs,

exterior; Rep. gr. 63 ; Bumper (front) .
noise insulation .

– Vehicles with radiator blind (bottom): Detach water radiator for
charge air cooling circuit from radiator with coolant hoses con‐
nected, and tie it up to one side ⇒ page 99 .

– Remove bolt -arrow- for retaining clip.
– Remove bolt -2- (both sides) for radiator bracket -1-.
– Remove bolt -2- (both sides) for radiator bracket -1- using
suitable tool -3-.
– Detach radiator bracket -1- (both sides) in direction of
-arrow-.
Note:
Mark installation position of radiator bracket relative to rubber
bush (for re-installation).

– Press locking tabs on left and right sides of radiator cowl

-arrow- and at the same time lift radiator cowl off radiator.
– Take radiator cowl out downwards between radiator and lock
carrier, pressing bottom of radiator module as far forwards as
possible.
Installing
– Install lock carrier cover, air intake grille (left and right) and
closure plate at bumper cover ⇒ General body repairs, exte‐
rior; Rep. gr. 63 ; Bumper (front) .
Tightening torques
4.9 Removing and installing radiator fan -

V7-
Removing
• Secure all cable ties in the same locations when re-installing.
– Remove radiator cowl ⇒ page 101 .
– Unscrew bolts -arrows- and remove radiator fan.
Installing
• Do not remove balancing clamps from fan wheel.
– Install radiator cowl ⇒ page 101 .
Tightening torques

21 – Turbocharging/supercharging
1 Turbocharger
cylinder TDI engine, common rail; Rep. gr. 21 ; Turbocharger .
104 Rep. gr.21 - Turbocharging/supercharging

2 Charge air system

cylinder TDI engine, common rail; Rep. gr. 21 ; Charge air
system .
2. Charge air system 105

23 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview - fuel system”, page 106
⇒ “1.2 Overview of fitting locations - injection system”,
page 107
⇒ “1.3 Filling and bleeding fuel system”, page 114
⇒ “1.4 Checking fuel system for leaks”, page 114
1.1 Overview - fuel system

♦ Red = fuel supply
♦ Blue = fuel return
♦ Arrows = direction of fuel flow
1 - Fuel filter
2 - Water separator
❑ With water level sender
- G120-
❑ Depending on vehicle
equipment
3 - High-pressure pump
4 - Fuel metering valve - N290-
5 - Fuel temperature sender -
G81-
6 - Restrictor
7 - Fuel pressure sender -
G247-
8 - High-pressure reservoir
(rail)
9 - Fuel pressure regulating
valve - N276-
10 - Injectors
11 - Fuel tank
❑ With fuel system pres‐
surisation pump - G6-
12 - Restrictor
106 Rep. gr.23 - Mixture preparation - injection

1.2 Overview of fitting locations - injection system

Overview of fitting locations - engine compartment
1 - Air mass meter - G70-

❑ Exploded view
⇒ page 116
2 - Gear detection sensor -
G604-
❑ Fitting location
⇒ page 108
3 - Automatic glow period con‐
trol unit - J179-
4 - Exhaust flap control unit -
J883-
⇒ page 109
5 - Accelerator position sender
- G79- and accelerator position
sender 2 - G185-
⇒ page 108
6 - Brake servo pressure sen‐
sor - G294-
7 - Brake light switch - F-
⇒ page 108
8 - Clutch position sender -
G476-
⇒ page 108
9 - Engine control unit - J623-
❑ Exploded view
⇒ page 126
V188-
❑ Fitting location ⇒ page 109
11 - Left electrohydraulic engine mounting solenoid valve - N144-
12 - Water separator
❑ With water level sender - G120-
❑ Depending on vehicle equipment
13 - Control unit for NOx sender - J583-
❑ Exploded view ⇒ Servicing 4-cylinder TDI engine, common rail; Rep. gr. 23 ; Lambda probe; Exploded
view - Lambda probe
14 - Air filter bypass flap valve - N275-
❑ Depending on vehicle equipment; not installed on all vehicles
❑ Not applicable to more recent versions
1. Injection system 107

Fitting location of accelerator position sender - G79- / accelerator

position sender 2 - G185-
♦ Integrated in accelerator pedal module -3-. Accelerator posi‐
tion senders cannot be renewed separately if defective.
Exploded view ⇒ Fuel supply system; Rep. gr. 20 ; Accelerator
mechanism; Exploded view - accelerator pedal module
Fitting location of brake light switch - F-

♦ In plenum chamber on brake master cylinder
1- Electrical connector for brake light switch - F-
Exploded view ⇒ Brake system; Rep. gr. 47 ; Brake servo/brake
master cylinder; Exploded view - brake servo/brake master cyl‐
inder
Fitting location of clutch position sender - G476-

♦ Integrated in clutch master cylinder in plenum chamber on
driver's side. It cannot be renewed separately if defective.
5 - Electrical connector for clutch position sender - G476-
Exploded view ⇒ Rep. gr. 30 ; Clutch mechanism; Exploded view
- pedal cluster
Fitting location of gear detection sensor - G604-

♦ At top right of manual gearbox
1- Gear detection sensor - G604-
Removing and installing ⇒ Rep. gr. 34 ; Selector mechanism ;
Removing and installing gear detection sensor - G604-

Fitting location of electrohydraulic engine mounting solenoid

valves -N144- / -N145-
♦ Integrated in engine mounting. It cannot be renewed sepa‐
rately if defective.
Pfeil - Electrical connector for left electrohydraulic engine mount‐
ing solenoid valve - N144-
Removing and installing
Fitting location of charge air cooling pump - V188-

♦ In wheel housing (front left)
1- Electrical connector for charge air cooling pump - V188-
”, page 62
Fitting location of air filter bypass flap valve - N275-

♦ In air cleaner (bottom section) -arrow-
♦ Depending on vehicle equipment; not installed on all vehicles
Fitting location of exhaust flap control unit - J883-

♦ On catalytic converter
1- Electrical connector for exhaust flap control unit - J883-
Removing and installing ⇒ Servicing 4-cylinder TDI engine, com‐
mon rail; Rep. gr. 26 ; Emission control system; Removing and
installing exhaust flap control unit - J883- .
Overview of fitting locations - engine (view from left side)

1 - Oil level and oil temperature

sender - G266-
❑ Exploded view ⇒ Serv‐
icing 4-cylinder TDI en‐
gine, common rail; Rep.
gr. 17 ; Sump/oil pump;
Exploded view - sump/
oil pump
2 - Valve for oil pressure con‐
trol - N428-
oil pump
3 - Hall sender - G40- (cam‐
shaft position sensor)
gr. 28 ; Glow plug sys‐
tem; Exploded view -
glow plug system
J338-
❑ With throttle valve po‐
tentiometer - G69-
gr. 23 ; Intake manifold;
Exploded view - intake
manifold
5 - Oil pressure switch for re‐
duced oil pressure - F378-
❑ Exploded view ⇒ Servicing 4-cylinder TDI engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure
switches; Exploded view - oil filter housing/oil pressure switches
6 - Oil pressure switch - F22-
7 - Engine speed sender - G28-
❑ Exploded view ⇒ Servicing 4-cylinder TDI engine, common rail; Rep. gr. 28 ; Glow plug system; Exploded
view - glow plug system
Overview of fitting locations - engine (view from right side)

1 - Exhaust gas temperature

sender 4 - G648-
gr. 26 ; Exhaust gas
temperature control; Ex‐
ploded view - exhaust
gas temperature control
control motor 2 - V339-
❑ With exhaust gas recir‐
culation potentiometer 2
- G466-
gr. 26 ; Exhaust gas re‐
circulation; Exploded
view - exhaust gas recir‐
culation
3 - NOx sender - G295-
gr. 23 ; Lambda probe;
Exploded view - Lamb‐
da probe
4 - Lambda probe - G39- with
Lambda probe heater - Z19-
da probe
5 - Injector for reducing agent -
N474-
❑ Exploded view ⇒ Servicing 4-cylinder TDI engine, common rail; Rep. gr. 26 ; SCR (selective catalytic
reduction) system; Exploded view - reducing agent supply line
6 - Exhaust gas temperature sender 3 - G495-
❑ Exploded view ⇒ Servicing 4-cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas temperature
control; Exploded view - exhaust gas temperature control
9 - Auxiliary pump for heating - V488-
❑ Exploded view ⇒ “2.4.2 Removing and installing auxiliary pump for heating V488 ”, page 64
Overview of fitting locations - engine (view from above)

1 - Injector, cylinder 1 - N30-

gr. 23 ; Injectors/high-
pressure reservoir (rail);
Exploded view - injec‐
tors
tors
tors
tors
5 - Position sender for charge
pressure positioner - G581-
6 - Exhaust gas pressure sen‐
sor 1 - G450-
view - Lambda probe
7 - Pressure differential sender - G505-
view - Lambda probe
8 - Fuel pressure regulating valve - N276-
❑ Exploded view ⇒ Servicing 4-cylinder TDI engine, common rail; Rep. gr. 23 ; Injectors/high-pressure
reservoir (rail); Exploded view - high-pressure reservoir (rail)
9 - Glow plug 4 - Q13-
10 - Charge pressure sender - G31-
❑ Exploded view ⇒ Servicing 4-cylinder TDI engine, common rail; Rep. gr. 21 ; Charge air system; Ex‐
ploded view - charge air system
11 - Charge air temperature sender before charge air cooler - G810-
12 - Glow plug 3 - Q12-
❑ With internal cylinder pressure sender for cylinder 3 - G622-

13 - Charge pressure control solenoid valve - N75-

14 - Charge air temperature sender after charge air cooler - G811-
15 - Fuel temperature sender - G81-
16 - Glow plug 2 - Q11-
❑ Integrated in high-pressure pump
18 - Glow plug 1 - Q10-
19 - Coolant valve for cylinder head - N489-
❑ Exploded view ⇒ Servicing 4-cylinder TDI engine, common rail; Rep. gr. 19 ; Coolant pump/thermostat
assembly; Exploded view - coolant pump/thermostat
20 - Fuel pressure sender - G247-
Overview of fitting locations - engine (view from rear)


control motor - V338-
culation potentiometer -
G212-
culation
2 - Not fitted
3 - Heating element for crank‐
case breather - N79-
temperature sensor - G98-
equipment
culation
er - G62-
gr. 19 ; Coolant pump/
thermostat assembly;
Exploded view - coolant
temperature senders
1.3 Filling and bleeding fuel system

gine, common rail; Rep. gr. 23 ; Injection system; Filling and
bleeding fuel system .
1.4 Checking fuel system for leaks

gine, common rail; Rep. gr. 23 ; Injection system; Checking fuel
system for leaks .

2 Vacuum system
⇒ “2.1 Connection diagram - vacuum system”, page 115
⇒ “2.2 Checking vacuum system”, page 115
2.1 Connection diagram - vacuum system
1 - Vacuum supply line

❑ Leading from vacuum
pump to brake servo
2 - Vacuum line
❑ To charge pressure
control solenoid valve -
N75-
3 - Vacuum unit
❑ On turbocharger
4 - Control pipe for vacuum
❑ To vacuum unit on tur‐
bocharger
5 - Charge pressure control
solenoid valve - N75-
2.2 Checking vacuum system

gine, common rail; Rep. gr. 23 ; Vacuum system; Checking
vacuum system .
2. Vacuum system 115

3 Air cleaner
⇒ “3.1 Exploded view - air cleaner housing”, page 116
⇒ “3.2 Removing and installing air cleaner housing”, page 117
3.1 Exploded view - air cleaner housing
1 - Mounting
❑ For air cleaner housing
2 - Water drain
❑ Clean
3 - Air cleaner (bottom section)
❑ Remove any salt depos‐
its or dirt
stalling air cleaner hous‐
ing”, page 117
4 - Air duct
❑ For secondary air intake
❑ Observe installation
markings
❑ Only installed on vehi‐
cles with air filter bypass
flap valve - N275-
5 - Bolt
❑ Thread-forming
❑ Fit and screw in bolt by
hand so that it is
screwed into old thread.
Then tighten bolt to tor‐
que
❑ 3.5 Nm
6 - Air cleaner (top section)
its or dirt
⇒ Maintenance ; Book‐
let 830
7 - Bolt
❑ Thread-forming
❑ Fit and screw in bolt by hand so that it is screwed into old thread. Then tighten bolt to torque
❑ 3.5 Nm
8 - Air pipe
❑ Observe installation markings; fit on connection of turbocharger before fitting on air mass meter
❑ 3.5 Nm
10 - Air filter element
❑ Use genuine air filter element ⇒ Electronic parts catalogue
❑ Change intervals ⇒ Maintenance tables
❑ Removing and installing ⇒ Maintenance ; Booklet 830

11 - Heat shield
12 - Bolt
❑ Thread-forming
❑ 1.5 Nm
13 - Air duct
❑ On lock carrier
❑ Remove any salt deposits or dirt
14 - Air duct
❑ On lock carrier
15 - Snow screen
16 - Bolt
❑ Thread-forming
❑ 2.5 Nm
17 - Sealing element
3.2 Removing and installing air cleaner

housing
Removing
– Depending on vehicle version, electrical connector -2- for air
filter bypass flap valve - N275- must be unplugged.
– Remove wheel spoiler (front right) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liners; Removing and
installing wheel housing liner (front) .
N275- .
3. Air cleaner 117


– Move coolant hose clear at retaining clip -2-.



Installing
• If the air cleaner housing is being renewed and an air cleaner
housing without air filter bypass flap valve - N275- is being
fitted, the electrical connector at the wiring harness must be
tied back and the vacuum line must be sealed off.
• The air cleaner housing must always be clean.
• To prevent malfunctions, cover critical parts of the engine air
intake (air mass meter, air pipes, etc.) with a clean cloth when
blowing out the air cleaner housing with compressed air.
• Hose connections and air pipes/hoses must be free of oil and
grease prior to fitting.
• Use silicone-free lubricant when fitting air hoses.
– Check air pipe for salt residue, dirt and leaves.
– First fit air pipe on connection of turbocharger, then fit on air
mass meter.
– Check air duct leading from lock carrier to air cleaner housing
for dirt and leaves.
Tightening torques
♦ ⇒ “3.1 Exploded view - air cleaner housing”, page 116
charge air system
3. Air cleaner 119

4 Intake manifold
cylinder TDI engine, common rail; Rep. gr. 23 ; Intake manifold .

5 Injectors/high-pressure reservoir
(rail)
cylinder TDI engine, common rail; Rep. gr. 23 ; Injectors/high-
pressure reservoir (rail) .
5. Injectors/high-pressure reservoir (rail) 121

6 High-pressure pump
cylinder TDI engine, common rail; Rep. gr. 23 ; High-pressure
pump .

7 Senders and sensors

⇒ “7.1 Removing and installing air mass meter G70 ”, page 123
⇒ “7.2 Removing and installing fuel temperature sender G81 ”,
page 124
⇒ “7.3 Removing and installing fuel pressure sender G247 ”, page
124
⇒ “7.4 Checking fuel pressure regulating valve N276 ”,
page 124
⇒ “7.5 Removing and installing fuel pressure regulating valve
N276 ”, page 124
⇒ “7.6 Removing and installing pressure differential sender G505
”, page 124
7.1 Removing and installing air mass meter

- G70-
Removing

– Unscrew bolts -arrows- and detach air mass meter - G70- .
Installing
• If the air filter element is very dirty or wet, dirt particles or water
can reach the air mass meter and falsify the detected air mass
values. This will cause a loss of power as the calculated in‐
jection quantities will be too low.
• Check air filter element and inside of air cleaner housing for
dirt and clean if necessary ⇒ Maintenance ; Booklet 830 .
Tightening torques
charge air system
7. Senders and sensors 123

7.2 Removing and installing fuel tempera‐

ture sender - G81-
gine, common rail; Rep. gr. 23 ; Senders and sensors ; Removing
and installing fuel temperature sender - G81- .
7.3 Removing and installing fuel pressure

sender - G247-
gine, common rail; Rep. gr. 23 ; Senders and sensors; Removing
and installing fuel pressure sender - G247- .
7.4 Checking fuel pressure regulating valve

- N276-
gine, common rail; Rep. gr. 23 ; Senders and sensors; Checking
fuel pressure regulating valve - N276- .

regulating valve - N276-
and installing fuel pressure regulating valve - N276- .
7.6 Removing and installing pressure differ‐

ential sender - G505-
and installing pressure differential sender - G505- .

8 Lambda probe
cylinder TDI engine, common rail; Rep. gr. 23 ; Lambda probe .
8. Lambda probe 125

9 Engine control unit

⇒ “9.1 Exploded view - engine control unit”, page 126
⇒ “9.2 Removing and installing engine/motor control unit J623 ”,
page 126
9.1 Exploded view - engine control unit
1 - Bolt
❑ 9 Nm
2 - Mounting
❑ For engine control unit -
J623-
⇒ page 126
4 - Bolt
❑ 9 Nm
5 - Suspension turret
9.2 Removing and installing engine/motor

control unit - J623-
Removing
– If the engine control unit - J623- is renewed, the adaption val‐
ues must be read out and stored before the engine control unit
- J623- is removed.
– Select Diagnosis mode and then Start diagnosis .


♦ Drive train
♦ 01 - Functions component replacement
– Switch off ignition and remove ignition key after storing elec‐
tronic file containing adaption values.
• If the adaption values of the injectors cannot be read out of the
old (defective) engine control unit, the adaption values must
be entered into the new engine control unit manually and the
adaption procedure must be performed accordingly.
– Release catches -arrows- and detach engine control unit -
J623- -item 2-.
– Unplug electrical connectors -1-.
Installing
– If engine control unit - J623- has been renewed, perform adap‐
tions in Guided Functions mode, function 01 - Functions
component replacement .
9. Engine control unit 127

26 – Exhaust system
1 Exhaust pipes/silencers
⇒ “1.1 Exploded view - silencers”, page 128
⇒ “1.2 Removing and installing front exhaust pipe”, page 133
⇒ “1.3 Separating exhaust pipes/silencers”, page 136
⇒ “1.4 Removing and installing silencers”, page 138
⇒ “1.5 Stress-free alignment of exhaust system”, page 139
⇒ “1.6 Checking exhaust system for leaks”, page 140
1.1 Exploded view - silencers

⇒ “1.1.1 Exploded view - silencers, vehicles with front-wheel
drive”, page 128
⇒ “1.1.2 Exploded view - silencers, vehicles with four-wheel
drive”, page 131
1.1.1 Exploded view - silencers, vehicles with

front-wheel drive
• Observe safety precautions when working on exhaust system
⇒ Servicing 4-cylinder TDI engine, common rail (EA 288 Gen.
I); Rep. gr. 00 ; Safety precautions .
128 Rep. gr.26 - Exhaust system

1 - Rear silencer
❑ Combined in one unit
with centre silencer as
original equipment. Can
be renewed separately
for repair purposes
❑ Cutting point between
centre silencer and rear
silencer ⇒ page 136
⇒ page 138
❑ Align exhaust system so
it is free of stress
⇒ page 139
2 - Centre silencer
with rear silencers as
for repair purposes
⇒ page 139
3 - Rubber mounting
4 - Bolt
❑ 23 Nm
5 - Bracket
6 - Bolt
❑ 23 Nm
7 - Bracket
8 - Rubber mounting
9 - Gasket
10 - Nut
❑ Coat thread with high-temperature paste ⇒ Electronic parts catalogue
❑ 23 Nm
11 - Gasket
❑ Renew
12 - Front exhaust pipe
❑ With flexible joint
❑ Do not bend flexible joint more than 10°
❑ Install flexible joint so that it is not under tension.
❑ Take care not to damage wire mesh on flexible joint
❑ Align exhaust system so it is free of stress ⇒ page 139
1. Exhaust pipes/silencers 129

13 - Mounting
❑ Check preload ⇒ page 139
14 - Bolt
❑ 23 Nm
15 - Nut
❑ 25 Nm
16 - Catalytic converter
❑ Catalytic trap functions like an SCR catalytic converter or oxidation catalytic converter
❑ Protect against knocks and impact
❑ Removing and installing ⇒ Servicing 4-cylinder TDI engine, common rail; Rep. gr. 26 ; Emission control
system; Removing and installing catalytic converter
17 - Nut
❑ 10 Nm
18 - Exhaust flap control unit - J883-
❑ Removing and installing ⇒ Servicing 4-cylinder TDI engine, common rail; Rep. gr. 26 ; Emission control
system; Removing and installing exhaust flap control unit - J883-
19 - Bolt
20 - Clamp (front)
❑ Before tightening, align exhaust system so it is free of stress ⇒ page 139
❑ Installation position ⇒ page 131
❑ Tighten screw connections evenly to 23 Nm
21 - Clamp (rear)
❑ For separate replacement of centre and rear silencers
22 - Rubber mounting
23 - Bracket
24 - Bolt
❑ 23 Nm

Components of mountings for front exhaust pipe

1- Spacer sleeve
2- Bracket
3- Compression spring
4- Washer
5- Bolt, 23 Nm
6- Bolt, 23 Nm
7- Spacer sleeve
8- Buffer
9- Not fitted
10 - Not fitted
Installation position - front clamp

– Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.
• Bolt connection faces to right.
Installation position - clamp (rear) for vehicles with front-wheel

drive
– Fit clamp in position shown.
• Bolt connections face to left
• Nuts face downwards.
• Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.
1.1.2 Exploded view - silencers, vehicles with four-wheel drive

1 - Clamp (front)
❑ Before tightening, align
exhaust system so it is
free of stress
⇒ page 139
⇒ page 131
❑ Tighten screw connec‐
tions evenly to 23 Nm
2 - Centre silencer
for repair purposes
⇒ page 139
3 - Rubber mounting
4 - Clamp (rear)
❑ For separate replace‐
ment of centre and rear
silencers
free of stress
⇒ page 139
⇒ page 131
5 - Rear silencer
❑ Combined in one unit with centre silencer as original equipment. Can be renewed separately for repair
purposes
❑ Cutting point between centre silencer and rear silencer ⇒ page 136
6 - Bolt
❑ 23 Nm
7 - Mounting
8 - Rubber mounting
9 - Bracket
10 - Bolt
❑ 23 Nm

Installation position - clamp (rear) for vehicles with four-wheel

drive
• Bolted connection facing towards right
tom of clamp -arrow-.
1.2 Removing and installing front exhaust

pipe
♦ Tool set - T10395 A- with suitable tool insert
♦ Supplement tool set - T10395/8-/10-

♦ Flared ring spanner tool insert (17 mm) - V.A.G 1331/10-
Removing
– Remove drive shaft (right-side); to do so, loosen bolt securing
drive shaft (right-side) before raising vehicle ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Loosening and tight‐
ening bolt securing drive shaft .
– Remove front right wheel.
page 117 .


from front exhaust pipe using a tool from tool set - T10395 A- .
– Unscrew nut -1-. (Nuts -2- do not have to be removed at this

stage.)
– Remove noise insulation (centre and rear) ⇒ General body
repairs, exterior; Rep. gr. 66 ; Noise insulation; Exploded view
- noise insulation .
– Unscrew nuts -1 and 3- and remove drive shaft cover (right-

side) -2-.
(right-side).

– Remove bolts -arrows- securing drive shaft to flange shaft and

take out drive shaft.
– Detach drive shaft, taking care not to damage boot and coating
on drive shaft.
– Remove bolts -arrows- and take out subframe shield (right-

side).
Note
Guide shield out through opening by turning it (only possible in
one position).
– Remove nuts -2- using a small jointed socket wrench with an

extension.
– Remove bolt -1- and turn retaining tab downwards.

– Remove nuts -2- and bolts -1- and detach front exhaust pipe.

incorrectly.
Installing
• Renew gaskets and nuts after removing.
page 117 .
– Install drive shaft ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shaft; Removing and installing drive shaft .
– Align the exhaust system so it is free of stress ⇒ page 139 .
Tightening torques
♦ ⇒ “1.1 Exploded view - silencers”, page 128
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
Removing and installing heat shield for drive shaft
1.3 Separating exhaust pipes/silencers

♦ The connecting pipe can be cut through at the cutting point in
order to renew the centre or rear silencer separately.
♦ The cutting point is marked by an indentation on the circum‐
ference of the exhaust pipe.

♦ Chain pipe cutter - VAS 6254-
Version 1:
– Cut through exhaust pipe at right angle at centre notch
-arrow- using chain pipe cutter - VAS 6254- .
– Position centre of clamp -arrow- over cutting location.
Version 2:


– Fit clamp ⇒ page 131 .
Tightening torques
1.4 Removing and installing silencers

Removing
– Equipment version: Remove diagonal strut (left-side) ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66 ; Underbody trim .
– Loosen clamp -arrows- and push towards rear.

incorrectly.
– Lower front exhaust pipe slightly and detach clamp.

– Tie up front exhaust pipe.

Vehicles with front-wheel drive:

– Disengage rubber mounting -4-.
Note
• A second mechanic is required for removal of the rear silencer.
– Unscrew bolts -1, 3- and remove silencer -2-.
Vehicles with four-wheel drive:

– Disengage rubber mountings -2, 4-.
Note
• A second mechanic is required for removal of the rear silencer.
– Unscrew bolt -3- and remove silencer -1-.
Installing
• Renew gaskets and nuts after removing.
Tightening torques
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
trim
1.5 Stress-free alignment of exhaust system

Procedure
• The exhaust system must be aligned when it is cool.
– Slacken front clamp -arrows-.

– Push exhaust system towards front of vehicle -arrow- so that

mounting for exhaust pipe is preloaded by -a- = 6 ... 10 mm.
– Position clamp at front ⇒ page 131 and tighten bolted con‐
nections evenly.
– Check clearance between tailpipes and bumper:

• Distance -a- is the same on both sides.
Tightening torques
1.6 Checking exhaust system for leaks

gine, common rail; Rep. gr. 26 ; Exhaust pipes/silencers; Check‐
ing exhaust system for leaks .

2 Emission control system

cylinder TDI engine, common rail; Rep. gr. 26 ; Emission control
system .
2. Emission control system 141

3 SCR (selective catalytic reduction)

system
⇒ “3.1 Exploded view - reducing agent tank”, page 142
⇒ “3.2 Exploded view - reducing agent supply line”, page 143
⇒ “3.3 Draining reducing agent tank”, page 143
⇒ “3.4 Removing and installing reducing agent tank”, page 145
⇒ “3.5 Removing and installing injector for reducing agent N474
”, page 147
⇒ “3.6 Removing and installing control unit for reducing agent
metering system J880 ”, page 147
⇒ “3.7 Removing and installing reducing agent quality sensor
G849 ”, page 148
3.1 Exploded view - reducing agent tank
1 - Bolt
❑ 2 Nm
2 - Reducing agent quality sen‐
sor - G849-
equipment
⇒ page 148
3 - Seal
4 - Reducing agent tank
❑ With delivery unit for re‐
ducing agent metering
system - GX19-
❑ The following compo‐
nents are integrated in
the delivery unit for re‐
system - GX19- :
♦ Filter
♦ Tank sender for reducing
agent - G684-
♦ Temperature sender for re‐
ducing agent - G685-
♦ Pressure sender for reduc‐
ing agent metering system
- G686-
♦ Pump for reducing agent -
V437-
♦ Heater for reducing agent
tank - Z102-
♦ Heater 2 for reducing agent
tank (heater circuit 3) - Z167-
❑ Fitting location: on rear right under underbody
❑ Draining ⇒ page 143

5 - Nut
❑ 20 Nm
6 - Spacer sleeve
7 - Grommet
8 - Spacer sleeve
9 - Filler neck
❑ For fuel tank
10 - Filler cap
❑ For filler neck for reducing agent tank
11 - Bolt
❑ 8 Nm
12 - Filler neck
❑ For reducing agent tank
13 - Spacer sleeve
14 - Grommet
15 - Spacer sleeve
16 - Bolt
❑ 20 Nm
17 - Control unit for reducing agent metering system - J880-
❑ Checking ⇒ Vehicle diagnostic tester
❑ After renewing, perform adaption in Guided Functions ⇒ Servicing 4-cylinder TDI engine, common rail
(EA 288 Gen. I); Rep. gr. 00 ; Repair instructions
18 - Bolt
❑ 3 Nm
19 - SCR supply line
20 - Sealing plug
❑ For drain pipe
3.2 Exploded view - reducing agent supply

line
gine, common rail; Rep. gr. 26 ; SCR (selective catalytic reduc‐
tion) system; Exploded view - reducing agent supply line .
3.3 Draining reducing agent tank

♦ Safety goggles
Procedure
3. SCR (selective catalytic reduction) system 143

Note:
Wait until the reducing agent has been drawn back automatically,
because large amounts of reducing agent can escape when the
metering line is opened.
It can take up to 10 minutes after the ignition has been switched
off for the reducing agent to be drawn back completely.
– Open tank flap.
– Unscrew filler cap -arrow- from filler neck for reducing agent.
– Remove underbody trim (rear right) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody trim .
CAUTION
Risk of injury caused by escaping reducing agent
Reducing agent can cause eye and skin irritation, damage to
the respiratory tract and poisoning.
– Wear protective clothing.
– Ensure that there is sufficient fresh air. In enclosed spaces,
switch on the exhaust extraction system.

– Place drip tray underneath.

– Press release tab and remove sealing plug -arrow-.
– Allow reducing agent to drain off into drip tray.
NOTICE
Reducing agent must never be reused. For information regard‐
ing storage and disposal see ⇒ ServiceNet → Environmental
protection → Workshop waste management . Contact Importer
for country-specific information regarding storage and disposal.
Assembling
– Seal off drain pipe with sealing plug.
– Adapt learnt values after filling up reducing agent or renewing
components.
♦ Drive train
♦ 01 - Work steps after component replacement
Tightening torques
trim
3.4 Removing and installing reducing agent

tank
Removing
– Drain reducing agent tank ⇒ page 143 .

– Detach rear section of rear right wheel housing liner ⇒ General

moving and installing wheel housing liner (rear) .
A5 and A5 Cabriolet only:
– Remove rear bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (rear); Removing and installing bumper
cover .
All vehicles:
agent supply line .
– Detach electrical connector -4- from bracket.
– Unplug electrical connectors -1, 2- and move electrical wiring
harness clear.
– Vehicles with reducing agent quality sensor - G849- : Unplug

electrical connector -arrow-.
– Unscrew connections -arrows-.

– Lower reducing agent tank -1- slightly.
– Press release tabs on both sides and disconnect hoses -2-.
– Detach reducing agent tank.
Installing

– Connect SCR supply line.

• Plug-in connector must engage audibly when connecting.
– Pull to check that plug-in connectors are correctly engaged.
– Check that lines are clipped onto reducing agent tank.
– Fit bolts -arrows-, then slide reducing agent tank towards rear
of vehicle (with bolts in bolt holes) and finally tighten bolts
-arrows-.
– Adapt learnt values after filling up reducing agent or renewing
components.
♦ Drive train
Tightening torques
♦ ⇒ “3.1 Exploded view - reducing agent tank”, page 142
liners; Exploded view - wheel housing liner (rear)
3.5 Removing and installing injector for re‐

ducing agent - N474-
tion) system; Removing and installing injector for reducing agent
- N474- .
3.6 Removing and installing control unit for

reducing agent metering system - J880-
Removing

– Remove bolts -arrows- and detach control unit for reducing

agent metering system - J880- -item 1-.
Installing
– If control unit for reducing agent metering system - J880- was
renewed, reset learnt values.
♦ Drive train
Tightening torques
trim

quality sensor - G849-
Removing


– Unscrew bolts -arrows- and detach reducing agent quality
sensor - G849- .
Installing
• Renew seal after removing.
– Adapt SCR learnt values after filling up reducing agent or re‐
newing components.
♦ Drive train
Tightening torques

4 Exhaust gas temperature control

cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas
temperature control .

5 Exhaust gas recirculation

recirculation .
5. Exhaust gas recirculation 151

28 – Glow plug system

1 Glow plug system
⇒ “1.1 Exploded view - glow plug system”, page 152
⇒ “1.2 Removing and installing glow plug”, page 152
⇒ “1.3 Removing and installing automatic glow period control unit
J179 ”, page 152
⇒ “1.4 Removing and installing Hall sender G40 ”, page 152
⇒ “1.5 Removing and installing engine speed sender G28 ”, page
152
1.1 Exploded view - glow plug system

gine, common rail; Rep. gr. 28 ; Glow plug system; Exploded view
- glow plug system .
1.2 Removing and installing glow plug

gine, common rail; Rep. gr. 28 ; Glow plug system; Removing
and installing glow plug .
1.3 Removing and installing automatic glow

period control unit - J179-
Removing
– Pull off seal and lift plenum chamber cover slightly.
– Unplug electrical connector -1- and detach automatic glow pe‐
riod control unit - J179- .
Installing
Installation is carried out in reverse sequence.
Tightening torques
Component Nm
Automatic glow period control 4.5
unit - J179- to plenum chamber
1.4 Removing and installing Hall sender -

G40-
and installing Hall sender - G40- .
1.5 Removing and installing engine speed

sender - G28-
and installing engine speed sender - G28- .
152 Rep. gr.28 - Glow plug system

Service
Workshop Manual
Audi A4 2015 ➤
Audi A5 Sportback 2017 ➤
288 EVO)
Engine ID
DEZ DEZ
E B
Edition 07.2018

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system

Copyright © 2018 Audi AG, Ingolstadt D4B80884A1F

Audi A4 2015 ➤ , Audi A5 Sportback 2017 ➤
4-cylinder TDI engine, 2.0 ltr. 4-valve common rail (EA 288 EVO) - Edition 07.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Separating engine and gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Removing engine from scissor-type assembly platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.1 Exploded view - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2 Exploded view - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.3 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.4 Removing and installing seals for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.5 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.6 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.7 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.3 Removing and installing sump (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Contents i
1.4 Removing and installing sump (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.1 Exploded view - oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.2 Exploded view - oil pressure switches/oil pressure control . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.4 Removing and installing oil pressure sender G10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.5 Removing and installing valve for oil pressure control N428 . . . . . . . . . . . . . . . . . . . . . . . . 48
3.6 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.7 Removing and installing piston cooling jet control valve N522 . . . . . . . . . . . . . . . . . . . . . . 48
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.3 Exploded view - coolant valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.7 Removing and installing coolant circuit control unit GX28 . . . . . . . . . . . . . . . . . . . . . . . . 68
2.9 Removing and installing actuator for engine temperature regulation N493 . . . . . . . . . . . . 70
2.10 Removing and installing temperature sensor G18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.11 Removing and installing engine temperature sender G27 . . . . . . . . . . . . . . . . . . . . . . . . 71
2.12 Removing and installing engine temperature sender 2 G652 . . . . . . . . . . . . . . . . . . . . . . 72
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4 Radiators/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.1 Exploded view - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.1 Exploded view - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.2 Exploded view - hose connections for charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.3 Removing and installing charge pressure sender G31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.4 Removing and installing charge air temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

ii Contents

2 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.1 Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.2 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.3 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.1 Exploded view - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.2 Exploded view - high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.3 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.4 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.5 Removing and installing high-pressure pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.6 Removing and installing high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.1 Exploded view - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.3 Removing and installing NOx senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
8.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

1 Exhaust pipes/silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.1 Exploded view - silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.3 Separating exhaust pipes/silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.4 Removing and installing silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
2.1 Exploded view - emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.3 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.4 Removing and installing trap catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.5 Removing and installing exhaust flap control unit J883 . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Contents iii
5.1 Exploded view - exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.2 Removing and installing exhaust gas recirculation control motor V338 . . . . . . . . . . . . . . 126
5.3 Removing and installing exhaust gas recirculation control motor 2 V339 . . . . . . . . . . . . . . 126
5.4 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.5 Checking exhaust gas recirculation cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
iv Contents
1 Identification
(ARL005514; Edition 07.2018)
1. Identification 1


⇒ “1.2 Separating engine and gearbox”, page 13
⇒ “1.3 Removing engine from scissor-type assembly platform”,
page 19
page 19
1.1 Removing engine

♦ Scissor-type assembly platform - VAS 6131 B-

♦ Support set for Audi - VAS 6131/10-
♦ Adapter -VAS 6131/11-4- (2x) from support set, Audi A8

>2002 - VAS 6131/11- (not illustrated)
♦ Tapered mounting pins - VAS 6131/12-2- (2x) from support
set, Audi A6 >2005 - VAS 6131/12- (not illustrated)
♦ Threaded spindle (2x) from support set, Audi Q7 >2005 - VAS
6131/13-


♦ Wrench 21 mm - T40263-
♦ Safety goggles
Procedure
• The engine is removed from underneath together with the
gearbox and subframe (with lock carrier installed).
• Re-install all cable ties in the same locations when installing.
• Observe rules for cleanliness ⇒ Servicing 4-cylinder TDI en‐
gine, common rail; Rep. gr. 00 ; Repair instructions; Rules for
cleanliness .
• All bolts on running gear components with bonded rubber
bushes must be tightened with suspension in unladen position
(vehicle unladen).
• Bonded rubber bushes can only be turned to a limited extent.
Therefore, before tightening the bolts, suspension compo‐
nents with bonded rubber bushes must be brought into a
position corresponding to the normal position while driving
(unladen position). Otherwise, the bush would be subject to
torsion loading and its service life shortened.
– Before starting work, determine unladen position ⇒ Running
gear, axles, steering; Rep. gr. 00 ; Repair instructions; Lifting
suspension to unladen position (vehicles with coil springs) .
– Bring front wheels into straight-ahead position.
battery .

CAUTION
The cooling system is under pressure when the engine is hot.
Risk of scalding due to hot steam and hot coolant.

expansion tank.
Rep. gr. 63 ; Bumper (front); Exploded view - bumper cover .
– Remove wheel spoiler (both sides) and wheel housing liner
Wheel housing liners; Exploded view - wheel housing liner
(front) .
Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
– Remove noise insulation panels ⇒ General body repairs, ex‐
noise insulation .

– Open drain plug -1- at connection and drain off coolant.
– Lift retaining clip -arrow- and disconnect coolant hose.

– Release hose clip -2-, disconnect coolant hose from gearbox

and drain off coolant.
– Move retaining clips -arrows- clear with fuel hoses and press
to one side.
– Release hose clip -1- and disconnect air hose.

– Disconnect fuel hoses -1, 2, 3- ⇒ Fuel supply system; Rep.

gr. 20 ; Plug-in connectors; Disconnecting plug-in connectors .
– Move coolant hoses clear and tie up to right side.

-arrow A-.
– Move wiring duct clear at top.
– Release pressure in SCR system ⇒ Servicing 4-cylinder TDI

engine, common rail; Rep. gr. 26 ; SCR (selective catalytic
reduction) system; Releasing pressure in SCR system .
– Press release tab and disconnect SCR supply line -arrow-
from injector for reducing agent - N474- .
– Move SCR line clear at engine.


– Unplug electrical connector -arrow- for exhaust gas tempera‐

ture sender 4 - G648- and move wiring clear.
– If engine is to be separated from gearbox, detach electrical
connectors from bracket and move them clear.

move them clear.
switch - F66- .
– Lift retaining clips -3- and disconnect coolant hoses.

– Release hose clips -2, 4, 5- and disconnect coolant hoses.
– Unplug electrical connector -1- for Lambda probe 1 before
catalytic converter - GX10- .
– Lift retaining clips -1, 2- and disconnect coolant hoses.


– Unplug electrical connector -1- at engine control unit.
– Move electrical wiring harness clear and place down on top of
engine.
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Removing and installing subframe with steer‐
ing rack .
– Remove poly V-belt from air conditioner compressor ⇒ Serv‐
icing 4-cylinder TDI engine, common rail; Rep. gr. 13 ; Cylin‐
der block (pulley end); Removing and installing poly V-belt .
– Unplug electrical connectors and move electrical wiring clear:

1 - For parking lock solenoid - N486-
3 - For electric pump 2 for gearbox - V553-
NOTICE
Risk of irreparable damage due to electrostatic discharge.
– Do not touch connector contacts with your hands.
– Touch the lifting platform or other earthed object to discharge
static electricity.
– Unplug electrical connector -2- on gearbox.
– Remove bolts -arrows- and move manual release cable -1- for
parking lock clear.

CAUTION
Risk of injury caused by soot particles in the air.
Eyes and skin can suffer irritation or injuries.
– Release screw-type clip -arrow-.

Note:
To loosen screw-type clip, lock two nuts on threaded shaft of
screw and loosen screw.
– Remove nuts -arrows- and bolts -1- and detach front exhaust
pipe.
Set up the scissor-type assembly platform as follows:

– Set up scissor-type assembly platform - VAS 6131 B- as fol‐
lows:
Plat‐ Parts of -VAS 6131/10- , adapter -VAS 6131/11-4- ,
form co‐ tapered mounting pin - VAS 6131/12-2- and threaded
ordi‐ spindle from -VAS 6131/13-
nates
B7 /10-1 /12-2 Threaded /11-4
spindle from -
VAS 6131/13-
G7 /10-1 /12-2 Threaded /11-4
spindle from -
VAS 6131/13-
C15 /10-1 /10-2 /10-5 /10-6
F15 /10-1 /10-3 /10-5 /10-7
– Initially hand-tighten the support elements on the scissor-type
assembly platform.
– Position scissor-type assembly platform - VAS 6131 B- hori‐
zontally.
• Take note of spirit level (bubble gauge).
– Position scissor-type assembly platform - VAS 6131 B- below
engine/gearbox assembly.

– Position support elements from -VAS 6131/10- on tunnel cross

member, as shown.
– Make sure that threaded spindle (right-side) is screwed in
completely.
– Position support elements from -VAS 6131/10- , adapter -VAS

6131/11-4- , tapered mounting pin - VAS 6131/12-2- and
threaded spindle -1- from support set, Audi Q7 >2005 - VAS
6131/13- against engine on left and right, as shown.
– Screw in bolt -arrow- for engine mounting until it makes contact
with adapter.
– Turn remaining spindles for support elements upwards until all
locating lugs make contact with mounting points.
– Tighten base plates for support elements to 20 Nm on scissor-
type assembly platform - VAS 6131 B- .
– Remove bolts -arrows- on tunnel cross member.
NOTICE
– Check that all connections between engine, gearbox and
body have been detached.
– Carefully guide engine/gearbox assembly out of engine
compartment when lowering.
1.2 Separating engine and gearbox


♦ Lambda probe open ring spanner set - 3337-
♦ Adapter -VAS 6131/11-2- from support set, Audi A8 >2002 -

VAS 6131/11- (not illustrated)
♦ Engine support - T10533-

♦ Wrench 21 mm - T40263-
♦ Key -T40405- (not illustrated)

Procedure
• Engine/gearbox assembly removed and secured to scissor-
type assembly platform - VAS 6131 B-
– Release screw-type clip -arrow- for particulate filter.
CAUTION
– Release screw-type clips -arrows- and detach exhaust gas

recirculation pipe -1-.
– Unscrew union nuts -1, 4- and move pressure pipes clear.

– Unscrew bolts - 5- and nuts -3- and remove bracket -2-.
– Detach particulate filter.


– Position wrench, 21 mm - T40263- and key -T40405- on vi‐

bration damper.
• Notch -2- aligns with “OT” (TDC) marking -1- on vibration
damper.
NOTICE
Risk of engine damage if valve gear drive slips
– Only turn engine in normal direction of rotation.
– Counterhold crankshaft at vibration damper.
– Remove 3 bolts -arrow- from drive plate -1-. Turn crankshaft

120° in direction of engine rotation each time.

– Remove bolt -arrow-, move cable duct -1- with B+ wire clear
and push it to one side.

lows:
• The other support elements remain unchanged.
Platform Parts of support set for Audi - VAS 6131/10- ,
coordinates adapter -VAS 6131/11-2- and engine support -
T10533/1- with -T10533/5-
F5 Engine support - T10533/1- with -T10533/5-
C10 /10-1 /10-4 /10-5 /11-2
F10 /10-1 /10-4 /10-5 /10-6
– Secure engine support - T10533/1- to engine (right-side) with

-T10533/5- and nut -arrow-, as shown.
– Secure engine support to scissor-type assembly platform -
VAS 6131 B- and tighten to 20 Nm.

– Position support elements from -VAS 6131/10- and adapter -

VAS 6131/11-2- at left of gearbox, as shown.
– Position support elements from -VAS 6131/10- at right of gear‐

box, as shown.
– Turn spindles (left and right) upwards until all locating lugs
make contact with mounting points.

– Loosen clamping bolts on sides of scissor-type assembly plat‐

form - VAS 6131 B- , pull rear section of platform (together with
gearbox) slightly towards rear -arrow-, and at the same time
remove bolt for starter completely.
– Pull gearbox towards rear as far as it will go; lower it slightly
with front spindles if necessary.
1.3 Removing engine from scissor-type as‐

sembly platform
Removing engine from scissor-type assembly platform .

support

♦ All special tools specified in removal procedure
Procedure
angle.
• Engine positioned on scissor-type assembly platform - VAS
6131 B-
– Fit gearbox to engine ⇒ Gearbox; Rep. gr. 34 ; Removing and
installing gearbox; Installing gearbox .

Note:
gearbox.
– Install particulate filter ⇒ Servicing 4-cylinder TDI engine,
common rail; Rep. gr. 26 ; Emission control system; Removing
and installing particulate filter .
– Install tunnel cross member ⇒ Gearbox; Rep. gr. 34 ; As‐
sembly mountings; Exploded view - assembly mountings .
page 114 .
– Install manual release cable for parking lock ⇒ Gearbox; Rep.
gr. 34 ; Selector mechanism; Exploded view - selector mech‐
anism .
40 ; Subframe; Removing and installing subframe with steer‐
ing rack .
chamber cover .
– Fill up with engine oil (⇒ Maintenance ; Booklet 830 ; Main‐
tenance; Engine oil: filling up ), and check oil level (⇒ Mainte‐
nance ; Booklet 830 ; Maintenance; Engine oil: checking oil
level and correcting if necessary ).
– Fill coolant expansion tank and carry out bleeding routine us‐
ing ⇒ Vehicle diagnostic tester


ing battery .
NOTICE
sive voltage.
– Install wheel housing liner and wheel spoiler ⇒ General body

repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Removing
and installing wheel housing liner (front) .
Wheels, tyres .
– Install underbody trim ⇒ General body repairs, exterior; Rep.
gr. 66 ; Underbody trim; Exploded view - underbody trim .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Exploded view - noise insulation .
– After renewing engine, perform required adaptions using
⇒ Vehicle diagnostic tester ⇒ Servicing 4-cylinder TDI engine,
common rail; Rep. gr. 00 ; Repair instructions ; Performing
adaptions after renewing a component.
Tightening torques
♦ Tolerance for tightening torques: ± 15 %.
Component Nm
Bolts/nuts M6 10
M7 15
M8 20
M10 40
M12 65
box


♦ Exploded view - engine mounting ⇒ page 22
♦ Exploded view - gearbox mounting for dual clutch gearbox
⇒ page 23
Exploded view - engine mounting
1 - Subframe
2 - Bolt
❑ 20 Nm
3 - Bolt
❑ 10 Nm
⇒ page 26
⇒ page 23
5 - Bolt
❑ 55 Nm
6 - Engine support
⇒ page 31
7 - Heat shield
8 - Bolt
❑ 10 Nm
9 - Bolt
❑ 55 Nm
❑ with
valve - N144-
valve - N145-
⇒ page 24
11 - Bolt
❑ 90 Nm +90°
12 - Bolt
❑ 30 Nm


support mounting.
Exploded view - gearbox mounting for dual clutch gearbox
1 - Bolt
❑ Tightening torque ⇒
Gearbox; Rep. gr. 34 ;
Assembly mountings;
bly mountings
⇒ Gearbox; Rep. gr.
34 ; Assembly mount‐
ings; Exploded view -
assembly mountings
3 - Stop
⇒ page 27
5 - Gearbox
6 - Nut
Assembly mountings;
bly mountings
7 - Gearbox support
ing”, page 27
8 - Bolt
❑ Tightening torque ⇒ Gearbox; Rep. gr. 34 ; Assembly mountings; Exploded view - assembly mountings
9 - Bolt
10 - Nut

tion
Procedure
(left and right) as illustrated.
– Partly take up weight of engine with spindles.
Assembling

ings

ings
Removing
noise insulation .
– Remove front wheel on relevant side ⇒ Running gear, axles,
steering; Rep. gr. 44 ; Wheels, tyres .

– Remove relevant front wheel spoiler ⇒ General body repairs,

exterior; Rep. gr. 66 ; Wheel housing liners; Exploded view -
– Unplug electrical connector -arrow- for electrohydraulic engine

– Unplug electrical connector -1- for right electrohydraulic en‐
gine mounting solenoid valve - N145- .
– Remove nut -2- and move earth wire clear.
wiring harness.

ing is relieved.
Installing
angle.
– Detach support bracket - 10-222A- ⇒ page 24 .
Tightening torques
♦ ⇒ Running gear, axles, steering; Rep. gr. 44 ; Wheels, tyres
♦ Earth wire ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations

ing
Removing
noise insulation .
Installing
angle.
Tightening torques


mounting
– Remove tunnel cross member ⇒ Gearbox; Rep. gr. 34 ; As‐

box support -4-.
Installing
quence.
Tightening torques
♦ ⇒ Gearbox; Rep. gr. 34 ; Assembly mountings; Exploded view


page 29
page 31
34

end)

end)


poly V-belt

er
Removing
– Remove lock carrier cover and closure plate at bumper cover
⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper (front);
Exploded view - bumper cover .



CAUTION
– Unplug electrical connectors.

All other procedures are described in ⇒ Servicing 4-cylinder TDI
engine, common rail; Rep. gr. 13 ; Cylinder block (pulley end);
Installing
Additional work:
– Install closure plate at bumper cover and lock carrier cover ⇒
General body repairs, exterior; Rep. gr. 63 ; Bumper (front);
Tightening torques

cillaries

31
page 33

(left-side)
Removing


– Lift retaining clips -top arrows-, disconnect coolant hoses and
move them clear.
switch - F66- .
– Remove bolt -3- and place coolant expansion tank to one side.
– Remove bolts -arrows- and push coolant pipe (left-side) to one

side.


– Remove bolts -top arrows-.
page 24 .
– Unscrew bolts -bottom arrows- and remove engine support
(left-side) -1-.
Installing
angle.
– Install engine mounting (left-side)
page 24 .
Tightening torques

(right-side)
Removing
battery .
– Remove engine mounting (right-side) ⇒ page 24 .
side).
Installing
angle.
ing battery .
Tightening torques
charge air system


(pulley end)


(gearbox end) .

3 Crankshaft


conrods .


cylinder TDI engine, common rail; Rep. gr. 15 ; Toothed belt
drive .

2 Cylinder head
⇒ “2.1 Exploded view - cylinder head cover”, page 39
⇒ “2.2 Exploded view - cylinder head”, page 39
⇒ “2.3 Removing and installing cylinder head cover”, page 39
⇒ “2.4 Removing and installing seals for injectors”, page 39
⇒ “2.5 Removing and installing cylinder head”, page 39
⇒ “2.6 Removing and installing camshaft housing”, page 40
⇒ “2.7 Checking compression”, page 41
2.1 Exploded view - cylinder head cover

gine, common rail; Rep. gr. 15 ; Cylinder head; Exploded view -
cylinder head cover .
2.2 Exploded view - cylinder head

cylinder head .
2.3 Removing and installing cylinder head

cover
gine, common rail; Rep. gr. 15 ; Cylinder head; Removing and
installing cylinder head cover .
2.4 Removing and installing seals for injec‐

tors
installing seals for injectors .

Removing
– Remove air cleaner housing ⇒ page 100 .
2. Cylinder head 39

move them clear.
switch - F66- .
– Open clip -1- and move electrical wiring clear.

– Release screw-type clip -3- and detach air pipe.
CAUTION
– Remove bolts -arrows- and detach exhaust gas recirculation

pipe -1-.
coolant hoses.
engine, common rail; Rep. gr. 15 ; Cylinder head; Removing and
installing cylinder head .
Installing
Additional work:
2.6 Removing and installing camshaft hous‐

ing
installing camshaft housing .

2.7 Checking compression

gine, common rail; Rep. gr. 15 ; Cylinder head; Checking com‐
pression .
2. Cylinder head 41
3 Valve gear
cylinder TDI engine, common rail; Rep. gr. 15 ; Valve gear .



17 – Lubrication
1 Sump/oil pump
⇒ “1.3 Removing and installing sump (bottom section)”,
page 44
⇒ “1.4 Removing and installing sump (top section)”, page 45
er G266 ”, page 45

- sump/oil pump .
1.2 Engine oil

♦ Draining engine oil ⇒ Maintenance ; Booklet 830 ; Mainte‐
nance; Engine oil: draining
♦ Extracting engine oil ⇒ Maintenance ; Booklet 830 ; Mainte‐
nance; Engine oil: extracting
♦ Filling up with engine oil ⇒ Maintenance ; Booklet 830 ; Main‐
tenance; Engine oil: filling up
♦ Removing and installing oil filter element ⇒ Maintenance ;
Booklet 830 ; Maintenance; Engine oil: renewing oil filter
♦ Checking oil level ⇒ Maintenance ; Booklet 830 ; Mainte‐
nance; Engine oil: checking oil level and correcting if neces‐
sary
tenance tables .
1.3 Removing and installing sump (bottom

section)
installing sump (bottom section) .

1.4 Removing and installing sump (top sec‐

tion)
Removing
– Lift retaining clips -top arrows-, disconnect coolant hoses and
move them clear.
switch - F66- .
– Remove bolt -3- and place coolant expansion tank to one side.
installing sump (top section) .
Installing
Additional work:


installing oil level and oil temperature sender -G266- .
1. Sump/oil pump 45
2 Engine oil cooler

Engine oil cooler must not be separated from oil filter housing. In
the event of a fault, the engine oil cooler must be renewed with
the oil filter housing ⇒ Servicing 4-cylinder TDI engine, common
rail; Rep. gr. 17 ; Oil filter/oil pressure switches; Removing and
installing oil filter housing .


⇒ “3.1 Exploded view - oil filter”, page 47
⇒ “3.2 Exploded view - oil pressure switches/oil pressure control”,
page 47
⇒ “3.3 Removing and installing oil filter housing”, page 47
⇒ “3.4 Removing and installing oil pressure sender G10 ”,
page 47
⇒ “3.5 Removing and installing valve for oil pressure control N428
”, page 48
⇒ “3.6 Checking oil pressure”, page 48
⇒ “3.7 Removing and installing piston cooling jet control valve
N522 ”, page 48
3.1 Exploded view - oil filter

gine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switches;
Exploded view - oil filter .
3.2 Exploded view - oil pressure switches/oil

pressure control
Exploded view - oil pressure switches/oil pressure control .
3.3 Removing and installing oil filter housing

Removing and installing oil filter housing .
3.4 Removing and installing oil pressure

sender - G10-
Removing
move them clear.
switch - F66- .
engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switches;
Removing and installing oil pressure sender - G10- .
Installing
Additional work:
– Fill up with coolant ⇒ page 52 .
3. Oil filter/oil pressure switches 47

3.5 Removing and installing valve for oil

pressure control - N428-
Removing and installing valve for oil pressure control - N428- .
3.6 Checking oil pressure

Checking oil pressure .
3.7 Removing and installing piston cooling

jet control valve - N522-
gine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switch ;
Removing and installing piston cooling jet control valve - N522- .

19 – Cooling

auxiliary/supplementary heater”, page 49
iliary/supplementary heater”, page 50

vehicles without auxiliary/supplementa‐
ry heater

cooling circuit
2 - Radiator
3 - Engine temperature sender
2 - G652-
4 - Coolant pump
- G27-
block
cooler
9 - Coolant pump for high-tem‐
perature circuit - V467-
10 - Bleeder hole
12 - Gear oil cooler
13 - Thermostat
gearbox
15 - Filler cap
❑ For coolant expansion
tank
❑ Checking pressure re‐
lief valve ⇒ page 52
16 - Restrictor
19 - Throttle valve module - GX3-
21 - Restrictor
23 - Temperature sensor - G18-
25 - Actuator for engine temperature regulation - N493-
26 - Coolant pump for low-temperature circuit - V468-
27 - Coolant circuit control unit - GX28-

vehicles with auxiliary/supplementary
heater



cooling circuit
2 - Radiator
2 - G652-
4 - Coolant pump
- G27-
block
8 - Auxiliary/supplementary
heater
V55-
cooler
10 - Coolant pump for high-
temperature circuit - V467-
12 - Restrictor
valve - N279-
14 - Bleeder hole
16 - Gear oil cooler
17 - Thermostat
gearbox
19 - Filler cap
20 - Restrictor
25 - Restrictor

gine, common rail; Rep. gr. 19 ; Cooling system/coolant; Check‐
ing cooling system for leaks .

Draining coolant ⇒ page 54
Filling and bleeding coolant circuit ⇒ page 55
Bleeding high-temperature cooling circuit and low-temperature
cooling circuit ⇒ page 59


♦ Safety goggles
Draining coolant
CAUTION

expansion tank.
noise insulation .
– Lift retaining clip -2-, disconnect coolant hose and drain off
coolant (new illustration).


off coolant.

off coolant.
– Connect coolant hoses.
Filling and bleeding coolant circuit:
NOTICE
Risk of damage to engine if cooling system is insufficiently filled/
bled.
– After it is filled, the cooling system must be bled using the
Note

ical climates.
♦ The refractometer - T10007A- MUST be used to determine the
current level of frost protection.
♦ Read off the level of frost protection on the scale for the rele‐
vant coolant additive.
♦ The temperature indicated on the refractometer - T10007A-
ses.

to -25 °C
to -36 °C
• Coolant ⇒ Electronic parts catalogue (ETKA)

To fill up with coolant:

• To simplify filling procedure, place reservoir on as high a sur‐
face as possible, e.g. on a workshop trolley or the engine and
gearbox jack.
– Fill reservoir of cooling system charge unit -VAS 6096- with at
least 8 litres of premixed coolant (according to recommended
ratio):
V.A.G 1274/8- .
– Switch on ignition and select following menu options:
♦ 0001 - Systems with diagnostic capability
♦ 0001 - Charge/bleed coolant circuit
– Start selected program and follow instructions shown on dis‐
play of vehicle diagnostic tester.
Note:
rection of flow).

zone.
in the green zone.
sequent filling.
ess.
tained.
– Open valve -A-.
is then filled.

engages).

Bleeding high-temperature cooling circuit and low-temperature

cooling circuit:
– Coolant must be topped up to “max” mark.
• Activate electromechanical parking brake.
• Vehicles with automatic gearbox: Move selector lever to posi‐
tion P .
• ⇒ Vehicle diagnostic tester must be connected.
– Start engine.
– Set temperature to “HI”.
– Set fresh air blower to lowest setting.
– If vehicle diagnostic tester is not yet connected: Connect ⇒ Ve‐
hicle diagnostic tester.
♦ 0001 - Charge/bleed coolant circuit
– Start selected program and follow instructions shown on dis‐
play of vehicle diagnostic tester.
Procedure for bleeding low-temperature cooling circuit:
CAUTION
– Engine must be switched off.
– Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.
expansion tank.
– Fit cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/8- onto coolant expansion tank.
– Using hand pump on cooling system tester, build up a pres‐
sure of 1.0 bar.
– Follow instructions shown on display of vehicle diagnostic
tester.
Checking coolant level after bleeding:
Note
Checking coolant level without bleeding ⇒ page 60
CAUTION
The coolant level can be above the “MAX” marking when the en‐
gine is warm.
– Fill up coolant to approx. 8 mm above max. marking when en‐
gine is cold.
Note
The increased coolant level is necessary as the coolant level

drops during the bleeding process.
– Install engine cover panel.

– If previously removed, install plenum chamber cover ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 50 ; Bulkhead; Removing
and installing plenum chamber cover .
Checking coolant level without bleeding:
CAUTION

gine is cold.
engine is warm.

⇒ “2.3 Exploded view - coolant valves”, page 65
page 65
page 65
⇒ “2.7 Removing and installing coolant circuit control unit GX28
”, page 68
N489 ”, page 70
⇒ “2.9 Removing and installing actuator for engine temperature
regulation N493 ”, page 70
⇒ “2.10 Removing and installing temperature sensor G18 ”, page
70
⇒ “2.11 Removing and installing engine temperature sender G27
”, page 71
⇒ “2.12 Removing and installing engine temperature sender 2
G652 ”, page 72

stat

♦ Exploded view - coolant pump for high-temperature circuit -
V467- ⇒ page 62
♦ Exploded view - coolant pump for low-temperature circuit -
V468- ⇒ page 63
Exploded view - coolant pump for high-temperature circuit - V467-

1 - Bolt
❑ 1.5 Nm
2 - Spacer bush
3 - Rubber bush
4 - Bracket
❑ For coolant pump for
high-temperature circuit
- V467-
5 - Bolt
❑ 9 Nm
6 - Coolant pipe
7 - Coolant pipe
8 - Coolant hose
9 - Coolant pump for high-tem‐
⇒ page 67
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 20 Nm
12 - Bolt
❑ 9 Nm
Exploded view - coolant pump for low-temperature circuit - V468-

1 - Bracket
❑ For coolant pump for
low-temperature circuit -
V468-
2 - Bolt
❑ 20 Nm
3 - Coolant hose
4 - Coolant pump for low-tem‐
⇒ page 65
5 - Bolt
❑ 9 Nm
6 - Coolant hose

2.3 Exploded view - coolant valves
1 - Coolant circuit control unit -

GX28-
stalling actuator for en‐
gine temperature regu‐
lation N493 ”,
page 70
2 - Coolant hose
3 - Bracket
❑ For coolant circuit con‐
trol unit - GX28-
4 - Bolt
5 - Washer
6 - Rubber bush
7 - Spacer bush
8 - Nut
❑ 9 Nm
9 - Coolant hoses

senders

pump
⇒ “2.5.1 Removing and installing coolant pump for high-temper‐
ature circuit V467 ”, page 65
⇒ “2.5.2 Removing and installing coolant pump for low-tempera‐
ture circuit V468 ”, page 67
2.5.1 Removing and installing coolant pump

for high-temperature circuit - V467-

♦ Hose clamps, up to 25 mm - 3094-
Removing
• Engine cold.
open carefully).
– Close filler cap again.

move them clear.
switch - F66- .


3094- .
– Release hose clips -arrows- and detach coolant hoses from
coolant pump for high-temperature circuit - V467- .
Installing
– Bleed high-temperature cooling circuit and low-temperature
cooling circuit ⇒ page 59 .
Tightening torques
♦
2.5.2 Removing and installing coolant pump

for low-temperature circuit - V468-

Removing
• Engine cold.
open carefully).

– Remove bolts -arrows- and detach coolant pump for low-tem‐
perature circuit - V468- .
Installing
Tightening torques

2.7 Removing and installing coolant circuit

control unit - GX28-

Removing
• Engine cold.
open carefully).
– Remove wheel spoiler (front left) and unfasten front section of
wheel housing liner (front left) ⇒ General body repairs, exte‐
rior; Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel


3094- .
– Release hose clips -1- and detach coolant hoses.
– Remove nuts -arrows- and detach coolant circuit control unit -
GX28- .
Installing
Tightening torques
♦ ⇒ “2.3 Exploded view - coolant valves”, page 65

sembly; Removing and installing coolant valve for cylinder head
- N489- .
2.9 Removing and installing actuator for en‐

gine temperature regulation - N493-
engine, common rail; Rep. gr. 19 ; Coolant pump/thermostat as‐
sembly; Removing and installing actuator for engine temperature
regulation - N493- .
2.10 Removing and installing temperature

sensor - G18-
sembly ; Removing and installing temperature sensor - G18- .

2.11 Removing and installing engine temper‐

ature sender - G27-
Removing
• Engine cold.
open carefully).

move them clear.
switch - F66- .
– Unscrew bolt -3-, detach coolant lines and press to one side.
– Unscrew bolt -2- and pull off engine temperature sender -
G27- .
Note:
If an O-ring or spacer ring remains lodged in cylinder head, lift it
out with a piece of wire, taking care not to damage sealing sur‐
face.
Installing
• Renew spacer ring if damaged.
Tightening torques
♦ ⇒ “3.1 Exploded view - intake manifold”, page 102


ature sender 2 - G652-
Removing
– Drain coolant
move them clear.
switch - F66- .
sembly ; Removing and installing engine temperature sender 2 -
G652- .
Installing
Additional work:

3 Coolant pipes
page 76

♦ Exploded view - coolant pipe on engine ⇒ page 73
♦ Exploded view - coolant pipe for gearbox ⇒ page 73
The arrow markings on coolant pipes and on ends of hoses must
align.
Exploded view - coolant pipe on engine
1 - Bolt
❑ 9 Nm
2 - Coolant pipe (left-side)
⇒ page 74
3 - Bolt
❑ 9 Nm
Exploded view - coolant pipes for gearbox
3. Coolant pipes 73
1 - Coolant hoses
2 - Coolant hoses
3 - Bolt
❑ 9 Nm
⇒ page 76
5 - Bolt
❑ 9 Nm



Removing
noise insulation .
– Unplug electrical connector -arrow- for air conditioner com‐
pressor.
3. Coolant pipes 75

3094- .
coolant hoses.
– Remove bolts -arrows- and detach coolant pipe (left-side).
Installing
Tightening torques

for gearbox


Removing
noise insulation .
– Detach coolant pipes.
Installing
Tightening torques
3. Coolant pipes 77
4 Radiators/radiator fan

♦ Exploded view - radiators ⇒ page 78
♦ Exploded view - radiator cowl and radiator fan ⇒ page 79
Exploded view - radiators
1 - Radiator
⇒ page 80
condensers
2 - Drain plug
❑ 1.5 … 3 Nm
3 - O-ring
4 - Coolant hose
tach
❑ Connecting
⇒ page 79
5 - O-rings
6 - Coolant hose
tach
❑ Connecting
⇒ page 79
7 - Coolant pipe
tank
8 - O-ring

9 - Rubber mounting
❑ For radiator
10 - Sleeve
11 - Retaining pin
12 - Coolant hoses
❑ If there are slight impressions on the fins, refer to ⇒ Servicing 4-cylinder TDI engine, common rail; Rep.
gr. 00 ; Repair instructions; Installing radiators and condensers
14 - Air duct
15 - Rubber bush
❑ For radiator
17 - Bolt
❑ 5 Nm
18 - Washer
19 - Bolt
❑ 4.5 Nm

– Remove old O-ring -2- from coolant hose -3-.
ant hose.
bly.
Exploded view - radiator cowl and radiator fans
4. Radiators/radiator fan 79
1 - Radiator cowl
⇒ page 85
2 - Bolt
❑ 5 Nm
unit - J293-
⇒ page 87
4 - Air flow flap
catalogue

diator cowl.

♦ Electric drill
♦ Pop rivets ⇒ Electronic parts catalogue
Removing
CAUTION

noise insulation .
The following step is required on A4 vehicles with LED headlights
or matrix LED headlights:
– Remove headlight (left-side) ⇒ Electrical system; Rep. gr. 94 ;
Headlights; Removing and installing headlights .
(bottom right).


⇒ page 84 .


G65- .
NOTICE
Danger of damage to refrigerant lines and hoses when detach‐
ing and pivoting condenser.
– Do NOT stretch, kink or bend refrigerant lines and hoses.
NOTICE
Risk of damage to fasteners if handled incorrectly.
– Release fasteners carefully.


Installing
⇒ page 84 .
Tightening torques



Removing
– Remove closure plate at bumper cover and air intake grille (left
Bumper (front); Exploded view - bumper cover .
– Move air ducts -1, 3- (left and right) clear at water radiator for

Installing

Removing
– Remove closure plate at bumper cover, lock carrier cover and
air intake grille (left and right) ⇒ General body repairs, exterior;

noise insulation .


– Press locking tabs on left and right sides of radiator cowl si‐
multaneously -arrow-, lift radiator cowl off radiator and remove
from below.
Installing
– Install air intake grille, lock carrier cover and closure plate for
bumper cover ⇒ General body repairs, exterior; Rep. gr. 63 ;
Tightening torques

V7-
Removing
Installing
• Do not remove balancing clamps from fan wheel.
Tightening torques
1 Turbocharger
⇒ “1.1 Exploded view - turbocharger”, page 88
⇒ “1.2 Removing and installing turbocharger”, page 88
1.1 Exploded view - turbocharger

gine, common rail; Rep. gr. 21 ; Turbocharger; Exploded view -
turbocharger .
1.2 Removing and installing turbocharger

Removing
engine, common rail; Rep. gr. 21 ; Turbocharger; Removing and
installing turbocharger .
Installing
Additional work:

2 Charge air system

⇒ “2.1 Exploded view - charge air system”, page 89
⇒ “2.2 Exploded view - hose connections for charge air system”,
page 89
⇒ “2.3 Removing and installing charge pressure sender G31 ”,
page 89
⇒ “2.4 Removing and installing charge air temperature sender”,
page 89
⇒ “2.5 Checking charge air system for leaks”, page 89
2.1 Exploded view - charge air system

gine, common rail; Rep. gr. 21 ; Charge air system; Exploded
view - charge air system .
2.2 Exploded view - hose connections for

charge air system
view - hose connections for charge air system .
2.3 Removing and installing charge pres‐

sure sender - G31-
gine, common rail; Rep. gr. 21 ; Charge air system; Removing
and installing charge pressure sender - G31- .
2.4 Removing and installing charge air tem‐

perature sender
gine, common rail; Rep. gr. 21 ; Charge air system ; Removing
and installing charge air temperature sender.
2.5 Checking charge air system for leaks

Procedure
– Move fuel hoses clear at retaining clip -2-.
– Release screw-type clips -arrows- and detach air pipe -1-.
engine, common rail; Rep. gr. 21 ; Charge air system; Checking
charge air system for leaks .
Tightening torques
charge air system


1 Injection system
page 91

1 - Fuel filter
4 - Fuel pressure sender for
low pressure - G410-
5 - Restrictor
G247-
(rail)
valve - N276-
9 - Injectors
10 - Fuel tank
11 - Restrictor

1.2 Overview of fitting locations - injection

system
♦ Overview of fitting locations - engine compartment
⇒ page 91
♦ Overview of fitting locations - engine (left-side), part 1
⇒ page 93
♦ Overview of fitting locations - engine (left-side), part 2
⇒ page 94
♦ Overview of fitting locations - engine (right-side) ⇒ page 95
♦ Overview of fitting locations - engine (from above)
⇒ page 96
♦ Overview of fitting locations - engine (rear) ⇒ page 98
1 - Right electrohydraulic en‐

gine mounting solenoid valve -
N145-
⇒ Fig. ““Fitting location
of electrohydraulic en‐
valves -N144- / -N145-
”“ , page 93
2 - Automatic glow period con‐
trol unit - J179-
stalling automatic glow
period control unit J179
”, page 128
J883-
of exhaust flap control
unit -J883- ”“ ,
page 93
4 - Accelerator pedal module -
GX2-
❑ with
♦ Accelerator position sender
- G79-
2 - G185-
of accelerator pedal
module -GX2- ”“ ,
page 92
❑ With brake pedal position sender - G100-
⇒ Fig. ““Fitting location of brake light switch -F- / brake pedal position sender -G100- ”“ , page 92
6 - Cruise control system switch - E45-

❑ Fitting location: in steering column switch module
❑ Exploded view ⇒ “8.1 Exploded view - engine control unit”, page 111
⇒ Fig. ““Fitting location of coolant pump for low-temperature circuit -V468- ”“ , page 93
❑ Fitting location ⇒ Fig. ““Fitting location of coolant circuit control unit -GX28- ”“ , page 93
⇒ Fig. ““Fitting location of electrohydraulic engine mounting solenoid valves -N144- / -N145- ”“ ,
page 93
view - Lambda probe
❑ Exploded view ⇒ “2.1 Exploded view - air cleaner housing”, page 99
Fitting location of accelerator pedal module - GX2-

♦ On mounting bracket for pedal cluster
♦ The components of the accelerator pedal module -3- cannot
be renewed separately.
Fitting location of brake light switch - F- / brake pedal position

sender - G100-
1- Electrical connector for brake light switch - F- / brake pedal
position sender - G100-
inder


valves -N144- / -N145-
Pfeil - -Arrow- Electrical connector for left electrohydraulic engine
mounting solenoid valve - N144-
Fitting location of coolant pump for low-temperature circuit - V468-

1- Electrical connector for coolant pump for low-temperature
circuit - V468-
Exploded view
⇒ “2.2 Exploded view - electric coolant pump”, page 62 .
Fitting location of coolant circuit control unit - GX28-

2 - Electrical connector for coolant circuit control unit - GX28-
Exploded view ⇒ “2.3 Exploded view - coolant valves”, page 65 .

♦ -Item 2- on trap catalytic converter
Exploded view ⇒ Servicing 4-cylinder TDI engine, common rail;
Rep. gr. 26 ; Emission control system; Exploded view - emission
control system
Overview of fitting locations - engine (left-side), part 1

trol - N428-
oil pump
2 - Starter-alternator - C29-
❑ Exploded view ⇒ Elec‐
trical system; Rep. gr.
27 ; Alternator; Explo‐
ded view - alternator
temperature senders
❑ Integrated in high-pres‐
sure pump
5 - Charge pressure sender -
G31-
gr. 21 ; Charge air sys‐
charge air system
6 - Intake air temperature
sender - G42-
gine, common rail; Rep. gr. 21 ; Charge air system; Exploded view - charge air system
7 - Exhaust gas recirculation valve 1 - GX5-
❑ with
♦ Exhaust gas recirculation potentiometer - G212-
♦ Exhaust gas recirculation control motor - V338-
❑ Exploded view ⇒ Servicing 4-cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas recirculation;
Exploded view - exhaust gas recirculation
8 - Coolant pump for high-temperature circuit - V467-
❑ Different versions
❑ Exploded view ⇒ “2.2 Exploded view - electric coolant pump”, page 62
10 - Oil level and oil temperature sender - G266-
❑ Exploded view ⇒ Servicing 4-cylinder TDI engine, common rail; Rep. gr. 17 ; Sump/oil pump; Exploded
view - sump/oil pump
Overview of fitting locations - engine (left-side), part 2

1 - Oil pressure sender - G10-

gr. 17 ; Oil filter/oil pres‐
sure switches; Explo‐
ded view - oil filter hous‐
ing/oil pressure
switches
2 - Actuator for engine temper‐
ature regulation - N493-
temperature senders
2 - G652-
temperature senders
- G27-
temperature senders
7 - Hall sender - G40- (camshaft position sensor)
❑ With cylinder 3 combustion chamber pressure sender - G679-
10 - Piston cooling jet control valve - N522-
Overview of fitting locations - engine (right-side)
1 - Heating element for crank‐

case breather - N79-
gr. 21 ; Turbocharger;
Exploded view - turbo‐
charger
2 - Control unit for turbocharg‐
er 1 - J724-
charger
sender 2 - G448-
4 - Lambda probe 1 before cat‐
alytic converter - GX10-
❑ with
♦ Lambda probe - G39-
♦ Lambda probe heater -
Z19-
Exploded view - Lambda probe
❑ Exploded view ⇒ Servicing 4-cylinder TDI engine, common rail; Rep. gr. 26 ; SCR (selective catalytic
reduction) system; Exploded view - reducing agent supply line


tors
tors
tors
tors
valve - N276-
gr. 23 ; Injectors/high-pressure reservoir (rail); Exploded view - high-pressure reservoir (rail)
❑ With throttle valve module - J338-
❑ Exploded view ⇒ Servicing 4-cylinder TDI engine, common rail; Rep. gr. 23 ; Intake manifold; Exploded
view - intake manifold
8 - Fuel pressure sender for low pressure - G410-
assembly; Exploded view - coolant pump/thermostat
11 - Control unit for NOx sender - GX30-
❑ with
♦ NOx sender - G295-
♦ Control unit for NOx sender - J583-

view - Lambda probe
Overview of fitting locations - engine (rear)

sor 1 - G450-
da probe
valve 2 - GX6-
❑ with
♦ Exhaust gas recirculation
potentiometer 2 - G466-
culation
sender 4 - G648-


system for leaks .

2 Air cleaner
1 - Support
2 - Water drain
❑ Clean
its or dirt
ing”, page 100
4 - Not fitted
5 - Bolt
❑ Thread-forming
hand so that it is
que
❑ 3.5 Nm
its or dirt
let 830 ; Maintenance;
Air cleaner: renewing fil‐
ter element and clean‐
ing housing
7 - Bolt
❑ Thread-forming
hand so that it is
screwed into old thread. Then tighten bolt to torque
❑ 3.5 Nm
8 - Air pipe
❑ Observe installation markings; fit on connection of turbocharger before fitting on air mass meter
❑ 3.5 Nm
❑ Removing and installing ⇒ Maintenance ; Booklet 830 ; Maintenance; Air cleaner: renewing filter element
and cleaning housing
2. Air cleaner 99
11 - Heat shield
12 - Bolt
❑ Thread-forming
❑ 1.5 Nm
13 - Air duct
❑ On lock carrier
14 - Air duct
❑ On lock carrier
15 - Snow screen
❑ Equipment version
16 - Bolt
❑ Thread-forming
❑ 2.5 Nm

housing
Removing

– Move retaining clips -arrows- clear with fuel hoses and press
to one side.
Installing
• If the air cleaner housing is being renewed and an air cleaner
housing without air filter bypass flap valve - N275- is being
fitted, the electrical connector at the wiring harness must be
tied back and the vacuum line must be sealed off.
– Check air pipe for salt residue, dirt and leaves.
– First fit air pipe on connection of turbocharger, then fit on air
mass meter.
Tightening torques
charge air system
2. Air cleaner 101

3 Intake manifold
⇒ “3.1 Exploded view - intake manifold”, page 102
⇒ “3.2 Removing and installing throttle valve module J338 ”, page
102
⇒ “3.3 Removing and installing intake manifold”, page 102
3.1 Exploded view - intake manifold

gine, common rail; Rep. gr. 23 ; Intake manifold; Exploded view
- intake manifold .
3.2 Removing and installing throttle valve

module - J338-
Component designation in current flow diagram: throttle valve
module - GX3-
Removing
Installing
Additional work:
3.3 Removing and installing intake manifold

Removing
– Drain coolant
move them clear.
switch - F66- .


and installing intake manifold .
3. Intake manifold 103

(rail)
⇒ “4.1 Exploded view - injectors”, page 104
⇒ “4.2 Exploded view - high-pressure reservoir (rail)”, page 104
⇒ “4.3 Checking injectors”, page 104
⇒ “4.4 Removing and installing injectors”, page 104
⇒ “4.5 Removing and installing high-pressure pipes”, page 104
⇒ “4.6 Removing and installing high-pressure reservoir (rail)”,
page 105
4.1 Exploded view - injectors

gine, common rail; Rep. gr. 23 ; Injectors/high-pressure reservoir
(rail); Exploded view - injectors .
4.2 Exploded view - high-pressure reservoir

(rail)
(rail); Exploded view - high-pressure reservoir (rail) .
4.3 Checking injectors

(rail); Checking injectors .
♦ Performing adaption of correction values for injectors
♦ Checking for injectors sticking open
♦ Checking return flow rate of injectors with engine running
♦ Checking return flow rate of injectors at starter cranking speed
4.4 Removing and installing injectors

(rail); Removing and installing injectors .
4.5 Removing and installing high-pressure

pipes
(rail); Removing and installing high-pressure pipes .


reservoir (rail)
Removing
engine, common rail; Rep. gr. 23 ; Injectors/high-pressure res‐
ervoir (rail); Removing and installing high-pressure reservoir
(rail) .
Tightening torques
charge air system

pump .


page 108
108
page 108
N276 ”, page 108
”, page 108

- G70-
Removing


Installing
dirt; clean if necessary ⇒ Maintenance ; Booklet 830 ; Main‐
tenance work; Air cleaner: renewing filter element and clean‐
ing housing .
Tightening torques
charge air system

ture sender - G81-

sender - G247-

- N276-
gine, common rail; Rep. gr. 23 ; Senders and sensors; Checking
fuel pressure regulating valve - N276- .


and installing pressure differential sender - G505- .

7 Lambda probe
⇒ “7.1 Exploded view - Lambda probe”, page 109
⇒ “7.2 Removing and installing Lambda probe”, page 109
⇒ “7.3 Removing and installing NOx senders”, page 109
7.1 Exploded view - Lambda probe

gine, common rail; Rep. gr. 23 ; Lambda probe; Exploded view -
Lambda probe .
7.2 Removing and installing Lambda probe

Removing
– Remove bolts -arrows- and detach air ducts -1, 2-.
engine, common rail; Rep. gr. 23 ; Lambda probe; Removing and
installing Lambda probe .
Installing
Additional work:
Tightening torques
7.3 Removing and installing NOx senders

⇒ “7.3.1 Removing and installing NOx sender G295 ”,
page 109
⇒ “7.3.2 Removing and installing NOx sender 2 G687 ”,
page 110
7.3.1 Removing and installing NOx sender -

G295-
Removing
– Release fastener -arrow-, detach control unit for NOx sender
- J583- -item 1- and move it clear.
engine, common rail; Rep. gr. 23 ; Lambda probe ; Removing
and installing NOx senders.
Installing
Additional work:
7. Lambda probe 109

7.3.2 Removing and installing NOx sender 2 -

G687-
Removing
– Unfasten underbody trim (left-side) and lower it slightly ⇒
General body repairs, exterior; Rep. gr. 66 ; Underbody trim;
Exploded view - underbody trim .
– Release fasteners -arrows- and move control unit for NOx
sender 2 - J881- clear.
engine, common rail; Rep. gr. 23 ; Lambda probe ; Removing
and installing NOx senders.
Tightening torques
trim; Exploded view - underbody trim


⇒ “8.2 Removing and installing engine control unit J623 ”,
page 111
1 - Bolt
❑ 9 Nm
2 - Mounting
J623-
⇒ page 111
4 - Bolt
❑ 9 Nm
8.2 Removing and installing engine control

unit - J623-
Removing
- J623- is removed.


♦ Self-diagnosis compatible systems
♦ 0001 - Engine electronics
♦ 0001 - Adapt learnt values - after component re-
placement
J623- -item 2-.
Installing
After renewing component, perform required adaptions using

1 Exhaust pipes/silencer
⇒ “1.1 Exploded view - silencer”, page 113
⇒ “1.3 Separating exhaust pipes/silencer”, page 115
⇒ “1.4 Removing and installing silencer”, page 116
1.1 Exploded view - silencer

⇒ Servicing 4-cylinder TDI engine, common rail; Rep. gr. 00 ;
Safety precautions .
1 - Clamp (rear)
❑ To enable individual re‐
newal of silencer and
exhaust pipe
free of stress
⇒ page 117
⇒ page 114
2 - Bolt
❑ 23 Nm
3 - Bracket
4 - Rubber mounting
❑ Red-coloured mounting
must be renewed after it
has been pulled off
⇒ page 117
5 - Clamp (front)
free of stress
⇒ page 117
⇒ page 114
6 - Bolt
❑ 23 Nm
1. Exhaust pipes/silencer 113

7 - Bracket
8 - Rubber mounting
❑ Red-coloured mounting must be renewed after it has been pulled off
9 - Silencer
❑ Cutting point between silencer and exhaust pipe ⇒ page 115
10 - Mounting
11 - Bolt
❑ 23 Nm
12 - Exhaust pipe
Installation position - clamp

tom of clamp -arrow-.

pipe
Removing
noise insulation .
CAUTION

Note:
To loosen screw-type clip, lock two nuts on threaded shaft of
screw and loosen screw.

NOTICE
Risk of damage to flexible joint if handled incorrectly.
– Remove nuts -arrows- and bolts -1- and detach front exhaust
pipe.
Installing
• Renew seals, gaskets, nuts and screw-type clip after removal.
• To install, turn screw-type clip so that screw head is accessible
from below. When doing so, ensure that there is enough clear‐
ance from the surrounding components.
Tightening torques
♦ ⇒ “1.1 Exploded view - silencer”, page 113
1.3 Separating exhaust pipes/silencer

♦ The connecting pipe can be cut through at the cutting point
provided in order to renew the silencer and exhaust pipe sep‐
arately.
Procedure
CAUTION



– Fit clamp ⇒ page 114 .
Tightening torques
1.4 Removing and installing silencer

Removing
CAUTION

– Tie up front exhaust pipe with trap catalytic converter.
– Remove tunnel cross-piece ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underbody trim; Exploded view - underbody
struts .
Note
• A second mechanic is required for removal of the silencer.
– Unscrew bolts -1, 3- and remove silencers.
Installing
• Renew seals and nuts after removing.
Tightening torques
trim


Procedure
CAUTION

nections evenly.

• Dimension -x- (left-side) = dimension -x- (right-side)
Tightening torques



⇒ “2.1 Exploded view - emission control system”, page 118
⇒ “2.2 Removing and installing catalytic converter”, page 118
⇒ “2.3 Removing and installing particulate filter”, page 118
⇒ “2.4 Removing and installing trap catalytic converter”,
page 118
⇒ “2.5 Removing and installing exhaust flap control unit J883 ”,
page 118
2.1 Exploded view - emission control sys‐

tem
gine, common rail; Rep. gr. 26 ; Emission control system; Explo‐
ded view - emission control system .
2.2 Removing and installing catalytic con‐

verter
Removing
engine, common rail; Rep. gr. 26 ; Emission control system; Re‐
moving and installing catalytic converter .
Installing
Additional work:
2.3 Removing and installing particulate filter

gine, common rail; Rep. gr. 26 ; Emission control system; Re‐
moving and installing particulate filter
2.4 Removing and installing trap catalytic

converter
gine, common rail; Rep. gr. 26 ; Emission control system ;
Removing and installing trap catalytic converter.
2.5 Removing and installing exhaust flap

moving and installing exhaust flap control unit - J883- .


system
”, page 123
G849 ”, page 124
1 - Bolt
❑ 2 Nm
sor - G849-
equipment
⇒ page 124
3 - Seal
system - GX19-
system - GX19- :
♦ Filter
agent - G684-
- G686-
♦ Pump for reducing agent -
V437-
♦ Heater for reducing agent
tank - Z102-
♦ Heater 2 for reducing agent
tank (heater circuit 3) - Z167-

5 - Nut
❑ 20 Nm
6 - Spacer sleeve
7 - Grommet
8 - Spacer sleeve
9 - Filler neck
❑ For fuel tank
10 - Filler cap
11 - Bolt
❑ 8 Nm
12 - Filler neck
13 - Spacer sleeve
14 - Grommet
15 - Spacer sleeve
16 - Bolt
❑ 20 Nm
❑ After renewing, perform required adaptions using ⇒ Vehicle diagnostic tester and refer to ⇒ Servicing
4-cylinder TDI engine, common rail; Rep. gr. 00 ; Repair instructions
18 - Bolt
❑ 3 Nm
20 - Sealing plug
❑ For drain pipe

line

♦ Safety goggles
Procedure

Note:
Wait until the reducing agent has been drawn back automatically,
because large amounts of reducing agent can escape when the
metering line is opened.
It can take up to 10 minutes after the ignition has been switched
off for the reducing agent to be drawn back completely.
– Open tank flap.
CAUTION

Assembling
After filling with reducing agent or renewing component, perform
required adaptions using ⇒ Vehicle diagnostic tester ⇒ Servicing
4-cylinder TDI engine, common rail; Rep. gr. 00 ; Repair instruc‐
tions .
Tightening torques
trim

tank

Removing
agent supply line .
harness clear.


Installing

– Connect SCR supply line.

-arrows-.
tions .
Tightening torques

- N474- .

Removing


Installing
Tightening torques
trim

Removing
sensor - G849- .
Installing
• Renew gasket after removing.
tions .
Tightening torques


4. Exhaust gas temperature control 125


⇒ “5.1 Exploded view - exhaust gas recirculation system”,
page 126
⇒ “5.2 Removing and installing exhaust gas recirculation control
motor V338 ”, page 126
motor 2 V339 ”, page 126
⇒ “5.4 Removing and installing exhaust gas recirculation cooler”,
page 126
⇒ “5.5 Checking exhaust gas recirculation cooler for leaks”, page
127
5.1 Exploded view - exhaust gas recircula‐

tion system
gine, common rail; Rep. gr. 26 ; Exhaust gas recirculation system;
Exploded view - exhaust gas recirculation system .
5.2 Removing and installing exhaust gas re‐

circulation control motor - V338-
Component designation in current flow diagram: exhaust gas re‐
circulation valve 1 - GX5-
gine, common rail; Rep. gr. 26 ; Exhaust gas recirculation;
Removing and installing exhaust gas recirculation control motor
- V338- .

circulation control motor 2 - V339-
Component designation in current flow diagram: exhaust gas re‐
Removing
engine, common rail; Rep. gr. 26 ; Exhaust gas recirculation;
Removing and installing exhaust gas recirculation control motor
2 - V339- .
Installing
Additional work:

circulation cooler
Removing


engine, common rail; Rep. gr. 26 ; Exhaust gas recirculation;
Removing and installing exhaust gas recirculation cooler .
Installing
Additional work:
5.5 Checking exhaust gas recirculation

cooler for leaks
Checking exhaust gas recirculation cooler for leaks .


1 Glow plug system
J179 ”, page 128
128

gine, common rail; Rep. gr. 28 ; Glow plug system; Exploded view
- glow plug system .


Removing
Installing
Tightening torques
Component Nm
Automatic glow period control 4.5
unit - J179- to plenum chamber

G40-
and installing Hall sender - G40- .

sender - G28-
and installing engine speed sender - G28- .

Service
Workshop Manual
Audi A4 2015 ➤
Audi A4 China 2016 ➤
Audi A5 2016 ➤
4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI,
EA 888 Gen. III)
Engine ID
CYM CYR CYR CWP DDW DKN DKW DLH DDW
C B C B A A A B B
Edition 02.2019

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system
28 - Ignition system

Copyright © 2019 Audi AG, Ingolstadt D4B80597353

Audi A4 2015 ➤ , Audi A4 China 2016 ➤ , Audi A5 2016 ➤
4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III) - Edition 02.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

1 Timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.1 Exploded view - timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.2 Removing and installing timing chain cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.2 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.3 Installing ball for slider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.4 Removing and installing cam adjustment actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.5 Removing and installing camshaft control valve 1 N205 . . . . . . . . . . . . . . . . . . . . . . . . . . 70
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Contents i
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3 Crankcase breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.4 Exploded view - coolant valve for gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.7 Removing and installing toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.10 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 98
2.11 Removing and installing coolant valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.1 Exploded view - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

2 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
ii Contents

3.4 Cleaning throttle valve module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.5 Checking intake manifold change-over function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.1 Exploded view - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.2 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.4 Cleaning injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.1 Removing and installing intake air temperature sender G42 / intake manifold pressure sender
G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
5.3 Checking fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
5.4 Removing and installing fuel pressure sender for low pressure G410 . . . . . . . . . . . . . . . . 148
6.1 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
6.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

1.3 Removing and installing front silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3.1 Exploded view - exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.2 Removing and installing exhaust gas temperature sender 3 G495 . . . . . . . . . . . . . . . . . . 169
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Contents iii
iv Contents
1 Identification
(ARL006278; Edition 02.2019)
All information can be found in ⇒ Servicing 4-cylinder engine, 1.8
ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Identification .
1. Identification 1
ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Safety precautions .

ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Repair instructions .

page 37
1.1 Removing engine

⇒ “1.1.1 Removing engine - vehicles with alternator”, page 4
⇒ “1.1.2 Removing engine - vehicles with starter-alternator”, page
19
1.1.1 Removing engine - vehicles with alter‐

nator




♦ Locking pin - T10060A-
♦ -T40093/6- from engine support supplementary set - T40093-
♦ Wrench, 21 mm - T40263-
♦ Adapter - T40314-
♦ Safety goggles
Procedure

– Observe rules for cleanliness ⇒ Servicing 4-cylinder engine,

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Repair instructions;
Rules for cleanliness .
– On vehicle versions with manual gearbox: Select 4th gear.
CAUTION
– Release fastener -arrow- (if necessary) and open filler cap

-1- on coolant expansion tank.
noise insulation .
liner (front) .
– On relevant equipment version: Unplug electrical connector

-2- for variable intake manifold changeover valve - N335- and
pull water drain -1- off downwards -arrow-.


– Disconnect vacuum hose -3-.

– Lift off air cleaner housing -1-.

-arrow A-.
– Remove nuts -1- (accessible from above) for front silencer.

(Nut -2- and bolt -3- will be removed in a later step).

– Unplug electrical connector -1- for charge pressure sender -

G31- .
– Loosen screw-type clip -2- and detach air pipe from throttle
valve module - J338- .

– Release hose clip -1-, disconnect air hose and detach it down‐
wards.

NOTICE
– Swivel tensioner in anti-clockwise direction -arrow- and detach

poly V-belt from pulley for air conditioner compressor.
– Lock tensioner with locking pin - T10060A- .
– Remove bolt -1- for support mounting -2- (both sides).
– Unscrew bolt -arrow-, detach wiring duct -1- from sump (top
section) towards front and press it downwards.

– Release hose clip -arrow- and detach air hose (right-side) from
turbocharger.

– Move engine wiring harness clear.

– Remove heat shield for drive shaft (right-side) ⇒ Running
installing heat shield for drive shaft .
– Remove nut -2- and bolt -3- for front silencer.

NOTICE
– Loosen bolted connections -arrows- and push clamp towards

rear.
– Detach front silencer.
– Remove nut -2- from underneath. (Nuts -1- do not have to be

removed at this stage.)

– Counterhold crankshaft using wrench, 21 mm - T40263- and

adapter -T40314- when slackening bolts for flywheel.
NOTICE

rotation -arrow-.

1332/14- and adapter - VAS 6948- .

1332/14- and adapter - VAS 6948- .


– Remove bolt -2- for engine mounting on both sides.
– Unplug electrical connector -1- for Lambda probe after cata‐

lytic converter - G130- -item 2- and move wiring clear. (Instal‐
lation position varies.)

– Unscrew Lambda probe - G39- -item 2- using a tool from
Lambda probe open ring spanner set - 3337- .
– Unscrew nuts -1- and detach catalytic converter upwards.


– Release hose clip -2- and disconnect hose for activated char‐
coal filter system.
– Pull back heat shield slightly.


move them clear.
switch - F66- .


– Release hose clip -arrow- on coolant pipe (left-side) and de‐

tach coolant hose.


– Move electrical wiring harness clear and place down on top of
engine.


to gearbox.

to gearbox.



VAS 6100- as shown in illustration.
CAUTION
Risk of injury if power unit drops when it is lifted.
Danger of trapping or crushing parts of the body.

NOTICE
when lifting engine out.

compartment.
1.1.2 Removing engine - vehicles with starter-

alternator




♦ Wrench, 21 mm - T40263-
♦ Safety goggles
Procedure


CAUTION

expansion tank.
noise insulation .
– Remove wheel spoiler (left and right) as well as wheel housing
liner (front right) ⇒ General body repairs, exterior; Rep. gr.
66 ; Wheel housing liners; Exploded view - wheel housing liner
(front) .
– Remove lock carrier cover, air intake grille (left and right) and
rior; Rep. gr. 63 ; Bumper (front); Exploded view - bumper
cover .



-arrow A-.
NOTICE
– To slacken poly V-belt turn tensioner in direction of -arrow-.


G31- .

wards.

– Remove bolts -arrows- and press wiring duct -1- downwards.

(Different versions.)
turbocharger.


– Move clear electrical wiring harness leading to engine.
– Remove bolt -1- on both sides.



– Push radiator slightly forwards.
(right-side).
– Detach intermediate steering shaft from steering rack and
move clear by telescoping together ⇒ Running gear, axles,
steering; Rep. gr. 48 ; Steering column; Removing and instal‐
ling intermediate steering shaft .

– Unscrew nuts -arrows- for front silencer.
NOTICE
– Unscrew bolts -arrows- (shown on right side).

– Remove bolt -arrow- on bracket for particulate filter.

– Remove bolt -arrow- on bracket for catalytic converter.
– Remove nut -2- for catalytic converter. (Nuts -1- do not have
to be removed at this stage.)
– Counterhold crankshaft using wrench, 21 mm - T40263- and

adapter -T40314- when slackening bolts for flywheel.
NOTICE

rotation -arrow-.


1332/14- and adapter - VAS 6948- .

1332/14- and adapter - VAS 6948- .


– Unplug electrical connector -1- for exhaust gas temperature

sender 4 - G648- and move wiring clear.

– Remove bolt -1- and move pressure differential sender -
G505- clear.
– Unplug electrical connector -1- at vacuum sender - G608-

-item 2-.
– Remove nuts -arrows- and press particulate filter -1- to rear.

– Move electrical wiring clear at heat shield -1-.

– Remove nuts -arrows- and bolt -2- and detach heat shield
(shown with particulate filter removed).
– Take electrical connector -2- for exhaust gas temperature

sender 3 - G495- out of bracket and unplug.
– Release retaining clip -3- and move vacuum hose clear.
– Remove bolt -1- and push bracket to one side. (Different ver‐
sions.)

lytic converter - G130- -item 1- and move wiring clear.

– Unplug electrical connector -1- for Lambda probe - G39-

-item 2-. (Installation position varies.)
– Move electrical wiring harness clear at engine and tie up to left
side.
– Unscrew nuts -1- and detach catalytic converter upwards to‐

wards rear.

coal filter system.


move them clear.
switch - F66- .


tach coolant hose.



– Unplug electrical connector -arrow- for starter-alternator.

to gearbox.


to gearbox.

(Engine has been removed in illustration).
onto gearbox.

CAUTION
Risk of injury if power unit drops when it is lifted.

NOTICE
when lifting engine out.

compartment.


support
All procedures are described in ⇒ Servicing 4-cylinder engine,
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 10 ; Removing and installing
engine; Securing engine to engine and gearbox support .

Procedure
angle.
• On vehicles with manual gearbox, a needle bearing must be
fitted in the drive plate ⇒ Servicing 4-cylinder engine, 1.8 ltr.,
2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder block (gearbox
end); Renewing needle bearing in drive plate .
– Attach engine to gearbox, but do not yet tighten gearbox/en‐
gine connecting bolts ⇒ Gearbox; Rep. gr. 34 ; Removing and
Note:
gearbox.



– Screw in bolts -2- (left and right) for engine mounting.

– Detach workshop hoist - VAS 6100- and lifting tackle - 2024A- .
– Tighten gearbox/engine connecting bolts ⇒ Gearbox; Rep. gr.
34 ; Removing and installing gearbox; Tightening torques for
gearbox .
note the following:
– Connect fuel hose ⇒ Fuel supply system; Rep. gr. 20 ; Plug-
– Install Lambda probe - G39- ⇒ Servicing 4-cylinder engine,
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Lambda probe; Re‐
moving and installing Lambda probe .
– Secure drive shaft with bolts ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Install poly V-belt ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0
ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder block (pulley end);
– Install catalytic converter ⇒ page 164 .
– Install bracket and heat shield at cylinder head
⇒ Fig. ““Bracket for heat shield - tightening torque”“ ,
page 58 .
– Install engine cover panel ⇒ Servicing 4-cylinder engine, 1.8
ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 10 ; Engine cover panel;
Removing and installing engine cover panel .
ing battery .
NOTICE
sive voltage.
– If engine was renewed, perform adaptions listed in Guided

Function “01 - Functions, engine mechanics” ⇒ Vehicle diag‐
nostic tester.
Note:
Risk of damage to components: Only perform additional adap‐
tions for those components which were renewed after removal.


– Install wheel housing liners and wheel spoiler ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
Wheels, tyres .
insulation .
Tightening torques
Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65
box


♦ Exploded view - gearbox mounting for manual gearbox
⇒ page 42
⇒ page 43
1 - Subframe
2 - Bolt
❑ 20 Nm
3 - Bolt
❑ 10 Nm
⇒ page 47
⇒ page 42
5 - Bolt
❑ 55 Nm
6 - Engine support
⇒ page 50
7 - Heat shield
8 - Bolt
❑ 10 Nm
9 - Bolt
❑ 55 Nm
❑ with
valve - N144-
valve - N145-
⇒ page 45
11 - Bolt
❑ 90 Nm +90°
12 - Bolt
❑ 30 Nm

support mounting.
Exploded view - gearbox mounting for manual gearbox
1 - Nut
mountings; Exploded
ings
2 - Bolt
mountings; Exploded
ings
⇒ 6-speed manual
Assembly mountings;
bly mountings
4 - Stop plate
⇒ page 47
6 - Bolt
mountings; Exploded
ings

7 - Gearbox
8 - Nut
assembly mountings
9 - Gearbox support
10 - Bolt
assembly mountings
11 - Bolt
❑ 9 Nm
12 - Bracket
1 - Bolt
mountings
Assembly mountings;
bly mountings
3 - Stop plate
⇒ page 47
5 - Gearbox
6 - Nut
mountings
7 - Gearbox support
⇒ page 47
8 - Bolt
9 - Bolt
10 - Nut

tion
Procedure
– Remove engine cover panel ⇒ Servicing 4-cylinder engine,
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 10 ; Engine cover panel;
– Set up support bracket - 10-222A- on upper wheel housing
longitudinal members (left and right), as shown.
– Take up weight of engine with spindles, but do not lift.
Assembling


ings

ings
Removing
terior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .
– Remove front wheel spoiler ⇒ General body repairs, exterior;

– Release hose clip -arrow- and detach air hose.
wiring harness.

Note:
Risk of damage to drive shafts: When lifting the engine, the drive
shafts must not make contact with the suspension struts.
weight with spindles -10-222A/11- until load on engine mount‐
ing is relieved.
– Remove bolts -arrows- and detach engine mounting -1-.
Installing
angle.
Tightening torques
♦ ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI;
Rep. gr. 21 ; Charge air system; Exploded view - hose con‐
nections for charge air system
Fitting locations


ing
Removing
noise insulation .
Installing
angle.
Tightening torques

mounting

box support -4-.
Installing
quence.
Tightening torques

All procedures can be found in ⇒ Servicing 4-cylinder engine, 1.8
ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 10 ; Engine cover panel .

page 49
page 49

end)
All components are described in ⇒ Servicing 4-cylinder engine,
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder block (pulley
end); Exploded view - cylinder block (pulley end) .

end); Removing and installing poly V-belt .

poly V-belt
end); Removing and installing poly V-belt tensioner .

er
Removing
All further procedures are described in ⇒ Servicing 4-cylinder
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder block
(pulley end); Removing and installing vibration damper .
Installing
Additional work:

cillaries
end); Removing and installing bracket for ancillaries .


50
page 51

(left-side)
Removing
– Lift retaining clip -3-, disconnect coolant hose and move it
clear.
switch - F66- .
– Remove bolt -4- and push coolant expansion tank -2- to one
side.
– Remove top bolts -2- for engine support -1-. (Engine has been
removed in illustration).
– Remove support mounting (left-side) ⇒ page 47 .
– Remove engine mounting (left-side) ⇒ page 45 .
– Unplug electrical connector -arrow- for air conditioner com‐

pressor.

– Unscrew bottom bolts -3- and detach engine support (left-side)

-1-.
Installing
angle.
– Install support mountings ⇒ page 47 .
Tightening torques

(right-side)
Removing
– Remove nut -2- and move bracket with electrical wiring clear.
side). (Engine has been removed in illustration).
Installing
angle.
ing battery .
Tightening torques


All procedures and components can be found in ⇒ Servicing 4-
cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder
block (gearbox end) .

3 Crankshaft
cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ;
Crankshaft .
3. Crankshaft 53
4 Balance shaft
cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Balance
shaft .


cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Pistons
and conrods .


1 Timing chain cover
⇒ “1.1 Exploded view - timing chain cover”, page 56
⇒ “1.2 Removing and installing timing chain cover”, page 56
1.1 Exploded view - timing chain cover

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Timing chain cover;
Exploded view - timing chain cover .
1.2 Removing and installing timing chain

cover
⇒ “1.2.1 Removing and installing timing chain cover (top)”,
page 56
⇒ “1.2.2 Renewing timing chain cover (bottom)”, page 56
1.2.1 Removing and installing timing chain

cover (top)
Removing
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Timing chain
cover; Removing and installing timing chain cover .
Installing
Additional work:
Tightening torques
1.2.2 Renewing timing chain cover (bottom)

Removing and installing timing chain cover .

2 Chain drive
cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Chain
drive .
2. Chain drive 57
3 Cylinder head

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head; Exploded
view - cylinder head .
Heat shield - tightening torque
– Tighten nuts -arrows- and bolt -2- to 9 Nm.
Bracket for heat shield - tightening torque

– Tighten bolt -1- to 9 Nm.

⇒ “3.2.1 Removing and installing cylinder head - vehicles without
particulate filter”, page 58
⇒ “3.2.2 Removing and installing cylinder head - vehicles with
3.2.1 Removing and installing cylinder head -

vehicles without particulate filter
Removing
– Remove camshafts ⇒ page 65 .
NOTICE
Risk of irreparable damage to engine if valve timing is incorrect
– Do not turn the crankshaft after the camshafts have been
removed.
– Remove throttle valve module - J338- ⇒ page 145 .

– Unscrew bolts -arrows- for front silencer.

rear.
NOTICE
– Lower front silencer -2- slightly and secure it with a cable tie
-1-, as shown.
– Remove nut -arrow- and press bracket -1- with electrical wiring
harness to one side.
3. Cylinder head 59

– Place a cloth underneath to catch escaping engine oil.
– Unscrew bolt -1- and detach oil return connection.
– Remove heat shield -arrows-.
– Remove bolt -2- and detach oil supply line.

– Remove nuts -arrows- and pull turbocharger off studs.
– Remove bolts -arrows- at coolant pipe (right-side).


plug.
– Remove bolts -1- securing bracket.

– Vehicles with MPI engine: Unplug electrical connectors
-1, 2-.
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head;
Removing and installing cylinder head .
Tightening torques
♦ Bracket for wiring harness ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations

vehicles with particulate filter
Removing
NOTICE
Risk of irreparable damage to engine if valve timing is incorrect
– Do not turn the crankshaft after the camshafts have been
removed.

– Remove front silencer ⇒ page 159 .
3. Cylinder head 61





plug.
– Unplug electrical connector -2- at intake air temperature send‐

er - G42- / intake manifold pressure sender - G71- .
Removing and installing cylinder head .
Tightening torques
Rep. gr. 26 ; Emission control system; Exploded view - emis‐
sion control system
3. Cylinder head 63

ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head; Checking
compression .

4 Valve gear
⇒ “4.2 Removing and installing camshaft”, page 65
⇒ “4.3 Installing ball for slider”, page 70
⇒ “4.4 Removing and installing cam adjustment actuators”, page
70
⇒ “4.5 Removing and installing camshaft control valve 1 N205 ”,
page 70

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Exploded
view - valve gear .
4.2 Removing and installing camshaft

⇒ “4.2.1 Removing and installing camshaft - vehicles without par‐
ticulate filter”, page 65
⇒ “4.2.2 Removing and installing camshaft - vehicles with partic‐
ulate filter”, page 67
4.2.1 Removing and installing camshaft - ve‐

hicles without particulate filter
Removing
noise insulation .
– Unplug electrical connector -arrow- for oil level and oil tem‐
perature sender - G266- .
– Remove timing chain cover (top) ⇒ Servicing 4-cylinder en‐
gine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Timing chain
4. Valve gear 65
– Unplug electrical connectors -arrows- for cam adjustment ac‐

tuators.
– Unplug electrical connector -1- for charge pressure positioner

- V465- .
– Unplug electrical connector -2- for turbocharger air recircula‐
tion valve - N249- .

1- For Hall sender 3 - G300-
2- For Lambda probe - G39- (take out of bracket)
3- For activated charcoal filter solenoid valve 1 - N80-
– Remove ignition coils with output stages ⇒ Servicing 4-cylin‐
der engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition
system; Removing and installing ignition coils with output
stages .


– Release retainers -arrows-, detach wiring duct -1- with elec‐
trical wiring harness and move to one side.
coal filter system.
– Lift retaining clip -3-, detach coolant hose -2-, move it clear at
cylinder head and push it towards right side.
– Detach vacuum hose -4-, disconnect vacuum line -1- for intake
manifold flap valve - N316- and move clear at cylinder head.
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear;
Removing and installing camshaft .
Installing
Additional work:
Tightening torques

hicles with particulate filter
Removing
noise insulation .
– Remove timing chain cover (top) ⇒ Servicing 4-cylinder en‐
gine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Timing chain
4. Valve gear 67
– Unplug electrical connectors -arrows- for cam adjustment ac‐

tuators.


2- For Lambda probe - G39- (take out of bracket)
– Remove ignition coils with output stages ⇒ Servicing 4-cylin‐
der engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition
stages .


- V465- .
– Release hose clip -1-, disconnect coolant hose and move hose
clear.

coal filter system.

4. Valve gear 69

sions.)
Removing and installing camshaft .
Installing
Additional work:
– Install ignition coils with output stages ⇒ Servicing 4-cylinder
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition
stages .
– Install timing chain cover (top) ⇒ Servicing 4-cylinder engine,
Tightening torques
♦ ⇒ Fig. ““Heat shield - tightening torque”“ , page 58
♦ ⇒ Fig. ““Bracket for heat shield - tightening torque”“ ,
page 58
4.3 Installing ball for slider

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Installing
ball for slider .
4.4 Removing and installing cam adjust‐

ment actuators
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Removing
and installing cam adjustment actuators .
4.5 Removing and installing camshaft con‐

trol valve 1 - N205-
The description applies to camshaft control valve 1 - N205- and
exhaust camshaft control valve 1 - N318- .
Removing
Exhaust camshaft control valve 1 - N318- :


Removing and installing camshaft control valve 1 - N205- .
Installing
Additional work:
Tightening torques

seals
and installing valve stem oil seals .
4. Valve gear 71

ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Inlet and exhaust valves .

17 – Lubrication
1 Sump/oil pump
page 73
er G266 ”, page 75

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump; Ex‐
ploded view - sump/oil pump .
1.2 Engine oil

sary
tenance tables .

section)
Removing
– Remove wheel spoilers (front) on both sides ⇒ General body
noise insulation .
1. Sump/oil pump 73
wiring harness.
– Remove bottom bolt -1- for support mounting -2- (both sides).


Note:
Risk of damage to drive shafts: When lifting the engine, the drive
shafts must not make contact with the suspension struts.
– Using spindle - 10-222A/11- -item 1-, raise engine through
distance -a-.
• Distance -a- = approx. 20 mm.
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump;
Removing and installing sump (bottom section) .
Tightening torques
♦ Bracket for electrical wiring harness ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump; Re‐
moving and installing oil pump .

tion)
moving and installing sump (top section) .

moving and installing oil level and oil temperature sender - G266- .
1. Sump/oil pump 75
2 Engine oil cooler

cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Engine
oil cooler .

3 Crankcase breather
Crankcase breather .
3. Crankcase breather 77

cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Oil
filter/oil pressure switches .

19 – Cooling

⇒ “1.1.1 Connection diagram - coolant hoses, equipment version
without auxiliary heater”, page 79
with auxiliary heater”, page 80

equipment version without auxiliary
heater
1 - Radiator
2 - Cylinder block
4 - Turbocharger
6 - Exhaust manifold
7 - Cylinder head
er - G62-
9 - Restrictors
10 - Non-return valves
11 - Coolant shut-off valve
❑ Activated by Climatronic
coolant shut-off valve -
N422- (negative pres‐
sure)
13 - Coolant circulation pump -
V50-
14 - Coolant pump
15 - Thermostat
gearbox
16 - ATF cooler
17 - Continued coolant circula‐
tion pump - V51-
18 - Restrictor
19 - Filler cap
❑ Checking pressure relief valve ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ;
Cooling system/coolant; Checking cooling system for leaks
22 - Radiator outlet coolant temperature sender - G83-

equipment version with auxiliary heater


1 - Radiator
2 - Cylinder block
4 - Turbocharger
7 - Cylinder head
er - G62-
9 - Restrictors
V55-
valve - N279-
14 - Coolant pump
15 - Thermostat
gearbox
16 - ATF cooler
tion pump - V51-
18 - Restrictor
19 - Filler cap

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Cooling system/coolant;
Checking cooling system for leaks .



♦ Safety goggles
Draining
CAUTION

noise insulation .

– Remove drain plug -1- at connection and drain off coolant.
– On relevant versions: Release hose clips -arrows-, disconnect

coolant hoses from ATF cooler and drain off coolant.
– Tighten drain plug and re-connect coolant hoses.
Coolant specifications
ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Cooling system/coolant;
Draining and filling cooling system .
NOTICE
Danger of corrosion damage if unsuitable mixtures of water and
coolant additives are used.
– Only use distilled water as this ensures optimum corrosion
protection.

to -25 °C
to -36 °C
• Coolant ⇒ Electronic parts catalogue

Filling cooling system

– Fill reservoir of -VAS 6096- with 10 litres of premixed coolant
(according to recommended ratio; for recommended ratio see
⇒ page 84 ).
coolant expansion tank -1-.
V.A.G 1274/8- .
Note:
rection of flow).
– Open valves in coolant circuit; select 01 - Coolant circuit
bleeding routine in Guided Functions ⇒ vehicle diag‐
nostic tester .

zone.
in the green zone.
sequent filling.
ess.
tained.
– Open valve -A-.
is then filled.

– Fill up pipe for cooling system tester - V.A.G 1274/10- with
coolant. If required, add further coolant when performing
bleeding procedure.
Bleeding cooling system
chamber cover .

– Release hose clip -1- on coolant hose going to heat exchanger

for heater and pull back hose until bleeder hole -arrow- is no
longer blocked by connection.
hose.
– Push coolant hose back onto connection and secure with
spring-type hose clip.
– Close filler cap on coolant expansion tank (make sure it en‐
gages).
– Start engine.
Time period Engine speed Air conditioner/heater setting
3 minutes 2000 rpm • Air conditioning system
“OFF”, LED in AC button not
lit
• Heating at “HI”, select low‐
est possible blower speed
(= 0)
Until both Idling • Air conditioning system

large coolant “OFF”
hoses at ra‐
diator be‐ • Heating at “HI”
come warm
“OFF”
• Heating at “HI”

chamber cover .
Checking coolant level
CAUTION
gine is cold.
engine is warm.
Tightening torques
♦ ⇒ “4.1 Exploded view - radiator/radiator fan”, page 109

page 90
⇒ “2.4 Exploded view - coolant valve for gearbox”, page 91
page 91
⇒ “2.7 Removing and installing toothed belt for coolant pump”,
page 95
”, page 96
⇒ “2.10 Removing and installing radiator outlet coolant tempera‐
ture sender G83 ”, page 98
⇒ “2.11 Removing and installing coolant valves”, page 98

stat
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Coolant pump/thermo‐
stat assembly; Exploded view - coolant pump/thermostat .

1 - Bolt
❑ 9 Nm
V50-
⇒ page 91
tion pump - V51-
⇒ page 93
4 - Bolt
❑ 9 Nm
5 - Rubber grommet
6 - Bolt
❑ 2.7 Nm
7 - Rubber grommet
8 - Bolt
❑ 2.7 Nm
9 - Bracket
❑ For electric coolant
pumps

2.3 Exploded view - coolant temperature senders
1 - Retaining clip
❑ Check for firm attach‐
ment
2 - O-ring
3, 4 - O-rings
❑ Installation instructions
⇒ Servicing 4-cylinder
engine, 1.8 ltr., 2.0 ltr. 4-
valve TFSI; Rep. gr. 19 ;
Coolant pump/thermo‐
stat assembly; Explo‐
ded view - coolant tem‐
perature senders
er - G62-
❑ On cylinder head (gear‐
box end)
stat assembly; Remov‐
ing and installing cool‐
ant temperature sender
- G62-
6 - Bolt
❑ Tightening torques ⇒
Servicing 4-cylinder en‐
gine, 1.8 ltr., 2.0 ltr. 4-
stat assembly; Explo‐
ded view - coolant tem‐
perature senders

2.4 Exploded view - coolant valve for gearbox
1 - Coolant valve for gearbox -

N488-
❑ Depending on version
⇒ page 98
2 - Coolant hose
3 - Bolt
❑ 23 Nm
4 - Bracket
❑ For coolant valve for
gearbox - N488-
5 - Nut
❑ 9 Nm
6 - Coolant hose

pump
⇒ “2.5.1 Removing and installing coolant circulation pump V50 ”,
page 91
⇒ “2.5.2 Removing and installing continued coolant circulation
pump V51 ”, page 93
2.5.1 Removing and installing coolant circula‐

tion pump - V50-

Removing
– Vehicles with particulate filter: Remove bolts -arrows- for
bracket -1-.


– Remove bolts -arrow- and detach coolant circulation pump -
V50- .
Installing
Tightening torques
2.5.2 Removing and installing continued cool‐

ant circulation pump - V51-
Removing


bracket -1-.

– Remove bolts -arrow- and detach continued coolant circula‐
tion pump - V51- .
Installing
Tightening torques

Removing

– Unplug electrical connectors -2 ... 5-.
– Remove bolt -1- and push bracket -2- with engine wiring har‐
ness to one side.
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Coolant pump/
thermostat assembly; Removing and installing coolant pump .
Installing
Additional work:
2.7 Removing and installing toothed belt for

coolant pump
Removing
ness to one side.


– Lift retaining clips -1, 2-, disconnect coolant hoses and press
to one side.
thermostat assembly; Removing and installing toothed belt for
coolant pump .
Installing
Additional work:

Removing
move them clear.
switch - F66- .
thermostat assembly ; Removing and installing actuator for en‐
gine temperature regulation - N493- .
Installing
Additional work:

ature sender - G62-
⇒ “2.9.1 Removing and installing coolant temperature sender G62
- vehicles without particulate filter”, page 96
- vehicles with particulate filter”, page 97
2.9.1 Removing and installing coolant temper‐

ature sender - G62- - vehicles without
particulate filter
stat assembly; Removing and installing coolant temperature
sender - G62- .


ature sender - G62- - vehicles with par‐
ticulate filter
Removing

– Remove bolt -1- and press pressure differential sender -
G505- to side.

– Remove bolt -1- and detach bracket. (Different versions.)
thermostat assembly; Removing and installing coolant tempera‐
ture sender - G62- .
Installing
Additional work:
Tightening torques
page 58
Rep. gr. 15 ; Cylinder head; Exploded view - cylinder head

2.10 Removing and installing radiator outlet

coolant temperature sender - G83-
Removing
• Engine cold.
tener -arrow- (if necessary) and briefly opening filler cap -1- on
noise insulation .

– Detach retaining clip -1- and pull out radiator outlet coolant
temperature sender - G83- .
• Renew O-rings after removing.
– To avoid loss of coolant, insert new coolant temperature send‐
er immediately.
– Check coolant level ⇒ page 87 .
Tightening torques
2.11 Removing and installing coolant valves

⇒ “2.11.1 Removing and installing coolant valve for gearbox N488
”, page 98
2.11.1 Removing and installing coolant valve

for gearbox - N488-
Coolant valve for gearbox - N488- is fitted on some vehicle ver‐
sions.

Removing
insulation .
– Remove nuts -arrows- and detach coolant valve for gearbox -
N488- .
Installing
Tightening torques
♦ ⇒ “2.4 Exploded view - coolant valve for gearbox”, page 91

3 Coolant pipes
page 106

♦ Exploded view - coolant pipes on engine ⇒ page 100
♦ Exploded view - coolant pipes for gearbox ⇒ page 100
align.
Exploded view - coolant pipes on engine
1 - Bolt
❑ 9 Nm
2 - Coolant hose
⇒ page 101
4 - Coolant hose
5 - Bolt
❑ 20 Nm
6 - Bolt
❑ 9 Nm
7 - Bolt
❑ 20 Nm
⇒ page 103
9 - O-ring
10 - Coolant hose
❑ To remove, fold back
heat insulation sleeve
and lift retaining clip
❑ Connecting
⇒ page 110
11 - O-ring
12 - Bolt
❑ 6 Nm
13 - Coolant hose
Exploded view - coolant pipes for gearbox

1 - Coolant hoses
2 - Coolant hoses
3 - Bolt
❑ 9 Nm
⇒ page 106
5 - Bolt
❑ 9 Nm

page 101
⇒ “3.2.2 Removing and installing coolant pipe (right-side) - vehi‐
cles without particulate filter”, page 103
cles with particulate filter”, page 105

(left-side)
3. Coolant pipes 101

Removing
CAUTION
– Release fastener -arrow- (if necessary) and briefly open filler

cap -1- on coolant expansion tank.


– Remove bolts -1, 2-.
3094- , release hose clips -arrows- and disconnect hoses.
– Detach coolant pipe.
Installing
Tightening torques

(right-side) - vehicles without particulate
filter
♦ Socket Torx T30 - T10405-
Removing
• Re-install all heat insulation sleeves in the same locations
when installing.



– Remove nuts -1- from above and move catalytic converter to‐
wards rear.
– Remove bolt -arrow- and detach crankcase breather hose

from turbocharger.

– Fold back heat insulation sleeve, lift retaining clip -2- and dis‐
connect coolant hose.
– Remove bolts -arrows- and -1-, detach coolant pipe (right-
side) from cylinder block and remove coolant pipe.
Installing
Tightening torques

(right-side) - vehicles with particulate fil‐
ter
Removing
when installing.

– Remove catalytic converter ⇒ Servicing 4-cylinder engine, 1.8

ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 26 ; Emission control system;
Removing and installing catalytic converter .
Installing
– Install catalytic converter ⇒ Servicing 4-cylinder engine, 1.8
Tightening torques

for gearbox


Removing
CAUTION
– Release fastener -arrow- and briefly open filler cap -1- on

noise insulation .


– Loosen hose clips -2- and detach coolant pipes.
Installing
Tightening torques

⇒ “4.1 Exploded view - radiator/radiator fan”, page 109
4.1 Exploded view - radiator/radiator fan

♦ Exploded view - radiator ⇒ page 109
♦ Exploded view - radiator cowl and radiator fan ⇒ page 110
Exploded view - radiator
1 - Radiator
⇒ page 111
cylinder engine, 1.8 ltr.,
2.0 ltr. 4-valve TFSI;
Rep. gr. 00 ; Repair
notes; Installing radia‐
tors and condensers
2 - Drain plug
❑ 1.5 … 3 Nm
3 - O-ring
4 - Coolant hose
tach
❑ Connecting
⇒ page 110
5 - O-rings
6 - Coolant hose
tach
❑ Connecting
⇒ page 110
7 - Coolant pipe
tank
8 - O-ring
9 - Rubber bush
❑ For radiator

10 - Sleeve
11 - Retaining pin
12 - Air duct
13 - Rubber bush
❑ For radiator
15 - Bolt
❑ 5 Nm
16 - Washer
17 - Bolt
❑ 4.5 Nm

ant hose.
bly.
Exploded view - radiator cowl and radiator fan

1 - Radiator cowl
⇒ page 114
2 - Bolt
❑ 5 Nm
unit - J293-
⇒ page 116
4 - Radiator blind
equipment

diator cowl.

Removing
noise insulation .
– A4: Remove headlight (left-side) ⇒ Electrical system; Rep. gr.
94 ; Headlights; Removing and installing headlights .
(bottom right).
CAUTION



– Remove charge air cooler ⇒ page 121 .

G65- .
NOTICE
Danger of irreparable damage to refrigerant lines if the inside
film is torn.
– Never bend refrigerant lines which have a radius smaller
than r = 100 mm.
– Release fasteners -arrows- on both sides, carefully disengage

condenser -1- from radiator and tie up to one side.
• Renew radiator if fasteners are irreparably damaged.


Installing
4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ;
Repair notes; Installing radiators and condensers .
• Change coolant in entire system after renewing radiator.
– Install charge air cooler ⇒ page 121 .
Tightening torques

Removing
noise insulation .

CAUTION
Risk of injury as the radiator fans may start up automatically.
– Unclip air duct (bottom) -arrow-.
suitable tool -3-.
-arrow-.
Note:


possible.
Installing
Tightening torques

V7-
Removing
Note:
Missing balancing clamps on fan wheel can cause noises due to
imbalances.
Installing
Tightening torques

1 Turbocharger

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbocharger; Exploded
view - turbocharger .

⇒ “1.2.1 Removing and installing turbocharger - vehicles without
⇒ “1.2.2 Removing and installing turbocharger - vehicles with
1.2.1 Removing and installing turbocharger -

Removing
– Open hose clip -arrow-, detach air hose and swivel to side.
1. Turbocharger 117

rear.
NOTICE
-1-, as shown.
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbocharger;
Removing and installing turbocharger .
Installing
Additional work:
Tightening torques

Removing
– Remove catalytic converter ⇒ page 165 , ⇒ page 164 .

engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbocharger;
Removing and installing turbocharger .
Installing
Additional work:
Tightening torques
1. Turbocharger 119
2 Charge air system

page 121
⇒ “2.3 Removing and installing charge air cooler”, page 121
page 122

⇒ page 121
tors and condensers
2 - Air hose
❑ Must be free of oil and
grease when installing
3 - From turbocharger
4 - Bolt
❑ Repair method if fasten‐
er breaks off
❑ Thread-forming
hand so that it is
que
❑ 7 Nm
G31-
⇒ page 122
6 - O-ring
7 - To intake manifold
8 - Seal
9 - Air pipe
❑ Must be free of oil and grease when installing
10 - Seal


charge air system
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Charge air system;
Exploded view - hose connections for charge air system .
2.3 Removing and installing charge air cool‐

er
Removing
– Release hose clip -1- on both sides and detach air pipe from
charge air cooler.
– Release fasteners -arrows- on both sides and carefully disen‐
gage charge air cooler from radiator.
• Renew charge air cooler if fasteners are broken.
– Take out charge air cooler from underneath.
Installing
Tightening torques


sure sender - G31-
Removing
– Turn charge pressure sender - G31- -item 2- anti-clockwise
and pull it out of air pipe.
Installing
• Repair solution if fastener on air pipe has broken off: Secure
charge pressure sender - G31- with two bolts, refer to ⇒ Elec‐
tronic parts catalogue .
– Place charge pressure sender - G31- in installation position
and turn it clockwise until it engages.
Tightening torques
♦ ⇒ “2.1 Exploded view - charge air system”, page 120

♦ Charge air system tester - V.A.G 1687- with end seal - V.A.G
1687/6- and adapters -V.A.G 1687/3- , -V.A.G 1687/13-2- , -
V.A.G 1687/15-
Procedure

– Loosen hose clips -arrows-.

– Disconnect vacuum hose -2- and remove air pipe -1-.
– Fit end seal - V.A.G 1687/6- and adapter - V.A.G 1687/13-2-

on turbocharger.

rear.
NOTICE
-1-, as shown.

– Seal off front silencer with adapters -V.A.G 1687/3- and -V.A.G
1687/15- .
– Connect charge air system tester - V.A.G 1687- with connec‐

tion -5- to end seal - V.A.G 1687/6- .
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Charge air
system; Checking charge air system for leaks .
Assembling
Tightening torques
Rep. gr. 21 ; Charge air system; Exploded view - charge air
system


1 Injection system
page 125

system
⇒ page 125
⇒ page 128
♦ Overview of fitting locations - engine (inlet side) ⇒ page 130
♦ Overview of fitting locations - engine (exhaust side)
⇒ page 131
♦ Overview of fitting locations - engine (view from front), vehicles
without particulate filter ⇒ page 133
♦ Overview of fitting locations - engine (view from front), vehicles
with particulate filter ⇒ page 133

1 - Lambda probe after catalyt‐

ic converter - G130- with
Lambda probe 1 heater after
catalytic converter - Z29-
⇒ page 128
2 - Coolant shut-off valve -
N82-
❑ On equipment version
with auxiliary heating:
heater coolant shut-off
valve - N279-
G604-
with manual gearbox
⇒ page 127
sor - G294-
sender 2 - G185-
⇒ page 127
⇒ page 127
G476-
❑ With clutch pedal switch
- F36- / clutch pedal
switch for engine start -
F194-
❑ For equipment version with manual gearbox
8 - Coolant circulation pump - V50- , continued coolant circulation pump - V51-
❑ Exploded view ⇒ page 88
12 - Right electrohydraulic engine mounting solenoid valve - N145-
14 - Lambda probe - G39- with Lambda probe heater - Z19-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Lambda probe;



♦ In engine compartment on brake master cylinder
inder

♦ Integrated in clutch master cylinder in plenum chamber on
driver's side. It cannot be renewed separately if defective.
Exploded view ⇒ Rep. gr. 30 ; Clutch mechanism; Exploded view
- pedal cluster

Removing and installing ⇒ 6-speed manual gearbox; Rep. gr.
34 ; Selector mechanism ; Removing and installing gear detection
sensor - G604-

Fitting location of radiator outlet coolant temperature sender -

G83-
♦ In coolant connection on radiator at bottom left
2 - Electrical connector for radiator outlet coolant temperature
sender - G83-
Exploded view ⇒ page 90 .
Fitting location of Lambda probe after catalytic converter - G130-

with Lambda probe 1 heater after catalytic converter - Z29-
♦ In catalytic converter
1- Electrical connector for Lambda probe after catalytic con‐
verter - G130- and Lambda probe 1 heater after catalytic
converter - Z29-
2- Lambda probe after catalytic converter - G130- with Lambda
probe 1 heater after catalytic converter - Z29-
Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-
valve TFSI; Rep. gr. 24 ; Lambda probe; Exploded view - Lambda
probe

valves -N144- / -N145-
Overview of fitting locations - engine (from above)

1 - Ignition coil 1 with output

stage - N70-
icing 4-cylinder engine,
1.8 ltr., 2.0 ltr. 4-valve
TFSI; Rep. gr. 28 ; Igni‐
tion system; Exploded
view - ignition system
stage - N127-
stage - N291-
stage - N292-
5 - Hall sender 3 - G300-
tion system; Exploded view - ignition system
6 - Fuel pressure regulating valve or fuel metering valve
❑ Depending on version of high-pressure pump:
♦ Fuel pressure regulating valve - N276- or
♦ Fuel metering valve - N290-
❑ Integrated in high-pressure pump; cannot be renewed separately
7 - Injector 2, cylinder 4 - N535- , MPI
❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors;
Exploded view - fuel rail with injectors
8 - Fuel pressure sender for low pressure - G410- , MPI
9 - Intake air temperature sender - G42- / intake manifold pressure sender - G71-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold;
Exploded view - intake manifold


12 - Intake manifold flap potentiometer - G336-
14 - Activated charcoal filter solenoid valve 1 - N80-
Overview of fitting locations - engine (inlet side)

TFSI; Rep. gr. 19 ; Cool‐
ant pump/thermostat
assembly; Exploded
view - coolant pump/
thermostat
2 - Injector, cylinder 2 - N31- ,
FSI
TFSI; Rep. gr. 24 ; In‐
jectors; Exploded view -
fuel rail with injectors
FSI
G247-
J338-
❑ with
♦ Throttle valve drive (for electric throttle) - G186-
♦ Throttle valve drive angle sender - G187-
♦ Throttle valve drive angle sender 2 - G188-

6 - Intake manifold flap valve - N316-

7 - Hall sender - G40-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition system;
Exploded view - ignition system
8 - Injector, cylinder 4 - N33- , FSI
10 - Stage 3 oil pressure switch - F447-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Oil filter/oil
pressure switches; Exploded view - oil pressure switches/oil pressure control
12 - Knock sensor 1 - G61-
Overview of fitting locations - engine (exhaust side)


er - G62-
ant pump/thermostat
assembly; Exploded
view - coolant tempera‐
ture senders
2 - Cam adjustment actuator 8
- F373- (for cylinder No. 4)
TFSI; Rep. gr. 15 ;
Valve gear; Exploded
view - valve gear
TFSI; Rep. gr. 15 ;
view - valve gear
TFSI; Rep. gr. 15 ;
view - valve gear
icing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Exploded view - valve gear
6 - Cam adjustment actuator 4 - F369- (for cylinder No. 2)
❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear;
Exploded view - valve gear
10 - Charge pressure positioner - V465- with position sender for charge pressure positioner - G581-
11 - Turbocharger air recirculation valve - N249-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbocharger;
Exploded view - turbocharger
❑ Exploded view ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump;
Exploded view - sump/oil pump

Overview of fitting locations - engine (view from front), vehicles

without particulate filter
1 - Exhaust camshaft control

valve 1 - N318-
TFSI; Rep. gr. 15 ; Tim‐
ing chain cover; Explo‐
ded view - timing chain
cover
2 - Camshaft control valve 1 -
N205-
cover
TFSI; Rep. gr. 17 ; Oil
filter/oil pressure
switches; Exploded
view - oil pressure
switches/oil pressure
control
filter/oil pressure
switches; Exploded
view - oil pressure
control
6 - Valve for oil pressure control - N428-

with particulate filter


filter/oil pressure
switches; Exploded
view - oil pressure
control
valve 1 - N318-
cover
N205-
cover
4 - Piston cooling jet control
valve - N522-
filter/oil pressure
switches; Exploded
view - oil pressure
control
5 - Oil pressure switch for reduced oil pressure - F378-
❑ Exploded view ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator

2 Air cleaner
1 - Snow screen
❑ Country-specific version
2 - Air duct
❑ On lock carrier
its or dirt
3 - Sealing element
4 - Water drain
❑ Clean
6 - Air duct
❑ For country-specific ver‐
sion with variable intake
manifold change-over
valve - N335-
❑ Not fitted after air clean‐
er (bottom section) has
been renewed
⇒ page 138
its or dirt
❑ Country-specific ver‐
sion: variable intake
manifold changeover
valve - N335- is not fitted
after air cleaner (bottom
section) has been re‐
newed ⇒ page 138
⇒ page 136
9 - Bolt
❑ Thread-forming
❑ 3.5 Nm
2. Air cleaner 135

11 - Air pipe
❑ Observe installation markings
❑ Tightening torque for hose clips ⇒ Servicing 4-cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr.
21 ; Charge air system; Exploded view - hose connections for charge air system
12 - Bolt
❑ Thread-forming
❑ 1.5 Nm
13 - Heat shield
14 - Air duct
❑ On lock carrier
15 - Bolt
❑ Thread-forming
❑ 2.5 Nm

housing
Removing

– Version with air filter bypass flap valve - N275- : Unplug elec‐
trical connector -2-.
2. Air cleaner 137


– Release hose clip -2- and detach air hose.
– Seal off turbocharger with sealing plug (thoroughly cleaned)
from engine bung set - VAS 6122- .
Installing
• Country-specific version:
variable intake manifold changeover valve - N335- is not fitted
after renewal; fit a mating plug onto electrical connector in
electrical wiring harness ⇒ Electronic parts catalogue .
– Check water drain in air cleaner (bottom section) for dirt and
other obstructions and clean if necessary.
– Check for dirt in air duct going from lock carrier to air cleaner
housing.
Tightening torques

3 Intake manifold
145
⇒ “3.4 Cleaning throttle valve module”, page 145
⇒ “3.5 Checking intake manifold change-over function”,
page 145

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Ex‐
ploded view - intake manifold .

⇒ “3.2.1 Removing and installing intake manifold - vehicles with‐
out particulate filter”, page 139
⇒ “3.2.2 Removing and installing intake manifold - vehicles with
3.2.1 Removing and installing intake manifold

- vehicles without particulate filter
Removing
– If there is no B+ cover on the alternator, disconnect battery to
avoid short circuits ⇒ Electrical system; Rep. gr. 27 ; Battery;
1- For intake manifold flap potentiometer - G336-
2- For fuel pressure sender for low pressure - G410- (vehicles
with MPI engine)
3- Main connector for injectors (vehicles with MPI engine)
4- For intake air temperature sender - G42-
5- For Hall sender - G40-
6- For throttle valve module - J338-
– Unplug electrical connector -1- for intake manifold flap valve -

N316- .

– Unscrew nut -2- and bolt -1- and remove support for intake
manifold.

– Remove bolts -1 and 2- and press coolant pipe (left-side) to
the side.
CAUTION
The fuel system is pressurised.
Risk of injury as fuel may spray out.
– Release pressure (wrap a clean cloth around connection
and open connection carefully).
– Unscrew bolt -arrow- and union nuts -1, 2-.

– Detach high-pressure pipe.
– Vehicles with MPI engine: Release hose clip -arrow- and dis‐
connect fuel hose.

– Move coolant line -2- clear at intake manifold and push to one
side.
– Move vacuum line -1- for intake manifold flap valve - N316-
clear at intake manifold.

G31- .
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold;
Removing and installing intake manifold .
Installing
Additional work:
ing battery .
Tightening torques

- vehicles with particulate filter
Removing


with MPI engine)
3- Main connector for injectors (vehicles with MPI engine)
6- For throttle valve module - J338-

N316- .
– Remove nut -arrow- on heat shield (shown with particulate fil‐

ter removed).

G505- to side.

manifold.



the side.
CAUTION

– Unscrew bolt -arrow- and union nuts -1, 2-.

side.

G31- .
Installing
Additional work:
ing battery .
Tightening torques
page 58


module - J338-
Removing
G31- .
– Loosen screw-type clip -2-, detach air pipe downwards from
throttle valve module - J338- and tie it to side.
Removing and installing throttle valve module - J338- .
Installing
Additional work:
Tightening torques
3.4 Cleaning throttle valve module

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Clean‐
ing throttle valve module .
3.5 Checking intake manifold change-over

function
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Check‐
ing intake manifold change-over function .

4 Injectors
⇒ “4.1 Exploded view - fuel rail with injectors”, page 146
⇒ “4.2 Removing and installing fuel rail”, page 146
⇒ “4.4 Cleaning injectors”, page 146
4.1 Exploded view - fuel rail with injectors

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Exploded view
- fuel rail with injectors .
4.2 Removing and installing fuel rail

Removing
– Remove intake manifold ⇒ page 139 .
– Unplug electrical connector -1- for fuel pressure sender -
G247- .
– Move wiring duct -2- clear of fuel rail and detach fuel rail from
injectors.
Note:
Unplug electrical connectors of any injectors that remained
lodged in fuel rail.
Installing
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Removing
and installing fuel rail .

and installing injectors .
4.4 Cleaning injectors

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Cleaning
injectors .


⇒ “5.1 Removing and installing intake air temperature sender
G42 / intake manifold pressure sender G71 ”, page 147
147
⇒ “5.3 Checking fuel pressure sender G247 ”, page 148
⇒ “5.4 Removing and installing fuel pressure sender for low pres‐
sure G410 ”, page 148
5.1 Removing and installing intake air tem‐

perature sender - G42- / intake manifold
pressure sender - G71-
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and sensors;
Removing and installing intake air temperature sender - G42- /
intake manifold pressure sender - G71- .

sender - G247-
⇒ “5.2.1 Removing and installing fuel pressure sender G247 - ve‐
hicles with alternator”, page 147
hicles with starter-alternator”, page 148
5.2.1 Removing and installing fuel pressure

sender - G247- - vehicles with alternator
Removing
manifold.
– Remove bonded rubber bush -3-.
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and
sensors; Removing and installing fuel pressure sender - G247- .
Installing
Additional work:
ing battery .


sender - G247- - vehicles with starter-
alternator
Removing and installing fuel pressure sender - G247- .
5.3 Checking fuel pressure sender - G247-

Checking fuel pressure sender - G247- .

sender for low pressure - G410-
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and sensors ;
Removing and installing fuel pressure sender for low pressure -
G410- .

⇒ “6.1 Exploded view - high-pressure pump”, page 149
⇒ “6.2 Removing and installing high-pressure pump”, page 149
6.1 Exploded view - high-pressure pump

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; High-pressure pump;
Exploded view - high-pressure pump .

pump
⇒ “6.2.1 Removing and installing high-pressure pump - vehicles
without particulate filter”, page 149
with particulate filter”, page 149
6.2.1 Removing and installing high-pressure

pump - vehicles without particulate filter
Removing and installing high-pressure pump .

pump - vehicles with particulate filter
Removing
– Remove nuts -arrows- and bolt -2- and press heat shield up‐
wards slightly (shown with particulate filter removed).

G505- to side.
6. High-pressure pump 149


sions.)
engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; High-pressure
pump; Removing and installing high-pressure pump .
Installing
Additional work:
Tightening torques
page 58

7 Lambda probe
cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Lambda
probe .
7. Lambda probe 151


page 152
1 - Bolt
❑ 9 Nm
2 - Mounting
J623-
⇒ page 152
4 - Bolt
❑ 9 Nm

unit - J623-
Removing
– If engine control unit is renewed, run 01 - Replace control
unit in Guided Functions mode of ⇒ Vehicle diagnostic
tester.


J623- -item 2-.
Installing
After installing a new engine control unit:
– Activate engine control unit ⇒ Vehicle diagnostic tester, Gui-
ded Functions , Replace engine control unit .

⇒ “1.3 Removing and installing front silencers”, page 159

drive”, page 154
drive”, page 156
1.1.1 Exploded view - silencers, vehicles with front-wheel drive
1 - Mounting
⇒ page 162
2 - Bolt
❑ 23 Nm
3 - Bracket
4 - Centre silencer
with rear silencer as
for repair purposes
❑ Cutting point
⇒ page 158
⇒ page 162
5 - Bolt
❑ 23 Nm
6 - Bracket
7 - Mounting
⇒ page 162
8 - Front silencer
❑ With flexible joint:
♦ Do not bend more than 10°

♦ Install so that it is not under

tension
♦ Take care not to damage wire mesh on flexible joint
9 - Gasket
10 - Nut
❑ 23 Nm
11 - Mounting
12 - Bolt
❑ 23 Nm
13 - Clamp (front)
14 - Mounting
15 - Retainer
16 - Bolt
❑ 23 Nm
17 - Rear silencer
purposes
❑ Cutting point ⇒ page 158
18 - Clamp (rear)

Components of mountings for front silencer

1- Spacer sleeve
3- Washer
4- Bolt, 23 Nm
5- Bolt, 23 Nm
6- Spacer sleeve
7- Buffer
8- Bracket
9- Spacer sleeve

• Angle -α- = approx. 20°
• Bolt connections facing towards right
Installation position - rear clamp

tom of clamp.

1 - Centre silencer
for repair purposes
❑ Cutting point
⇒ page 158
⇒ page 162
2 - Mounting
⇒ page 162
3 - Bolt
❑ 23 Nm
4 - Bracket
5 - Front silencer
❑ With flexible joint:
♦ Do not bend more than 10°
♦ Install so that it is not under
tension
♦ Take care not to damage
wire mesh on flexible joint
⇒ page 159
⇒ page 162
6 - Gasket
7 - Nut
❑ 23 Nm
8 - Bolt
❑ 23 Nm
9 - Mounting
10 - Clamp (front)
11 - Rear silencer
purposes
12 - Mounting


13 - Bolt
❑ 23 Nm
14 - Clamp (rear)
15 - Retainer
16 - Bolt
❑ 23 Nm
17 - Mounting

♦ The connecting pipe can be cut through at the cutting location
in order to renew the centre and rear silencers separately.
Procedure
– Cut through exhaust pipes at right angle at notch -arrow- using
chain pipe cutter - VAS 6254- .

– Position centre of clamps -arrows- over cutting location.

– Fit clamps ⇒ page 156 .
1.3 Removing and installing front silencers

⇒ “1.3.1 Removing and installing front silencer - vehicles without
⇒ “1.3.2 Removing and installing front silencer - vehicles with
1.3.1 Removing and installing front silencer -

Removing
insulation .

NOTICE

Installing
• Renew gaskets and self-locking nuts after removal.
Tightening torques

Removing
– Unscrew bolts -arrows- for front silencer (shown on right side).

NOTICE

Installing
Tightening torques

Removing
– Depending on country/equipment version: Remove diagonal
struts (left and right) ⇒ General body repairs, exterior; Rep.
gr. 66 ; Underbody trim; Exploded view - underbody struts .
NOTICE
– Lower front silencer slightly and detach clamp.

– Tie up front silencer.
CAUTION
Risk of accident caused by weight of silencers.
– Perform the following work with the assistance of a second
mechanic.
– Disengage mounting -4- at exhaust system.


CAUTION
mechanic.
– Disengage mounting -2, 4- at exhaust system.

– Unscrew bolts -3- and remove silencer -1-.
Installing
Tightening torques
trim; Exploded view - underbody struts

Procedure

mounting -1- for exhaust pipe is preloaded by -a- = 6 ... 10 mm.
nections evenly.

– Check clearance between tailpipes and bumper on both sides:

Tightening torques

1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 26 ; Exhaust pipes/silencers;
Checking exhaust system for leaks .



tem
1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 26 ; Emission control sys‐
tem; Exploded view - emission control system .

verter
⇒ “2.2.1 Removing and installing catalytic converter - vehicles
2.2.1 Removing and installing catalytic con‐

verter - vehicles without particulate filter
Removing
– Remove front silencer
⇒ “1.3.1 Removing and installing front silencer - vehicles with‐
out particulate filter”, page 159 .
– Remove Lambda probe - G39- ⇒ Servicing 4-cylinder engine,

– Remove electrical connector -1- for Lambda probe after cata‐

lytic converter - G130- -item 2- from bracket and unplug con‐
nector.
– Remove nuts -1- from above and lift out catalytic converter.
Installing
– Install Lambda probe - G39- ⇒ Servicing 4-cylinder engine,
– Install front silencers
⇒ “1.3.1 Removing and installing front silencer - vehicles with‐
out particulate filter”, page 159 .
Tightening torques
sion control system

verter - vehicles with particulate filter
Removing
– Remove particulate filter ⇒ page 166 .

– Remove electrical connector -2- for Lambda probe after cata‐

lytic converter - G130- -item 1- from bracket and unplug con‐
nector.
– Unscrew nuts -1 and 2- and detach catalytic converter up‐

wards towards rear.
Installing
– Install particulate filter ⇒ page 166 .
Tightening torques
sion control system

Removing
particulate filter”, page 160 .


– Remove nuts -arrows- and move particulate filter -1- slightly

to rear.

G505- to side.



Installing
– Install intermediate steering shaft ⇒ Running gear, axles,
– Install front silencers
particulate filter”, page 160 .
Note
If the particulate filter has been renewed, the ash deposit volume
must be reset using ⇒ Vehicle diagnostic tester.

♦ 01 - Functions, engine mechanics
Tightening torques
page 58
sion control system


⇒ “3.1 Exploded view - exhaust gas temperature control”,
page 169
⇒ “3.2 Removing and installing exhaust gas temperature sender 3
G495 ”, page 169
G648 ”, page 170
3.1 Exploded view - exhaust gas temperature control
1 - Pressure differential sender

- G505-
❑ ⇒ Servicing 4-cylinder
Lambda probe; Explo‐
ded view - Lambda
probe
ded view - Lambda
probe
3 - Lambda probe 1 after cata‐
lytic converter - GX7-
ded view - Lambda
probe
sender 3 - G495-
⇒ page 169
❑ 45 Nm
sender 4 - G648-
⇒ page 170
❑ 45 Nm
3.2 Removing and installing exhaust gas

temperature sender 3 - G495-

Removing
– Unplug electrical connector -2- and move electrical wire clear.
– Remove exhaust gas temperature sender 3 - G495- -item 1-.
Installing
• Take care to protect exhaust gas temperature sender from
knocks and impact; if dropped, the exhaust gas temperature
sender can no longer be used.
– When installing, ensure sufficient clearance.
Tightening torques
♦ ⇒ “3.1 Exploded view - exhaust gas temperature control”, page
169


Removing
Installing
Tightening torques
169

28 – Ignition system
1 Ignition system
cylinder engine, 1.8 ltr., 2.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition
system .
172 Rep. gr.28 - Ignition system

Service
Workshop Manual
Audi A4 2015 ➤
Audi A5 2016 ➤
4-cylinder direct injection engine (1.4 ltr. 4-valve TFSI
EA211)
Engine ID
CVN
A
Edition 10.2019

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system

Copyright © 2019 Audi AG, Ingolstadt D4B805938BF

4-cylinder direct injection engine (1.4 ltr. 4-valve TFSI EA211) - Edition 10.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Safety precautions when working on the fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 2
2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 3
2.4 Safety precautions when working on the subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Safety precautions when working on the ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.6 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.7 Safety precautions when working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Routing and attachment of pipes, hoses and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Installing radiators and condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.6 Nuts, bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.7 Identification plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.8 Use of impact wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 Exploded view - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.7 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.1 Exploded view - cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3 Removing and installing sealing flange (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.4 Renewing needle bearing in drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Contents i
4.1 Exploded view - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.3 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.5 Separating parts of new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.6 Checking radial clearance of conrod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

1.1 Exploded view - toothed belt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.2 Exploded view - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.3 Removing and installing toothed belt cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
1.4 Detaching toothed belt from camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.5 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.2 Exploded view - camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.2 Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.1 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.1 Exploded view - engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
2.2 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3.1 Exploded view - crankcase breather system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3.2 Removing and installing oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.1 Exploded view - oil filter/oil pressure switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.2 Removing and installing oil pressure switch F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.3 Removing and installing oil pressure switch for reduced oil pressure F378 . . . . . . . . . . . . 146
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
ii Contents

2.5 Removing cover of toothed belt for coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
2.8 Removing and installing toothed belt sprocket for coolant pump . . . . . . . . . . . . . . . . . . . . 175
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4 Radiators/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
1.3 Removing and installing charge pressure positioner V465 . . . . . . . . . . . . . . . . . . . . . . . . 200

2 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
4 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
5.1 Removing and installing intake manifold pressure sender G71 . . . . . . . . . . . . . . . . . . . . 230
Contents iii

6.3 Removing and installing high-pressure pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
8.2 Removing and installing motor control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.1 Exploded view - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.2 Removing and installing ignition coils with output stages . . . . . . . . . . . . . . . . . . . . . . . . . . 255
1.3 Removing and installing knock sensor 1 G61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
1.4 Removing and installing Hall senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
iv Contents
1 Identification
(ARL006668; Edition 10.2019)
⇒ “1.1 Engine number/engine data”, page 1
1.1 Engine number/engine data

Engine number
♦ The engine number (“engine code” and “serial number”) is lo‐
cated on the left side at the joint between engine and gearbox
-arrow-.
♦ Additionally there is a sticker on the toothed belt cover (top)
with engine code and serial number.
ers.
Engine data
For allocation of engine code, refer to ⇒ Technical data for en‐
gines; Rep. gr. 00 ; Overview of engines .
1. Identification 1
⇒ “2.1 Safety precautions when working on the fuel supply sys‐
tem”, page 2
⇒ “2.2 Safety precautions when working on vehicles with start/
stop system”, page 2
⇒ “2.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 3
⇒ “2.4 Safety precautions when working on the subframe”,
page 3
⇒ “2.5 Safety precautions when working on the ignition system”,
page 3
⇒ “2.6 Safety precautions when working on the cooling system”,
page 4
⇒ “2.7 Safety precautions when working on the exhaust system”,
page 4
2.1 Safety precautions when working on the fuel supply system

Risk of injury - fuel system operates under high pressure
The fuel system is pressurised. There is a risk of injury as fuel
may spray out.
Before opening the fuel system:
– Release pressure (wrap a clean cloth around connection and
open connection carefully).
Risk of fire due to escaping fuel

If the battery is connected, the door contact switch activates the
fuel pump when the driver's door is opened. Escaping fuel may
ignite, causing a fire.
– Before opening the fuel system, disconnect power supply to
fuel pump.
2.2 Safety precautions when working on vehicles with start/stop system

Risk of injury - engine may start unexpectedly
The engine can start unexpectedly if the vehicle's start/stop sys‐
tem is activated. A message in the instrument cluster indicates
whether the start/stop system is activated.
– To deactivate the start/stop system, switch off the ignition.

2.3 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury if test equipment is not secured
If an accident occurs and the front passenger's airbag is triggered,
test equipment which is not secured adequately may be catapul‐
ted through the vehicle with potentially serious consequences.
– Secure test equipment on the rear seat with a strap.
Or:
– Have a second mechanic operate test equipment on the rear
seat.
2.4 Safety precautions when working on the subframe

Risk of damage to components
Lowering the vehicle onto its wheels can damage components if
the assembly mountings, steering rack or subframe cross brace
are not properly fitted.
– Never lower vehicle onto its wheels with suspension compo‐
nents unfastened or detached.
– Never support weight of vehicle on subframe or subframe
cross brace with suspension components unfastened or de‐
tached.
2.5 Safety precautions when working on the ignition system

Risk of injury due to electric shock
When the engine is running, there are high voltage levels in the
ignition system. There is a risk of electric shock when touching
the ignition system!
– Never touch or disconnect ignition wiring when the engine is
running or being turned at cranking speed.

Washing the engine or connecting/disconnecting electrical wiring
may result in components being damaged if the engine is running.
– Switch off ignition before connecting/disconnecting electrical
wiring.
– Switch off ignition before cleaning engine.
2.6 Safety precautions when working on the cooling system

Risk of scalding as hot coolant can escape
The cooling system is under pressure when the engine is hot. Risk
of scalding due to hot steam and hot coolant.
2.7 Safety precautions when working on the exhaust system

incorrectly.
Risk of injury caused by components of the exhaust system

Danger of injury to hands and other parts of the body due to hot
or sharp parts of the exhaust system.
– Allow exhaust system to cool down.

⇒ “3.2 Foreign particles in engine”, page 5
⇒ “3.3 Contact corrosion”, page 5
⇒ “3.4 Routing and attachment of pipes, hoses and wiring”, page
6
⇒ “3.5 Installing radiators and condensers”, page 6
⇒ “3.6 Nuts, bolts”, page 6
⇒ “3.7 Identification plates”, page 6
⇒ “3.8 Use of impact wrenches”, page 7

ply system, turbocharger and injection system:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Immediately seal open lines and connections with clean plugs,
for example from engine bung set - VAS 6122- .
♦ Place removed parts on a clean surface and cover them. Use
only lint-free cloths.
be unpacked immediately prior to installation. Do not use parts
that have not been stored in their packing (e.g. in tool boxes
etc.).
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ Make sure that no fuel runs onto the fuel hoses. Should this
occur, the fuel hoses must be cleaned again immediately.
3.2 Foreign particles in engine

♦ When performing assembly work on the engine, all open pas‐
sages in the intake and exhaust systems must be sealed with
suitable plugs (e.g. from engine bung set - VAS 6122- ) to
prevent foreign particles from entering the engine.
♦ If the turbocharger has suffered mechanical damage
3.3 Contact corrosion

Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
fitted.
Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Please note:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend using Audi Genuine Accessories.
♦ Damage caused by contact corrosion is not covered by war‐
ranty.
3.4 Routing and attachment of pipes, hoses

and wiring
♦ Mark fuel lines, hydraulic lines, vacuum lines, lines for activa‐
ted charcoal filter and electrical wiring etc. before removal so
they can be re-installed in the original positions and correctly
connected. Make sketches or take photographs if necessary.
♦ Because of the limited space in the engine compartment, it is
important to ensure that there is adequate clearance to any
moving or hot components to avoid damage to lines and wir‐
ing.
3.5 Installing radiators and condensers

Even when the radiator, condenser and charge air cooler are cor‐
rectly installed, slight impressions may be visible on the fins of
these components. This does not mean that the components are
damaged. If the fins are only very slightly distorted, this does not
justify renewal of the radiator, condenser or charge air cooler.
3.6 Nuts, bolts

♦ Loosen bolts in reverse sequence to specified tightening se‐
quence.
♦ Bolts and nuts used to secure covers and housings must be
tightened in steps according to the specified tightening se‐
quence and method.
♦ Bolts and nuts which secure covers and housings should be
loosened and tightened in diagonal sequence and in stages if
no tightening sequence is specified.
♦ Always renew self-locking bolts and nuts.
♦ Unless otherwise specified, use a wire brush to clean the
threads of bolts which are secured with locking fluid. Then in‐
stall bolts with locking fluid; for locking fluid refer to ⇒ Elec‐
♦ Threaded holes which take self-locking bolts or bolts coated
with locking fluid must be cleaned using a thread tap or similar.
Otherwise there is a danger of the bolts shearing off the next
time they are removed.
♦ The tightening torques stated apply to non-oiled nuts and
bolts.
3.7 Identification plates

When renewing vehicle components, the identification plates on
the old parts that have a replacement part number (see ⇒ Elec‐
tronic parts catalogue ) must be attached to the new parts due to
approval regulations.

3.8 Use of impact wrenches

In general, it is permitted to use an impact wrench to unscrew
bolts and nuts. An exception to this is when work is performed
inside an open high-voltage battery. For this work, it is not per‐
mitted to use an impact wrench.
An impact wrench may be used to screw in bolts and nuts when
performing repair work if the following requirements are observed.
In general, electric and compressed-air impact wrenches should
be used.
Requirements:
• Only screw in bolts with locking fluid or self-locking nuts at low
speed.
• Use a suitable impact wrench with variable speed and adjust‐
able torque range.
• Use suitable bits when working in the vicinity of sensitive sur‐
faces, e.g. plastic-coated bits for aluminium rims.
• When working in the vicinity of natural gas systems, observe
the information in the Workshop Manual “Natural gas engines
- General information”.
Use:
• Fit bolts/nuts by hand.
• Only use an impact wrench to screw in bolts/nuts until the head
of the bolt/nut makes contact and then continue tightening with
a torque wrench.
• Clean threaded pins before unscrewing the bolt/nut.

♦ Hand vacuum pump - VAS 6213-
Procedure
– Check all vacuum lines in the complete vacuum system for:
♦ Cracks
♦ Traces of animal bites
♦ Kinked or crushed lines
♦ Porous or leaking lines
– Check vacuum line to solenoid valve and from solenoid valve

to corresponding component.
– If an entry is stored in the event memory, check all vacuum
lines leading to the corresponding component and also check
the remaining vacuum lines leading to other components.
– If it is not possible to build up pressure with the hand vacuum
pump - VAS 6213- or if the pressure drops again immediately,
check the hand vacuum pump and connecting hoses for leaks.


page 20
1.1 Removing engine




♦ Locking pin - T10060 A-
♦ Wrench, 21 mm - T40263-
♦ Safety goggles
Procedure
• Observe ⇒ “3.1 Rules for cleanliness”, page 5 .


WARNING

♦ The cooling system is under pressure when the engine is
hot.
♦ To allow pressure to dissipate, cover filler cap on coolant
expansion tank with cloth and open carefully.

expansion tank.
Rep. gr. 63 ; Bumper (front); Removing and installing attach‐
ments .



-arrow A-.
– Remove drive shaft cover on both sides ⇒ General body re‐
– Remove wheel spoilers and unfasten front section of wheel
housing liner (front) on both sides and press slightly towards
rear ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel
housing liners; Removing and installing wheel housing liner
(front) .
tion .

– Lift retaining clip -2- and disconnect coolant hose (bottom)
from radiator.
– Drain off coolant.


– Release catches -arrows- and move wiring duct -1- clear at

sump.
– Press wiring duct down.
– Counterhold crankshaft with wrench, 21 mm - T40263- , adapt‐

er - T40314- and socket, 21 mm.
• When performing the next step, turn the crankshaft only in the
normal direction of rotation -arrow-.

– Remove 3 bolts -arrow- for flywheel -1-, turning crankshaft

120° in normal direction of rotation each time.

1332/14- and adapter - VAS 6948- .
– Unplug electrical connector -arrow- for charge air cooling

pump - V188- and move electrical wiring clear.

Caution
Running a used poly V-belt in the opposite direction could

cause irreparable damage.
♦ Before removing the poly V-belt, mark the direction of ro‐
tation with chalk or a felt-tip pen for re-installation.
– To slacken poly V-belt, turn tensioner in anti-clockwise direc‐

tion -arrow-.
– Remove subframe shield (right-side) ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Subframe; Removing and installing
subframe shield .

coal filter system.
– Take electrical connectors -1, 2- for Lambda probes out of

bracket, unplug them and move electrical wiring clear.

– Release screw-type clip -arrow- and move it onto intake funnel

of turbocharger.
– Release hose clip -arrow- and disconnect coolant hose from

thermostat housing.

move them clear.
switch - F66- .

– Release fastener -arrow- and disconnect vacuum hose -1-,

taking care not to damage it.

– Unplug electrical connector -1- for engine control unit - J623- .
– Remove bolt -arrow- and move coolant hose -5- clear.

– Loosen hose clips -1, 3- and disconnect coolant pipes on left.


– Separate starter from gearbox and leave in position.
Note:



WARNING

♦ The support hooks and retaining pins on the lifting tackle
must be secured with locking pins -arrows-.

Caution
Danger of damage to hoses, pipes and wiring connections and

to engine compartment.
♦ Check that all hoses and wiring connections between en‐
gine, gearbox, subframe and body have been detached.
♦ Carefully guide engine out of engine compartment when
lifting out.

compartment.

support
♦ Engine and gearbox support - VAS 6095A-
♦ Nut M12

Procedure
• Engine attached to workshop hoist - VAS 6100- using lifting
tackle - 2024A-
• To adjust to the centre of gravity of the assembly, the perfo‐
rated rails must be positioned as shown.
WARNING

– Remove drive plate

⇒ “2.2 Removing and installing drive plate”, page 48 .
– Remove appropriate dowel sleeve.
– Attach engine to engine and gearbox support - VAS 6095- by

securing support element -2- with a nut, M12 -item 1-.
Tightening torque
Component Nm
Bolts/nuts M6 10
M8 20
M10 45
M12 65
Assembling
– Install drive plate



Procedure
angle.
• On vehicles with manual gearbox, a needle bearing must be
fitted in the drive plate
⇒ “2.4 Renewing needle bearing in drive plate”, page 57 .
• Before fitting, check vacuum hoses for damage and renew if
necessary.
and gearbox:
flywheel/torque converter and gearbox housing from below, as
illustrated.
• The assembly aid must engage in the semi-circular recess
-1- and in the inspection hole -2-.
Note:
There is only one inspection hole on the circumference; turn the
flywheel accordingly.



gearbox are fitted in cylinder block; install missing dowel
sleeves.
can be reused; if so, apply marking ⇒ Gearbox; Rep. gr. 34 ;
box .
– Bring gearbox into position on engine and tighten bolts
-3, 4, 5-. Tightening torques ⇒ Gearbox; Rep. gr. 34 ; Re‐
moving and installing gearbox; Tightening torques for gearbox
– Release spindle of support bracket - 10-222A- .


– Screw in bolts -2- (left and right) for engine mounting.

– Screw in bolts -6 ... 10- securing engine to gearbox and tight‐

en.
• The following step is necessary to ensure that the flywheel is

– Bolt flywheel -1- onto drive plate as follows:

Note:
– Tighten first bolt -arrow- to 10 Nm and loosen again; then
tighten to 2 Nm (hand-tight).

– Turn crankshaft 120° further in direction of normal engine ro‐

tation -arrow- using wrench, 21 mm - T40263- , adapter -
T40314- and socket, 21 mm.
– With crankshaft in this position, tighten next bolt ⇒ 6-speed
manual gearbox; Rep. gr. 30 ; Clutch; Exploded view - clutch
module , or ⇒ 7-speed dual clutch gearbox; Rep. gr. 34 ;
box .
– Turn crankshaft by 120° each time and tighten remaining 2
bolts to specified torque.
note the following:

Note:
– Install coolant pipes (left-side)
⇒ “3.1 Exploded view - coolant pipes”, page 180 .
chamber cover .
– Install catalytic converter
⇒ “2.2 Removing and installing catalytic converter”,
page 250 .
– Align the exhaust system so it is free of stress
⇒ “1.5 Stress-free alignment of exhaust system”, page 247 .
– Install poly V-belt
⇒ “1.3 Removing and installing poly V-belt”, page 38 .
page 215 .
– Top up engine oil/check oil level ⇒ Maintenance ; Booklet 830 .
ing battery .
Caution

sive voltage.
♦ Never use battery charging equipment for boost starting.

Function 01 - Functions, engine mechanics ⇒ Vehicle
diagnostic tester.
Caution
Risk of damage to components.

♦ Only perform additional adaptions for those components
which were renewed after removal.

– Connect coolant hose with plug-in connector

⇒ Fig. ““Connecting coolant hose with plug-in connector”“ ,
page 183 .
– Install engine cover panel
⇒ “3.1 Removing and installing engine cover panel”,
page 34 .
– Install wheel housing liners, wheel spoilers and drive shaft
covers ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel
housing liners; Exploded view - wheel housing liner (front) .
insulation .
Tightening torques
Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65
box


Engine mounting
1 - Subframe
2 - Engine mounting
❑ Version with left electro‐
hydraulic engine mount‐
ing solenoid valve -
N144-
stalling engine mount‐
ings”, page 31
3 - Bolt
❑ 55 Nm
4 - Bolt
❑ 55 Nm
5 - Engine support
6 - Heat shield
7 - Bolt
❑ 10 Nm
8 - Bolt
❑ 90 Nm +90°
9 - Bolt
❑ 30 Nm
Gearbox mounting for manual gearbox

1 - Nut
mountings; Exploded
ings
2 - Bolt
mountings; Exploded
ings
⇒ 6-speed manual
Assembly mountings;
bly mountings
4 - Stop plate
ing”, page 33
6 - Bolt
7 - Final drive
8 - Nut
assembly mountings
9 - Gearbox support
❑ Removing and installing ⇒ “2.4 Removing and installing gearbox mounting”, page 33
10 - Bolt
assembly mountings
11 - Bolt
❑ 9 Nm
12 - Bracket
Gearbox mounting for dual clutch gearbox
1 - Bolt
mountings
Assembly mountings;
bly mountings
3 - Stop plate
ing”, page 33
5 - Final drive
6 - Nut
mountings
7 - Gearbox support
8 - Bolt
9 - Bolt
10 - Nut

tion

Procedure
– Remove engine cover panel
page 34 .
– Attach spindle - 10-222A/11- to rear engine lifting eye.
– Take up weight of engine with the spindle, but do not lift.
Assembling
Assemble in reverse order.

ings
Removing
insulation .
or; Rep. gr. 66 ; Wheel housing liners; Removing and installing
wiring harness.

– Unplug electrical connector -arrow-.
Caution
Risk of damage to drive shafts.

♦ When lifting the engine, the drive shafts must not make
contact with the suspension struts.

ing is relieved.
Installing
angle.
Tightening torques


mounting
– Remove tunnel cross member ⇒ 6-speed manual gearbox;
mountings , or ⇒ 7-speed dual clutch gearbox; Rep. gr. 34 ;

box support -4-.
Installing
quence.
Tightening torques

⇒ “3.1 Removing and installing engine cover panel”, page 34
3.1 Removing and installing engine cover

panel
Removing
Installing
– Press engine cover panel into rubber grommets first on the left
side and then at front.

⇒ “1.1 Exploded view - poly V-belt drive”, page 35
page 39
⇒ “1.7 Renewing crankshaft oil seal (pulley end)”, page 42
44
1.1 Exploded view - poly V-belt drive
1 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen
❑ Do not kink
stalling poly V-belt”,
page 38
❑ Routing of poly V-belt
⇒ Fig. ““Routing of poly
V-belt”“ , page 36
❑ When installing, make
sure it is properly seated
on pulleys.
2 - Bolt
Caution
Risk of irreparable dam‐
age to engine.
To
♦ avoid disturbing valve
timing, do not turn crank‐
shaft when bolt is re‐
moved.
❑ Tightening torque
⇒ Item 1 (page 37)
3 - Vibration damper
stalling vibration damp‐
er”, page 41

Caution
age to engine.
To
shaft when vibration
damper is removed.
4 - Tensioner for poly V-belt

❑ Pivot with socket to slacken poly V-belt
❑ Lock in position with locking pin - T10060A- .
❑ Removing and installing ⇒ “1.4 Removing and installing tensioner for poly V-belt”, page 39
5 - Bolt
❑ 23 Nm
6 - Bolt
❑ Tightening torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
7 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
8 - Dowel sleeve
❑ For air conditioner compressor
9 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant hoses or pipes
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Detaching
and attaching air conditioner compressor at bracket
10 - Bolt
❑ Tightening torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Exploded view
- air conditioner compressor drive unit
Routing of poly V-belt

1- Vibration damper
2- Tensioner for poly V-belt
3- Alternator
4- Air conditioner compressor

1.2 Exploded view - sealing flange (pulley end)
1 - Bolt
❑ Use counterhold tool -
T10475- when loosen‐
ing and tightening
Caution
age to engine.
To
shaft when bolt is re‐
moved.
❑ 150 Nm +180°
stalling vibration damp‐
er”, page 41
Caution
age to engine.
To
shaft when vibration
damper is removed.
3 - Oil seal
❑ For crankshaft (pulley
end)
❑ Renewing
⇒ “1.7 Renewing crank‐
shaft oil seal (pulley
end)”, page 42
❑ Do not lubricate with oil
4 - Sealing flange (pulley end)
❑ Should be positioned on dowel pins
❑ Removing and installing ⇒ “1.8 Removing and installing sealing flange (pulley end)”, page 44
5 - Bolt
❑ Different thread diameters ⇒ Electronic parts catalogue
❑ Tightening torque and sequence
⇒ Fig. ““Sealing flange (pulley end) - tightening torque and sequence”“ , page 38
6 - Gasket
7 - Cylinder block
8 - Bolt
⇒ Fig. ““Sealing flange (pulley end) - tightening torque and sequence”“ , page 38

9 - Dowel pin
❑ 2x
Sealing flange (pulley end) - tightening torque and sequence

angle.
– Tighten bolts in stages in the sequence shown:
Stage Bolts Tightening torque/angle specification
1. -1 … 12- Screw in by hand until contact is made
2. -1 … 12- 8 Nm in diagonal sequence
3. -7, 8- 20 Nm
4. -1 … 12- Turn 90° further in diagonal sequence

Removing
Caution


– To slacken poly V-belt, turn tensioner in anti-clockwise direc‐

tion -arrow-.
Installing
– Fit poly V-belt ⇒ Fig. ““Routing of poly V-belt”“ , page 36 .
– Turn tensioner anti-clockwise -arrow- and remove locking pin
- T10060A- .
– Release tensioner.
– Check that poly V-belt is properly seated.
– Start engine and check that poly V-belt runs properly.

poly V-belt
Removing
– Detach poly V-belt from tensioner
– Remove bolts -arrows- and detach tensioner -1- for poly V-
belt.
Installing
Tightening torques
♦ ⇒ “1.1 Exploded view - poly V-belt drive”, page 35

39
page 40

(left-side)
Removing
page 34 .
clear.
switch - F66- .
side.

– Unscrew bolt -arrow- and press coolant pipes -1- slightly to

one side.
– Move electrical wiring harness clear at retaining clip -arrow-.

– Remove top bolts -2- for engine support.
– Detach poly V-belt from air conditioner compressor pulley
⇒ “2.3 Removing and installing engine mountings”, page 31 .
– Unscrew bottom bolts -1, 3- and detach engine support (left-
side). (Engine has been removed in illustration).
Installing
angle.
page 183 .
page 34 .
Tightening torques
⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐

(right-side)
Removing
– Remove engine mounting (right-side)
⇒ “2.3 Removing and installing engine mountings”, page 31 .

– Unscrew nut -2- and move bracket with electrical wiring clear.
side).
Installing
angle.
ing battery .
Tightening torques

er
♦ Counterhold tool - T10475-
Removing
noise insulation .
– Remove poly V-belt

– Loosen bolt -arrow- using counterhold tool - T10475- .

– Remove bolt and take off pulley/vibration damper.
Caution
Risk of irreparable damage to engine.

♦ To avoid disturbing valve timing, do not turn crankshaft
when vibration damper is removed.
Installing
angle.
• All contact surfaces between bolt, vibration damper and crank‐
shaft sprocket must be free of oil and grease.
– Screw in bolt -arrow- by hand until it makes contact (lubricate

thread of bolt).
– Tighten bolt using counterhold tool - T10475- .
note the following:
Tightening torques
1.7 Renewing crankshaft oil seal (pulley

end)
♦ Assembly tool - T10485/1-3-

♦ Extractor tool - T20143-
Procedure
– Remove toothed belt
⇒ “1.4 Detaching toothed belt from camshaft”, page 75 .
– Remove radiator cowl
⇒ “4.4 Removing and installing radiator cowl”, page 190 .
– Pry out oil seal using extractor tool -T20143/2- -arrow-.
– Clean contact surface and sealing surface.
• Do not lubricate new oil seal.

– Slide oil seal -1- over fitting sleeve -T10485/3- onto guide
sleeve -T10485/2- .
• Fitting position: closed side of oil seal faces guide sleeve.
– Detach fitting sleeve from guide sleeve.

– Fit guide sleeve -T10485/2- with oil seal -1- onto crankshaft.
– Use thrust piece -T10485/1- and bolt -1- for pulley to pull in oil
seal -2- onto stop.
– Install radiator cowl
– Install toothed belt (adjust valve timing)

(pulley end)
♦ Flat scraper
♦ Sealant ⇒ Electronic parts catalogue
Removing
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Remove toothed belt
– Remove sump (bottom section)
page 132 .

– Remove bolts -1 ... 12- and carefully release sealing flange

from bonded joint.
– Drive out oil seal with sealing flange removed.
Installing
Caution
Make sure sealant residue does not enter lubrication system.

♦ Place a clean cloth over the exposed section of the sump.
– Remove sealant residue from sealing flange and sump (top

section).
– Clean sealing surfaces; they must be free of oil and grease.
• Note expiry date of sealant.

– Cut off nozzle of tube at front marking (nozzle ∅ approx.
2 mm).
– Slide gasket -1- onto dowel pins in cylinder block.

– Apply a thin bead of sealant at the edge of the joint between
the cylinder block and the sump -arrows-.

– Apply a thin coat of sealant to bottom sealing surface -arrow-

on sealing flange.
• Install sealing flange within 5 minutes of applying the sealant.
– Carefully fit sealing flange onto dowel pins in cylinder block.
• Sealant must not be allowed to get into threaded holes.
– Tighten sealing flange bolts.
– Install crankshaft oil seal (pulley end)
⇒ “1.7 Renewing crankshaft oil seal (pulley end)”, page 42 .
– Install sump (bottom section)
page 132 .
Tightening torques
♦ ⇒ Fig. ““Sealing flange (pulley end) - tightening torque and se‐
quence”“ , page 38
♦ ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view
- alternator


⇒ “2.1 Exploded view - cylinder block (gearbox end)”, page 47
⇒ “2.2 Removing and installing drive plate”, page 48
⇒ “2.3 Removing and installing sealing flange (gearbox end)”,
page 49
⇒ “2.4 Renewing needle bearing in drive plate”, page 57
2.1 Exploded view - cylinder block (gearbox end)

• Secure engine to engine and gearbox support when perform‐
ing assembly work
⇒ “1.2 Securing engine to engine and gearbox support”, page
20 .
1 - Bolt
❑ 60 Nm +90°
2 - Drive plate
stalling drive plate”,
page 48
❑ Can only be installed in
one position
3 - Sealing flange (gearbox
end)
❑ With oil seal and sender
wheel for engine speed
sender - G28-
❑ Do not separate from
sealing flange
stalling sealing flange
(gearbox end)”,
page 49
4 - Intermediate plate
❑ Do not damage or bend
❑ Installing
⇒ Fig. ““Installing inter‐
mediate plate”“ ,
page 48
5 - Crankshaft
6 - Dowel pin
❑ 2x
7 - Needle bearing
with manual gearbox
❑ Removing and installing ⇒ “2.4 Renewing needle bearing in drive plate”, page 57
8 - Bolt
⇒ Fig. ““Sealing flange (gearbox end) - tightening torque and sequence”“ , page 48

Sealing flange (gearbox end) - tightening torque and sequence

– Tighten bolts -arrows- in stages as follows:
Stage Tightening torque
1. Screw in by hand until contact is made
2. Tighten in stages and in diagonal sequence; final torque
10 Nm.
Installing intermediate plate

– Engage intermediate plate -1- on sealing flange -2- -arrow B-
and push onto dowel sleeves -arrows A-.
2.2 Removing and installing drive plate

♦ Counterhold tool - 3067-

Removing
• Gearbox removed ⇒ Gearbox; Rep. gr. 34 ; Removing and
installing gearbox; Removing gearbox .
– Insert counterhold tool - 3067- to slacken bolts.
Caution
Take care not to damage outer surface of bearing flange on

drive plate.
♦ Use a multi-point socket bit with a length of at least 40 mm
to slacken and tighten the drive plate bolts.
– Remove bolts and take off drive plate -1-.

Installing
angle.
• For equipment version with manual gearbox, a needle bearing
is fitted in the drive plate. Before installing, check that the nee‐
dle bearing is fitted. Removing and installing needle bearing
in drive plate (pressing in and out)
⇒ “2.4 Renewing needle bearing in drive plate”, page 57 .
– Fit counterhold tool - 3067- the other way round to tighten
bolts.
Tightening torques
♦ ⇒ “2.1 Exploded view - cylinder block (gearbox end)”,
page 47

(gearbox end)
Illustrations show procedures with engine removed.
♦ Open ring spanner - V.A.G 1332/11-

♦ Depth gauge - VAS 6082-
♦ Locking pin - T10340-
♦ Wrench, 21 mm - T40263-

♦ Bolt, M6x35 (3x)

Procedure
– Move electrical wiring harness clear at retaining clip -1- and
press to one side.
Rotate crankshaft to “TDC” as follows:
– Unscrew plug -2- for “TDC” hole on cylinder block.
Caution
Risk of damage to engine.

♦ If the locking pin - T10340- cannot be screwed in far
enough for the head of the pin to make contact, the crank‐
shaft is not in the correct position.
♦ If this is the case, unscrew the locking pin and turn the
crankshaft 90° in the direction of normal engine rotation.
– Screw locking pin - T10340- into cylinder block as far as stop

and tighten to 30 Nm.
– Using wrench, 21 mm - T40263- , adapter - T40314- and sock‐

et (21 mm), turn crankshaft in direction of engine rotation
-arrow- as far as stop.
• The crank web is now in contact with the locking pin.
Note:
The locking pin - T10340- locks the crankshaft only in the direction
of engine rotation.
– Remove sump (top section)
⇒ “1.4 Removing and installing sump (top section)”,
page 134 .
– Remove engine speed sender - G28-
⇒ “1.5 Removing and installing engine speed sender G28 ”,
page 260 .

– Detach intermediate plate -1- from dowel sleeves -arrows A-.

– Guide intermediate plate upwards; at the same time, pull re‐
taining tab -arrow B- out of opening behind sealing flange
-2-.
– Remove bolts -arrows- for sealing flange -1-.
Note:
The sealing flange -1- is pressed off the crankshaft -3- together
with the sender wheel -2-.
– To press off, screw 3 bolts M6x35 -arrows- alternately into
sealing flange not more than 1/2 turn at a time.
– Detach sealing flange together with sender wheel.
Pressing in sealing flange with sender wheel

♦ The sealing flange with PTFE oil seal is fitted with a sealing lip
support ring -2-. This support ring acts as an assembly sleeve
and must not be removed before installation.
♦ Sealing flange and sender wheel -1- must not be separated or
rotated out of position after removal from packaging.
♦ The sender wheel is held in its installation position by a locat‐
ing pin on the assembly tool - T10134- .
♦ The sealing flange and oil seal are one unit and can only be
replaced together with the sender wheel.
♦ The assembly tool - T10134- is held in the correct position rel‐
ative to the crankshaft by a guide pin which is inserted into a
hole in the crankshaft.

Construction of assembly tool - T10134- :

A - Tensioning flats
B - Nut
C - Assembly housing
D - Locating pin
E - Hexagon socket head bolts (2x)
F - Guide pin for diesel engines (black handle)
G - Guide pin for petrol engines (red handle)
H - Knurled screws (3x)
Fitting sealing flange with sender wheel onto assembly tool -

T10134- :
– Unscrew nut -B- until it is just in front of tightening flats -A- on
threaded spindle.
– Clamp assembly tool - T10134- in a vice -1- on tightening flats

-A- of threaded spindle.
– Press assembly housing -C- downwards -arrow- so that it rests
on nut -B-.
• Inner part of assembly device and assembly housing must
align (be level) with each other.
– If fitted, remove securing clip -arrow- from new sealing flange.

• Do not take the sender wheel out of the sealing flange or rotate
it out of position.

– Place sealing flange (with front side downwards) on a clean

flat surface.
– Press sealing lip support ring -1- downwards in direction of
-arrow- until it touches flat surface.
• Upper edge of sealing lip support ring -1- must be flush

-arrows- with front edge of sealing flange -2-.
– Place front side of sealing flange -1- on assembly tool -

T10134- so that locating pin -D- is seated in hole -3- in sender
wheel -2-.
• Ensure that sealing flange lies flat on assembly tool.
– Screw knurled screws -H- onto sealing flange -1-.

– When tightening, press sealing flange and sealing lip support
ring -2- against surface of assembly tool - T10134- .
– This prevents locating pin from sliding out of hole in sender
wheel.
– Ensure that sender wheel remains fixed on assembly tool
when installing sealing flange.

Securing assembly tool - T10134- with sealing flange -1- on

crankshaft flange:
• Crankshaft flange must be free of oil and grease.
• Engine is at “TDC” position.
– Screw nut -B- to end of threaded spindle.
– Press threaded spindle of assembly tool - T10134- in direction
of -arrow- until nut -B- makes contact with assembly housing
-C-.
– Position flat edge of assembly housing towards sealing sur‐
face for sump on cylinder block.
– Secure assembly tool - T10134- with sealing flange -1- to

crankshaft flange -2-.
– To do so, screw hexagon socket head bolts -E- approx. 5 turns
into crankshaft flange with hexagon key.
– Insert guide pin for petrol engines (red handle) -F- into crank‐
shaft flange.
– Screw 2 bolts M6x35 -item 2- into cylinder block to guide seal‐

ing flange -1-.
Securing assembly tool - T10134- on crankshaft flange:

– Press assembly housing -C- by hand in direction of -arrow-
until sealing lip support ring -1- touches surface of crankshaft
flange -2-.
– Check that guide pin for petrol engines (red handle) -F- is fitted
correctly in hole in crankshaft. This ensures that sender wheel
reaches its final installation position.
• The guide pin for diesel engines (black handle) must not be
inserted into threaded hole in crankshaft.
– Tighten the two hexagon socket head bolts on assembly tool
hand-tight.
– Screw nut -B- onto threaded spindle by hand until it touches
assembly housing -C-.

Pressing sender wheel onto crankshaft flange with assembly tool

- T10134- :
– Tighten nut -B- on assembly tool - T10134- to 35 Nm.
• There must be a small gap between cylinder block and sealing
flange -1- after nut has been tightened to 35 Nm.
Checking installation position of sender wheel on crankshaft:

– Remove both bolts -2- from cylinder block.
– Unscrew knurled screws -H- from sealing flange -1-.
– Unbolt assembly tool - T10134- from crankshaft flange (re‐
move hexagon socket head bolts -E- from crankshaft flange).
– Detach sealing lip support ring.
– Apply depth gauge - VAS 6082- to crankshaft flange -2-.
– Measure distance -a- between crankshaft flange -2- and send‐

er wheel -1-.
• Specification: Distance -a- = 0.5 mm.
– Press sender wheel in further if measurement is too small
⇒ page 57 .
– If reading matches specification, continue with assembly
⇒ page 57 .

Pressing sender wheel in further:

– Secure assembly tool - T10134- to crankshaft flange.
– Ensure that locating pin of assembly tool - T10134- is fitted in
hole in sender wheel.
– Hand-tighten hexagon socket head bolts -E-.
– Slide assembly tool - T10134- onto sealing flange -1- by hand.
assembly tool - T10134- .
– Insert guide pin for petrol engines (red handle) -F- into crank‐
shaft flange.
ing flange -1-.

– Check installation position of sender wheel on crankshaft
again ⇒ page 56 .
– Tighten nut on assembly tool - T10134- to 45 Nm if measure‐
ment is too small.
again ⇒ page 56 .
Assembling:
– Tighten bolts for sealing flange in diagonal sequence.
– Install sump (upper section)
page 134 .
– Install intermediate plate
⇒ Fig. ““Installing intermediate plate”“ , page 48 .
– If sender wheel was renewed together with sealing flange,
perform adaptions listed in Guided Function “01 - Functions,
engine mechanics” ⇒ Vehicle diagnostic tester.
Tightening torques
♦ ⇒ Fig. ““Sealing flange (gearbox end) - tightening torque and
sequence”“ , page 48
♦ ⇒ Fig. ““Plug for TDC drilling in cylinder block - tightening tor‐
que”“ , page 72
page 47
♦ Engine speed sender - G28-
⇒ “1.1 Exploded view - ignition system”, page 254
2.4 Renewing needle bearing in drive plate

A needle bearing is fitted in the drive plate only on vehicles with
manual gearbox.

♦ Tube - VW 418 A-
♦ Tube - VW 421-
♦ Support - 40 - 103-
Procedure
– Place support - 40 - 103- under drive plate when pressing out
and pressing in needle bearing.
– Use tube - VW 421- and workshop press and press out needle
bearing.
• Smaller diameter of tube -VW 421- faces drive plate.

– Carefully press in needle bearing as far as stop, using tube -

VW 418 A- and workshop press.
• Installation position: closed side of needle bearing faces en‐
gine.

3 Crankshaft
Caution
Risk of deformation of the cylinder block bearing pedestals.

♦ The crankshaft must not be removed. Even loosening the
main bearing cap bolts will cause deformation of the cyl‐
inder block bearing pedestals. This will result in reduced
bearing clearance. Even if bearing shells are not renewed,
a change in bearing clearance can cause bearing dam‐
age.
♦ If the bearing cap bolts are loosened, the cylinder block
must be renewed together with the crankshaft.
♦ Crankshaft bearing clearance cannot be measured using
workshop equipment.


⇒ “4.1 Exploded view - pistons and conrods”, page 61
⇒ “4.2 Removing and installing pistons”, page 64
⇒ “4.3 Removing and installing oil spray jets”, page 65
⇒ “4.4 Checking pistons and cylinder bores”, page 67
⇒ “4.5 Separating parts of new conrod”, page 68
⇒ “4.6 Checking radial clearance of conrod bearings”,
page 69
4.1 Exploded view - pistons and conrods

• All bearing and running surfaces must be oiled before assem‐
bling.
1 - Bolts
❑ Use old bolts when
measuring radial clear‐
ance
❑ Lubricate threads and
contact surface
❑ 30 Nm +90°
2 - Conrod bearing cap
❑ Due to the cracking
method used to sepa‐
rate the bearing cap
from the conrod in man‐
ufacture, the caps only
fit in one position and
only on the appropriate
conrod
❑ Mark cylinder and con‐
rod allocation in colour
-B-
❑ Installation position: Lug
-A- on conrod bearing
cap faces towards pul‐
ley end
3 - Bearing shells
⇒ Fig. ““Bearing shell -
installation position ”“ ,
page 64
❑ Renew used bearing
shells
❑ Check that it is securely
seated
4 - Conrod
❑ With industrially
cracked conrod bearing cap
❑ Only renew as a complete set
❑ Mark cylinder and conrod bearing cap allocation in colour -B-
❑ Measuring radial clearance ⇒ “4.6 Checking radial clearance of conrod bearings”, page 69
❑ Separating parts of new conrod ⇒ “4.5 Separating parts of new conrod”, page 68
❑ Installation position: Lug -A- on conrod bearing cap faces towards pulley end

5 - Pressure relief valve

❑ 27 Nm
6 - Oil spray jet
❑ For piston cooling
❑ Removing and installing ⇒ “4.3 Removing and installing oil spray jets”, page 65
7 - Circlip
❑ 2x
8 - Piston pin
❑ Removing and installing ⇒ “4.2 Removing and installing pistons”, page 64
9 - Piston
❑ Mark installation position and cylinder number
⇒ Fig. ““Piston installation position and cylinder allocation”“ , page 62
❑ Checking pistons and cylinder bores ⇒ “4.4 Checking pistons and cylinder bores”, page 67
10 - Compression rings
❑ Install using piston ring pliers -VAS 211 003- ⇒ Fig. ““Installing compression rings”“ , page 63
❑ Measuring ring gap ⇒ Fig. ““Measuring piston ring gap”“ , page 67
❑ Measuring ring-to-groove clearance ⇒ Fig. ““Measuring ring-to-groove clearance”“ , page 68
❑ Allocation ⇒ Fig. ““Allocation of piston rings”“ , page 63
❑ Installation position: marking “TOP” or side with lettering faces towards piston crown.
❑ Offset gaps by 120°
11 - Oil scraper ring
❑ Three-part
❑ Carefully remove and install by hand
❑ Gap cannot be measured
❑ Ring-to-groove clearance cannot be checked
❑ Installation position ⇒ Fig. ““Installing oil scraper ring”“ , page 63
Piston installation position and cylinder allocation

– If you intend to re-install used pistons, mark the cylinder num‐
ber on the piston crown using paint.
• Arrow on piston crown points to pulley end -arrow-.

Allocation of piston rings

1- Compression ring with chamfer -arrow A- (inner side, top)
2- Compression ring with shoulder -arrow B- (outer side, bot‐
tom)
3- Three-part oil scraper ring
Installing compression rings

• Installation position: marking “TOP” or side with lettering faces
towards piston crown.
• Open up compression ring -2- using piston ring pliers -VAS
211 003- just far enough to be able to slide it over piston -1-.
Installing oil scraper ring

– Note installation position of spring:
• Ends of fins -2, 3- and spring -1- must be offset from one an‐
other by at least 90°.
– Install by hand.
Installation sequence:
1. Insert spring -1- in groove.
2. Insert bottom fin -3- in groove.
3. Insert top fin -2- in groove.

Bearing shell - installation position

– Insert bearing shells centrally in conrod and conrod bearing
cap.
• Dimension -a- = dimension -a-
4.2 Removing and installing pistons

♦ Pin - VW 222A-
♦ Piston ring clamp, commercially available

Removing
• Engine secured to engine and gearbox support
20
– Remove cylinder head
⇒ “2.3 Removing and installing cylinder head”, page 101 .
– Remove sump (top section)
page 134 and detach baffle plate.
– Mark installation position and matching of:
♦ Pistons to cylinders
♦ Conrods to cylinders ⇒ Item 4 (page 61)
– Remove conrod bearing cap and pull out piston and conrod
upwards.

– Take circlip -2- out of piston pin boss.

– Use drift - VW 222A- to drive out piston pin -3-.
Note:
If piston pin is difficult to remove, heat piston to approx. 60 °C.
– Detach piston -1- from conrod -4-.
Installing
angle.
• When installing, offset top gap of 3-part oil scraper ring by 120°
to next compression ring.
– Install compression rings
⇒ Fig. ““Installing compression rings”“ , page 63 .
– Install oil scraper ring
⇒ Fig. ““Installing oil scraper ring”“ , page 63 .
– Lubricate running surfaces of bearing shells and cylinder wall
with engine oil.
– Install piston using commercially available piston ring clamp;
note installation position
⇒ Fig. ““Piston installation position and cylinder allocation”“ ,
page 62 .
– Install conrod bearing cap; note installation position
⇒ Item 2 (page 61) .
page 134 .
– Install cylinder head
Tightening torques
♦ ⇒ “4.1 Exploded view - pistons and conrods”, page 61
4.3 Removing and installing oil spray jets

♦ Socket - T10545- (no illustration)
♦ Wrench, 21 mm - T40263-

Removing
– Remove sump (top section) ⇒ page 134 and detach baffle
plate.
-arrow- until corresponding bolt is accessible.
– Keeping it as vertical as possible, insert socket - T10545- into

pressure relief valve and ensure that teeth of socket - T10545-
and pressure relief valve engage well in each other.
– Unscrew pressure relief valve -1- using socket - T10545- .

– Remove oil spray jet -2-.

Installing
• Installation position: Align locating edge of oil spray jet -2- with
machined surface of cylinder block.
Caution
Risk of damage to oil spray jets.

♦ Do not bend oil spray jets.
♦ Check that oil spray jets have adequate clearance after
re-installing pistons.
♦ Always renew bent oil spray jets.

page 134 .
Tightening torques
♦ ⇒ “1.1 Exploded view - sump/oil pump”, page 129
4.4 Checking pistons and cylinder bores

Checking piston
– Using a micrometer, measure approx. 10 mm from the lower
edge, perpendicular to the piston pin axis.
• Maximum deviation from nominal dimension: 0.04 mm.
Piston ∅ mm
Nominal dimension 74.421)
• 1) Dimensions not including coating
• Coating thickness of pistons manufactured by “Federal-Mo‐
gul”: 0.018 mm on each side
• Coating thickness of pistons manufactured by “Mahle”: 0.015
mm on each side
Measuring piston ring gap

– Insert ring at right angle to cylinder wall from above and push
down into lower cylinder opening approx. 15 mm from bottom
of cylinder.
– To do so, use a piston without rings.
Piston ring new Wear limit
mm mm
Compression ring 0.20 + 0.15 1.0
Oil scraper ring Cannot be measured

Measuring ring-to-groove clearance

– Clean groove in piston before checking clearance.
mm mm
1st compression ring 0.05 … 0.09 0.15
Manufacturer: “Federal-
Mogul”
Manufacturer: “Mahle”
2nd compression ring 0.03 … 0.07 0.15
Oil scraper ring Cannot be measured
Measuring cylinder bore
Caution
Risk of damage to the surface of the cylinder bore.

♦ Do not machine cylinder bore (reboring, honing, grinding)
with workshop equipment.
– Use a cylinder gauge - VAS 6078- to take measurements at 3

points in transverse direction -A- and in longitudinal direction
-B-.
Cylinder bore ∅ mm
Nominal dimension 74.5 +0.015
+0.005
• Measuring the cylinder bores must not be done when the cyl‐
inder block is mounted to the engine and gearbox support , as
incorrect measurements may result.
4.5 Separating parts of new conrod

Procedure
It is possible that the two parts of a new conrod are not completely
separated as intended. If it is not possible to detach conrod bear‐
ing cap by hand, proceed as follows:
– Clamp conrod -1- lightly in a vice using aluminium jaw covers
• To avoid any risk of damage, the conrod should only be clam‐
ped lightly.
• The conrod is clamped in a position below the dotted line.
– Loosen the two bolts -2- approx. 5 turns.

– Using a plastic hammer, carefully knock conrod bearing cap

-1- loose in direction of -arrow-.
4.6 Checking radial clearance of conrod

bearings
♦ Plastigauge
Procedure
– Remove conrod bearing cap.
– Clean bearing cap and bearing journal.
– Place a length of Plastigauge corresponding to the width of the
bearing on the bearing journal or in the bearing shell.
– Fit conrod bearing cap and secure with old bolts
⇒ Item 1 (page 61) without rotating crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigauge with measurement scale.
• Radial clearance: 0.028 ... 0.065 mm
– When carrying out final assembly, renew bolts.


⇒ “1.1 Exploded view - toothed belt cover”, page 70
⇒ “1.2 Exploded view - toothed belt”, page 71
⇒ “1.3 Removing and installing toothed belt cover”, page 73
⇒ “1.4 Detaching toothed belt from camshaft”, page 75
⇒ “1.5 Removing and installing toothed belt”, page 86
1.1 Exploded view - toothed belt cover
1 - Bolt
❑ Tightening torque and
sequence
⇒ Fig. ““Toothed belt
cover (centre) - tighten‐
ing torque and se‐
2 - Bolt
❑ 8 Nm
3 - Coolant lines
4 - Toothed belt cover (centre)
installing toothed belt
cover (centre)”,
page 73
5 - Toothed belt cover (top)
cover (top)”, page 73
6 - Bolt
❑ 8 Nm
7 - Toothed belt cover (bottom)
cover (bottom)”,
page 75
8 - Bolt
❑ 8 Nm

Toothed belt cover (centre) - tightening torque and sequence

angle.
Stage Tightening torque/angle specification
1. 7 Nm
2. 40 Nm
3. Turn 90° further
1.2 Exploded view - toothed belt
1 - Toothed belt
❑ Check for wear
❑ Removing from cam‐
shafts
⇒ “1.4 Detaching tooth‐
ed belt from camshaft”,
page 75
❑ Removing
stalling toothed belt”,
page 86
❑ Installing (adjusting
valve timing)
⇒ page 81
2 - Bolt
❑ 25 Nm
3 - Tensioning roller
4 - Bolt
❑ 8 Nm
❑ Slacken off and tighten
alternately in stages (di‐
agonal sequence)
⇒ “3.6 Nuts, bolts”, page
6
5 - Sealing cap
6 - Bolt
❑ 50 Nm +135°
1. Toothed belt drive 71

7 - Camshaft sprocket for exhaust camshaft

❑ With camshaft adjuster
8 - Guide sleeves
9 - Camshaft sprocket for inlet camshaft
❑ With camshaft adjuster
10 - Bolt
❑ 50 Nm +135°
11 - O-rings
12 - Plug
❑ 20 Nm
13 - Spacer sleeve
14 - Idler roller
15 - Bolt
❑ 45 Nm
16 - Crankshaft sprocket
❑ Contact surface between sprocket and crankshaft must be free of oil
❑ Can only be installed in one position
Plug for “TDC” drilling in cylinder block - tightening torque

– Tighten plug -2- to 30 Nm.

1.3 Removing and installing toothed belt

cover
⇒ “1.3.1 Removing and installing toothed belt cover (top)”,
page 73
⇒ “1.3.2 Removing and installing toothed belt cover (centre)”,
page 73
⇒ “1.3.3 Removing and installing toothed belt cover (bottom)”,
page 75
1.3.1 Removing and installing toothed belt

cover (top)
Removing
– Release clips -arrows- and detach toothed belt cover (top)
-1-.
Installing
Tightening torques
♦ ⇒ “1.1 Exploded view - toothed belt cover”, page 70

cover (centre)

Removing
page 215 .
– Remove toothed belt cover (top)
page 73 .
– Remove tensioner for poly V-belt
⇒ “1.4 Removing and installing tensioner for poly V-belt”, page
39 .
– Remove bolt -2- for alternator.
– Loosen (do not remove) bolt -1-, and pivot alternator -3- slight‐
ly to left side -arrow-.
– Move electrical wiring harness -2- clear.

– Unscrew bolts -arrows- and detach coolant lines -1-.
– Remove bolts -arrows- for toothed belt cover (bottom) -1-.

– Remove bolts -arrows- and detach toothed belt cover (centre)

-1-.
Installing
page 215 .
Tightening torques
♦ ⇒ “1.1 Exploded view - turbocharger”, page 193
- alternator

cover (bottom)
Removing
– Remove vibration damper
⇒ “1.6 Removing and installing vibration damper”, page 41 .
– Remove bolts -arrows- and detach toothed belt cover (bot‐
tom).
Installing
– Install vibration damper
Tightening torques
1.4 Detaching toothed belt from camshaft

♦ Torque wrench - VAS 6583-

♦ Counterhold tool - T10172A-
♦ Camshaft clamp - T10494-

♦ Special wrench, 30 mm - T10499-
♦ Counterhold tool - T10554/1- with knurled screws - T10554/2-
♦ Wrench, 21 mm - T40263-

Preparing tool
– Secure counterhold tool - T10554/1- to counterhold tool -
T10554/2- using knurled screws - T10172A- -arrows-.
Procedure
– Remove cover of toothed belt for coolant pump
⇒ “2.5 Removing cover of toothed belt for coolant pump”, page
168 .
– Remove toothed belt cover (centre)
page 73 .
Note
♦ Danger of chemical damage to seal for coolant pump if oil en‐

ters between coolant pump and cylinder head.
♦ Cover coolant pump with a cloth.
♦ Catch escaping engine oil with a cloth.
– Unscrew bolts -arrows- and detach sealing cap -1-.

press to one side.

Caution

crankshaft 90° further in the direction of normal engine ro‐
tation.
– Screw locking pin - T10340- by hand into cylinder block until

head of pin makes contact, then tighten to 30 Nm.

Note:
of engine rotation.
• On both camshafts, asymmetrically positioned grooves on

gearbox end must now face upwards -arrows-.
• The camshafts have two pairs of grooves: one positioned
symmetrically and one positioned asymmetrically. In TDC po‐
sition, the asymmetrically positioned pair of grooves must be
above the imaginary horizontal centre line.
– If camshafts are not positioned as described, unscrew locking
pin - T10340- , turn crankshaft one rotation further and return
to TDC position.

• It should be possible to insert the camshaft clamp - T10494-

easily.
• Do not knock camshaft clamp into place with any kind of tool.
– When camshafts are positioned as described, insert camshaft
clamp - T10494- into camshafts as far as stop and hand-tight‐
en bolt -arrow-.
If it is not possible to insert the camshaft clamp - T10494- easily:

– Press down toothed belt -arrow- using assembly tool -T10487-
and at the same time, insert camshaft clamp - T10494- into
camshafts as far as stop and hand-tighten bolt.
Caution
Risk of damage to engine due to oil on toothed belt.

♦ Place a cloth underneath to catch escaping engine oil.
Risk of damage to camshaft.
♦ The camshaft clamp - T10494- must not be used as a
counterhold tool.
– Remove bolts -arrows- ⇒ Item 4 (page 71) .

– Detach filler cap -1-.
– Unscrew plug -2- using counterhold tool - T10172A- with coun‐
terhold tool - T10554- .

– Loosen bolts -1, 2- approx. 1 turn (use counterhold tool -

T10172A- with counterhold tool - T10554- ).
– Loosen bolt -1-.

– Release tensioning roller on eccentric adjuster -2- using spe‐
cial wrench, 30 mm - T10499- -arrow-.
– Detach toothed belt from camshaft sprockets.
• The bending radius of the toothed belt must be at least 25 mm
(approx. half the diameter of the crankshaft sprocket).
Caution
Risk of damage to valves and piston crowns.

♦ Do not turn the crankshaft after the toothed belt has been
removed.
Installing (adjusting valve timing)

angle.
• Renew O-rings and oil seal after removing.
– Check “TDC” position of camshaft and crankshaft:
• Camshaft clamp - T10494- must be fitted to camshaft housing.

• Locking pin - T10340- is screwed into cylinder block as far as

stop and tightened to 30 Nm.
• Crankshaft is turned in normal direction of rotation until it
makes contact with locking pin - T10340- = “TDC” position.
– Fit new bolts -1, 2- for camshaft sprockets and screw them in
loosely.
• It should just be possible to turn the adjusters on the camshafts
without axial movement.
• Metal lug -arrow- of tensioning roller must engage in cast re‐

cess on cylinder head.
Note correct sequence for fitting toothed belt:

– Pull toothed belt -1- upwards and fit tensioning roller -2- and
camshaft sprockets -3, 4-.

– Using special wrench, 30 mm - T10499- , turn eccentric ad‐

juster -2- of tensioning roller in direction of -arrow- until ad‐
justment indicator -3- is positioned approx. 10 mm to right of
adjustment window.
– Turn eccentric adjuster back until adjustment indicator is posi‐
tioned exactly in adjustment window.
– Hold eccentric adjuster in this position and tighten bolt -1- us‐
ing insert tool, 13 mm - T10500- with torque wrench - VAS
6583- .
Note:
Turning the engine further or running the engine may lead to slight
differences in the position of the adjustment indicator -3- in rela‐
tion to the adjustment window. This does not affect the toothed
belt tension.
Caution
Risk of damage to camshafts.

counterhold tool.
– Tighten bolts -1, 2- initially to 50 Nm (use counterhold tool -

– Remove locking pin - T10340- .
– Remove bolt -arrow- and detach camshaft clamp - T10494- .

Checking valve timing:

et (21 mm), turn crankshaft two turns in direction of engine
rotation -arrow-.
Caution

tation.


Note:
of engine rotation.

easily.
– Insert camshaft clamp - T10494- into camshafts as far as stop
and hand-tighten with bolt -arrow-.


and then insert camshaft clamp - T10494- into camshafts as
far as stop and hand-tighten bolt.
If it is not possible to insert camshaft clamp - T10494- , valve tim‐
ing is not OK.
– Adjust valve timing again ⇒ page 81 .
If it is possible to insert camshaft clamp - T10494- , valve timing
is OK.
– Tighten bolts -1, 2- (use counterhold tool - T10172A- with

counterhold tool - T10554- ).

– Tighten plug -2- and bolts -arrows- for sealing cap -1- using
counterhold tool - T10172A- with counterhold tool - T10554- .
Further installation is carried out in the reverse order; note the
following:
– Install toothed belt cover (centre)
page 73 .
– Install cover of toothed belt for coolant pump
168 .
Tightening torques
♦ ⇒ “1.2 Exploded view - toothed belt”, page 71
que”“ , page 72
♦ ⇒ “2.2 Exploded view - camshaft housing”, page 99


♦ Special wrench, 30 mm - T10499-

♦ Counterhold tool - T10554/1- with knurled screws - T10554/2-
♦ Wrench, 21 mm - T40263-
Preparing tool
– Secure counterhold tool - T10554/1- to counterhold tool -
T10554/2- using knurled screws - T10172A- -arrows-.
Procedure
168 .
– Remove toothed belt cover (centre)
page 73 .

Note
♦ Danger of chemical damage to seal for coolant pump if oil en‐

ters between coolant pump and cylinder head.
♦ Cover coolant pump with a cloth.
♦ Catch escaping engine oil with a cloth.
– Unscrew bolts -arrows- and detach sealing cap -1-.

press to one side.
Caution

tation.


Note:
of engine rotation.

• On both camshafts, asymmetrically positioned grooves on

gearbox end must now face upwards -arrows-.
• The camshafts have two pairs of grooves: one positioned
symmetrically and one positioned asymmetrically. In TDC po‐
sition, the asymmetrically positioned pair of grooves must be
above the imaginary horizontal centre line.
– If camshafts are not positioned as described, unscrew locking
pin - T10340- , turn crankshaft one rotation further and return
to TDC position.
– Remove toothed belt cover (bottom)
page 75 .

easily.
– When camshafts are positioned as described, insert camshaft
clamp - T10494- into camshafts as far as stop and hand-tight‐
en bolt -arrow-.


Caution
Risk of damage to engine due to oil on toothed belt.

♦ Place a cloth underneath to catch escaping engine oil.
Risk of damage to camshaft.
counterhold tool.
– Remove bolts -arrows- ⇒ Item 4 (page 71) .

– Detach filler cap -1-.
– Unscrew plug -2- using counterhold tool - T10172A- with coun‐
terhold tool - T10554- .
– Loosen bolts -1, 2- approx. 1 turn (use counterhold tool -

Caution
If a used belt runs in the opposite direction when it is refitted,

this can cause breakage.
♦ Before removing, mark direction of rotation of toothed belt
with chalk or felt-tip pen for re-installation.

– Release tensioning roller on eccentric adjuster -2- using spe‐
cial wrench, 30 mm - T10499- -arrow-.
– Take off toothed belt.
• The bending radius of the toothed belt must be at least 25 mm
(approx. half the diameter of the crankshaft sprocket).

– Detach crankshaft sprocket -1- -arrow-.
Caution

♦ Do not turn the crankshaft after the toothed belt has been
removed.

angle.

– Fit new bolts -1, 2- for camshaft sprockets and screw them in
loosely.
• It should just be possible to turn the adjusters on the camshafts
without axial movement.

• Metal lug -arrow- of tensioning roller must engage in cast re‐

cess on cylinder head.
– Fit crankshaft sprocket onto crankshaft.

• Contact surface between poly V-belt pulley and crankshaft
sprocket must be free of oil and grease.
• Machined surface -arrow- of crankshaft sprocket must be posi‐
tioned over machined surface of crankshaft journal.
Note correct sequence for fitting toothed belt:

1- Crankshaft sprocket
2- Idler roller
3- Tensioning roller
4- Camshaft sprocket, exhaust side
5- Camshaft sprocket, inlet side
– Install toothed belt cover (bottom)
page 75 .

– Using special wrench, 30 mm - T10499- , turn eccentric ad‐

juster -2- of tensioning roller in direction of -arrow- until ad‐
justment indicator -3- is positioned approx. 10 mm to right of
adjustment window.
– Turn eccentric adjuster back until adjustment indicator is posi‐
tioned exactly in adjustment window.
– Hold eccentric adjuster in this position and tighten bolt -1- us‐
ing insert tool, 13 mm - T10500- with torque wrench - VAS
6583- .
Note:
Turning the engine further or running the engine may lead to slight
differences in the position of the adjustment indicator -3- in rela‐
tion to the adjustment window. This does not affect the toothed
belt tension.
Caution

counterhold tool.
– Tighten bolts -1, 2- initially to 50 Nm (use counterhold tool -



et (21 mm), turn crankshaft two turns in direction of engine
rotation -arrow-.
Caution

tation.


Note:
of engine rotation.

easily.
– Insert camshaft clamp - T10494- into camshafts as far as stop
and hand-tighten with bolt -arrow-.


If it is not possible to insert camshaft clamp - T10494- , valve tim‐
ing is not OK.
– Adjust valve timing again ⇒ page 92 .
If it is possible to insert camshaft clamp - T10494- , valve timing

is OK.
– Tighten bolts -1, 2- (use counterhold tool - T10172A- with

counterhold tool - T10554- ).

– Tighten plug -2- and bolts -arrows- for sealing cap -1- using
counterhold tool - T10172A- with counterhold tool - T10554- .
following:
– Install toothed belt cover (centre)
page 73 .
168 .
Tightening torques
que”“ , page 72

2 Cylinder head
⇒ “2.2 Exploded view - camshaft housing”, page 99
1 - Cylinder head gasket

❑ Renewing
stalling cylinder head”,
page 101
able; for allocation refer
to ⇒ Electronic parts
catalogue
❑ Note installation posi‐
tion: part number must
face cylinder head
2 - Dowel sleeve
❑ 2x
3 - Cylinder head
page 101
❑ Checking for distortion
⇒ Fig. ““Checking cylin‐
der head for distortion”“ ,
page 99
4 - Dowel pins
5 - Not fitted
6 - Gasket
7 - Camshaft housing
stalling camshaft hous‐
ing”, page 105
8 - Bolt
⇒ Fig. ““Camshaft housing - tightening torque and sequence”“ , page 101
9 - Bolt
❑ Correct sequence when slackening ⇒ page 104
❑ Tightening torque and sequence ⇒ Fig. ““Cylinder head - tightening torque and sequence”“ , page 99

Cylinder head - tightening torque and sequence

angle.
1. -1 … 10- 40 Nm
2. -1 … 10- Turn 90° further
3. -1 … 10- Turn 90° further
4. -1 … 10- Turn 90° further
Heat shield - tightening torque

– Tighten bolts -arrows- to 9 Nm.
Checking cylinder head for distortion

– Use straight edge 500 mm - VAS 6075- and feeler gauge to
measure cylinder head for distortion at several points.
• Max. permissible distortion: 0.05 mm.
2.2 Exploded view - camshaft housing
2. Cylinder head 99
1 - Dowel pin
2 - Seal
❑ Inserted into cylinder
head
3 - Gasket
4 - Oil seal
❑ For inlet camshaft
❑ Renewing
installing inlet camshaft
oil seal (pulley end)”,
page 113
5 - Oil seal
❑ For exhaust camshaft
(pulley end)
❑ Renewing
installing exhaust cam‐
end)”, page 115
6 - Bolt
sequence
⇒ Fig. ““Camshaft hous‐
ing - tightening torque
and sequence”“ ,
page 101
7 - Bolt
❑ 8 Nm
8 - Bracket
9 - Ball stud
❑ For engine cover panel
❑ 8 Nm
10 - O-rings
11 - Plug
12 - O-ring
❑ Lubricate lightly with engine oil
❑ Check for damage and renew if necessary; supplied together with camshaft control valve 1
13 - Camshaft control valve 1
♦ Camshaft control valve 1 - N205-
♦ Exhaust camshaft control valve 1 - N318-
❑ Removing and installing ⇒ “3.4 Removing and installing camshaft control valve 1 N205 ”, page 118
14 - Bolt
❑ 8 Nm
15 - Filler cap
16 - Seal
❑ For filler cap

17 - Hall sender
♦ Hall sender - G40-
♦ Hall sender 3 - G300-
❑ Exploded view ⇒ “1.1 Exploded view - ignition system”, page 254
18 - Bolt
❑ Tightening torque ⇒ Item 6 (page 254)
19 - O-ring
20 - Oil seal
❑ For exhaust camshaft (gearbox end)
❑ Renewing ⇒ “3.3.3 Removing and installing exhaust camshaft oil seal (gearbox end)”, page 116
21 - Toothed belt drive sprocket
❑ For coolant pump
⇒ “2.8 Removing and installing toothed belt sprocket for coolant pump”, page 175
22 - Bolt
23 - Bolt
❑ 8 Nm
24 - Sealing cap
25 - O-ring
❑ Removing and installing ⇒ “2.4 Removing and installing camshaft housing”, page 105
Camshaft housing - tightening torque and sequence

angle.
1. -1 … 15- 10 Nm
2. -1 … 15- Turn 180° further

2. Cylinder head 101

♦ Socket - 3410-
♦ Scraper; blade width at least 40 mm (commercially available)

Removing
when installing.
– Remove camshaft housing
⇒ “2.4 Removing and installing camshaft housing”,
page 105 .
– Remove intake manifold
⇒ “3.2 Removing and installing intake manifold”, page 219 .
– Remove turbocharger
⇒ “1.2 Removing and installing turbocharger”, page 196 .
– Unplug electrical connectors:
1- At oil pressure switch for reduced oil pressure - F378-
2- At fuel pressure sender - G247-
3- At injectors -N30- ... -N33-
– Remove bolts -arrows- and -2- and detach heat shield -1-.

– Unplug electrical connector -1- for coolant temperature sender

- G62- .

– Loosen and remove cylinder head bolts in sequence

-1 ... 10-.
– Take off cylinder head and set it down on a soft surface (foam
plastic).
Installing
WARNING
Risk of eye injury due to sealant residue.

Note
♦ Risk of damage to sealing surfaces if handled incorrectly.

♦ Carefully remove sealant residue from cylinder head and cyl‐
inder block.
♦ Do NOT use abrasive materials (sandpaper, sanding discs,
sanding pads, abrasive web, wire wool, etc.).
♦ When removing sealant residue, make sure none of the resi‐
due enters the open channels of the engine.
♦ Ensure that nearby workspaces are kept clean and that the
abrasive materials listed above are not being used there.
♦ Use of non-approved abrasive materials can lead to subse‐
quent damage to the turbocharger, conrod bearings, etc.
– Sealant residue may only be removed from the cylinder head

and cylinder block using a commercially available scraper
(blade width at least 4 cm).
– Remove loose residue with a lint-free cloth.
• Sealing surfaces must NOT be damaged.
• No oil or coolant must be allowed to remain in the blind holes
for the cylinder head bolts in the cylinder block.
• Renew bolts tightened with specified tightening angle.
and O-rings.
• When installing an exchange cylinder head, oil the contact
surfaces between the roller rocker fingers and the running
surfaces of the cams.
• After fitting a new cylinder head or cylinder head gasket,
change the engine oil and the coolant in the entire cooling
system.
• Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
• Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
– Carefully remove sealant residue from cylinder head and cyl‐
inder block.

– Clean blind holes for cylinder head bolts in cylinder block so

that they are free of oil and coolant residue.
– Fit cylinder head gasket -1-.

♦ Note position of centring pins in cylinder block -arrows-.
♦ Note installation position of cylinder head gasket. Part No.
should be legible from inlet side.
– If crankshaft has been rotated: Set piston of cylinder 1 to top
dead centre and then turn crankshaft back slightly.
– Fit cylinder head.
– Insert and hand-tighten cylinder head bolts.
– Tighten cylinder head bolts
⇒ Fig. ““Cylinder head - tightening torque and sequence”“ ,
page 99 .
Note:
Cylinder head bolts do not have to be torqued down again later
after repair work.
note the following:
– Install turbocharger
– Install intake manifold
– Install camshaft housing
page 105 .
– Change engine oil ⇒ Maintenance ; Booklet 830 .
– Fill cooling system with fresh coolant
Tightening torques
♦ ⇒ Fig. ““Cylinder head - tightening torque and sequence”“ ,
page 99
♦ ⇒ “2.1 Exploded view - cylinder head”, page 98

ing
Removing
page 34 .
– Remove coolant pump
⇒ “2.6 Removing and installing coolant pump”, page 169 .
– Remove ignition coils
⇒ “1.2 Removing and installing ignition coils with output
stages”, page 255 .

– Detach toothed belt from camshafts

– Remove high-pressure pipe
⇒ “6.3 Removing and installing high-pressure pipe”,
page 236 .
– Release hose clip -2- and detach fuel supply hose.

– Remove bolts -arrows- and detach heat shield -1-.
– Unplug electrical connector -arrow- for starter.

– Remove bolts -arrows-, disconnect oil supply line -1- and

press it slightly to one side. (Shown with engine support re‐
moved.)

1- For camshaft control valve 1 - N205- / exhaust camshaft
control valve 1 - N318-
2- For Hall sender - G40- / Hall sender 2 - G163-
– Loosen and remove bolts for camshaft housing in the se‐

quence -15 ... 1-.
– Carefully release camshaft housing from bonded joint and de‐
tach.
– Mark original positions of roller rocker fingers and compensa‐
tion elements for re-installation.
– Remove roller rocker fingers together with compensation ele‐
ments and put down on a clean surface.
Installing
angle.
• Renew gasket and spring-type clips after removing.

Caution
Risk of damage to valve gear.

♦ The camshafts must not be moved axially when turning.

– Make sure that all roller rocker fingers make contact with the
valve ends correctly and are clipped into their respective sup‐
port elements.
– Fit gasket onto dowel pins -arrows-.

– Screw 2 studs -items 2, 4- (e.g. -T10288/4- ) into cylinder head.

– Carefully lower camshaft housing -3- vertically onto studs in
cylinder head.
• Make sure that camshaft housing is kept straight.
– Tighten camshaft housing bolts
⇒ Fig. ““Camshaft housing - tightening torque and sequence”“ ,
page 101 .
note the following:
– Install high-pressure pipe
page 236 .
– Install ignition coils
– Install coolant pump
page 34 .
Caution
Risk of damage to valves and piston crowns after working on

valve gear.
♦ Turn the engine carefully at least 2 rotations to ensure that
none of the valves make contact when the starter is op‐
erated.
Tightening torques

♦ Spark plug spanner - 3122 B-

♦ Compression tester - V.A.G 1763-
Procedure
• Engine oil temperature at least 30 ℃
• Battery voltage at least 12.5 V
– To interrupt voltage supply to fuel system pressurisation pump
- G6- , remove fuse for fuel pump control unit - J538- ⇒ Current
flow diagrams, Electrical fault finding and Fitting locations.
– Start engine and allow it to run at idling speed until it stops.
– Remove spark plugs with spark plug spanner - 3122 B- .
– Check compression pressure with compression tester -
V.A.G 1763- (see ⇒ operating instructions for details of how
to use tester).
• A second mechanic is required for the following step.
– Have a second mechanic press down the accelerator pedal
completely and at the same time operate the starter until the
pressure on the tester display no longer increases.
– Repeat procedure on each cylinder.
Compression pressure bar
When new 10.0 … 15.0
Wear limit 7.0
Maximum difference between cylinders 3.0
Assembling
– Install spark plugs ⇒ Maintenance ; Booklet 830 .
– Insert fuse for fuel pump control unit - J538- .
– Erase any entries in event memory resulting from testing ⇒ Ve‐

3 Valve gear
⇒ “3.2 Measuring axial clearance of camshaft”, page 112
page 118
1 - Inlet valve
❑ Do not machine, only
grinding-in is permitted
❑ Valve dimensions
⇒ “4.3 Valve dimen‐
sions”, page 128
❑ Checking valve guides
⇒ “4.1 Checking valve
guides”, page 127
2 - Exhaust valve
sions”, page 128
guides”, page 127
3 - Cylinder head
4 - Valve stem oil seal
❑ Renewing
stalling valve stem oil
seals”, page 119
5 - Valve spring
⇒ Fig. ““Position of valve
spring”“ , page 112
6 - Valve spring plate
7 - Valve cotters
8 - Roller rocker finger
stalling camshaft housing”, page 105
❑ Mark installation position for re-installation
❑ Check roller bearings for ease of movement
❑ Lubricate contact surfaces before installing
9 - Securing clip
❑ For hydraulic compensation element
10 - Hydraulic compensation element
❑ Do not interchange
3. Valve gear 111

❑ Lubricate contact surface
Position of valve spring

• The smaller ∅ -a- faces the valve spring plate.
• The larger ∅ -b- faces the cylinder head.
3.2 Measuring axial clearance of camshaft

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge - VAS 6079-
Procedure
page 105 .
– Secure dial gauge - VAS 6079- to camshaft housing with uni‐
versal dial gauge bracket - VW 387- as shown in illustration.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
Axial clearance:
• Wear limit: 0.25 mm.


seal
⇒ “3.3.1 Removing and installing inlet camshaft oil seal (pulley
end)”, page 113
⇒ “3.3.2 Removing and installing exhaust camshaft oil seal (pulley
end)”, page 115
⇒ “3.3.3 Removing and installing exhaust camshaft oil seal (gear‐
box end)”, page 116
3.3.1 Removing and installing inlet camshaft

oil seal (pulley end)
♦ Assembly tool - T10478 B-
Removing
– Unscrew bolt -2- and remove camshaft sprocket.
3. Valve gear 113

– Pull out oil seal -1- using extractor hook -T20143/1- .
Installing
sleeve -T10478/2- .
– Fit guide sleeve -T10478/2- with oil seal -1- onto camshaft.
– Use thrust piece -T10478/1A- and bolt -1- for camshaft sprock‐
et to pull in oil seal onto stop.

3.3.2 Removing and installing exhaust cam‐

shaft oil seal (pulley end)
♦ Assembly tool - T10478 B-
Removing
– Unscrew bolt -1- and remove camshaft sprocket.
– Pull out oil seal -1- using extractor hook -T20143/1- .
3. Valve gear 115

Installing
sleeve -T10478/2- .
– Fit guide sleeve -T10478/2- with oil seal -1- onto camshaft.
– Pull in thrust piece -T10478/1A- with bolt -T10478/5- as far as

stop.
3.3.3 Removing and installing exhaust cam‐

shaft oil seal (gearbox end)

♦ Assembly tool - T10479 A-
Removing
– Remove toothed belt sprocket for coolant pump
⇒ “2.8 Removing and installing toothed belt sprocket for cool‐
ant pump”, page 175 .
– Carefully slide extractor hook -T20143/1- between camshaft
and oil seal -1-.
– Pry out oil seal.
Installing
– If necessary, use fine sandpaper (grit 220 ... 1000) to remove
any burrs that have formed on the outside of the outer grooves
on the exhaust camshaft -arrows-.
3. Valve gear 117

sleeve -T10479/2- .
– Fit guide sleeve -T10479/2- with oil seal -2- onto camshaft so
that it is centred.
– Secure guide sleeve onto camshaft using bolt -1- for coolant
pump drive sprocket.
– Slide oil seal onto camshaft and unbolt guide sleeve.
– Use thrust piece -T10479/1- and bolt -1- for coolant pump drive
sprocket to pull in oil seal -2- onto stop.
– Install toothed belt sprocket for coolant pump
⇒ “2.8 Removing and installing toothed belt sprocket for cool‐
ant pump”, page 175 .

Removing
page 34 .

– Unplug electrical connector:

1- For exhaust camshaft control valve 1 - N318-
2- For camshaft control valve 1 - N205-
– Remove appropriate bolt -arrows- and detach camshaft con‐
trol valve.
Installing
• Lubricate O-ring with engine oil before installing.
• Check O-ring for damage and renew if necessary (supplied
together with camshaft control valve 1 ⇒ Electronic parts
catalogue ).
page 34 .
Tightening torques

seals
⇒ “3.5.1 Removing and installing valve stem oil seals (cylinder
head installed)”, page 119
head removed)”, page 123
3.5.1 Removing and installing valve stem oil

seals (cylinder head installed)
♦ Spark plug spanner - 3122 B-
♦ Valve stem oil seal fitting tool - 3365-
3. Valve gear 119

♦ Removal and installation device for valve cotters - VAS 5161

A- with set -VAS 5161 A/32-
♦ Valve shaft pliers - VAS 6770-
♦ Assembly sleeve ⇒ Electronic parts catalogue

Procedure
page 105 .
– Unscrew spark plugs using spark plug socket - 3122 B- .


– Set piston of appropriate cylinder to “bottom dead centre”.
– Fit guide plate -VAS 5161 A/32- onto cylinder head and secure
with knurled screws -VAS 5161/12- .
– Screw adapter - T40012- with seal hand-tight into the corre‐
sponding spark plug thread.
– Connect adapter to compressed air line using a commercially
available connection piece and apply constant air pressure.
• Minimum pressure: 6 bar
– Apply drift -VAS 5161/3A- to guide plate and use plastic-head‐
ed hammer to release sticking valve cotters.
– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Insert assembly cartridge -VAS 5161 A/32-1- (slide on sleeve
-VAS 5161 A/32-2- ) in guide plate.
– Attach pressure fork -VAS 5161/2- to snap-in device 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 assembly cartridge.
– Release pressure fork.
– Take out assembly cartridge.
– Detach guide plate and turn to one side.
• The compressed air hose remains connected.
– Detach valve spring with valve spring plate.
3. Valve gear 121

– Pull off valve stem oil seal with valve shaft pliers - VAS 6770- .
• To avoid damaging new valve stem oil seal -4- during instal‐
lation, fit assembly sleeve -item 3- onto valve stem -2-.
– Lightly oil sealing lip of valve stem oil seal.
– Insert valve stem oil seal into valve stem oil seal fitting tool -
3365- and use assembly sleeve to carefully press it onto valve
guide -1- as far as stop.
– Remove assembly sleeve .
If valve cotters have been removed from assembly cartridge, they

must first be inserted in insertion device -VAS 5161 A/32-3- .
• Larger diameter of valve cotters faces upwards.
– Press assembly cartridge onto insertion device from above
and pick up valve cotters.
– Insert valve spring and valve spring plate; installation position
of valve spring ⇒ Fig. ““Position of valve spring”“ , page 112 .

– Secure guide plate -VAS 5161 A/32- back onto cylinder head.
– Insert assembly cartridge -VAS 5161 A/32-1- with sleeve -VAS
5161 A/32-2- into guide plate.
– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions - this will insert the valve
cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
Assembling
– Install spark plugs ⇒ Maintenance ; Booklet 830 .
page 105 .

seals (cylinder head removed)
♦ Valve stem oil seal fitting tool - 3365-

A- with set -VAS 5161 A/32-
3. Valve gear 123

♦ Cylinder head tensioning device - VAS 6419-
♦ Valve shaft pliers - VAS 6770-

Procedure
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .
– Secure cylinder head in cylinder head tensioning device, as
shown in illustration.
– Connect cylinder head tensioning device to compressed air
supply.
– Using lever -arrow-, slide air pad under combustion chamber
where valve stem oil seals are to be removed.
– Apply just enough compressed air to bring air pad into contact
with valve heads.

– Fit guide plate -VAS 5161 A/32- onto cylinder head and secure
with knurled screws -VAS 5161/12- .
– Apply drift -VAS 5161/3A- to guide plate and use plastic-head‐

– Insert assembly cartridge -VAS 5161 A/32-1- (slide on sleeve
-VAS 5161 A/32-2- ) in guide plate.
– Pull off valve stem oil seal with valve shaft pliers - VAS 6770- .
3. Valve gear 125

– Insert valve stem oil seal into valve stem oil seal fitting tool -
3365- and use assembly sleeve to carefully press it onto valve

must first be inserted in insertion device -VAS 5161 A/32-3- .
– Insert valve spring and valve spring plate; installation position
of valve spring ⇒ Fig. ““Position of valve spring”“ , page 112 .
– Secure guide plate -VAS 5161 A/32- back onto cylinder head.
– Insert assembly cartridge -VAS 5161 A/32-1- with sleeve -VAS
5161 A/32-2- into guide plate.
cotters.
tion.


⇒ “4.1 Checking valve guides”, page 127
⇒ “4.2 Checking valves”, page 128
⇒ “4.3 Valve dimensions”, page 128
4.1 Checking valve guides

Test sequence
• If the valve has to be renewed as part of a repair, use a new
valve for the measurement.
• Only insert inlet valve into inlet valve guide and exhaust valve
into exhaust valve guide, as the stem diameters are different.
– Attach dial gauge - VAS 6079- with universal dial gauge brack‐
et - VW 387- to cylinder head.
– Insert valve into guide.
• End of valve stem must be flush with valve guide.
– Measure the amount of sideways play.
– 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.

4.2 Checking valves

– Visually inspect for scoring on valve stems and valve seat sur‐
faces.
– Renew valve if scoring is clearly visible.
4.3 Valve dimensions

• Inlet and exhaust valves must not be machined. Only grinding-
in is permitted.
Dimension Inlet valve Exhaust valve
∅a mm 28.5 25.0
∅b mm 4.973 4.963
c mm 110.25 110.09
α ∠° 45 30

17 – Lubrication
1 Sump/oil pump
page 132
er G266 ”, page 138

♦ 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 in order to prevent further damage
occurring later. In addition, renew oil spray jets, engine oil
cooler and oil filter.
♦ Oil spray jet and pressure relief valve
1. Sump/oil pump 129

1 - Nut
❑ 9 Nm
sender - G266-
stalling oil level and oil
temperature sender
G266 ”, page 138
3 - Seal
4 - O-ring
❑ Lubricate lightly with en‐
gine oil
5 - Sealing plug
❑ Tighten as far as stop
6 - Bolt
❑ Tightening sequence
⇒ Fig. ““Sump (bottom
section) - tightening tor‐
que and sequence”“ ,
page 131
7 - Sump (bottom section)
stalling sump (bottom
section)”, page 132
8 - Gasket
9 - Bolt
❑ 5 Nm +90°
10 - Oil intake pipe
❑ Clean strainer if dirty
11 - O-ring
12 - Cover
❑ For oil pump drive chain sprocket
13 - Drive chain
❑ For oil pump
❑ Before removing, mark running direction with paint
14 - Bolt
⇒ Fig. ““Sump (top section) - tightening torque and sequence”“ , page 131
15 - Oil filter
❑ See note ⇒ page 129

16 - Baffle plate
17 - Dowel pin
18 - Sump (top section)
❑ Removing and installing ⇒ “1.4 Removing and installing sump (top section)”, page 134
19 - Oil strainer
20 - Dowel sleeve
❑ 2x
21 - Oil pump
❑ Removing and installing ⇒ “1.5 Removing and installing oil pump”, page 137
22 - Bolt
❑ 10 Nm
Sump (bottom section) - tightening torque and sequence

• Renew bolts after removing.
2. 5 Nm in diagonal sequence
3. 12 Nm in diagonal sequence
Sump (top section) - tightening torque and sequence

angle.
2. -Arrows- Screw in by hand until contact is made
3. -1 … 19- 8 Nm
4. -1 … 19- Turn 90° further
5. -Arrows- Tightening torque ⇒ Gearbox; Rep.
gr. 34 ; Removing and installing gear‐
box; Tightening torques for gearbox
1.2 Engine oil

Oil capacities, oil specifications and viscosity grades ⇒ Mainte‐
nance tables .

Caution
Risk of damage to catalytic converter.

♦ The oil level must not be above the “MAX” mark on the
dipstick.

section)
Removing
– Remove wheel spoilers (left and right) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Removing
and installing wheel housing liner (front) .
noise insulation .
– Remove bolt -arrow- and move bracket -1- for electrical wiring
harness clear.

– Support engine in installation position


distance -a-.
• Distance -a- = approx. 40 mm.
Note:
If it is not possible to unplug electrical connector -2- for oil level
and oil temperature sender - G266- , release catches -arrow- and
detach protective cable cover -1-.
– Unplug electrical connector -2- for oil level and oil temperature
sender - G266- .
– Loosen and remove bolts -arrows- in diagonal sequence and
detach sump (bottom section) -1-.
Installing
• Renew gasket and bolts after removing.
830 .
Tightening torques
♦ ⇒ Fig. ““Sump (bottom section) - tightening torque and se‐
Exploded view - drive shaft


tion)
♦ Electric drill with plastic brush
♦ Safety goggles
Removing
– Remove subframe cross brace ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Subframe; Removing and installing subframe
cross brace .
Caution
Risk of damage to running gear components.

♦ The vehicle must NOT be lowered onto its wheels if the
engine/gearbox mountings, steering rack or subframe
cross brace are not properly installed.
– Remove steering rack ⇒ Running gear, axles, steering; Rep.

gr. 48 ; Steering rack; Removing and installing steering rack .
– Detach air conditioner compressor from bracket and tie up ⇒
Heating, air conditioning; Rep. gr. 87 ; Air conditioner com‐
pressor; Detaching and attaching air conditioner compressor
at bracket .
– Remove oil pump
⇒ “1.5 Removing and installing oil pump”, page 137 .

– Remove bolts -arrows- securing gearbox to sump (top sec‐

tion).
– Slacken and remove bolts in the sequence: -19 ... 1-.
– Carefully release sump (top section) from bonded joint.
– Detach baffle plate.
Installing
angle.
Caution
Protect lubrication system against contamination.

♦ Cover exposed parts of the engine.
– Remove sealant remaining on cylinder block with flat scraper.
WARNING
Risk of eye injury.

– Use e.g. a rotating plastic brush to remove sealant residue on

sump (top section) flange.
– Check oil passages in sump (top section) and in cylinder block
for dirt.
– Check that dowel pin -2- is securely seated in cylinder block.

– Attach baffle plate -1- to cylinder block.


2 mm).
Caution
Make sure lubrication system is not clogged by excess sealant.

♦ The sealant bead must not be thicker than specified.
– Apply bead of sealant -arrow- onto clean sealing surface of

sump (top section) as shown in illustration.
• Thickness of sealant bead: 2 ... 3 mm
• Install sump (top section) within 5 minutes of applying sealant.
– Carefully fit sump (top section) with the help of a second me‐
chanic but do not press sealant bead on yet.
– First, screw all bolts in by hand and then tighten.
note the following:
– Install oil pump
– Install steering rack ⇒ Running gear, axles, steering; Rep. gr.
48 ; Steering rack; Removing and installing steering rack .
830 .
Tightening torques
♦ ⇒ Fig. ““Sump (top section) - tightening torque and se‐


Removing
page 132 .
– Unclip cover for oil pump drive chain sprocket -arrows-.

– Guide out oil pump with drive chain sprocket under drive chain.
Installing
– Check that dowel sleeves -1, 3- are fitted in oil pump.
– Insert oil strainer -2- into oil pump.
– Turn oil pump drive chain sprocket by hand to check oil pump
for ease of movement.
• Renew oil pump if it does not turn easily.
– Fit oil pump with drive chain sprocket into drive chain and se‐
cure.
page 132 .
830 .
Tightening torques


Removing
Note:
If it is not possible to unplug electrical connector -2- for oil level
and oil temperature sender - G266- , release catches -arrow- and
detach protective cable cover -1-.

– Remove nuts -1- and detach oil level and oil temperature
sender - G266- -item 3-.
Installing
• Renew seal -4- after removing.
830 .
Tightening torques

2 Engine oil cooler

⇒ “2.1 Exploded view - engine oil cooler”, page 139
⇒ “2.2 Removing and installing engine oil cooler”, page 139
2.1 Exploded view - engine oil cooler
1 - Bolt
❑ 8 Nm +90°
2 - Seals
❑ See note
⇒ “1 Sump/oil pump”,
page 129
stalling engine oil cool‐
er”, page 139
❑ If renewed, refill system
with fresh coolant
2.2 Removing and installing engine oil cool‐

er

Removing
page 34 .
– Drain coolant
move them clear.
switch - F66- .
– Remove coolant pipes
⇒ “3.2 Removing and installing coolant pipes”, page 180 .
– Unscrew bolts -arrows- and detach engine oil cooler -1-.

Installing
• Renew seals after removing.
– Connect coolant hoses with plug-in connector
page 183 .
page 34 .
Tightening torques
♦ ⇒ “2.1 Exploded view - engine oil cooler”, page 139

⇒ “3.1 Exploded view - crankcase breather system”, page 141
⇒ “3.2 Removing and installing oil separator”, page 142
3.1 Exploded view - crankcase breather system
1 - Bolt
❑ Self-locking
❑ 9 Nm
2 - Oil separator
stalling oil separator”,
page 142
3 - Hose
❑ For crankcase breather
5 - O-ring
gine oil
❑ Check for damage and
renew if necessary; sup‐
plied together with non-
return valve
6 - Cover
❑ For oil separator
7 - Hose
Oil separator - tightening torque and sequence

– Tighten bolts in the sequence -1 ... 9- to 9 Nm.

3.2 Removing and installing oil separator

♦ Flat scraper
♦ Studs, M6x20 mm
♦ Sealant remover
Removing
– Remove engine support (left-side)
page 39 .
– Release fasteners -2- -arrow- on cover -1- for oil separator and
detach cover.

– Carefully release oil separator from bonded joint.
Installing
Caution


– Screw 2 studs a few turns into holes -arrows-.


2 mm).
Caution

– Apply bead of sealant -arrow- onto clean sealing surface of oil

separator as shown in illustration.
• Install oil separator within 5 minutes after applying the sealant.
– Carefully fit oil separator onto studs but do not press sealant
bead on yet.
– Screw in bolts hand-tight at first.
– Unscrew studs again.
– Screw in last two bolts and tighten all bolts.
– Check oil level ⇒ Maintenance ; Booklet 830 .
– Install engine support (left-side)
page 39 .
Tightening torques
♦ ⇒ Fig. ““Oil separator - tightening torque and sequence”“ ,
page 141


⇒ “4.1 Exploded view - oil filter/oil pressure switches”,
page 144
⇒ “4.2 Removing and installing oil pressure switch F22 ”,
page 145
⇒ “4.3 Removing and installing oil pressure switch for reduced oil
pressure F378 ”, page 146
”, page 147
4.1 Exploded view - oil filter/oil pressure switches
1 - Oil filter
let 830
2 - O-ring
gine oil
renew if necessary; sup‐
plied together with valve
for oil pressure control -
N428- ⇒ Electronic
parts catalogue
3 - Bolt
❑ 8 Nm
trol - N428-
stalling valve for oil
pressure control N428 ”,
page 147
❑ Opening/closing pres‐
sure 2.15 ... 2.95 bar
❑ Blue insulation
❑ Checking ⇒ Vehicle di‐
agnostic tester
❑ If seal -6- is not available
separately, refer to ⇒
Electronic parts cata‐
logue ; renew oil pres‐
sure switch after remov‐
al
❑ Removing and installing ⇒ “4.2 Removing and installing oil pressure switch F22 ”, page 145
❑ 20 Nm
6 - Seal
❑ Renew if removed; check availability in ⇒ Electronic parts catalogue
❑ Cut seal open to renew


❑ Opening/closing pressure 0.3 ... 0.6 bar
❑ Green insulation
❑ If seal -8- is not available separately, refer to ⇒ Electronic parts catalogue ; renew oil pressure switch
after removal
⇒ “4.3 Removing and installing oil pressure switch for reduced oil pressure F378 ”, page 146
❑ 20 Nm
8 - Seal
❑ Renew if removed; check availability in ⇒ Electronic parts catalogue
❑ Cut seal open to renew

switch - F22-
♦ Articulated wrench, 24 mm - T40175-
Procedure
page 215 .
– Unscrew oil pressure switch - F22- .
• Renew seal after removing
page 144 .
– Fit new oil pressure switch immediately so that as little oil as
possible is lost.
page 215 .
Tightening torques
♦ ⇒ “4.1 Exploded view - oil filter/oil pressure switches”,
page 144


switch for reduced oil pressure - F378-
Procedure
– Unscrew oil pressure switch for reduced oil pressure - F378- .
• Renew seal after removing
page 144 .
possible is lost.
Tightening torques
page 144

♦ Oil pressure tester - V.A.G 1342-
Procedure
• Oil level has been checked and is OK ⇒ Maintenance ; Booklet
830

• Engine oil temperature at least 80 °C (radiator fan must have

run once).
– Remove oil pressure switch for reduced oil pressure - F378-
⇒ “4.3 Removing and installing oil pressure switch for reduced
oil pressure F378 ”, page 146 .
– Screw oil pressure tester - V.A.G 1342- into hole for oil pres‐
sure switch.
– Screw oil pressure switch for reduced oil pressure - F378- into
hole in oil pressure tester - V.A.G 1342- to seal it off.
– Start engine.
• Oil pressure at idling speed: at least 0.6 bar.
• Minimum oil pressure at 2000 rpm: 1.5 bar.
Assembling
– Install oil pressure switch for reduced oil pressure - F378-
oil pressure F378 ”, page 146 .

Procedure
noise insulation .
– Remove bolt -2- and detach valve for oil pressure control -
N428- .
• Check O-ring for damage ⇒ Item 2 (page 144) .
– Fit new valve for oil pressure control immediately so that as
little oil as possible is lost.
Tightening torques
page 144

19 – Cooling

auxiliary heater”, page 148
iliary heater”, page 149

vehicles without auxiliary heater


cooling circuit
2 - Radiator
3 - Radiator outlet coolant tem‐
perature sender - G83-
4 - Turbocharger
block
er - G62-
7 - Coolant pump
❑ With thermostat hous‐
ing
8 - Bleeder hole
- V488-
12 - ATF cooler
13 - Thermostat
gearbox
❑ Vehicles with dual
clutch gearbox only
14 - Suction-jet pump
16 - Filler cap

vehicles with auxiliary heater


cooling circuit
2 - Radiator
4 - Turbocharger
block
er - G62-
7 - Coolant pump
❑ With thermostat hous‐
ing
V55-
valve - N279-
10 - Bleeder hole
- V488-
14 - ATF cooler
15 - Thermostat
gearbox
❑ Vehicles with dual clutch gearbox only
16 - Suction-jet pump
18 - Filler cap


♦ Cooling system tester adapter - V.A.G 1274B/15- for filler cap,

version 1 (not illustrated)
♦ Cooling system tester adapter - V.A.G 1274/9- for filler cap
(version 2)
♦ Safety goggles
Procedure
• Engine must be warm.

WARNING

♦ Cover filler cap on expansion tank with a cloth and open

expansion tank.

sure of approx. 1.0 bar.
• The pressure should not drop more than 0.2 bar within 10 mi‐
nutes.
– If the pressure drops more than 0.2 bar, locate leak and elim‐
inate fault.
Note:
The drop in pressure of 0.2 bar within 10 minutes is caused by
the decrease in coolant temperature. The colder the engine is,
the less the pressure will fall. If necessary, check again when the
engine is cold.
Checking pressure relief valve in filler cap, version 1

V.A.G 1274 B/15- onto filler cap.


sure of approx. 2 bar.
Blue filler cap
• The pressure must be reduced to 1.6 ... 1.4 bar and kept at
this level.
Black filler cap
this level.
All filler caps
– Renew filler cap if pressure relief valve does not react as de‐
scribed.

V.A.G 1274/9- onto filler cap.
– Build up pressure with hand pump on cooling system tester.
Blue filler cap

• The pressure relief valve should open at a pressure of
1.4 ... 1.6 bar.
Black filler cap
1.6 ... 1.8 bar.
All filler caps
– Renew filler cap if pressure relief valve does not open as de‐
scribed.




♦ Safety goggles
Draining
WARNING

hot.

expansion tank.
insulation .

– Lift retaining clip -2- and disconnect coolant hose (bottom)
from radiator.
– Drain off coolant.
– Connect coolant hose with plug-in connector to radiator
page 183 .
Filling

Note

ical climates.
++ and G12evo.
tection.
the coolant.
ses.

to -25 °C
to -36 °C

Procedure
– Fill reservoir of -VAS 6096- with at least 10 litres of premixed
coolant (according to recommended ratio).
V.A.G 1274/8- .
Note:
rection of flow).

zone.
in the green zone.
sequent filling.
ess.
tained.
– Open valve -A-.
is then filled.


cedure.

hose.
– Push coolant hose back onto connection and secure with hose
clip.


engages).
– On vehicles with auxiliary heater, switch heater on (for about
30 seconds) and then off again.
– Start engine.
– Set temperature to “HI” in all zones.
– Start engine and run alternately at approx. 1500 rpm and max.
2800 rpm until radiator fan cuts in.
chamber cover .
WARNING

hot.
gine is cold.
engine is warm.
Tightening torques


page 165
page 165
⇒ “2.5 Removing cover of toothed belt for coolant pump”,
page 168
⇒ “2.8 Removing and installing toothed belt sprocket for coolant
pump”, page 175
”, page 176
2.1 Exploded view - coolant pump/thermostat
1 - Thermostat housing
installing thermostat for
small coolant circuit”,
page 174
2 - Thermostat
❑ For small coolant circuit
❑ Starts to open at approx.
105 ℃
installing thermostat for
small coolant circuit”,
page 174
3 - Gasket
4 - Coolant pump
stalling coolant pump”,
page 169
5 - Bolt
❑ Thread-forming
hand so that it is
que
sequence
⇒ Fig. ““Thermostat
housing to coolant
pump - tightening torque

and sequence”“ , page 162

6 - Gasket
7 - Toothed belt cover
❑ For toothed belt for coolant pump
❑ Removing and installing ⇒ “2.5 Removing cover of toothed belt for coolant pump”, page 168
8 - Bolt
❑ 20 Nm +90°
9 - Toothed belt
❑ Before removing, mark direction of rotation with chalk or felt-tip pen
❑ When reinstalling, check for damage and renew if necessary
10 - Toothed belt sprocket
⇒ “2.8 Removing and installing toothed belt sprocket for coolant pump”, page 175
11 - Bolt
❑ 8 Nm
12 - Bolt
❑ Thread-forming
⇒ Fig. ““Cover for thermostat to thermostat housing - tightening torque”“ , page 162
13 - Cover
❑ For thermostat
14 - Gasket
15 - Thermostat
❑ For large coolant circuit
❑ Different versions available ⇒ Electronic parts catalogue
❑ Starts to open at approx. 87 °C
⇒ “2.7.2 Removing and installing thermostat for small coolant circuit”, page 174
16 - Bolt
❑ Tightening torque and sequence ⇒ page 171

Thermostat housing to coolant pump - tightening torque and se‐

quence
– Tighten bolts in the sequence -A ... F- to 7 Nm.
Cover for thermostat to thermostat housing - tightening torque

– Tighten bolts for cover in the sequence -1 ... 4- to 7 Nm.

⇒ “2.2.1 Exploded view - charge air cooling pump V188 ”,
page 162
⇒ “2.2.2 Exploded view - auxiliary pump for heating V488 ”, page
164
2.2.1 Exploded view - charge air cooling pump - V188-


V188-
installing charge air
cooling pump V188 ”,
page 165
2 - Bracket
❑ For charge air cooling
pump - V188-
3 - Nut
❑ 8 Nm
4 - Nut
❑ 8 Nm

2.2.2 Exploded view - auxiliary pump for heating - V488-
1 - Bolt
❑ 9 Nm
V488-
installing auxiliary pump
for heating V488 ”, page
167
3 - Bolt
❑ 9 Nm
4 - Retainer
❑ For auxiliary pump for
heating - V488-
5 - Rubber grommet
6 - Bolt
❑ 2.7 Nm

1 - Retaining clip
ment
⇒ “2.10 Removing and
installing radiator outlet
coolant temperature
sender G83 ”,
page 178
3 - O-ring
4 - Bolt
❑ 8 Nm
er - G62-
stalling coolant temper‐
ature sender G62 ”,
page 176
6 - O-rings
❑ Renew after removal;
part of coolant tempera‐
ture sender - G62-

pump
”, page 165
⇒ “2.4.2 Removing and installing auxiliary pump for heating V488
”, page 167

ing pump - V188-


Removing
– Remove wheel spoiler (front left) ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liners; Exploded view -
– Clamp off coolant hoses using hose clamps -3094- , release
hose clips -2- and disconnect coolant hoses.
– Clamp off coolant hose with hose clamps up to 25 mm - 3094-
and detach coolant hose.
– Remove nut -3-, release retaining bracket and detach charge
air cooling pump - V188- .
Installing
Tightening torques
♦ ⇒ “2.2.1 Exploded view - charge air cooling pump V188 ”, page
162
2.4.2 Removing and installing auxiliary pump

for heating - V488-

Removing
Fitting location: beneath coolant expansion tank in vicinity of ple‐
num chamber partition panel
– Remove bolts -arrows- and detach auxiliary pump for heating
- V488- from bracket.
Installing
Tightening torques
♦ ⇒ “2.2.2 Exploded view - auxiliary pump for heating V488 ”,
page 164
2.5 Removing cover of toothed belt for cool‐

ant pump
Removing
page 34 .

– Remove bolt -2- and move fuel line -1- clear.

hose -6- clear.
- G31- .
– Press release tabs on both sides and disconnect hose -2-

leading to activated charcoal filter.
– Remove bolts -arrows-, detach crankcase breather hose -1-
and move it towards rear.
– Unscrew bolts -arrows- and remove cover -1- for toothed belt
for coolant pump and bracket -2-.
Installing
• Renew O-rings after removing. See note
page 34 .
Tightening torques


Removing
– Drain coolant
168 .
– Remove bolt -arrow- for coolant pipes -1-.


– Mark rotation direction of toothed belt with chalk or felt-tip pen
before removing.
– Detach coolant pump with toothed belt.
Installing
• Renew seal and O-rings after removal.
• When reinstalling toothed belt of coolant pump, check it for
damage and renew if necessary.
– Set cylinder 1 to TDC position (for description of procedure
refer to
⇒ “1.5 Removing and installing toothed belt”, page 86 ).

– Check that gaskets are correctly seated -arrows-.

– Lubricate seal for coolant pump lightly with coolant.
– Fit toothed belt so that it is centred and move coolant pump
into installation position.
– Tighten bolts to initial torque in the specified sequence:

Stage Bolts Tightening torque
2. -1 … 5- 10 Nm
– Loosen all bolts again by one turn.

– Apply torque wrench - VAS 6583- with hexagon key (10 mm)
-item 6- to coolant pump.
– Have a second mechanic apply a torque (clockwise) of 30 Nm
to coolant pump.
– For ease of handling, apply torque wrench - VAS 6583- verti‐
cally.
• Do not support torque wrench with your other hand.
• Do not apply excessive force to torque wrench.
• A second mechanic must tighten the bolts -2-, -1- and -5- while
the first mechanic maintains the torque on the torque wrench
- VAS 6583- .
– Keep coolant pump under tension.
– At the same time, have a second mechanic turn bolts securing
coolant pump anti-clockwise to an initial torque of 10 Nm, be‐
ginning with bolt -2-, -1- and -5- (»stage 3«).
• The necessary belt tension is attained by tightening bolts -2-,
-1- and -5-.
– Torque wrench - VAS 6583- can be removed after tightening
bolts to initial torque.
– Then tighten bolts to »stage 4«.
4a. -2, 1, 5- 10 Nm
4b. -3, 4, 5, 1, 2- 12 Nm
note the following:
168 .
Tightening torques
♦ Coolant pump ⇒ page 171

⇒ “2.7.1 Removing and installing thermostat for large coolant cir‐
cuit”, page 172
⇒ “2.7.2 Removing and installing thermostat for small coolant cir‐
cuit”, page 174
2.7.1 Removing and installing thermostat for

large coolant circuit

♦ Key - T10508-
Removing
– Drain coolant
page 34 .
– Unscrew bolts in the sequence -4 ... 1- and remove cover from
thermostat housing.

– Turn thermostat 45° anti-clockwise -arrow- using special

wrench - T10508- and detach.
Installing
– Lubricate gasket lightly with coolant.
– Bring thermostat into position with special wrench - T10508- ,
press down slightly and turn 45° clockwise as far as stop.
page 34 .
Tightening torques
♦ ⇒ Fig. ““Cover for thermostat to thermostat housing - tighten‐
ing torque”“ , page 162
2.7.2 Removing and installing thermostat for

small coolant circuit
Removing
– Remove bolts in the sequence -F … A-.
– Detach coolant pump from thermostat housing.
– Detach thermostat -2- from coolant pump -1-.

Installing
– Lubricate gasket lightly with coolant.

– Fit thermostat housing onto coolant pump.

• Centring pins on thermostat must be fitted in guides -arrows-
on coolant pump.
– Tighten bolts for thermostat housing
⇒ Fig. ““Thermostat housing to coolant pump - tightening tor‐
que and sequence”“ , page 162 .
Tightening torques
♦ ⇒ Fig. ““Thermostat housing to coolant pump - tightening tor‐
que and sequence”“ , page 162

sprocket for coolant pump
♦ Counterhold tool - T10172A- with adapters -T10172/2-
Removing
– Loosen bolt -1- using counterhold tool - T10172A- with adapt‐
ers -T10172/2- .
– Remove bolt and take off toothed belt drive sprocket -2-.

Installing
– Fit toothed belt drive sprocket:
• Grooves -1, 2- in camshaft are arranged asymmetrically.
• Openings -arrows- in toothed belt sprocket are also arranged
asymmetrically.
– Fit toothed belt sprocket onto camshaft so that asymmetrical
grooves are positioned exactly in centre of openings.
Tightening torques
♦ ⇒ “2.1 Exploded view - coolant pump/thermostat”, page 160

ature sender - G62-
Procedure
• Engine cold.
– To relieve residual pressure in cooling system, release fas‐
tener -arrow- and briefly open filler cap -1- on coolant expan‐
sion tank.
page 34 .
page 215 .



hose -6- clear.
- G31- .

of turbocharger.
– Press catalytic converter slightly to right side.


– Unscrew bolt -1- and pull off coolant temperature sender -
G62- -item 2-.
• If O-ring with support ring remains lodged in cylinder head, lift
it out using a piece of wire.
• Renew O-rings after removing. See note
– Fit new coolant temperature sender immediately so that as
little coolant as possible is lost.
page 250 .
page 215 .
page 34 .
Tightening torques
♦ ⇒ “2.3 Exploded view - coolant temperature senders”,
page 165

Procedure
• Engine cold.
sion tank.


– Detach retaining clip -1- and pull out radiator outlet coolant
temperature sender - G83- .
Tightening torques

3 Coolant pipes

must align.
1 - Coolant hoses
2 - Coolant pipes
stalling coolant pipes”,
page 180
3 - Coolant hoses
4 - Clip
5 - Bolt
❑ Thread-forming
hand so that it is
que
❑ 4 Nm
6 - Sealing plug


Removing
– Drain coolant
page 34 .
– Remove bolt -arrow- and move coolant hose -5- clear.
– Loosen hose clips -1, 2, 4- and disconnect coolant pipes.
Installing
• Renew seals/gaskets and O-rings after removal.
page 34 .
Tightening torques

4 Radiators/radiator fan

Radiator cowl and radiator fan ⇒ page 183
Connecting coolant hose with plug-in connector ⇒ page 183
1 - Radiator
stalling radiator”,
page 184
fer to
⇒ “3.5 Installing radia‐
tors and condensers”,
page 6
2 - Drain plug
❑ 1.5 … 3 Nm
3 - O-ring
4 - Coolant hose
tach
❑ Connecting
⇒ Fig. ““Connecting
coolant hose with plug-
in connector”“ ,
page 183
5 - O-rings
6 - Coolant hose
tach
❑ Connecting
page 183
7 - Coolant pipe
❑ To coolant expansion tank
❑ Connecting ⇒ Fig. ““Connecting coolant hose with plug-in connector”“ , page 183

8 - O-ring
9 - Rubber bush
❑ For radiator
10 - Sleeve
11 - Retaining pin
12 - Coolant hoses
⇒ “4.3 Removing and installing water radiator for charge air cooling circuit”, page 188
❑ If there are slight impressions on the fins, refer to ⇒ “3.5 Installing radiators and condensers”, page 6
14 - Air duct
15 - Rubber bush
❑ For radiator
17 - Bolt
❑ 5 Nm
18 - Support
19 - Bolt
❑ 4.5 Nm

– Check O-Ring -2- for damage and, if necessary, remove from
coolant hose -3-.
– If it is renewed, lightly lubricate new O-ring with coolant and fit
O-ring in coolant hose.
bly.
Radiator cowl and radiator fans

1 - Radiator cowl
stalling radiator cowl”,
page 190
2 - Bolt
❑ 5 Nm
unit - J293-
stalling radiator fan V7 ”,
page 191
4 - Air flow flap
catalogue

diator cowl.

Removing
WARNING

♦ Even when the ignition is switched off, the radiator fans
can start up without warning due to accumulated heat in
the engine compartment, etc.

noise insulation .
– A4 with LED and matrix LED headlights: Remove headlight
(left-side) ⇒ Electrical system; Rep. gr. 94 ; Headlights; Re‐
moving and installing headlights .
(bottom right).



⇒ “4.3 Removing and installing water radiator for charge air
cooling circuit”, page 188 .

G65- .
Caution
Risk of irreparable damage to radiator.

♦ The radiator must be renewed if the fasteners are dam‐
aged.
Risk of damage to refrigerant lines and hoses
♦ Do NOT stretch, kink or bend refrigerant lines and hoses.




Installing
• If there are slight impressions on the fins, refer to
⇒ “3.5 Installing radiators and condensers”, page 6 .
⇒ “4.3 Removing and installing water radiator for charge air
cooling circuit”, page 188 .
page 183 .
– If removed: Install headlight (left-side) ⇒ Electrical system;
Rep. gr. 94 ; Headlights; Removing and installing headlights .
Tightening torques



Removing
– Remove closure plate at bumper cover and air intake grille (left
Bumper (front); Removing and installing attachments .
– Move air guides -1, 3- (left and right) clear at water radiator for


3094- , lift hose clips -2- and disconnect hoses.
Caution

aged.

Installing
Bumper (front); Removing and installing attachments .

Removing
WARNING

♦ Unplug electrical connectors before working in vicinity of
radiator cowl.
rior; Rep. gr. 63 ; Bumper (front); Removing and installing
attachments .
noise insulation .
– Move coolant hoses to water radiator for charge air cooling
circuit clear.

– Unplug electrical connector -2- for radiator outlet coolant tem‐

multaneously -arrow- and detach radiator cowl downwards
from radiator.
Installing
Tightening torques

V7-
Removing

Caution
Risk of noise due to imbalance in fan wheel.

♦ Do not remove balancing clamps from fan wheel.
Installing
Tightening torques

1 Turbocharger
⇒ “1.3 Removing and installing charge pressure positioner V465
”, page 200

Turbocharger
1 - Connection
2 - Bolt
❑ 8 Nm
3 - Bolt
❑ Always renew all three
bolts if one or more are
loose.
❑ 8 Nm +45°
4 - Charge pressure positioner
- V465-
stalling charge pressure
positioner V465 ”,
page 200
❑ After renewal, perform
adaptions listed in Gui‐
ded Function “01 - Func‐
tions, engine mechan‐
ics” ⇒ Vehicle diagnos‐
tic tester
5 - Connecting rod
6 - Securing clips
7 - Turbocharger
❑ Can only be renewed to‐
gether with exhaust
manifold
stalling turbocharger”,
page 196
8 - Heat shield
9 - Bolt
❑ 8 Nm
10 - Bolt
❑ 20 Nm
11 - Seal
1. Turbocharger 193
12 - Nut
❑ Tightening torques and sequence
⇒ Fig. ““Turbocharger - tightening torques and sequence”“ , page 194
13 - Gasket
14 - O-ring
Turbocharger - tightening torques and sequence

– Tighten nuts -arrows- in stages as follows:
1. Screw in by hand until contact is made (work in clock‐
wise direction)
2. 10 Nm (work in clockwise direction)
3. 14 Nm (work in clockwise direction)
Pipes and lines on turbocharger

1 - Bolt
❑ 9 Nm
2 - Coolant lines
❑ Supply and return
3 - Bolt
❑ 9 Nm
4 - Gasket
5 - O-rings
6 - Bolt
❑ 9 Nm
7 - Oil supply line
8 - Bolt
❑ 9 Nm
9 - O-ring
10 - Bolt
❑ 9 Nm
11 - Turbocharger
❑ Can only be renewed to‐
gether with exhaust
manifold
page 196
12 - Crankcase breather pipe
13 - Bolt
❑ 9 Nm
14 - O-rings
15 - O-ring
16 - Oil return line
17 - Bolt
❑ 9 Nm
18 - Bolt
❑ 9 Nm
1. Turbocharger 195
Caution
If the turbocharger has suffered mechanical damage (e.g.

damaged compressor wheel), it is not sufficient merely to fit a
new turbocharger. The following work must be performed in
order to avoid further damage:
♦ Check air cleaner housing, air filter element and air hoses
for dirt and foreign particles.
♦ Check the entire charge air system (including the charge
air cooler) for foreign matter.
♦ If foreign matter is found in the charge air system, clean
all relevant ducts and hoses and renew charge air cooler
if necessary.


Removing
– Observe rules for cleanliness
⇒ “3.1 Rules for cleanliness”, page 5 .
page 34 .
page 215 .

hose -6- clear.
- G31- .
– Remove bolt -bottom arrow-, detach crankcase breather hose

-1- and move it towards rear.
1. Turbocharger 197

– Remove bolts -arrows- and move coolant lines -1- to one side.

– Unplug electrical connector -arrow- for starter.
– Remove bolts -arrows- and -2-.

– Detach oil supply line -1-, press it slightly to one side an detach
oil return line -3-. (Shown with engine support removed.)
– Seal off open lines and connections with clean plugs from en‐
gine bung set - VAS 6122- .


of turbocharger.

– Remove nuts -arrows- and detach turbocharger -1-.
Installing
• Renew seal, gasket and O-rings after removal. See note
⇒ Item 4 (page 217) .
• Fill turbocharger with engine oil at connection for oil supply
line.
• After installing the turbocharger, allow the engine to idle for
approx. 1 minute without pressing the accelerator to ensure
that the turbocharger is supplied with oil.
page 250 .
page 215 .
– Check coolant level and top up if necessary ⇒ page 159 .
page 34 .
– If a turbocharger with a new charge pressure positioner -
V465- has been installed, select Guided Functions on ⇒ Ve‐
hicle diagnostic tester and perform function 0001 - Adapt/
set charge pressure adjuster -V465 .
Tightening torques
1. Turbocharger 199

sure positioner - V465-
Removing
page 34 .
– Loosen screw-type clip -2- and detach air pipe -1- from air filter
housing.
– Unscrew bolt -arrow-, pivot air pipe with connection to left side
and detach it.

– Detach securing clip -2-.
– Remove bolts -arrows- and detach charge pressure positioner
- V465- -3-.
Installing
page 34 .
– If charge pressure positioner - V465- has been renewed, se‐
lect Guided Functions on ⇒ Vehicle diagnostic tester and
perform function 0001 - Adapt/set charge pressure po-
sitioner V465 .
Tightening torques
♦ ⇒ “2.2 Exploded view - hose connections for charge air sys‐
tem”, page 202

2 Charge air system

page 202
page 203

• Check that all air pipes, air hoses and vacuum lines are cor‐
rectly fitted and that there are no leaks before carrying out tests
or repairs.
1 - Intake manifold
⇒ “3.2 Removing and installing
intake manifold”, page 219
2 - Bolt
❑ Tightening torques
3 - Bracket
❑ For air pipe
4 - O-rings
❑ Renew after removal
(apply thin coating of
clean engine oil prior to
installation)
5 - Connection
6 - Fuel line
7 - Bolt
❑ Thread-forming
hand so that it is
que
❑ 4 Nm
8 - Air pipe
9 - Bolt
❑ Thread-forming
ers break off
❑ 4 Nm
❑ Removing and installing ⇒ “2.3 Removing and installing charge pressure sender G31 ”, page 203
11 - O-ring
❑ If necessary, renew after removing

12 - O-ring
❑ Renew after removal (apply thin coating of clean engine oil prior to installation)
13 - Gasket
14 - Sealing strip
❑ Removing and installing ⇒ “2.4 Removing and installing charge air cooler”, page 203
❑ If renewed, refill system with fresh coolant
16 - Bolt
❑ Thread-forming
❑ 15 Nm
17 - Coolant hoses

charge air system
• Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
• The screw sections of used screw-type clips must be sprayed
with rust remover prior to fitting so that the air hoses can be
attached securely to the hose connections.
Tightening torque for
1- Hose clip with width -a- = 13 mm: 5.5 Nm
2- Hose clip with width -b- = 9 mm: 3.4 Nm


sure sender - G31-
Removing
page 34 .
– Release catches -arrows- and detach charge pressure sender
- G31- .
Installing
• If necessary, renew O-ring after removal.
Note:
Repair solution if fasteners have broken off: Secure charge pres‐
sure sender - G31- with two bolts, refer to ⇒ Electronic parts
catalogue .
page 34 .
Tightening torques

er

Removing
• Engine cold.
page 34 .
clear.
switch - F66- .
side.

one side.

– Remove bolts -arrows- and detach charge air cooler.
– Seal off open passages in the intake system with clean cloths.

Installing
• If there are slight impressions on the fins, refer to
⇒ “3.5 Installing radiators and condensers”, page 6 .
• Renew sealing strip and gasket after removing.
– Attach sealing strip -1- to charge air cooler -2- (-arrow-).
– Insert gasket into groove on intake manifold.
page 183 .
page 34 .
Tightening torques

♦ Charge air system tester - V.A.G 1687-
Procedure
ments .


– Being careful not to damage it, detach vacuum hose -2-.
– Detach air pipe -1-.
– Connect adapter - V.A.G 1687/15- with -V.A.G 1687/11- to

turbocharger.
– Connect hose -1- of charge air system tester -V.A.G 1687- to
adapter.

Prepare charge air system tester - V.A.G 1687- as follows:

– Unscrew pressure control valve -2- completely and close
valves -3- and -4-.
• Make sure knob is pulled out before turning pressure control
valve -2-.
– Using a commercially available connection piece, connect
charge air system tester - V.A.G 1687- to compressed air -1-.
– If there is water in sight glass, remove drain plug -6- and drain
water.
– Open valve -3-.
Caution
Risk of damage if pressure is set too high.

♦ The pressure must not exceed 0.2 bar.
– Adjust pressure to 0.2 bar via pressure control valve -2-.

– Open valve -4- and wait until test system is pressurised. If
necessary, adjust pressure to 0.2 bar again.
– Check charge air system for audible leaks or leaks that can be
felt with the hand; apply commercially available leak detecting
spray or use ultrasonic tester - V.A.G 1842- (refer to ⇒ oper‐
ating manual ).
Note:
A small amount of air escapes through the valves and enters the
engine. Therefore it is not possible to perform a pressure retention
test.
– Release pressure in test circuit by detaching hose coupling
from adapter before removing adapter.
Assembling
necessary.
ments .
Tightening torques
tem”, page 202


1 Injection system
page 208


ic converter - G130- and Lamb‐
da probe heater 1 after catalyt‐
ic converter - Z29-
❑ Exploded view
⇒ “7.1 Exploded view -
Lambda probe”,
page 239
G604-
❑ For vehicles with man‐
ual gearbox
of gear detection sensor
-G604- ”“ , page 210
sender 2 - G185-
⇒ Fig. ““ Accelerator po‐
sition sender -G79- and
accelerator position
sender 2 -G185- ”“ ,
page 209
of brake light switch -F-
”“ , page 209
G476-
with manual gearbox
of clutch position sender -G476- ”“ , page 210
6 - Auxiliary pump for heating - V488-
❑ Exploded view ⇒ “8.1 Exploded view - engine control unit”, page 241
❑ Exploded view ⇒ “2.2 Exploded view - electric coolant pump”, page 162


⇒ Fig. ““Fitting location of radiator outlet coolant temperature sender -G83- ”“ , page 210
⇒ Fig. ““Fitting location of left electrohydraulic engine mounting solenoid valve -N144- ”“ , page 210
12 - Lambda probe - G39- and Lambda probe heater - Z19-
❑ Exploded view ⇒ “7.1 Exploded view - Lambda probe”, page 239
Fitting location of auxiliary pump for heating - V488-

• In engine compartment, beneath coolant expansion tank in vi‐
cinity of plenum chamber partition panel
1 - Electrical connector for auxiliary pump for heating - V488-
Exploded view
⇒ “2.2.2 Exploded view - auxiliary pump for heating V488 ”, page
164 .
Accelerator position sender - G79- and accelerator position send‐

er 2 - G185-
♦ In accelerator pedal module -3- The accelerator position send‐
er - G79- and accelerator position sender 2 - G185- are
integrated in the accelerator pedal module and cannot be re‐
newed individually.

inder


♦ In plenum chamber on driver's side.

♦ On right of gearbox.
Removing and installing ⇒ Gearbox; Rep. gr. 34 ; Selector
mechanism

G83-
• In coolant connection on radiator at bottom left.
sender - G83-
Exploded view
Fitting location of left electrohydraulic engine mounting solenoid

valve - N144-
Pfeil - Electrical connector for electrohydraulic engine mounting
solenoid valve


N205-
❑ Exploded view
camshaft housing”,
page 99
valve 1 - N318-
❑ Exploded view
camshaft housing”,
page 99
stage - N70-
❑ Exploded view
ignition system”,
page 254
stage - N127-
❑ Exploded view
ignition system”,
page 254
stage - N291-
❑ Exploded view
ignition system”,
page 254
stage - N292-
❑ Exploded view
ignition system”,
page 254
8 - Hall sender - G40- (camshaft position sensor)
❑ Exploded view ⇒ “6.1 Exploded view - high-pressure pump”, page 234
10 - Intake manifold pressure sender - G71-
❑ Exploded view ⇒ “3.1 Exploded view - intake manifold”, page 217


sender - G266-
❑ Exploded view
sump/oil pump”,
page 129
❑ Exploded view
ignition system”,
page 254
❑ Exploded view
oil filter/oil pressure
switches”, page 144
G247-
❑ Exploded view
fuel rail with injectors”,
page 223
❑ Exploded view
page 223
❑ Exploded view
page 223
❑ Exploded view ⇒ “4.1 Exploded view - fuel rail with injectors”, page 223
❑ Exploded view ⇒ “4.1 Exploded view - fuel rail with injectors”, page 223
❑ with


er - G62-
❑ Exploded view
coolant temperature
senders”, page 165
- V465-
❑ Exploded view
turbocharger”,
page 193
❑ Exploded view
trol - N428-
❑ Exploded view

2 Air cleaner
1 - Snow screen
2 - Air duct
❑ On lock carrier
its or dirt
3 - Sealing element
4 - Water drain
❑ Clean
6 - Not fitted
its or dirt
ing”, page 215
❑ Use genuine air filter el‐
ement ⇒ Electronic
parts catalogue
❑ Change intervals ⇒
Maintenance tables
let 830
9 - Bolt
❑ Thread-forming
hand so that it is screwed into old thread. Then tighten bolt to torque
❑ 3.5 Nm
11 - Air pipe
❑ Tightening torque for screw-type clips
⇒ “2.2 Exploded view - hose connections for charge air system”, page 202
12 - Bolt
❑ Thread-forming
❑ 1.5 Nm

13 - Heat shield
14 - Air duct
❑ On lock carrier
15 - Bolt
❑ Thread-forming
❑ 2.5 Nm

housing
Removing
ments .
2. Air cleaner 215


Installing
• Use silicone-free lubricant when fitting air hose.
housing.
ments .
Tightening torques
tem”, page 202

3 Intake manifold
220
1 - Intake manifold
❑ Combined with charge
air cooler
stalling intake manifold”,
page 219
2 - Bolt
sequence
⇒ Fig. ““Intake manifold
- tightening torque and
3 - Gaskets
4 - O-rings
renew if necessary
❑ Allocation
⇒ Fig. ““Allocation of O-
rings to
connection -1-”“ ,
page 218
5 - Connection
❑ From activated charcoal
filter
6 - O-ring
❑ If necessary, renew af‐
ter removing
7 - Intake manifold pressure
sender - G71-
stalling intake manifold
pressure sender G71 ”, page 230
8 - Bolt
❑ Thread-forming
❑ Repair method if fasteners break off
❑ 1.5 Nm
9 - Retaining clip
❑ For air pipe
10 - Bolt
❑ Thread-forming

❑ 7 Nm
❑ Removing and installing ⇒ “3.3 Removing and installing throttle valve module J338 ”, page 220
❑ Cleaning ⇒ “3.4 Cleaning throttle valve module”, page 221
❑ After renewal, perform adaptions listed in Guided Function “01 - Functions, engine mechanics” ⇒ Vehicle
diagnostic tester
12 - Seal
13 - Vacuum line
14 - O-ring
❑ Check for damage and renew if necessary
15 - Hose
Intake manifold - tightening torque and sequence

1. Starting in centre, screw in bolts alternately by hand until
they make contact
2. Starting in centre, screw in bolts alternately: 8 Nm
Allocation of O-rings to connection -1-

– Check O-rings for damage and renew if necessary.
2 - Blue O-ring
3 - O-ring, green


Removing
– Remove throttle valve module - J338-
⇒ “3.3 Removing and installing throttle valve module J338 ”,
page 220 .
– Unplug electrical connectors -1 and 2- and move electrical
wiring clear.
– Press release tabs on both sides and disconnect hose -3- for
activated charcoal filter system.

one side.
– Disconnect crankcase breather hose -arrow-.


– Detach intake manifold -2-; at the same time pull off charge air
cooler -1-.
– Block off intake ports with clean cloths.
Installing
• Check gaskets/seals and O-rings for damage and renew as
necessary; see notes
⇒ “3.1 Exploded view - intake manifold”, page 217 .
necessary.
– Install throttle valve module - J338- ⇒ page 220 .
Tightening torques
♦ ⇒ Fig. ““Intake manifold - tightening torque and sequence”“ ,
page 218

module - J338-
Removing
page 34 .

hose -6- clear.
- G31- .


– Remove bolts -arrows- and detach throttle valve module -
J338- -item 1- with adapter -2-.
Installing
• Check gaskets/seals and O-rings for damage and renew as
necessary; see notes
⇒ “3.1 Exploded view - intake manifold”, page 217 .
page 34 .
– If throttle valve module - J338- was renewed, perform adap‐
tions listed in Guided Function “01 - Functions, engine me‐
chanics” ⇒ Vehicle diagnostic tester.
Tightening torques

Carbon deposits and dirt in the limit stop can lead to incorrect
adaption values.
♦ Acetone (commercially available)
♦ Brush
Procedure
page 220 .
• Take care not to scratch the throttle valve housing when clean‐
ing it.
– Open throttle valve by hand and lock it in open position with a
wedge (plastic or wood) -arrow-.
WARNING
Acetone is highly flammable.

♦ Please observe all accident prevention regulations and
safety precautions when handling flammable liquids.
♦ Do not use compressed air when cleaning the throttle
valve.
♦ Wear safety goggles and protective clothing to avoid any
contact with skin and risk of injury.

– Clean throttle valve housing thoroughly, especially around the

points -arrows- where the throttle valve closes, using com‐
mercially available acetone and a small brush.
– Wipe out throttle valve housing with a lint-free cloth.
– Allow acetone to flash off completely.
– Install throttle valve module - J338-
page 220 .
– Erase learnt values and perform adaption ⇒ Vehicle diagnostic
tester.

4 Injectors

G247-
❑ Checking
⇒ “5.3 Checking fuel
pressure sender G247 ”,
page 231
stalling fuel pressure
sender G247 ”,
page 230
❑ Lubricate taper and
threads lightly with
clean engine oil
❑ 22 Nm
2 - Fuel rail
stalling fuel rail”,
page 224
3 - High-pressure pipe
❑ Can be reused
❑ Connections must not
be damaged
❑ Do not alter shape
stalling high-pressure
pipe”, page 236
❑ Lubricate threads lightly
with clean engine oil
❑ 16 Nm + 45°
4 - Bolt
❑ 8 Nm + 90°
5 - Support ring
❑ Via this support ring, the fuel rail exerts the clamping force that holds the injector in the cylinder head
❑ Clipped to -item 8-
6 - O-ring
❑ Lubricate lightly with clean engine oil
4. Injectors 223
7 - Spacer ring
8 - Injector
❑ Removing and installing ⇒ “4.3 Removing and installing injectors”, page 224
9 - Combustion chamber ring seal
❑ Do not apply grease or use any other lubricants
❑ Renewing ⇒ “4.3 Removing and installing injectors”, page 224

Removing
– Remove intake manifold
page 236 .
– Place a cloth underneath to catch escaping fuel.
– Remove bolts -arrows- and pull fuel rail off injectors.
– If necessary, unplug electrical connectors at injectors.
Installing
• Renew support rings after removing.
– Apply mountings on fuel rail onto injectors.
– Press fuel rail onto injectors as far as stop (first on right side,
then on left side).
– Press fuel rail down firmly in vicinity of bracket and hold, and
screw bolts in up to base.
– Tighten bolts to specified torque.
• The fuel rail must not be pulled on using the bolts.
page 236 .
– Install intake manifold
Tightening torques
♦ ⇒ “4.1 Exploded view - fuel rail with injectors”, page 223


♦ Tool set for FSI engines - T10133 C- with -T10133/16A- and

-T10133/19-
Removing
• Remove injection valves only when the engine is cold.
– Remove fuel rail
⇒ “4.2 Removing and installing fuel rail”, page 224 .
– Remove O-ring -4- from injector -2-.
– Unplug electrical connector from corresponding injector.
– Use screwdriver -2- to prise support ring -1- off injector.
4. Injectors 225
– Slide sleeve -T10133/18- over injector.

– Carefully knock against stop sleeve several times with a plas‐
tic hammer -1- to loosen injector.
– Apply puller -T10133/19- to groove on injector.

– Attach puller -T10133/16A- .
– Pull out injector by screwing bolt -1- in with torque wrench.
• The torque must not exceed 5 Nm to avoid irreparable damage
to the injector.
– If injector does not come loose after 5 Nm is reached, remove
puller and repeat procedure using stop sleeve to loosen in‐
jector.
– Carefully remove old combustion chamber ring seal -1-. To do

so, cut open seal using knife or prise open with small screw‐
driver and then detach.
• Take care not to damage the groove on the injector.
– Repeat procedure for each injector.
Installing
• Use complete repair set when installing.
• Renew support ring.
• Renew combustion chamber ring seal before re-installing in‐
jector.
• Lightly lubricate O-rings for injectors with clean engine oil.

– Clean bore in cylinder head with nylon cylinder brush -

T10133/4- .
– When re-installing an injector, clean any combustion residue
off groove for combustion chamber ring seal and injector stem
with a clean cloth.
– Fit assembly cone -T10133/5- with new combustion chamber

ring seal -1- onto injector -2-.
– Using assembly sleeve -T10133/6- , push combustion cham‐

ber ring seal onto assembly cone -T10133/5- as far as it will
go.
– Turn round assembly sleeve -T10133/6- and slide combustion

chamber ring seal into groove.
4. Injectors 227
Note:
The combustion chamber ring seal is widened when it is pushed
onto the injector. After pushing it on, it therefore has to be com‐
pressed again. This is done in two stages, as described below.
– Push calibration sleeve -T10133/7- onto injector as far as it will
go and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve -T10133/7- off again by turning it in the
opposite direction.

opposite direction.
– Before installing new injector -2-, lubricate new O-ring -4- light‐
ly with clean engine oil.
• The combustion chamber ring seal -1- must not be lubricated.
– Press injector by hand as far as it will go into aperture in cyl‐
inder head (aperture must be free of oil and grease).
• It should be possible to insert the injector easily; if necessary
wait until the combustion chamber ring seal has contracted
sufficiently.
– Ensure that the injector is properly seated in the cylinder head.
• Electrical connector of injector must engage in recess in cyl‐
inder head.
– Fit support ring onto injector.
– Install fuel rail
⇒ “4.2 Removing and installing fuel rail”, page 224 .
– Connect vehicle diagnostic tester and perform the function
“Delete injector adaption values” in Guided Functions.

♦ Ultrasonic cleaning unit - VAS 6418-
♦ Mounting plate for injectors - VAS 6418/1-
♦ Cleaning fluid - VAS 6418/2-

Procedure
– Close drain tap -arrow- on ultrasonic cleaning unit - VAS 6418-
(located on right side of housing).
– Fill up ultrasonic cleaning unit - VAS 6418- .
• Ratio of cleaning fluid: 2,100 ml of tap water which has been
allowed to settle for a few minutes and 20 ml of cleaning fluid
- VAS 6418/2-
• The ideal fluid level is approx. 1 ... 4 mm above the base of
the mounting plate. The ultrasonic cleaning unit - VAS 6418-
can be damaged if the fluid level is too low.
– Remove injectors
⇒ “4.3 Removing and installing injectors”, page 224 .
– Place mounting plate for injectors - VAS 6418/1- on top of

cleaning unit.
• It is important to read the safety notes in the operating instruc‐
tions before switching on the ultrasonic cleaning unit - VAS
6418- .
– Insert FSI injectors all the way into guides of mounting plate
for injectors - VAS 6418/1- .
– Switch on cleaning unit by pressing on/off button -C-.

– Select a cleaning time of 30 minutes with rotary control -A-.
– Set rotary control -B- to a temperature of 50°C.
– Press ► button -D- to start cleaning procedure.
• The actual cleaning process commences when the tempera‐
ture reaches at least 50 ℃ and must last for at least 30
minutes.
– Install injectors with new combustion chamber seal
4. Injectors 229

⇒ “5.1 Removing and installing intake manifold pressure sender
G71 ”, page 230
230

Removing
page 34 .
– Release fasteners -arrows- and remove intake manifold pres‐
sure sender - G71- .
Installing
• If necessary, renew O-ring after removal.
Note:
Repair solution if fasteners have broken off: Secure intake mani‐
fold pressure sender - G71- with two bolts, refer to ⇒ Electronic
parts catalogue .
page 34 .
Tightening torques

sender - G247-
♦ Socket, 27 mm - T40218-

Removing
WARNING

hot.

– Unscrew fuel pressure sender - G247- -item 2- using socket,
27 mm - T40218- .
Installing
• Lubricate taper and threads lightly with clean engine oil
Tightening torques

♦ Test instrument adapter/DSO (3-pin) - VAS 5570-
♦ Pressure sensor tester - VAS 6394-

Procedure
– Remove fuel pressure sender - G247-
⇒ “5.2 Removing and installing fuel pressure sender G247 ”,
page 230 .

– Lubricate taper seal of adapter -VAS 6394/3- with clean en‐

gine oil and screw into fuel rail (22 Nm).
– Unscrew plug -2- and screw fuel pressure sender - G247- into
tester -VAS 6394/1- .
– Connect pressure line -1- of tester to adapter - VAS 6394/3- .
– Connect vehicle and fuel pressure sender - G247- electrically
using test instrument adapter/DSO (3-pin) - VAS 5570- .

– Switch on tester -VAS 6394/1- by pressing button -A- once

briefly.
• The digital pressure gauge - VAS 6394/1- should indicate
0 bar.
– If different value is shown, zero the tester by pressing button
-C- briefly.
– Connect vehicle diagnostic tester .
– Start engine and run at idling speed.
– Select “Engine electronics” in vehicle self-diagnosis.
– Select “Measured values”.
– Select “Fuel pressure” from list.
– Compare fuel pressure indicated on tester -VAS 6394/1- with
actual value displayed on vehicle diagnostic tester .
– Observe fuel pressure displayed on vehicle diagnostic tester.
• The pressure readings must not deviate by more than 5 bar.
– If the deviation is more than 5 bar, fit a new fuel pressure
sender - G247- to test it.
WARNING

♦ Release pressure (wrap clean cloth around connection
– Screw a new fuel pressure sender - G247- into pressure gauge

- VAS 6394/1- .
– Repeat the test with the new fuel pressure sender - G247- and
compare the two pressure values.
– If measured values are still not the same, check electrical con‐
nection between fuel pressure sender - G247- and engine
control unit ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
– If measured values are now the same, install new fuel pres‐
sure sender - G247-
⇒ “5.2 Removing and installing fuel pressure sender G247 ”,
page 230 .

⇒ “6.3 Removing and installing high-pressure pipe”, page 236
1 - Bolt
sequence
⇒ Fig. ““High-pressure
pump - tightening torque
and sequence”“ ,
page 235
❑ With fuel metering valve
- N290-
❑ Do not dismantle
pump”, page 235
3 - O-ring
❑ When installing lubri‐
cate lightly with clean
engine oil
4 - Roller tappet
❑ When installing lubri‐
cate lightly with clean
engine oil
5 - Fuel return line
6 - Spring-type clip
❑ Can be reused
pipe”, page 236
❑ Connections must not be damaged
❑ Lubricate threads of union nuts with clean engine oil
❑ 16 Nm +45°

High-pressure pump - tightening torque and sequence

angle.
To prevent flange of high-pressure pump from being deformed
during installation, fit high-pressure pump as follows:
2. Tighten one turn alternately until flange of high-pressure
pump makes contact with camshaft housing
3. 8 Nm

pump
♦ Wrench, 21 mm - T40263-
♦ Safety goggles
Removing
• Engine cold.
page 236 .


– Release hose clip -2- and detach fuel supply hose.
– Unscrew bolts -arrows- and detach high-pressure pump with
roller tappet.
Installing
• Renew O-ring and spring-type clip after removal.
angle. See note ⇒ Item 7 (page 234) .
– Check roller tappet -1- for damage and renew if necessary.
– Lightly lubricate roller tappet with oil and insert it so that lug
-arrow A- slides into guide notch -arrow B-.

– Have a second mechanic turn crankshaft with wrench, 21 mm
- T40263- , adapter - T40314- and socket, 21 mm in direction
of normal engine rotation -arrow- until roller tappet in camshaft
housing reaches its lowest point.
– Lubricate O-ring lightly with clean engine oil when installing.
– Insert high-pressure pump with O-ring and tighten bolts in
stages.
– Secure fuel hose with spring-type clip.
page 236 .
– Check fuel system for leaks.
Tightening torques
♦ ⇒ Fig. ““High-pressure pump - tightening torque and se‐

pipe

♦ Tool insert - T10395/3- from tool set - T10395 A-
♦ Safety goggles
Removing
page 220 .
WARNING

• Put on safety goggles.
• Put on protective gloves.
• Release pressure (wrap a clean cloth around connection


– Unscrew union nuts -arrows- and detach high-pressure pipe
-1-.
Installing
• High-pressure pipe does not have to be renewed after remov‐
al. See note ⇒ Item 7 (page 234) .
– Lubricate threads of union nuts with clean engine oil.
– Hand-tighten union nuts for high-pressure pipe (make sure
that pipe is not under tension).
– First tighten union nut at high-pressure pump and then at fuel
rail.
– Install throttle valve module - J338-
page 220 .
Tightening torques
♦ ⇒ “6.1 Exploded view - high-pressure pump”, page 234

7 Lambda probe
❑ Exploded view
emission control sys‐
tem”, page 249
stalling Lambda probe”,
page 239
❑ Fitting instructions
⇒ page 240
❑ 55 Nm
page 239
❑ Fitting instructions
⇒ page 240
❑ 55 Nm

7. Lambda probe 239

Removing
page 34 .
– Unplug corresponding electrical connector:
1- For Lambda probe - G39- and Lambda probe heater - Z19-
2- For Lambda probe after catalytic converter - G130- and
Lambda probe heater 1 after catalytic converter - Z29-
– Unscrew corresponding Lambda probe using a tool from

1- Lambda probe after catalytic converter - G130-
2- Lambda probe - G39-
Installing
• New Lambda probes are coated with an assembly paste. The
paste must not get into the slots on the Lambda probe body.
• In the case of a used Lambda probe grease only the thread
with high-temperature paste. The paste must not get into the
slots on the Lambda probe body. High-temperature paste ⇒
Electronic parts catalogue
• The electrical wiring of the lambda probe must be secured at
the original locations when installing. The wiring must NOT
come into contact with the exhaust pipe.
page 34 .
Tightening torques
♦ ⇒ “7.1 Exploded view - Lambda probe”, page 239


⇒ “8.2 Removing and installing motor control unit J623 ”,
page 241
1 - Bolt
❑ 9 Nm
2 - Mounting
J623-
stalling motor control
unit J623 ”, page 241
4 - Bolt
❑ 9 Nm
8.2 Removing and installing motor control

unit - J623-
Removing
• If engine control unit is renewed, run “01 - Replace control unit”
in Guided Functions mode of ⇒ Vehicle diagnostic tester.


J623- -item 2-.
Installing
– If engine control unit - J623- was renewed, perform adaptions
listed in Guided Function “01 - Functions, engine mechanics”

1 - Clamp (rear)
free of stress
⇒ “1.5 Stress-free align‐
ment of exhaust sys‐
tem”, page 247
⇒ Fig. ““Installation po‐
sition - rear clamp”“ ,
page 244
2 - Rubber mounting
3 - Bolt
❑ 23 Nm
4 - Bracket
5 - Centre silencer
tem”, page 247
6 - Bolt
❑ 23 Nm
7 - Bracket
8 - Rubber mounting
9 - Front silencer
❑ Do not bend flexible joint
more than 10° - other‐
wise it can be damaged
❑ Install flexible joint so that it is not under tension.
❑ Take care not to damage wire mesh on flexible joint
❑ Removing and installing ⇒ “1.3 Removing and installing front silencers”, page 245
10 - Gasket

11 - Nut
❑ 23 Nm
12 - Clamp (front)
❑ Before tightening, align exhaust system so it is free of stress
❑ Installation position ⇒ Fig. ““Installation position - front clamp”“ , page 244
13 - Bracket
14 - Bolt
❑ 23 Nm
16 - Rear silencer
purposes
❑ Removing and installing ⇒ “1.4 Removing and installing silencers”, page 246
❑ Align exhaust system so it is free of stress ⇒ “1.5 Stress-free alignment of exhaust system”, page 247


tom of clamp.

in order to renew the centre and rear silencers separately.

Procedure
– Cut through exhaust pipe at right angle at notch -arrow- using

– Fit clamp
⇒ Fig. ““Installation position - rear clamp”“ , page 244 .

Removing

Caution
Risk of damage to flexible joint.

♦ Do not bend flexible joint more than 10°.
♦ Install flexible joint so that it is not under tension.
♦ Take care not to damage wire mesh on flexible joint.

Installing
• Renew gaskets, seals and self-locking nuts after removal.
Tightening torques

Removing

– Depending on equipment version: Remove diagonal strut (left-

side) ⇒ General body repairs, exterior; Rep. gr. 66 ; Under‐
body trim; Exploded view - underbody trim .
– Disengage rubber mounting -4-.
WARNING

♦ A second mechanic is required for removal of the rear si‐
lencer.

Installing
Tightening torques

Procedure

– Position clamp at front
⇒ Fig. ““Installation position - front clamp”“ , page 244 and
tighten bolted connections evenly.

– Check clearance between tailpipe and bumper:

Tightening torques

Procedure
– Start the engine and run at idling speed.
– Plug tailpipe during leak test (e.g. with cloth or plugs).
– Listen for noise at the connection points of cylinder head/ex‐
haust manifold, turbocharger/front exhaust pipe etc. to locate
any leaks.
– Rectify any leaks that are found.


2.1 Exploded view - emission control system
❑ Protect against knocks
and impact
stalling catalytic con‐
verter”, page 250
tem”, page 247
❑ Exploded view
Lambda probe”,
page 239
❑ Exploded view
Lambda probe”,
page 239
4 - Screw-type clip
⇒ Fig. ““Screw-type clip
- installation position”“ ,
page 250
sequence
⇒ Fig. ““Installing cata‐
lytic converter - tighten‐
ing torque and se‐
5 - Seal
6 - Turbocharger
❑ Exploded view ⇒ “1.1 Exploded view - turbocharger”, page 193

Screw-type clip - installation position

– Position screw-type clip as shown.
Installing catalytic converter - tightening torque and sequence

1. – Position screw-type clip on • Do not bend clip
intake funnel of turbo‐ open.
charger.
2. – Guide catalytic converter • Protrusion -1- on cat‐
into installation position. alytic converter must
engage in groove -2-
on turbocharger.
3. – Move screw-type clip into

installation position (do not
tighten).
3. – Fit bolt -4- by hand without
tightening.
– Tighten screw-type clip. 15 Nm
4. – Tighten bolts -4-. 20 Nm
Components of mountings (front) for catalytic converter on gear‐

box
1- Spacer sleeve
3- Washer
4- Bolt, 23 Nm
5- Bolt, 23 Nm
6- Spacer sleeve
7- Buffer
8- Bracket
9- Spacer sleeve

verter
♦ High-temperature paste ⇒ Electronic parts catalogue
Removing


noise insulation .
⇒ “1.3 Removing and installing front silencers”, page 245 .
– Unscrew bolts -1, 2- and detach retainer.
page 215 .
page 34 .


hose -6- clear.
- G31- .



of turbocharger.
– Remove bolt -arrow- and detach bracket -1-.

– Remove nut -1- and bolt -3- and push coolant pipes on right
of longitudinal member slightly to right side (shown with engine
removed).
– Lift out catalytic converter.
Installing
• Renew seal and screw-type clip after removing.
page 215 .
page 34 .
Tightening torques
♦ ⇒ Fig. ““Installing catalytic converter - tightening torque and

1 Ignition system
⇒ “1.2 Removing and installing ignition coils with output stages”,
page 255
⇒ “1.3 Removing and installing knock sensor 1 G61 ”,
page 258
⇒ “1.4 Removing and installing Hall senders”, page 258
260
1.1 Exploded view - ignition system
1 - Spark plug
❑ Removing and instal‐
ling, tightening torque
let 830
❑ Change interval ⇒
Maintenance tables
2 - Spark plug connectors
3 - Ignition coil with output
stage
♦ Ignition coil 1 with output
stage - N70-
stage - N127-
stage - N291-
stage - N292-
stalling ignition coils
with output stages”,
page 255
4 - Bolt
❑ 8 Nm
5 - Nut
❑ 8 Nm
6 - Bolt
❑ 8 Nm
7 - Hall sender
♦ Hall sender - G40- (inlet
side)
♦ Hall sender 2 - G163- (exhaust side)
❑ Removing and installing ⇒ “1.4 Removing and installing Hall senders”, page 258
8 - O-ring
❑ Renew

9 - Sealing flange (gearbox end)

❑ With oil seal and sender wheel for engine speed sender - G28-
❑ Do not separate from sealing flange
❑ Removing and installing ⇒ “2.3 Removing and installing sealing flange (gearbox end)”, page 49
❑ Removing and installing ⇒ “1.5 Removing and installing engine speed sender G28 ”, page 260
11 - Bolt
❑ 4.5 Nm
12 - Bolt
❑ Tightening torque influences the function of the knock sensor
❑ 20 Nm
❑ Removing and installing ⇒ “1.3 Removing and installing knock sensor 1 G61 ”, page 258
1.2 Removing and installing ignition coils

with output stages
♦ Puller - T10530-
Removing
page 34 .
Ignition coils, cylinders 2, 3:
– Remove nut -arrows- and move earth wires clear.
Ignition coil, cylinder 3:
1. Ignition system 255

Ignition coil, cylinder 4:


hose -6- clear.
- G31- .
All ignition coils (continued):

– Press puller - T10530- into hole in ignition coil -1- as far as

stop.
– Tighten knurled nut -2- clockwise -arrow-.

– Pull ignition coil out of camshaft housing with puller - T10530-

-arrow-.
Installing
– Push spark plug connector -2- onto ignition coil -1- by hand as
far as stop.
• The arrow markings on the spark plug connector and the ig‐
nition coil must be aligned, as shown.

Caution
Ignition coils can be damaged irreparably if the wrong lubricant

is used.
♦ Use only the approved silicone paste ⇒ Electronic parts
catalogue .
– Apply a thin bead of silicone paste all around end of sealing

hose of ignition coil with output stage -arrow-.
– Press ignition coils onto spark plugs by hand evenly (do not
use tools).
page 34 .
Tightening torques
♦ ⇒ “1.1 Exploded view - ignition system”, page 254
1.3 Removing and installing knock sensor 1

- G61-
Removing
page 34 .
– Unscrew bolt -2- and remove knock sensor 1 - G61- .
Installing
page 34 .
Tightening torques
1.4 Removing and installing Hall senders


Removing
page 34 .
Hall sender - G40- :
– Unscrew bolt -2- and remove Hall sender - G40- .
Hall sender 2 - G163- :


hose -6- clear.
- G31- .


– Unscrew bolt -2- and remove Hall sender 2 - G163- .
Installing
page 34 .
Tightening torques

sender - G28-
♦ Socket, AF 4 mm - T10370-

Removing
– Remove coolant pipes
move them clear.
switch - F66- .
– Release and unplug electrical connector with assembly tool -

T10118- .
– Unscrew bolt -2- using socket, AF 4 mm - T10370- and remove
engine speed sender - G28- .
Installing
page 183 .
– Install coolant pipes
Tightening torques

Service
Workshop Manual
Audi A4 2015 ➤
Audi A5 2016 ➤
4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI,
EA 888 Gen. III, B cycle)
Engine ID
CVK DBP CWN CVLA DEM DHD DKU DKU DKY
B A A A A A B A
DLVA DLVB CVK DEM DTA DTA
C B A B
Edition 01.2020

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system

Copyright © 2019 Audi AG, Ingolstadt D4B80595B99

4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III, B cycle) - Edition 01.2020
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Safety precautions when working on vehicles with natural gas systems . . . . . . . . . . . . . . 2
2.2 Safety precautions for all vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Removing and installing poly V-belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.4 Removing and installing actuators for camshaft adjustment . . . . . . . . . . . . . . . . . . . . . . . . 87
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Contents i
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.5 Removing and installing stage 3 oil pressure switch F447 . . . . . . . . . . . . . . . . . . . . . . . . 95
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
4.3 Removing and installing radiator blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.4 Removing and installing radiator blind control motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
ii Contents


2 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.3 Removing and installing throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
5 Gas injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5.1 Exploded view - gas rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
5.2 Removing and installing gas rail with gas injection valve N366 / N367 / N368 / N369 . . . . 190
5.3 Removing and installing gas injection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
6 Gas pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
6.1 Exploded view - gas pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
6.2 Removing and installing gas pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
7.6 Removing and installing gas rail temperature and pressure sensor GX21 . . . . . . . . . . . . 202
7.7 Removing and installing sensor module GX23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
9 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Contents iii
1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
iv Contents
1 Identification
(ARL006806; Edition 01.2020)
ltr. 4-valve TFSI; Rep. gr. 00 ; Identification .
1. Identification 1
⇒ “2.1 Safety precautions when working on vehicles with natural
gas systems”, page 2
⇒ “2.2 Safety precautions for all vehicles”, page 2
2.1 Safety precautions when working on vehicles with natural gas systems
– Never drive a vehicle with a natural gas system into the work‐
shop if you can clearly hear gas escaping. Instead, park the
vehicle outside and set up a protected area ⇒ Natural gas
engines - General information; Rep. gr. 20 ; Fuel tanks; Set‐
ting up and marking a protected area .
– Work on natural gas systems may only be performed by spe‐
cially trained persons ⇒ Natural gas engines - General infor‐
mation; Rep. gr. 00 ; Safety briefing/employee qualification .
– Gas tank must be closed manually on vehicles with natural gas
systems if gas can be heard escaping and smelt ⇒ Fuel supply
system - g-tron; Rep. gr. 20 ; Fuel tanks; Closing fuel tank
shut-off valves mechanically .
Risk of explosion due to flammable natural gas - risk of death!

Risk of explosion due to static discharge near natural gas systems
– Wear protective clothing consisting of at least 35% cotton.
– Wear protective gloves consisting of at least 35% cotton.
– Wear safety shoes with ESD protection.
Risk of injury due to high pressure

Uncontrolled gas escape may occur under high pressure. Danger
of frostbite to hands and other parts of the body.
– Dissipate high pressure in natural gas system before perform‐
ing work on natural gas system ⇒ Fuel supply system - g-tron;
Rep. gr. 20 ; Fuel tanks; Dissipating pressure in natural gas
high-pressure pipe .
– Check for leaks after performing work on the natural gas sys‐
tem.
2.2 Safety precautions for all vehicles

ltr. 4-valve TFSI; Rep. gr. 00 ; Safety precautions .

ltr. 4-valve TFSI; Rep. gr. 00 ; Repair instructions .

page 54
1.1 Removing engine

⇒ “1.1.1 Removing engine - vehicles without particulate filter”,
page 4
⇒ “1.1.2 Removing engine - vehicles with particulate filter”,
page 20
⇒ “1.1.3 Removing engine - vehicles with natural gas system”,
page 38
1.1.1 Removing engine - vehicles without par‐

ticulate filter




♦ Ratchet wrench (21 mm) - T40263-
♦ Safety goggles

Procedure
Note
♦ The engine is removed upwards without gearbox.

♦ Re-install all cable ties in original positions.

WARNING

• Cover filler cap on expansion tank with a cloth and open

expansion tank.
noise insulation .
(front) .

– On relevant equipment version: Unplug electrical connector

-2- for variable intake manifold changeover valve - N335- and
pull water drain -1- off downwards -arrow-.
Vehicles with starter-alternator:
Remove air intake grille (left and right) and closure plate at bump‐
er cover ⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper
(front); Exploded view - bumper cover .


– Seal off turbocharger connection with sealing plug (thoroughly

-arrow A-.

Note
The nut -2- and bolt -3- are removed at a later stage.

G31- .
valve module - GX3- .

– Lift retaining clip -2-, disconnect coolant hose from radiator
(bottom right) and drain off coolant.
wards.

Vehicles without belt-driven starter-alternator:
Caution


Vehicles with belt-driven starter-alternator:
Caution



turbocharger.

– If fitted, remove bolt -1- for support mounting on both sides.

Vehicles with belt-driven starter-alternator:




(right-side).
Note
-Item 1- is already removed.
Caution
Risk of damage to flexible joints in front silencer.

♦ Do NOT bend the flexible joints in the front silencer more
than 10°.


– Remove nut -2- for catalytic converter.
Note
The nuts -1- are removed at a later stage.
– Counterhold crankshaft using ratchet wrench, 21 mm -

T40263- and adapter -T40314- when slackening bolts for
flywheel.
Caution
Irreparable engine damage can be caused if the camshaft tim‐

ing chain slips.
♦ Only turn crankshaft in direction of engine rotation.

rotation -arrow-.


1332/14- and adapter - VAS 6948- .

1332/14- and adapter - VAS 6948- .

– Unplug electrical connector -1- for Lambda probe 1 after cat‐

alytic converter - GX7- -item 2- and move wiring clear. (Instal‐
lation position varies.)


catalytic converter - GX10- -item 2-. (Installation position var‐
ies.)
– Unscrew Lambda probe 1 before catalytic converter - GX10-
-item 2- using a tool from Lambda probe open ring spanner
set - 3337- .

coal filter system. (Different versions.)


move them clear.
switch - F66- .


tach coolant hose.




to gearbox.

to gearbox.


onto gearbox.
Note
Shown in illustration with engine removed.

WARNING
Risk of accident.

Caution

lifting out.

compartment.
1.1.2 Removing engine - vehicles with partic‐

ulate filter





♦ Safety goggles
Procedure
Note


WARNING



expansion tank.
noise insulation .
(front) .
cover .


-arrow A-.

Caution



G31- .
wards.


– Remove bolts -arrows- and press wiring duct -1- downwards.

turbocharger.





(right-side).
Caution

than 10°.
– Unscrew bolts -arrows- (shown on right side).


Note


flywheel.
Caution

ing chain slips.

rotation -arrow-.

1332/14- and adapter - VAS 6948- .


1332/14- and adapter - VAS 6948- .


– Remove nuts -arrows- and press particulate filter -1- to rear.

Pressure differential sender for particulate filter - G1037- - version

1:
– Unplug electrical connector -1- for pressure differential sender
for particulate filter - G1037- .
– Unclip bracket with pressure differential sender from intake
manifold -arrow- and move clear.
– Unplug electrical connector -1- for vacuum sender - G608-

-item 2-.

2:
– Remove bolt -1- and move pressure differential sender for
particulate filter - G1037- clear.



sions.)
All versions (continued):

alytic converter - GX7- -item 1- and move wiring clear.

catalytic converter - GX10- -item 2-.
– Move electrical wiring harness clear at engine and tie up to left
side.

– Unscrew nuts -1- and detach catalytic converter upwards to‐

wards rear.

coal filter system.

move them clear.
switch - F66- .



tach coolant hose.



– Unplug electrical connector -arrow- for starter-alternator.

to gearbox.

to gearbox.


onto gearbox.
Note

WARNING
Risk of accident.

Caution

lifting out.

compartment.
1.1.3 Removing engine - vehicles with natural

gas system





♦ Safety goggles
Procedure
Note

– Observe safety precautions ⇒ Servicing 4-cylinder engine, 2.0

system ⇒ page 2 .
2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Repair notes; Rules for
cleanliness .
WARNING

Uncontrolled escape of natural gas may occur if the manual
fuel tank shut-off valve is defective. In addition, third parties
may activate the natural gas system unintentionally.
♦ Pressure in natural gas high-pressure pipe must be dissi‐
pated by a specially instructed person.
♦ Shut off natural gas fuel tanks electrically and manually.

– Dissipate pressure in natural gas high-pressure pipe ⇒ Fuel

supply system - g-tron; Rep. gr. 20 ; Fuel tanks; Dissipating
fuel pressure in high-pressure section .
– Switch off ignition and remove ignition key.
– Detach electrical connectors -2- from bracket and unplug.
J623- -item 3-.
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
– Release catches -arrows B- and open cover -1- -arrow A-.
WARNING


expansion tank.
noise insulation .
(front) .


– Unplug electrical connector -2- for air mass meter - G70- and
move connector clear.

-arrow A-.
Note
The nut -2- and bolt -3- are removed at a later stage.

– Release hose clip -arrow- and detach air hose downwards

from throttle valve module - GX3- .

– Release hose clip -2- and detach from coolant pipe -1-.
– Unscrew bolt -3- on both sides and tie up coolant pipe to side.

G31- .
wards.

Note
♦ Running a used poly V-belt in the opposite direction could

♦ Before removing the poly V-belt, mark the direction of rotation
with chalk or a felt-tip pen for re-installation.

– Remove bolt -1- for support mounting -2- (both sides).

turbocharger.



Caution
Avoid damage to flexible joints.

♦ Do not bend flexible joints more than 10°.
– Loosen clamp -arrow-.

– Detach front exhaust pipe from front silencer and remove.
Note


flywheel.
Caution

ing chain slips.

rotation -arrow-.

1332/14- and adapter - VAS 6948- .

1332/14- and adapter - VAS 6948- .




catalytic converter - GX10- -item 2-. (Installation position var‐
ies.)
set - 3337- .

WARNING

– Release hose clip -1- and detach fuel hose.

coal filter system.

– Release hose clip -1- on rear coolant pipe and detach coolant
hose.

– Move coolant hose -3- clear and move it to right side.



tach coolant hose.


– Unscrew natural gas low-pressure pipe -1- from gas rail; to do
so, counterhold at connection with a suitable tool.
– Release hose clip -2- on rear coolant pipe and detach coolant
hose.


to gearbox.

to gearbox.

onto gearbox.
Note


WARNING
Risk of accident.

Caution

lifting out.

compartment.

support
2.0 ltr. 4-valve TFSI; Rep. gr. 10 ; Removing and installing engine;

Tightening torques
Note

Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65


box
Procedure
Note
♦ After removing, renew bolts tightened with specified tightening

angle.
♦ Renew self-locking nuts and bolts as well as seals, gaskets
♦ On vehicles with manual gearbox, a needle bearing must be
fitted in the drive plate ⇒ Servicing 4-cylinder engine, 2.0 ltr.
4-valve TFSI; Rep. gr. 13 ; Cylinder block (gearbox end); Re‐
newing needle bearing in drive plate .
♦ Hose connections and hoses for charge air system must be
free of oil and grease prior to fitting.
♦ Secure all hose connections with correct type of hose clips (as
♦ If you intend to secure the charge air hoses at their connec‐
tions with used hose clips, spray rust remover onto the worm
threads before installing.
– Attach engine to gearbox, but do not yet tighten gearbox/en‐

gine connecting bolts ⇒ Gearbox; Rep. gr. 34 ; Removing and
onto engine mountings.

– Tighten bolts -2- (left and right) for engine mounting.

– Tighten gearbox/engine connecting bolts ⇒ Gearbox; Rep. gr.
gearbox .
note the following:
– Vehicles with natural gas system: Secure natural gas low-
pressure pipe to gas rail ⇒ page 189 (counterhold at connec‐
tion with a suitable tool).
– Install Lambda probe 1 before catalytic converter - GX10- ⇒
Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ;
Lambda probe; Removing and installing Lambda probe .
– If removed previously, install intermediate steering shaft ⇒
Running gear, axles, steering; Rep. gr. 48 ; Steering column;
Removing and installing intermediate steering shaft .
– If unfastened previously, bolt on radiator ⇒ page 140 .
– Install poly V-belt ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-
valve TFSI; Rep. gr. 13 ; Cylinder block (pulley end); Remov‐
ing and installing poly V-belt tensioner .
– If removed previously, install plenum chamber partition panel
⇒ General body repairs, exterior; Rep. gr. 50 ; Bulkhead;
Exploded view - plenum chamber partition panel .
cover .
ltr. 4-valve TFSI; Rep. gr. 26 ; Emission control system; Re‐
ing battery .

Caution

sive voltage.

Function “01 - Functions, engine mechanics” ⇒ Vehicle diag‐
nostic tester.
Caution

Note
Do not reuse coolant.

ltr. 4-valve TFSI; Rep. gr. 10 ; Engine cover panel; Removing
and installing engine cover panel .
– Install wheel housing liners and wheel spoiler ⇒ General body
Wheels, tyres .
insulation .

Vehicles with natural gas system:
WARNING

♦ Natural gas system must be re-started by a specially in‐
structed person.
– Open manual shut-off mechanisms of mechanical tank shut-

off valves using extension -T40333- and hand wheel -
T50026- , and plug in electrical connectors if necessary.
WARNING

Leaks in the natural gas system can cause uncontrolled es‐
cape of natural gas.
♦ Check natural gas system for leaks.
– Perform leak test on low-pressure section of natural gas sys‐

tem ⇒ Natural gas engines - General information; Rep. gr.
00 ; Checking natural gas system .


♦ Exploded view - gearbox mounting for manual gearbox
⇒ page 60
⇒ page 61
1 - Subframe
2 - Bolt
❑ For vehicles with sup‐
port mounting
❑ 20 Nm
3 - Bolt
❑ For vehicles with sup‐
port mounting
❑ 10 Nm
❑ Depending on equip‐
ment version; for correct
type refer to ⇒ Electron‐
ic parts catalogue
⇒ page 67
⇒ page 60
5 - Bolt
❑ 55 Nm
6 - Engine support
catalogue
⇒ page 71
7 - Heat shield
8 - Bolt
❑ 10 Nm
9 - Bolt
❑ 55 Nm
❑ Equipment version with:
♦ Left electrohydraulic engine mounting solenoid valve - N144-
♦ Right electrohydraulic engine mounting solenoid valve - N145-

❑ Solenoid valve integrated in engine mounting; cannot be renewed separately if defective
11 - Bolt
❑ 90 Nm +90°
12 - Bolt
❑ 30 Nm

support mounting.
Exploded view - gearbox mounting for manual gearbox

1 - Nut
mountings; Exploded
ings
2 - Bolt
mountings; Exploded
ings
⇒ 6-speed manual
Assembly mountings;
bly mountings
4 - Stop plate
⇒ page 68
6 - Bolt
mountings; Exploded
ings
7 - Final drive
8 - Nut
assembly mountings
9 - Gearbox support
10 - Bolt
assembly mountings
11 - Bolt
❑ 9 Nm
12 - Bracket
1 - Bolt
mountings
Assembly mountings;
bly mountings
3 - Stop plate
⇒ page 68
5 - Final drive
6 - Nut
mountings
7 - Gearbox support
ing”, page 68
8 - Bolt
9 - Bolt
10 - Nut

tion

Procedure
2.0 ltr. 4-valve TFSI; Rep. gr. 10 ; Engine cover panel; Re‐
moving and installing engine cover panel .
– Take up weight of engine with spindles, but do not lift.
Assembling
Assembly is carried out in reverse sequence; note the following.

ings
⇒ “2.3.1 Removing and installing engine mountings - vehicles
without natural gas system”, page 63
⇒ “2.3.2 Removing and installing engine mountings - vehicles with
natural gas system”, page 65

ings - vehicles without natural gas sys‐
tem
Removing
noise insulation .

– If fitted, unscrew bolt -1- for support mounting.

– If fitted, remove support mounting (right-side) ⇒ page 67 .
wiring harness.

Caution


ing is relieved.
Installing
Note
After removing, renew bolts tightened with specified tightening

angle.

Tightening torques
♦ ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr.
21 ; Charge air system; Exploded view - hose connections for
charge air system

ings - vehicles with natural gas system
Removing
noise insulation .
– Release hose clip -arrow- and detach air hose downwards
from throttle valve module - GX3- .

G31- .
wards.



wiring harness.
Caution


ing is relieved.

Installing
Note

angle.

Tightening torques
charge air system

ing
Removing
noise insulation .

Installing
Note

angle.

Tightening torques

mounting

box support -4-.
Installing
quence.
Tightening torques


ltr. 4-valve TFSI; Rep. gr. 10 ; Engine cover panel .

⇒ “1.3 Removing and installing poly V-belt tensioner”, page 70
page 70

end)
2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder block (pulley end);

1.3 Removing and installing poly V-belt ten‐

sioner
Removing and installing poly V-belt tensioner .

er
Removing
– Vehicles with natural gas system: Unscrew bolt -3- on both
sides and press coolant pipe towards rear.
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder block (pulley
end); Removing and installing vibration damper .
Installing
Additional work:
Tightening torques

cillaries


⇒ “1.6.1 Removing and installing engine support (left-side) - ve‐
hicles without natural gas system”, page 71
⇒ “1.6.2 Removing and installing engine support (left-side) - ve‐
hicles with natural gas system”, page 72
page 73

(left-side) - vehicles without natural gas
system
Removing
clear.
switch - F66- .
side.
– Remove top bolts -2- for engine support -1-.
Note
♦ Shown in illustration with engine removed.

♦ Bolts -3- are removed at a later stage.
– If fitted, remove support mounting (left-side) ⇒ page 67 .

– Unplug electrical connector -arrow- at air conditioner com‐

pressor.

– Unscrew bottom bolts -3- and detach engine support (left-side)

-1-.
Note
Installing
Note

angle.

– Install engine mountings ⇒ page 63 .
– If removed previously, install support mounting ⇒ page 67 .
Tightening torques

(left-side) - vehicles with natural gas
system
Removing
– Remove poly V-belt ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-
ing and installing poly V-belt .

– Unscrew bolts -2, 3- and detach engine support (left-side)

-1-. (Engine has been removed in illustration).
Installing
Note

angle.

– Install poly V-belt ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-
ing and installing poly V-belt .
Tightening torques

(right-side)
Removing
– Remove nut -2- and move bracket with electrical wiring clear.
side).
Note
Installing
Note

angle.

ing battery .
Tightening torques


cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder block
(gearbox end) .

3 Crankshaft
cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Crankshaft .
3. Crankshaft 75
4 Balance shaft
cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Balance shaft .


cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Pistons and
conrods .



2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Timing chain cover; Exploded
view - timing chain cover .

cover
page 78

cover (top)
Removing
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Timing chain cover;
Installing
Additional work:
Tightening torques

2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Timing chain cover; Removing
and installing timing chain cover .

2 Chain drive
cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Chain drive .
2. Chain drive 79
3 Cylinder head

2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head; Exploded view
- cylinder head .

⇒ “3.2.1 Removing and installing cylinder head - vehicles without

Removing

rear.

Caution

-1-, as shown.
– Unplug electrical connectors and move wiring clear:

1 - For oil pressure switch - F22- -item 2-
3 - For oil pressure switch for reduced oil pressure - F378-
-item 4-
5 - For piston cooling jet control valve - N522- -item 7-
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head; Re‐
moving and installing cylinder head .
Tightening torques

Removing
3. Cylinder head 81

1:
– Move bracket with pressure differential sender clear at intake
manifold -arrow-.
Installing
Additional work:
– Install front silencers ⇒ page 223 .
Tightening torques
26 ; Emission control system; Exploded view - emission con‐
trol system

Removing


system ⇒ page 2 .
cleanliness .
WARNING


– Unbolt coolant pipes (rear) and press towards rear
⇒ page 135 .
3. Cylinder head 83
– Loosen clamp -arrow- and detach front exhaust pipe from front
silencer.
Caution

– Lower front exhaust pipe -2- slightly and secure it with a cable
tie -1-, as shown.

-item 4-
Installing
Additional work:
– Install rear coolant pipes ⇒ page 135 .
– Secure natural gas low-pressure pipe to gas rail
⇒ page 189 ; to do so, counterhold at connection with a suit‐
able tool.

WARNING

structed person.

WARNING


Tightening torques

ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head; Checking com‐
pression .
3. Cylinder head 85
4 Valve gear
⇒ “4.4 Removing and installing actuators for camshaft adjust‐
ment”, page 87
page 87

2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Exploded view -
valve gear .

⇒ “4.2.1 Removing and installing camshaft - vehicles without par‐
⇒ “4.2.2 Removing and installing camshaft - vehicles with partic‐
ulate filter”, page 86

hicles without particulate filter
2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Removing and
installing camshaft .

hicles with particulate filter
Removing


sions.)
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Removing
and installing camshaft .
Installing
Additional work:
Tightening torques
15 ; Cylinder head; Exploded view - cylinder head

2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Installing ball for
slider .
4.4 Removing and installing actuators for

camshaft adjustment
installing actuators for camshaft adjustment .

Removing camshaft control valve 1 - N205-
Removing exhaust camshaft control valve 1 - N318-
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Removing
and installing camshaft control valve 1 - N205- .
Installing
Additional work:
Tightening torques
4. Valve gear 87

seals


ltr. 4-valve TFSI; Rep. gr. 15 ; Inlet and exhaust valves .

17 – Lubrication
1 Sump/oil pump
page 90
er G266 ”, page 92

2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump; Exploded view
- sump/oil pump .
1.2 Engine oil

sary ; ⇒ Technical data for engines; Rep. gr. 00 ; Overview
of engines; Overview of engines with adjustment values (oil
gauge tester T40178)
tenance tables .

section)
Removing
noise insulation .

– Remove bolt -arrow- and move bracket -1- for electrical wiring
harness clear.
– Vehicles with natural gas system: Unscrew bolt -3- on both

sides and press coolant pipes upwards.
– If fitted, remove bolt -1- for support mounting (both sides).
– If fitted, remove bolt -2- for engine mounting (both sides).

1. Sump/oil pump 91
Caution


distance -a-.
• Dimension -a- = 20 mm
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump; Re‐
moving and installing sump (bottom section) .
Installing
Additional work:
– Detach support bracket ⇒ page 62 .
Tightening torques

2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump; Removing and

tion)

installing oil level and oil temperature sender - G266- .

2 Engine oil cooler

cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Engine oil
cooler .

cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Crankcase
breather .


page 95
page 95
⇒ “4.5 Removing and installing stage 3 oil pressure switch F447
”, page 95
”, page 97
N522 ”, page 97

2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Oil filter/oil pressure switches;

pressure control
2.0 ltr. TFSI, 4-valve; Rep. gr. 17 ; Oil filter/oil pressure switches;

switch - F22-
Removing and installing oil pressure switch - F22- .

Removing and installing oil pressure switch for reduced oil pres‐
sure - F378- .
4.5 Removing and installing stage 3 oil pres‐

sure switch - F447-
⇒ “4.5.1 Removing and installing stage 3 oil pressure switch F447
- vehicles without natural gas system”, page 95
- vehicles with natural gas system”, page 96
4.5.1 Removing and installing stage 3 oil pres‐

sure switch - F447- - vehicles without
natural gas system
2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Oil filter/oil pressure switches ;
Removing and installing stage 3 oil pressure switch - F447- .


sure switch - F447- - vehicles with nat‐
ural gas system
Procedure
– Clamp off coolant hose -1- with hose clamps up to 25 mm -
3094- .

Note
Place a cloth underneath to catch escaping coolant.
– Clamp off coolant hoses using hose clamps, up to 25 mm -

3094- , release hose clips -1 and 2- and disconnect hoses.
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Oil filter/oil pressure
switches; Removing and installing stage 3 oil pressure switch -
F447- .
Installing
Additional work:
Note


Removing and installing piston cooling jet control valve - N522- .


19 – Cooling

⇒ “1.1.3 Connection diagram - coolant hoses, vehicles with nat‐
ural gas system”, page 101
1.1.1 Connection diagram - coolant hoses, equipment version without auxiliary

heater
Note

♦ Arrows show direction of coolant flow.

1 - Radiator
2 - Cylinder block
4 - Turbocharger
7 - Cylinder head
er - G62-
9 - Restrictors
❑ Activated by Climatronic
coolant shut-off valve -
N422- (negative pres‐
sure)
V50-
14 - Coolant pump
15 - Thermostat
gearbox
16 - ATF cooler
tion pump - V51-
18 - Restrictor
19 - Filler cap
❑ Checking pressure relief valve ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Cooling
system/coolant; Checking cooling system for leaks
1.1.2 Connection diagram - coolant hoses, equipment version with auxiliary heat‐
er
Note

1 - Radiator
2 - Cylinder block
4 - Turbocharger
7 - Cylinder head
er - G62-
9 - Restrictors
V55-
valve - N279-
14 - Coolant pump
15 - Thermostat
gearbox
16 - ATF cooler
tion pump - V51-
18 - Restrictor
19 - Filler cap
❑ Checking pressure relief valve ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Cooling


1.1.3 Connection diagram - coolant hoses, vehicles with natural gas system
Note

1 - Radiator
4 - Turbocharger
7 - Cylinder head
er - G62-
9 - Restrictor
12 - Filler cap
lief valve ⇒ Servicing 4-
cylinder engine, 2.0 ltr.
4-valve TFSI; Rep. gr.
19 ; Cooling system/
coolant; Checking cool‐
ing system for leaks
13 - Bleeder hole
valve - N279-
16 - Gas pressure regulator
❑ With high-pressure
valve for gas mode -
N372-

17 - Cooling flange
18 - Thermostat
19 - ATF cooler
20 - Continued coolant circulation pump - V51-
21 - Coolant pump
22 - Coolant circulation pump - V50-

2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Cooling system/coolant;




Draining
– Vehicles with natural gas system: Release catches
-arrows B- and open cover -1- -arrow A-.
WARNING


expansion tank.
noise insulation .

WARNING


– Vehicles with natural gas system: Release hose clip -2- and
detach coolant hose from coolant pipe -1-.


off coolant (open heat insulation sleeve if fitted).
– Connect coolant hoses (version with plug-in connectors)
⇒ page 142 .
ltr. 4-valve TFSI; Rep. gr. 19 ; Cooling system/coolant; Draining
and filling cooling system .
Caution
Danger of corrosion damage if unsuitable mixtures of water

and coolant additives are used.
♦ Only use distilled water as this ensures optimum corrosion
protection.

to -25 °C
to -36 °C

⇒ page 105 ).
– To simplify filling procedure, place filled reservoir on as high a
surface as possible, e.g. on a workshop trolley or the engine
and gearbox jack.
V.A.G 1274/8- .
Note

rection of flow).
– Open valves in coolant circuit; select 01 - Coolant circuit
bleeding routine in Guided Functions ⇒ vehicle diag‐
nostic tester .


zone.
in the green zone.
sequent filling.
Note
♦ If the needle does not reach the green zone, repeat the proc‐
ess.
♦ Check cooling system for leaks if the vacuum is not main‐
tained.

– Open valve -A-.
is then filled.
– Detach cooling system charge unit - VAS 6096- and adapter
-V.A.G 1274/8- .


engages).
– Start engine.
“OFF”, LED in AC button not
lit
• Heating at “HI”, select low‐
est possible blower speed
(= 0)
Until both Idling • Air conditioning system

large coolant “OFF”
hoses at ra‐
diator be‐ • Heating at “HI”
come warm
“OFF”

WARNING

Vehicles without natural gas system:

gine is cold.
engine is warm.


• The top edge (= MAX marking) of the float -1- must be flush
with the opening -arrow- on the coolant expansion tank when
the engine is cold.
• The top edge of the float may be above the opening on the
coolant expansion tank when the engine is at operating tem‐
perature.
Tightening torques


page 111
page 111
page 120
”, page 123

stat
2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Coolant pump/thermostat as‐

1 - Bolt
❑ 9 Nm
V50-
ling:
♦ Vehicles without natural
gas system
⇒ “2.4.1 Removing and in‐
stalling coolant circulation
pump V50 - vehicles with‐
out natural gas system”,
page 111
♦ Vehicles with natural gas
system
stalling coolant circulation
pump V50 - vehicles with
natural gas system”,
page 112
tion pump - V51-
equipment
ling:
♦ Vehicles without natural
gas system
stalling continued coolant
circulation pump V51 - ve‐
hicles without natural gas
system”, page 114
♦ Vehicles with natural gas
system
⇒ “2.4.4 Removing and installing continued coolant circulation pump V51 - vehicles with natural gas system”,
page 116
4 - Bolt
❑ 9 Nm
5 - Rubber grommet
6 - Bolt
❑ 2.7 Nm
7 - Rubber grommet
8 - Bolt
❑ 2.7 Nm
9 - Bracket
❑ For electric coolant pumps
❑ Different versions available; for allocation refer to ⇒ Electronic parts catalogue


senders

pump
⇒ “2.4.1 Removing and installing coolant circulation pump V50 -
vehicles without natural gas system”, page 111
vehicles with natural gas system”, page 112
pump V51 - vehicles without natural gas system”, page 114
pump V51 - vehicles with natural gas system”, page 116

tion pump - V50- - vehicles without nat‐
ural gas system
Removing


bracket -1-.
Note

– Remove bolts -arrow- and detach coolant circulation pump -
V50- .
Installing
Note

Tightening torques

tion pump - V50- - vehicles with natural
gas system

Removing
– Detach electrical connectors -2- from bracket and unplug.
– Release fasteners -arrows-, detach engine control unit - J623-
-item 3- and place to one side.

Note

– Remove bolts -2- and detach coolant circulation pump - V50- .
Installing
Note

Tightening torques

ant circulation pump - V51- - vehicles
without natural gas system

Removing
bracket -1-.

Note

– Remove bolts -arrow- and detach continued coolant circula‐
tion pump - V51- .
Installing
Note

Tightening torques

with natural gas system

Removing
system ⇒ page 2 .
cleanliness .
WARNING



Note

– Carefully unscrew union nuts -1, 2- so that residual gas can
escape; counterhold at connections with a suitable tool.
Caution
Risk of gas leaks in gas pressure pipe due to improper han‐

dling.
♦ Do not attempt to bend gas pressure pipe to a different
shape
– Unscrew union nut -1- and move natural gas low-pressure

pipe to one side.
– Unclip high-pressure pipe from retainers.
– Unscrew union nut -2- and disconnect high-pressure pipe
slightly from gas pressure regulator.

1- For high-pressure valve for gas mode - N372-
2- For sensor module - GX23-
3- For coolant circulation pump - V50-
4- For continued coolant circulation pump - V51-
– Unscrew bolts -arrows- and remove pump unit with gas pres‐
sure regulator.
– Remove bolts -5- and detach continued coolant circulation
pump - V51- .
Installing
Note
– Install natural gas high-pressure pipe ⇒ page 194 .

ing battery .

WARNING

structed person.

WARNING

– Perform gas system inspection ⇒ Maintenance ; Booklet 830 ;

Maintenance; Natural gas system: checking for damage and
leaks .
Tightening torques
♦ ⇒ “6.1 Exploded view - gas pressure regulator”, page 194

Removing
– Remove coolant pipes (rear) ⇒ page 135 .
– Remove engine control unit - J623- ⇒ page 211 .


– Unplug electrical connectors -2 ... 5-.
– If necessary, move electrical wiring harness clear.

ness to one side. (Different versions.)
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Coolant pump/ther‐
mostat assembly; Removing and installing coolant pump .
Installing
Additional work:
Note

– Install engine control unit - J623- ⇒ page 211 .

coolant pump

Removing
– Remove engine control unit - J623- ⇒ page 211 .
– Release hose clips -1, 2- and disconnect coolant hoses.


to one side.
mostat assembly; Removing and installing toothed belt for coolant
pump .
Installing
Additional work:
Note


Removing


move them clear.
switch - F66- .
mostat assembly; Removing and installing actuator for engine
temperature regulation - N493- .
Installing
Additional work:
Note
– Vehicles with natural gas system: Install battery tray ⇒ Elec‐

trical system; Rep. gr. 27 ; Battery; Removing and installing
battery tray .

ature sender - G62-
- vehicles with particulate filter”, page 123

ature sender - G62- - vehicles without
particulate filter
G62- .

ature sender - G62- - vehicles with par‐
ticulate filter
Removing



2:
– Remove bolt -1- and move pressure differential sender for
particulate filter - G1037- clear.

– Remove bolt -1- and detach bracket.
mostat assembly; Removing and installing coolant temperature
sender - G62- .
Installing
Additional work:
Tightening torques

Procedure
• Engine cold.



expansion tank.
Radiator outlet coolant temperature sender - G83- - version 1:

Note
♦ Place a cloth underneath to catch escaping coolant.

♦ Renew O-ring after removal.
– Lift retaining clip -1- and pull out radiator outlet coolant tem‐

Radiator outlet coolant temperature sender - G83- - version 2:

Note

– Unscrew bolt -1- and pull off radiator outlet coolant tempera‐
Both versions:
Note
Insert new coolant temperature sender into connection immedi‐

ately to avoid loss of coolant.

Tightening torques
19 ; Coolant pump/thermostat assembly; Exploded view -
coolant temperature senders

3 Coolant pipes
page 136

♦ Coolant pipes on engine ⇒ page 127
♦ Coolant pipes for gearbox ⇒ page 128
Note
The arrow markings on coolant pipes and on ends of hoses must align.
Coolant pipes on engine
1 - Bolt
❑ 9 Nm
2 - Coolant hose
able; for correct version
refer to ⇒ Electronic
parts catalogue
⇒ page 129
4 - Coolant hose
5 - Bolt
❑ 20 Nm
6 - Bolt
❑ 9 Nm
7 - Bolt
❑ 20 Nm
♦ ⇒ “3.2.2 Removing and in‐
stalling coolant pipe (right-
side) - vehicles with alter‐
nator”, page 130
♦ ⇒ “3.2.3 Removing and in‐
stalling coolant pipe (right-
side) - vehicles with starter-
alternator”, page 133
9 - O-ring
10 - Coolant hose
❑ To remove, fold back heat insulation sleeve and lift retaining clip

11 - O-ring
12 - Bolt
❑ 6 Nm
13 - Coolant hose
Vehicles with natural gas system: Coolant pipe (rear) - tightening

torque
Coolant pipes for gearbox
1 - Coolant hoses
2 - Coolant hoses
3 - Bolt
❑ 9 Nm
⇒ page 136
5 - Bolt
❑ 9 Nm


page 129
cles with alternator”, page 130
cles with starter-alternator”, page 133
⇒ “3.2.4 Removing and installing rear coolant pipes - vehicles with

(left-side)
Removing
WARNING



expansion tank.
Note
♦ Place a cloth under coolant pipe to catch escaping coolant.

♦ Illustration shows installation position on a vehicle without nat‐
ural gas system.

Installing
Note

Tightening torques

(right-side) - vehicles with alternator

Removing
Note
Re-install all heat insulation sleeves in the same locations when

installing.

– Vehicles without natural gas system: Remove front silencer
⇒ page 223 .
– Vehicles with natural gas system: Remove front exhaust pipe
⇒ page 221 .
– Remove nut -2- from underneath.


– Remove nuts -1- from above and move catalytic converter to‐
wards rear.
– Remove bolt -arrow- and detach crankcase breather pipe from

turbocharger.

Installing
Note


Note

Tightening torques
21 ; Turbocharger; Exploded view - turbocharger

(right-side) - vehicles with starter-alter‐
nator

Removing
Note
Re-install all heat insulation sleeves in the same locations when

installing.

Installing
Note


Note

Tightening torques
21 ; Turbocharger; Exploded view - turbocharger

3.2.4 Removing and installing rear coolant

pipes - vehicles with natural gas system
Removing
WARNING



expansion tank.
Note

– Unscrew bolts -arrows- and detach coolant pipes (rear).
Installing
Note

Tightening torques
♦ ⇒ Fig. ““Vehicles with natural gas system: Coolant pipe (rear)
- tightening torque”“ , page 128

for gearbox



Removing
WARNING


expansion tank.
noise insulation .
– Vehicles with particulate filter: Remove front silencer
⇒ page 223 .

Note
– Clamp off coolant hoses using hose clamps up to 25 mm

-3094- , release hose clips -1- and disconnect hoses.
– Loosen hose clips -2- and detach coolant pipe.
Installing
Note

Tightening torques

⇒ “4.3 Removing and installing radiator blind”, page 149
⇒ “4.4 Removing and installing radiator blind control motor”, page
150

♦ Radiator - vehicles without natural gas system ⇒ page 140
♦ Radiator - vehicles with natural gas system ⇒ page 141
♦ Radiator blind ⇒ page 142
♦ Radiator cowl and radiator fan ⇒ page 143
Radiator - vehicles without natural gas system
1 - Radiator
⇒ page 144
2 - Plug
❑ Do not unscrew
❑ Not available as sepa‐
rate part
3 - O-ring
❑ Not available as sepa‐
rate part
4 - Coolant hose
tach
❑ Connecting
⇒ page 142
5 - O-rings
6 - Coolant hose
tach
❑ Connecting
⇒ page 142
7 - Coolant pipe
tank
❑ Press release ring to de‐
tach
❑ Connecting
⇒ page 142
8 - O-ring

9 - Rubber bush
❑ For radiator
10 - Sleeve
11 - Retaining pin
12 - Air duct
13 - Rubber bush
❑ For radiator
15 - Bolt
❑ 5 Nm
16 - Support
17 - Bolt
❑ 4.5 Nm
Radiator - vehicles with natural gas system
1 - Coolant hose
tach
❑ Connecting
⇒ page 142
2 - O-ring
3 - Drain plug
❑ 1.5 … 3 Nm
4 - O-ring
5 - Coolant hose
tach
❑ Connecting
⇒ page 142
6 - O-ring
7 - Radiator
⇒ page 144
8 - Rubber mounting
❑ For radiator
9 - Sleeve
10 - Retaining pin
❑ Use screwdriver to re‐
lease and pull off

11 - Coolant pipe
12 - Air duct
13 - Rubber bush
❑ For radiator
15 - Bolt
❑ 5 Nm
16 - Support
17 - Bolt
❑ 4.5 Nm
Note
If damaged, renew retaining clip -4-.

ant hose.
– Press coolant hose onto coolant pipe -1- until it engages with
a click.
Radiator blind

1 - Air duct
2 - Radiator blind
⇒ page 149
3 - Bolt
❑ 5 Nm
4 - Fin
5 - Bracket
6 - Bolt
❑ 8 Nm
7 - Carrier
8 - Bolt
❑ 2.5 Nm
tor - V544-
⇒ page 150
11 - Speed nut
12 - Air duct
13 - Spring element
14 - Bolt
❑ 8 Nm

1 - Radiator cowl
⇒ page 151
2 - Bolt
❑ 5 Nm
unit - J293-
⇒ page 153
4 - Air flow flap
catalogue
Note
diator cowl.


Removing
WARNING


noise insulation .
Equipment version without radiator blind:
General body repairs, exterior; Rep. gr. 63 ; Bumper (front);
Equipment version with radiator blind:
– Remove impact bar together with radiator blind ⇒ page 149 .
– A4: Remove headlight (left-side) ⇒ Electrical system; Rep. gr.
94 ; Headlights; Removing and installing headlights .




– Vehicles with natural gas system: Detach air duct -2-.



G65- .
Caution
Risk of irreparable damage to radiator if handled incorrectly.

♦ If fasteners are damaged, radiator must be renewed.
– Carefully release fasteners on both sides -arrows-.
Caution

– Disengage condenser -1- from radiator and tie condenser up

to one side.
– Vehicles without natural gas system: Lift retaining clips -1, 2-,
detach coolant connection from radiator and move connection
clear.

– Vehicles with natural gas system: Detach coolant connection

and coolant hose from radiator (lift retaining clip -1- and open
hose clip -2-).


Installing
Note
If there are slight impressions on the fins, refer to ⇒ Servicing 4-

cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Repair notes;
Installing radiators and condensers

Note

Tightening torques

Removing
WARNING
Risk of injury if components are triggered inadvertently.

♦ Before handling pyrotechnic components (e.g. plugging in
the electrical connector) the mechanic must discharge any
static electricity. This can be done by briefly touching the
door striker plate, or similar.

– Equipment version with pedestrian protection: Unplug electri‐

cal connector -1- at crash sensor for pedestrian protection and
move electrical wiring harness -2- clear.

– Detach radiator blind (top) -1- towards front.
Installing
Tightening torques

control motor
Removing

– Take electrical connector -1- for radiator blind control motor -

V544- out of bracket and unplug it.
– Carefully press connecting piece -3- upwards/downwards and
unscrew bolts -arrows-.
– Detach control motor with bracket -2- and fins.

- V544- -item 3-.
– Carefully unclip coupling -1- -arrow A- and at the same time,
detach it from bracket -5- together with control motor
-arrow B-.
– Pull off and detach control motor from coupling.
Installing
– Bring radiator blind control motor - V544- with bracket and fins
into installation position:
– Insert fins -1- one after another on both sides into holes on
radiator blind -2- -left arrows-.
– On both sides, guide fins into recesses on radiator blind
-right arrows-.
note the following:
Tightening torques

Removing
noise insulation .

WARNING

radiator cowl.
– Unclip air duct (bottom) -arrow-.
– Unplug electrical connector -2- and move coolant hose clear

at longitudinal member. (Different versions.)

from below.
Installing
Tightening torques

V7-
Removing
Caution

Installing
Tightening torques

1 Turbocharger

2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbocharger; Exploded view
- turbocharger .

⇒ “1.2.1 Removing and installing turbocharger - vehicles with al‐
ternator”, page 154
starter-alternator”, page 155

vehicles with alternator
Removing
– Vehicles without natural gas system: Loosen bolted connec‐

tions -arrows- and push clamp towards rear.

– Vehicles with natural gas system: Loosen clamp -arrow- and

detach front exhaust pipe from front silencer.
Caution

– Lower front silencer/front exhaust pipe -2- slightly and secure

it with a cable tie -1-, as shown.

– Remove nuts -1- from above and push catalytic converter to‐
wards rear.
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbocharger; Re‐
moving and installing turbocharger .
Installing
Additional work:
Tightening torques

vehicles with starter-alternator
Removing
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbocharger; Re‐
moving and installing turbocharger .
1. Turbocharger 155
Installing
Additional work:

2 Charge air system

page 158
page 159

⇒ page 158
cylinder engine, 2.0 ltr.
4-valve TFSI; Rep. gr.
00 ; Repair notes; Instal‐
ling radiators and con‐
densers
2 - Air hose
4 - Bolt
er breaks off
❑ Thread-forming
hand so that it is
que
❑ 7 Nm
G31-
⇒ page 159
6 - O-ring
8 - Seal
9 - Air pipe
10 - Seal


charge air system
2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Charge air system; Exploded

er
Removing
Note
Observe rules for cleanliness ⇒ Servicing 4-cylinder engine, 2.0

ltr. 4-valve TFSI; Rep. gr. 00 ; Repair notes; Rules for cleanli‐
ness .
cover .

charge air cooler.
Caution
Risk of irreparable damage to charge air cooler.

♦ The charge air cooler must be renewed if the fasteners are
damaged.
– Release fasteners -arrows- on both sides and disengage

charge air cooler from radiator.
Installing
Note
♦ If there are slight impressions on the fins, refer to ⇒ Servicing

4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Repair
notes; Installing radiators and condensers
cover .
Tightening torques
charge air system

sure sender - G31-
Removing
– Vehicles with natural gas system: Remove noise insulation
(front) ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise
insulation; Removing and installing noise insulation .


Installing
– Place charge pressure sender - G31- in installation position
and turn it clockwise until it engages.
Note

♦ If fastener on air pipe has broken off, secure charge pressure
positioner - G31- with two bolts, refer to ⇒ Electronic parts
catalogue .
Tightening torques

♦ End seal - V.A.G 1687/6- and adapters -V.A.G 1687/3- , -

V.A.G 1687/13-2- , -V.A.G 1687/15-

Procedure
Note
Observe rules for cleanliness ⇒ Servicing 4-cylinder engine, 2.0

ltr. 4-valve TFSI; Rep. gr. 00 ; Repair notes; Rules for cleanli‐
ness .


– Disconnect vacuum hose -2- and remove air pipe -1-.
– Fit end seal - V.A.G 1687/6- and adapter - V.A.G 1687/13-2-

on turbocharger.
Caution



– Loosen clamp (front) -arrows- and push towards rear.

– Loosen clamp -arrow-.

– Detach front exhaust pipe from front silencer.

-1-, as shown. (Shown on a vehicle without natural gas sys‐
tem.)

– Seal off front silencer with adapter - V.A.G 1687/3- and adapt‐
er - V.A.G 1687/15- .
– Connect charge air system tester - V.A.G 1687- with connec‐

tion -5- to end seal - V.A.G 1687/6- .
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Charge air system;
Checking charge air system for leaks .
Assembling
Additional work:
Tightening torques
charge air system


1 Injection system
page 164

Overview of fitting locations - engine compartment, vehicles with‐
out natural gas system

❑ Comprises:
♦ Lambda probe after catalyt‐
ic converter - G130-
♦ Lambda probe 1 heater af‐
ter catalytic converter -
Z29-
⇒ page 168
N82-
valve - N279-
G604-
with manual gearbox
⇒ page 168
for particulate filter - G1037-
❑ Vehicles with particulate
filter only
Rep. gr. 24 ; Lambda
probe; Exploded view -
Lambda probe
5 - Vacuum sender - G608-
- G79- and accelerator position sender 2 - G185-
8 - Coolant circulation pump - V50- , continued coolant circulation pump - V51-
9 - Clutch position sender - G476-
❑ With clutch pedal switch - F36- / clutch pedal switch for engine start - F194-


❑ Exploded view ⇒ Gearbox; Rep. gr. 30 ; Clutch mechanism; Exploded view - pedal cluster
15 - Lambda probe 1 before catalytic converter - GX10-
❑ Comprises:
♦ Lambda probe heater - Z19-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Lambda probe; Exploded
view - Lambda probe
Overview of fitting locations - engine compartment, vehicles with

natural gas system


❑ Comprises:
Z29-
⇒ page 168
N82-
valve - N279-
G604-
with manual gearbox
⇒ page 168
sor - G294-
sender 2 - G185-
⇒ page 167
⇒ page 167
7 - Gas pressure regulator/
sensor module - GX23-
❑ Removing and installing ⇒ “7.7 Removing and installing sensor module GX23 ”, page 203
8 - Clutch position sender - G476-
❑ With clutch pedal switch - F36- / clutch pedal switch for engine start - F194-
❑ Exploded view ⇒ Gearbox; Rep. gr. 30 ; Clutch mechanism; Exploded view - pedal cluster


❑ Comprises:
❑ Exploded view ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Lambda probe; Exploded
view - Lambda probe
Accelerator position sender - G79- and accelerator position send‐

er 2 - G185-

inder


Removing and installing ⇒ Gearbox; Rep. gr. 34 ; Selector
mechanism ; Removing and installing gear detection sensor -
G604-

G83-
♦ In coolant connection on radiator at bottom left. (Different ver‐
sions.)
sender - G83-
Fitting location of Lambda probe 1 after catalytic converter - GX7-

♦ In catalytic converter
1- Lambda probe 1 after catalytic converter - GX7-
2- Electrical connector for Lambda probe 1 after catalytic con‐
verter - GX7-
Note:
Installation position varies depending on model and version.
Exploded view ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve
TFSI; Rep. gr. 24 ; Lambda probe; Exploded view - Lambda
probe

valves -N144- / -N145-

Fitting locations on vehicles with natural gas system - gas pres‐

sure regulator/ sensor module - GX23- , coolant circulation pump
- V50- , continued coolant circulation pump - V51-
♦ On left of engine compartment
1- Electrical connector for gas pressure regulator with high-
pressure valve for gas mode - N372-
2- Electrical connector for sensor module - GX23-
Exploded view
⇒ “6.1 Exploded view - gas pressure regulator”, page 194 .
3 - Electrical connector for coolant circulation pump - V50-
4 - Electrical connector for continued coolant circulation pump -
V51-
Exploded view
Overview of fitting locations - engine (from above), vehicles with‐

out natural gas system

stage - N70-
Rep. gr. 28 ; Ignition
system; Exploded view -
ignition system
stage - N127-
ignition system
stage - N291-
ignition system
stage - N292-
ignition system
system; Exploded view - ignition system

6 - Fuel metering valve - N290- or fuel pressure regulating valve - N276-

❑ Fuel metering valve - N290- or fuel pressure regulating valve - N276- may be fitted, depending on version
❑ Injector 2, cylinder 4 - N535-
❑ Exploded view ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Exploded
view - fuel rail with injectors
9 - Fuel pressure sender for low pressure - G410- , MPI
❑ Exploded view ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Ex‐
ploded view - intake manifold
Overview of fitting locations - engine (from above), vehicles with

natural gas system


stage - N70-
ignition system
stage - N127-
ignition system
stage - N291-
ignition system
stage - N292-
ignition system
system; Exploded view - ignition system
6 - Fuel metering valve - N290- or fuel pressure regulating valve - N276-
❑ Fuel metering valve - N290- or fuel pressure regulating valve - N276- may be fitted, depending on version
8 - Gas injection valve 4 - N369-
❑ Exploded view ⇒ “5.1 Exploded view - gas rail”, page 189
9 - Gas injection valve for cylinder 3 - N368-
11 - Gas rail temperature and pressure sensor - GX21-



sender - G266-
Rep. gr. 17 ; Sump/oil
pump; Exploded view -
sump/oil pump
Rep. gr. 19 ; Coolant
pump/thermostat as‐
sembly; Exploded view -
coolant pump/thermo‐
stat
FSI
Rep. gr. 24 ; Injectors;
Exploded view - fuel rail
with injectors
FSI
Rep. gr. 24 ; Injectors;
Exploded view - fuel rail
with injectors
G247-
icing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Exploded view - fuel rail with injectors
❑ Comprises:
♦ Throttle valve module - J338-

7 - Actuator 1 for camshaft adjustment - F366- (for cylinder No. 1)

❑ Exploded view ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Exploded
view - valve gear
view - valve gear
view - valve gear
view - valve gear
view - valve gear
view - valve gear
view - valve gear
view - valve gear
❑ Exploded view ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition system; Ex‐
ploded view - ignition system
❑ Exploded view ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Oil filter/oil pressure
switches; Exploded view - oil pressure switches/oil pressure control


er - G62-
❑ Exploded view
coolant temperature
senders”, page 111
- V465- with position sender for
charge pressure positioner -
G581-
❑ Integrated in turbo‐
charger
3 - Turbocharger air recircula‐
tion valve - N249-
Rep. gr. 21 ; Turbo‐
charger; Exploded view
- turbocharger

with alternator


valve 1 - N318-
Rep. gr. 15 ; Timing
chain cover; Exploded
view - timing chain cover
N205-
Rep. gr. 17 ; Oil filter/oil
pressure switches; Ex‐
ploded view - oil pres‐
sure switches/oil pres‐
sure control
sure control
valve - N522-

with starter-alternator


sure control
valve 1 - N318-
N205-
valve - N522-
sure control

2 Air cleaner
1 - Snow screen
2 - Air duct
❑ On lock carrier
its or dirt
3 - Water drain
❑ Clean
4 - Mounting
5 - Sealing element
6 - Air duct
❑ For country-specific ver‐
sion with variable intake
manifold change-over
valve - N335-
❑ Not fitted after air clean‐
er (bottom section) has
been renewed
⇒ page 180
its or dirt
❑ Country-specific ver‐
sion: variable intake
manifold changeover
valve - N335- is not fitted
after air cleaner (bottom
section) has been re‐
newed ⇒ page 180
⇒ page 178
9 - Bolt
❑ Thread-forming
❑ 3.5 Nm
2. Air cleaner 177

11 - Seal
❑ Check for damage
12 - Bolt
❑ Thread-forming
❑ 3.5 Nm
14 - Air pipe
❑ Tightening torque for screw-type clips ⇒ page 158
15 - Bolt
❑ Thread-forming
❑ 1.5 Nm
16 - Heat shield
17 - Air duct
❑ On lock carrier
18 - Bolt
❑ Thread-forming
❑ 2.5 Nm

housing
Removing

Vehicles with air filter bypass flap valve - N275- :

N275- .

– Remove bolts -arrows- and detach air duct -2- from lock car‐
rier.
2. Air cleaner 179


Installing
Note
♦ The air cleaner housing must always be clean.

♦ Use soap solution when fitting air hose.
♦ Country-specific version:
variable intake manifold changeover valve - N335- is not fitted
after renewal; fit a mating plug onto electrical connector in
electrical wiring harness ⇒ Electronic parts catalogue .
housing.
Tightening torques
charge air system

3 Intake manifold
⇒ “3.3 Removing and installing throttle valve module GX3 ”, page
185

2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Exploded view
- intake manifold .


Removing
– Use assembly tool - T10118- to release electrical connector
for fuel pressure sender - G247- and unplug it.
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Re‐
moving and installing intake manifold .
Installing
Additional work:


Removing
sender 3 - G495- / exhaust gas temperature sender 4 - G648-
out of bracket and unplug.
sions.)


1:
– Move bracket with pressure differential sender clear at intake
manifold -arrow-.
Installing
Additional work:
Tightening torques

- vehicles with natural gas system

Removing
system ⇒ page 2 .
cleanliness .
WARNING




for fuel pressure sender - G247- and unplug it.

Installing
Additional work:
– Install battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
WARNING

structed person.

WARNING




module - GX3-
⇒ “3.3.1 Removing and installing throttle valve module GX3 - ve‐
hicles without natural gas system”, page 185
⇒ “3.3.2 Removing and installing throttle valve module GX3 - ve‐
3.3.1 Removing and installing throttle valve

module - GX3- - vehicles without natural
gas system
2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Removing and
installing throttle valve module - GX3- .
3.3.2 Removing and installing throttle valve

module - GX3- - vehicles with natural
gas system
Removing
moving and installing throttle valve module - GX3- .
Installing
Additional work:

4 Injectors

2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Exploded view - fuel
rail with injectors .

⇒ “4.2.1 Removing and installing fuel rail - vehicles with alterna‐
tor”, page 186
⇒ “4.2.2 Removing and installing fuel rail - vehicles with starter-
4.2.1 Removing and installing fuel rail - vehi‐

cles with alternator
2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Removing and in‐
stalling fuel rail .
4.2.2 Removing and installing fuel rail - vehi‐

cles with starter-alternator
Removing
– Unplug electrical connector -arrow- for fuel pressure sender -
G247- .
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Removing

⇒ “4.3.1 Removing and installing injectors - vehicles with FSI en‐
gine”, page 186
⇒ “4.3.2 Removing and installing injectors - vehicles with MPI en‐
gine”, page 187
⇒ “4.3.3 Removing and installing injector sleeves - vehicles with
4.3.1 Removing and installing injectors - ve‐

hicles with FSI engine
stalling injectors .


hicles with MPI engine
stalling injectors .
4.3.3 Removing and installing injector sleeves

♦ Puller -T40360-
♦ Thrust piece - T40361-
Note
♦ The protective sleeve must be renewed if the FSI injector or

the support has been renewed.
♦ It is not necessary to renew the protective sleeve if the re‐
moved FSI injector is re-installed.
♦ The FSI injector can be re-installed if the protective sleeve has
been renewed.
4. Injectors 187
Preparing puller -T40360-

– Turn nut -1- anti-clockwise -arrow B- by hand as far as stop on
circlip -2- (counterhold at hexagon head -4-).
– Turn nut -3- clockwise -arrow A- by hand as far as stop on
circlip -2- (counterhold at hexagon head -4-).
Removing
• FSI injectors removed ⇒ Servicing 4-cylinder engine, 2.0 ltr.
4-valve TFSI; Rep. gr. 24 ; Injectors; Removing and installing
injectors .
– Insert puller -T40360- all the way into relevant hole for injector.
Note
♦ Use a torque wrench to fix the injector sleeve in position.

♦ Set torque wrench to 5 Nm.
– To fix injector sleeve in position, turn nut -2- clockwise

-arrow A- until limit torque is reached (counterhold at hexagon
head -1-).
– To pull out injector sleeve, turn nut -3- anti-clockwise
-arrow B- (counterhold at hexagon head -1-).
Installing
– Use thrust piece - T40361- to carefully insert injector sleeve
-1- as far as it will go into hole in cylinder head -2-.

2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Cleaning injectors .

5 Gas injection valves

⇒ “5.1 Exploded view - gas rail”, page 189
⇒ “5.2 Removing and installing gas rail with gas injection valve
N366 / N367 / N368 / N369 ”, page 190
⇒ “5.3 Removing and installing gas injection valve”, page 193
5.1 Exploded view - gas rail
1 - O-ring
❑ Must be installed dry
2 - Gas injection valve
stalling gas rail with gas
injection valve N366 /
N367 / N368 / N369 ”,
page 190
❑ After removing, perform
leak test on low-pres‐
sure section of natural
gas system ⇒ Natural
gas engines - General
information; Rep. gr.
00 ; Checking natural
gas system
3 - O-ring
❑ Must be installed dry
4 - Retaining clip
❑ Ensure it is positioned
correctly on gas injec‐
tion valve and fuel rail
5 - Gas rail
❑ After removing, perform
leak test on low-pres‐
sure section of natural
gas system ⇒ Natural
gas engines - General
information; Rep. gr.
00 ; Checking natural
gas system
6 - Bolt
❑ 7 Nm
7 - Connection
❑ Not available as replacement part
8 - Natural gas low-pressure pipe
❑ Screw on union nut by hand until it makes contact
❑ 5 Nm +70°
5. Gas injection valves 189

9 - Gas rail temperature and pressure sensor - GX21-

⇒ “7.6 Removing and installing gas rail temperature and pressure sensor GX21 ”, page 202
❑ Lubricate taper seal and thread lightly with silicone-free oil
❑ After removing, perform leak test on low-pressure section of natural gas system ⇒ Natural gas engines
- General information; Rep. gr. 00 ; Checking natural gas system
❑ Counterhold at connection with a suitable tool to tighten on gas rail
❑ Tighten in stages:
• Pre-tighten to 27 Nm
• Turn back by 60°
• Final tightening torque: 34 Nm
Natural gas low-pressure pipe - installation position

– Bring natural gas low-pressure pipe into installation position
and screw on union nut -2- by hand until it makes contact.
• Locating element -4- must make contact with engine lifting eye
-3-.
– Tighten union nut; to do so, counterhold at connection -1- with
a suitable tool.
5.2 Removing and installing gas rail with

gas injection valve -N366- / -N367- / -
N368- / -N369-
Removing
system ⇒ page 2 .
cleanliness .

WARNING


– Move electrical wiring clear at intake manifold.
– Detach vacuum line -1- and coolant line -2- from intake mani‐
fold.
– Unscrew bolt -arrow- using socket Torx T30 - T10405- and

detach bracket -1- for electrical connectors.
– Unscrew union nut -2- for natural gas low-pressure pipe; to do

so, counterhold at connection -1- with a suitable tool.

– Move electrical wiring harness -1- clear at engine lifting eye.

– Unscrew bolts -arrows- for gas rail.
– Carefully lift out gas rail -2- with gas injection valves.
Installing
Note
Renew O-rings after removing.
– Lubricate O-rings with clean engine oil prior to installation.

– Press gas rail with gas injection valves by hand as far as it will
go into aperture of intake manifold (gas injection valves must
be free of oil and grease).
WARNING

structed person.

WARNING


Tightening torques
♦ ⇒ “5.1 Exploded view - gas rail”, page 189
24 ; Intake manifold; Exploded view - intake manifold

5.3 Removing and installing gas injection

valve
Removing
• Gas rail with gas injection valves -N366- / -N367- / -N368- / -
N369- removed ⇒ page 190
– Remove retaining clip -2- and detach gas injection valve -3-
from gas rail -1-.
2 - Retaining clip
3 - O-ring
5 - O-ring
Installing
Note
Renew retaining clips and O-rings after removal.
– Fit O-rings -3, 5- and check that they are seated correctly (O-
rings must be dry).
– Note correct installation position of retaining clip -2- relative to
gas injection valve -4-.
– Ensure that gas injection valve is seated correctly on connec‐
tion to gas rail -1-.

6 Gas pressure regulator

⇒ “6.1 Exploded view - gas pressure regulator”, page 194
⇒ “6.2 Removing and installing gas pressure regulator”,
page 195
6.1 Exploded view - gas pressure regulator
1 - Coolant hose
tank
2 - Coolant hose
❑ From engine
3 - Natural gas low-pressure
pipe
⇒ page 195
❑ If leaks are present, un‐
screw union nut com‐
pletely and re-tighten it
❑ 5 Nm +135°
4 - Pipe connection
❑ With O-rings (supplied
with pipe connection)
❑ Renew after loosening
❑ Apply locking fluid when
installing; refer to ⇒
logue
❑ 18 Nm
❑ Counterhold at pipe
connection when loos‐
ening
❑ Screw in union nut by
hand until it makes con‐
tact
❑ 17 Nm
6 - Pipe connection
❑ With O-rings (supplied with pipe connection)
❑ Renew after loosening
❑ Apply locking fluid when installing; refer to ⇒ Electronic parts catalogue
❑ 18 Nm
7 - Gas pressure regulator
❑ With high-pressure valve for gas mode - N372-
❑ Removing and installing ⇒ “6.2 Removing and installing gas pressure regulator”, page 195
8 - Sensor module - GX23-
❑ Removing and installing ⇒ “7.7 Removing and installing sensor module GX23 ”, page 203
❑ 20 Nm
9 - Bolt
❑ 8 Nm

10 - Bracket
11 - Bolt
❑ 2x
❑ 8 Nm
12 - Bolt
❑ 2x
❑ 8 Nm
13 - Bonded rubber bush
❑ Screw in by hand until contact is made
Natural gas low-pressure pipe - installation position

– Move natural gas low-pressure pipe into installation position.
• Angle -α- = max. 35°
6.2 Removing and installing gas pressure

regulator
6. Gas pressure regulator 195

Removing
system ⇒ page 2 .
cleanliness .
WARNING


WARNING


expansion tank.


– Carefully loosen union nuts -2- to release residual gas (coun‐
terhold at connection with a suitable tool).
– Unscrew union nut, move high-pressure pipe clear and detach
it slightly from gas pressure regulator.
Caution
Risk of gas leaks in gas pressure pipe due to improper han‐

dling.
♦ Do not attempt to bend gas pressure pipe to a different
shape

– Remove bolts -4- and detach gas pressure regulator.
Installing
ing battery .

WARNING

structed person.

WARNING


leaks .
Tightening torques


200
⇒ “7.6 Removing and installing gas rail temperature and pressure
sensor GX21 ”, page 202
⇒ “7.7 Removing and installing sensor module GX23 ”,
page 203

2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and sensors; Remov‐
ing and installing intake air temperature sender - G42- / intake
manifold pressure sender - G71- .


- G70-
Removing
– Remove bolts -arrows- and detach air mass meter - G70-
-item 1-.
Installing
To ensure that the air mass meter -G70- functions correctly, it is
important to observe the following notes and procedures.
Note
♦ If the air filter element is very dirty or wet, dirt particles or water
♦ Check air filter element and inside of air cleaner housing for
ing housing .
Tightening torques
charge air system

sender - G247-

Removing
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and sensors;
Installing
Additional work:


ing battery .

alternator
2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and sensors; Remov‐
ing and installing fuel pressure sender - G247- .

sender - G247- - vehicles with natural
gas system
Removing
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and sensors;
Installing
Additional work:

2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and sensors; Checking
fuel pressure sender - G247- .

⇒ “7.5.1 Removing and installing fuel pressure sender for low
pressure G410 - vehicles without natural gas system”,
page 201
pressure G410 - vehicles with natural gas system”, page 201

sender for low pressure - G410- - vehi‐
cles without natural gas system
stalling fuel pressure sender for low pressure - G410- .

cles with natural gas system

♦ Socket, 27 mm - T40218-
Removing
– Unscrew fuel pressure sender for low pressure - G410-
-item 2- using socket, 27 mm - T40218- .
Installing
Tightening torques
24 ; Injectors; Exploded view - fuel rail with injectors
7.6 Removing and installing gas rail temper‐

ature and pressure sensor - GX21-
Removing
system ⇒ page 2 .
cleanliness .
WARNING




– Unscrew gas rail temperature and pressure sensor - GX21-
-item 1-; to do so, counterhold at connection on gas rail with a
suitable tool.
Installing
WARNING

structed person.

WARNING


Tightening torques
♦ ⇒ “5.1 Exploded view - gas rail”, page 189
7.7 Removing and installing sensor module

- GX23-

♦ Socket, 27 mm - T40218-
Removing
system ⇒ page 2 .
cleanliness .
WARNING


– Unscrew sensor module - GX23- -2- from gas pressure regu‐
lator using socket, 27 mm - T40218- .

Installing
WARNING

structed person.

WARNING


leaks .
Tightening torques


⇒ “8.1.1 Exploded view - high-pressure pump, vehicles without
⇒ “8.1.2 Exploded view - high-pressure pump, vehicles with nat‐
8.1.1 Exploded view - high-pressure pump,

vehicles without natural gas system
2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; High-pressure pump; Exploded
view - high-pressure pump .
8.1.2 Exploded view - high-pressure pump, vehicles with natural gas system
1 - Vacuum pump
❑ Exploded view ⇒ Brake
system; Rep. gr. 47 ;
Vacuum system; Explo‐
ded view - vacuum
pump
2 - Roller tappet
❑ May remain lodged in
vacuum pump when
high-pressure pump is
removed
3 - O-ring
❑ Notes on installation ⇒
gine, 2.0 ltr. 4-valve
TFSI; Rep. gr. 24 ; High-
pressure pump; Explo‐
ded view - high-pres‐
sure pump
4 - Cooling flange
❑ For high-pressure pump
5 - O-ring
❑ Notes on installation ⇒
sure pump
❑ Depending on version,
with integrated fuel me‐
tering valve - N290- or
fuel pressure regulating
valve - N276-
❑ Removing and installing ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; High-pressure
pump; Removing and installing high-pressure pump

7 - Bolt
❑ Tighten in stages
♦ Screw in by hand until contact is made
♦ Tighten one turn alternately until flange of high-pressure pump makes contact with vacuum pump
♦ 8 Nm +90°
8 - Connection
9 - Fuel supply hose
❑ From fuel tank
❑ Notes on installation ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; High-pressure
pump; Exploded view - high-pressure pump
11 - Bolt
❑ 9 Nm
❑ From fuel tank
16 - Connection
❑ For fuel supply line
❑ Tightening torques and notes on installation ⇒ Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI; Rep.
gr. 24 ; High-pressure pump; Exploded view - high-pressure pump
❑ To fuel rail
18 - Bolt
19 - Coolant hoses


pump

pump - vehicles without particulate filter
2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; High-pressure pump; Remov‐
ing and installing high-pressure pump .

pump - vehicles with particulate filter
Removing

sender 3 - G495- / exhaust gas temperature sender 4 - G648-
out of bracket and unplug.
sions.)
engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; High-pressure pump;
Installing
Additional work:
Tightening torques

9 Lambda probe
cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Lambda probe .
9. Lambda probe 209


page 211

⇒ “10.1.1 Exploded view - engine control unit, vehicles without
⇒ “10.1.2 Exploded view - engine control unit, vehicles with nat‐
10.1.1 Exploded view - engine control unit, vehicles without natural gas system
1 - Bolt
❑ 9 Nm
2 - Mounting
J623-
❑ Before renewal, perform
tic tester.
⇒ page 211
4 - Bolt
❑ 9 Nm

10.1.2 Exploded view - engine control unit, vehicles with natural gas system
1 - Battery tray
2 - Mounting
J623-
3 - Bolt
❑ 9 Nm
4 - Nut
❑ 9 Nm
5 - Clip
6 - Clip
❑ Before renewal, perform
tic tester.
⇒ page 211
8 - Clip

Removing
Note
If engine control unit is renewed, run “01 - Replace control unit”

in Guided Functions mode of ⇒ Vehicle diagnostic tester.


J623- -item 2-.

J623- -item 2-.
Installing
– If engine control unit - J623- was renewed, perform adaptions
listed in Guided Function “01 - Functions, engine mechanics”


⇒ “1.1.1 Exploded view - silencers, front-wheel drive vehicles
⇒ page 216
drive”, page 219
1.1.1 Exploded view - silencers, front-wheel drive vehicles without natural gas
system

1 - Rubber mounting
has been pulled off
⇒ page 228
2 - Bolt
❑ 23 Nm
3 - Retainer
4 - Centre silencer
for repair purposes
❑ Cutting point
⇒ page 222
⇒ page 228
5 - Bolt
❑ 23 Nm
6 - Retainer
7 - Rubber mounting
has been pulled off
⇒ page 228
8 - Front silencer
Caution
Risk of damage to flexi‐
ble joint.
Do
♦ not bend flexible joint
more than 10°.
Install
♦ flexible joint so that
it is not under tension.
Take
♦ care not to damage
wire mesh on flexible
joint.

⇒ “1.4.1 Removing and installing front silencer - vehicles without particulate filter”, page 223
9 - Gasket

10 - Nut
❑ 23 Nm
11 - Mounting
12 - Bolt
❑ 23 Nm
13 - Clamp (front)
15 - Retainer
16 - Bolt
❑ 23 Nm
17 - Rear silencer
purposes
18 - Clamp (rear)
Components of mountings for front silencer - vehicles without

particulate filter
1- Spacer sleeve
3- Washer
4- Bolt, 23 Nm
5- Bolt, 23 Nm
6- Spacer sleeve
7- Buffer
8- Bracket
9- Spacer sleeve



• Bolted connections facing towards left
tom of clamp.
1.1.2 Exploded view - silencers, front-wheel drive vehicles with natural gas sys‐
tem

1 - Exhaust pipe
for repair purposes
❑ Cutting point
⇒ page 222
⇒ page 228
2 - Clamp (front)
free of stress
⇒ page 228
⇒ page 218
Caution
ble joint.
Do
more than 10°.
Install
Take
joint.

4 - Gasket
5 - Nut
❑ 23 Nm
6 - Bolt
❑ 23 Nm
7 - Mounting
8 - Front silencer
⇒ “1.4.3 Removing and installing front silencer - vehicles with natural gas system”, page 226
9 - Bolt
❑ Tightening torques ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded view -
underbody trim

10 - Retainer
13 - Retainer
14 - Bolt
❑ Tightening torques ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded view -
underbody trim
15 - Nut
❑ 23 Nm
16 - Retainer
18 - Bolt
❑ 23 Nm
19 - Rear silencer
❑ Combined with front silencer as original equipment. Can be renewed separately for repair purposes
20 - Clamp (rear)

• Bolted connections facing towards left
tom of clamp.

• Position clamp -1- so that it makes contact with retainer

-arrow-.

♦ Bolted connections facing towards left
♦ Nuts face downwards.
♦ Install clamp so that ends of bolts do not protrude beyond bot‐
tom of clamp.

1 - Centre silencer
for repair purposes
❑ Cutting point
⇒ page 222
⇒ page 228
2 - Rubber mounting
⇒ page 228
3 - Bolt
❑ 23 Nm
4 - Retainer
5 - Front silencer
Caution
ble joint.
Do
more than 10°.
Install
Take
joint.

⇒ “1.4.1 Removing and installing front silencer - vehicles without particulate filter”, page 223
6 - Gasket
7 - Nut
❑ 23 Nm
8 - Bolt
❑ 23 Nm
9 - Mounting
10 - Clamp (front)
11 - Rear silencer
purposes


12 - Mounting
13 - Bolt
❑ 23 Nm
14 - Clamp (rear)
15 - Retainer
16 - Bolt
❑ 23 Nm

pipe
Removing
– Remove nuts -1- (accessible from above) for front exhaust
pipe.
noise insulation .
– Remove bolts -arrows- for front exhaust pipe.

– Loosen clamp -arrows-.
Caution

– Carefully detach front exhaust pipe from front silencer and re‐
move.

in order to renew the centre silencer/exhaust pipe or rear si‐
lencer separately.
Procedure
– Cut through exhaust pipes at right angle at notch -arrow- using

– Position centre of clamps -arrows- over cutting location.

– Fit clamps ⇒ page 216 .
Tightening torques

⇒ “1.4.1 Removing and installing front silencer - vehicles without

Removing
noise insulation .

Caution


Installing
Note
Renew gaskets, seals and self-locking nuts after removal.

Tightening torques

Removing

– Unscrew bolts -arrows- for front silencer (shown on right side).
Caution


Installing
Note

Tightening torques


Removing
struts .
WARNING
Risk of accident caused by weight of silencer.

♦ A second mechanic is required for removal of the front
silencer.
– Loosen clamp -4-.

– Loosen clamp -2- and push to rear.
– Disconnect front silencer -3- from front exhaust pipe and re‐
move.
Installing
Tightening torques

⇒ “1.5.1 Removing and installing silencers - vehicles without nat‐
⇒ “1.5.2 Removing and installing silencers - vehicles with natural
gas system”, page 228
1.5.1 Removing and installing silencers - ve‐

hicles without natural gas system
Removing
– Depending on country/equipment version: Remove diagonal
struts (left and right) ⇒ General body repairs, exterior; Rep.
gr. 66 ; Underbody trim; Exploded view - underbody struts .
struts .

Caution

than 10°.
– Lower front silencer slightly and detach clamp.

– Tie up front silencer.
WARNING

lencer.
WARNING

lencer.

– Unscrew bolts -3- and remove silencer -1-.
Installing
Tightening torques

1.5.2 Removing and installing silencers - ve‐

hicles with natural gas system
Removing rear silencer without cutting point
– Remove diagonal struts (left and right) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded view -
underbody struts .
WARNING

lencers.
– Loosen clamp -1- and push to rear.

– Unscrew bolts -arrows- and remove silencer -2-.
– Screw in bolts again until contact is made.
Removing rear silencer with cutting point

– Loosen clamp -3-.
– Unscrew bolt -2-, slide clamp towards front and detach silenc‐
er -1-.
– Screw in bolts again until contact is made.
Installing
Tightening torques

Procedure


mounting -1- for exhaust pipe is preloaded by -a- = 6 ... 10 mm.
nections evenly.
A4/A5 before product upgrade

– Check clearance between tailpipes and bumper on both sides:
Tightening torques

2.0 ltr. 4-valve TFSI; Rep. gr. 26 ; Exhaust pipes/silencers;


cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 26 ; Emission
control system .

1 Ignition system
cylinder engine, 2.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition
system .

Service
Workshop Manual
Audi A4 2015 ➤
Audi A4 Avant 2015 ➤
Audi A5 2016 ➤
897 Gen. I)
Engine ID
CRT CSW
C B
Edition 11.2018

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system

Copyright © 2018 Audi AG, Ingolstadt D4B8058BF1E

Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Removing and installing support mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Contents i
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.6 Removing and installing oil temperature sender 2 G664 . . . . . . . . . . . . . . . . . . . . . . . . . . 79
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.1 Exploded view - coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.3 Exploded view - thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.7 Removing and installing thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.8 Removing and installing map-controlled engine cooling system thermostat F265 . . . . . . 95
2.10 Removing and installing temperature sender for engine temperature regulation G694 . . 95
2.11 Removing and installing coolant temperature sender 2 G802 . . . . . . . . . . . . . . . . . . . . . . 96
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
ii Contents

2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4.2 Removing and installing intake manifold (top section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
4.3 Removing and installing intake manifold (bottom section) . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.4 Removing and installing intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.3 Performing adaption of correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.4 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.5 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.6 Checking return flow rate of injectors at starter cranking speed . . . . . . . . . . . . . . . . . . . . 145
5.7 Checking restrictor in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
6.1 Removing and installing intake air temperature sender G42 . . . . . . . . . . . . . . . . . . . . . . 149
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Contents iii

2.2 Removing and installing emission control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.2 Removing and installing exhaust gas temperature sender . . . . . . . . . . . . . . . . . . . . . . . . 186
5.3 Removing and installing exhaust gas recirculation temperature sensor G98 . . . . . . . . . . 190
6 Exhaust manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
6.1 Exploded view - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
6.2 Removing and installing exhaust manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
iv Contents
1 Identification
(ARL006113; Edition 11.2018)
1. Identification 1


page 25
1.1 Removing engine



♦ Adapter (2x) -VAS 6131/13-2- from support set, Audi Q7
>2005 - VAS 6131/13-


♦ Ball joint ejector - VAS 251 805- (not illustrated)

♦ Ball joint puller - T40043-
♦ Wrench, 21 mm - T40263-
♦ Stepladder (commercially available)

Procedure
Note
♦ The engine is removed from underneath together with the

♦ Fit cable ties in the same locations when installing.
♦ Observe rules for cleanliness ⇒ Servicing 6-cylinder TDI en‐
cleanliness .
♦ All bolts on running gear components with bonded rubber
(vehicle unladen).
♦ Bonded rubber bushes can only be turned to a limited extent.

Note
♦ The electromechanical parking brake must be released before

disconnecting the battery, so that the propshaft can be turned
during removal.
♦ If the engine has been removed in order to remove the turbo‐
charger, the turbocharger 1 control unit - J724- must be moved
into the “closed” position using the vehicle diagnostic tester ⇒
Servicing 6-cylinder TDI engine, common rail; Rep. gr. 21 ;
Turbocharger; Removing and installing turbocharger .
Caution
Risk of irreparable damage to electronic components.

♦ Observe notes on procedure for disconnecting the battery.


WARNING
Risk of scalding as hot coolant can escape.

♦ Observe safety precautions ⇒ Servicing 6-cylinder TDI
engine, common rail; Rep. gr. 00 ; Safety precautions;
Safety precautions when working on the cooling system .

expansion tank.
liner (front) .
noise insulation .
– Remove propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;
Removing and installing propshaft .


Note
Disregard -item 1-.

N275- .
Note
Disregard -item 1-.


Caution
Risk of malfunctions caused by dirt.

♦ Observe rules for cleanliness when working on the fuel
supply system ⇒ Servicing 6-cylinder TDI engine, com‐
mon rail; Rep. gr. 00 ; Repair notes; Rules for cleanliness .
WARNING



-arrow A-.


coolant pipe (front).
– Unplug electrical connector -2- for intake air temperature

sender - G42- .
– Release hose clip -1-, detach air pipe and tie up to left side.


– Lift retaining clip -2- and disconnect coolant hose (top left) from
radiator.
– Take electrical connectors -1- out of bracket, disconnect them

and move electrical wiring clear.
– Remove bolts -arrows- and detach engine control unit - J623-
-item 2-.
– Unplug electrical connector “K” -arrow-.

– Place engine control unit - J623- on engine and secure to pre‐
vent it from dropping.

– Unplug electrical connector -2- and move wiring clear.

– Loosen nut -1- a few turns, move electrical connector -3- clear
and unplug.
– Remove nut -4- and move earth wires clear.
– Take electrical connector -2- out of bracket, unplug it and

move electrical wiring clear.
– Release hose clip -arrow- and detach air hose from air pipe.

mounting solenoid valve on both sides and move wiring clear.

– Open cover -1- -arrow- on suspension turret (both sides).
Caution
Danger of damage to the joints of the upper links.

♦ The weight of the wheel bearing housings must be sup‐
ported.
– Tie up wheel bearing housing -1- on both sides with tensioning

strap - T10038- as shown (use the handle of a hammer -2- to
do so).
– To protect thread, unscrew nut -arrow- on joint pin of track rod

ball joint until nut is flush with thread of joint pin.
WARNING
Risk of injury if parts are allowed to drop out.

♦ The track rod ball joint will release suddenly from the
wheel bearing housing when pressed out. Use engine and
gearbox jack - VAS 6931- or similar to provide support.
Caution
Risk of damage to ball joint puller.

♦ Make sure the two lever arms of the puller are parallel
when maximum force is exerted.
– Press track rod ball joint off wheel bearing housing using ball
joint ejector - VAS 251 805- ; counterhold with a 6 mm hexagon
socket.

– To protect thread, unscrew nut -arrow- on joint pin of guide link

until nut is flush with thread of joint pin. Counterhold joint pin
if necessary.
WARNING

♦ The swivel joint will release suddenly from the wheel bear‐
ing housing when pressed out. Use engine and gearbox
jack - VAS 6931- or similar to provide support.
– Press joint pin of guide link out of tapered seat using ball joint
puller - T40043- , taking care not to damage boot.
– Unscrew nut and move guide link clear at wheel bearing hous‐
ing; if necessary, counterhold at joint pin with a TX 40 socket
wrench.
– On appropriate versions: Remove nut -2- and move coupling

rod for vehicle level sender clear.
– Detach bolted connections -1, 3- for track control link.
– Swivel track control link towards front.
Note
To remove bolt -1-, turn steering to full left/right lock.
– On both sides, unscrew nut -3- and pull out bolt -1- for coupling
rod -2-.
– Remove bolt -arrow- for subframe shield on both sides.

– Remove poly V-belt from air conditioner compressor pulley ⇒
Cylinder block (pulley end); Removing and installing poly V-
belt .


1 - For parking lock solenoid - N486-
3 - For electric pump 2 for gearbox - V553-
Caution
Risk of irreparable damage to gearbox control unit (mecha‐

tronic unit) because of electrostatic discharge.
♦ Before unplugging or plugging in electrical connector, me‐
chanic must discharge static electricity. To do so, touch
vehicle earth, heater radiator, or lifting platform, with your
hand.
♦ Do NOT touch connector contacts in gearbox connector
with your hands.
– Unplug electrical connector -2- on gearbox.

– Remove underbody trim (front left) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody trim; Exploded view - un‐
derbody trim .

– Pull clip -3- off stud.
– Remove nuts -arrows- and loosen (do not remove) nut -4-.
– Tie bracket with control unit for NOx sender 2 - J881- to front
exhaust pipe.
Note
Disregard -item 2-.
WARNING
Reducing agent can cause skin irritation.

♦ Observe safety measures when handling reducing agent
⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr.
00 ; Safety precautions; Safety precautions when working
on the SCR system .
Note
Hold a clean cloth under separating point to catch escaping re‐

ducing agent.


– Disconnect SCR supply line -1- ⇒ Servicing 6-cylinder TDI
reduction) system; Exploded view - reducing agent supply
line .
parking lock clear.
If engine is to be separated from gearbox:

Caution
Irreparable damage can be caused if the camshaft timing chain

slips.
♦ Turn crankshaft only in direction of engine rotation
-arrow-.
– To slacken bolts for flywheel, counterhold crankshaft at vibra‐

tion damper using wrench, 21 mm - T40263- and adapter -
T40314- .

– Remove 6 bolts -arrow- for flywheel from drive plate -1-. Turn
crankshaft 60° in direction of engine rotation each time.

– Set up scissor-type assembly platform - VAS 6131 B- with
support set for Audi - VAS 6131/10- , adapter -VAS 6131/11-1-
and adapters -VAS 6131/13-2- as follows:
Platform Parts from -VAS 6131/10- , adapter -VAS
coordinates 6131/11-1- and adapter -VAS 6131/13-2-
C4 /10-1 /10-4 /10-5 /10-11
E4 /10-1 /10-4 /10-5 /10-11
E10 /10-1 /10-2 /10-5 /13-2
B15 /10-1 /10-3 /10-5 /11-1
F15 /10-1 /10-2 /10-5 /10-6
F17 /10-1 /10-2 /10-5 /13-2
assembly platform.
zontally.
– Position support elements from -VAS 6131/10- at both sides

of engine, as shown.
– Make sure that threaded spindles are screwed in completely.

– Support subframe as shown using support elements from -

VAS 6131/10- and adapter -VAS 6131/13-2- .
Note
The support elements only support the subframe; the base plate
is not secured to the scissor-type assembly platform.

VAS 6131/11-1- at tunnel cross member, as shown.

VAS 6131/13-2- under front exhaust pipe, as shown.
– Fix position of subframe ⇒ Running gear, axles, steering; Rep.
gr. 40 ; Subframe; Fixing position of subframe .

Note
Disregard -item 1-.
Caution

♦ Carefully guide out engine/gearbox assembly with sub‐
frame from engine compartment when lowering.
♦ Guide drive shafts carefully past gearbox.
– Lower scissor-type assembly platform - VAS 6131 B- with en‐

gine/gearbox assembly and pull out from underneath vehicle.
– Tie up drive shafts.



Procedure
wiring harness.
– Move SCR supply line -1- clear at subframe.
WARNING
Risk of accident caused by weight of subframe.

♦ A second mechanic is required for removal of the sub‐
frame.
– On both sides, remove bolt -2- and detach subframe to one

side (remove support elements).
Note
The illustration shows the installation position with the engine in‐
stalled.
– Unscrew NOx sender - G295- -arrow- using a tool from Lamb‐

da probe open ring spanner set - 3337- .
Note
stalled.

– Unscrew bolt -2- and loosen retaining clip.

– Detach injector for reducing agent - N474- -item 1- and press
to one side.
– Unplug electrical connectors -1, 2, 3- and move electrical wir‐

ing clear.
– Unplug electrical connector -2- at exhaust gas temperature

sender 4 - G648- and move electrical wiring clear.
Note
Disregard -item 1-.

– Move bracket -2- clear with pressure differential sender -
G505- .

– Remove bolt -2- at bracket for front exhaust pipe.
Note
Disregard -item 1-.
– Remove bolt -3- on retainer.
WARNING
Please note the following warnings when working on all parts

of the exhaust system:
♦ Wear gloves (e.g. rubber, not textile) and safety goggles
to avoid contact with eyes and skin - risk of injury.
– Open screw-type clip -1- and place it on intake funnel of emis‐

sion control module -2-.
– Detach emission control module with front exhaust pipe.

– Unscrew bolt -2- and move coolant hose to one side.
– Remove bolts -arrows- and move coolant pipe (right-side) to

one side.
Note
Disregard items -1 and 2-.


and adapter -VAS 6131/12-2- as follows:
Note
The other support elements remain unchanged.

coordinates adapter -VAS 6131/11-2- and adapter -
VAS 6131/12-2-
C7 /10-1 /12-2 /10-5 /10-12
E7 /10-1 /10-4 /10-5 /10-12
C10 /10-1 /10-4 /10-5 /11-2
F10 /10-1 /10-4 /10-5 /10-9

VAS 6131/12-2- at both sides of engine, as shown.

VAS 6131/11-2- at left of gearbox, as shown.

– Position support elements from -VAS 6131/10- at right of gear‐

box, as shown.

– Loosen bolt -1- for starter.
Note
Disregard -item A-.


support

♦ Lifting tackle - 3033-
♦ Universal mounting - VAS 6095/1- and bracket for V6 TDI en‐

gine - VAS 6095/1-14-

Procedure
type assembly platform - VAS 6131 B- (with engine detached
from gearbox)
– Attach lift arm extension - VAS 6101- to workshop hoist -
VAS 6100- .
– Attach lifting tackle - 3033- to engine lifting eyes and workshop
hoist as shown in illustration.
– Take up weight of engine with workshop hoist, but do not lift.
– Unscrew bolts -arrows- and remove engine support (left-side).

– Detach coolant pipe (left-side) -1- and move clear to side.
Note
Disregard -item 2-.

– Remove bolt -2- for earth wire.

– Remove bolts -arrows- and detach engine support -1-.
– Tie up starter on engine.
– Using universal mounting - VAS 6095/1- and bracket for V6

TDI engine - VAS 6095/1-14- , secure engine to engine and
gearbox support - VAS 6095A- (40 Nm), as shown.



Tightening torques
Note

♦ Additional lubricant such as engine oil or gearbox oil may be
used, but do not use lubricant containing graphite.
Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65
♦ Engine to gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Tightening torques for gearbox

Procedure
Note

angle.
♦ Do not remove plugs or protective caps until you are ready to
♦ Hose connections and air pipes/hoses must be free of oil and
♦ Re-install all cable ties in the same locations when installing.
Therefore, only tighten the bolted connections for the suspen‐
sion once the vehicle is in the unladen position or the reference
position.
– Install coolant pipes ⇒ page 97 .

– Install engine supports and engine mountings ⇒ page 35 .
• Engine with subframe positioned on scissor-type assembly
platform - VAS 6131 B-
– Before installing gearbox, remove residue from threaded holes
for engine/gearbox bolts in cylinder block using a thread tap.
and gearbox:
– Clean contact surface -1- on timing chain cover (bottom) and
on sealing element -2- with cleaning fluid - D 009 401 04- .
– Bond sealing element to timing chain cover (bottom).
– Move starter into installation position.


flywheel and torque converter from below, as illustrated.
• Assembly aid must engage in semi-circular recess -1-.
Note
Disregard -item 2-.
• Additionally, assembly aid must engage in holes -arrow A- and

-arrow B-.
Note
There is only one inspection hole -arrow B- on the circumference;

turn the flywheel accordingly.



gearbox are fitted in cylinder block.
can be reused; if so, apply marking ⇒ Rep. gr. 34 ; Removing
and installing gearbox; Tightening torques for gearbox .
– Bring gearbox into position on engine and tighten bolts
-3 … 10-.
Note
Apply a small amount of lubricant to the end seal if the starter

cannot be installed easily.
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Ex‐

ploded view - starter .
– Install front exhaust pipe and emission control module
⇒ page 175 .
– Tighten bolts for tunnel cross member ⇒ Rep. gr. 34 ; Re‐
moving and installing gearbox; Tightening torques for gear‐
box .
– Install subframe and subframe shield ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Subframe; Exploded view - subframe .
– Secure intermediate steering shaft to steering rack ⇒ Running
gear, axles, steering; Rep. gr. 48 ; Steering column; Removing
and installing intermediate steering shaft .
Note
The following step is necessary to ensure that the flywheel is


– Bolt flywheel onto drive plate as follows:
Caution

slips.
-arrow-.
– Turn crankshaft with wrench, 21 mm - T40263- and adapter -

T40314- .

Note
– Tighten first bolt -1- to 10 Nm and then slacken again; then

tighten again to 2 Nm (hand tight).
– Turn crankshaft by 180° in direction of engine rotation.
– Tighten bolt -4- to specified torque ⇒ Rep. gr. 30 ; Clutch;
Exploded view - flywheel and dual clutch .
– Turn crankshaft 60° at a time in direction of engine rotation
and tighten bolts in the sequence -5, 6, 1, 2, 3-.
note the following:
– Install manual release cable for parking lock ⇒ Rep. gr. 37 ;
Selector mechanism .
– Install coupling rod ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Exploded view - subframe .
– Install lower suspension links ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Lower suspension links, swivel joint; Exploded
view - lower suspension links, swivel joint .
– Install track rod ball joint ⇒ Running gear, axles, steering; Rep.
gr. 48 ; Steering rack; Exploded view - steering rack .
– Connect fuel hoses ⇒ Fuel supply system, diesel engines;
Rep. gr. 20 ; Plug-in connectors; Disconnecting plug-in con‐
nectors .
ing battery .
Caution

sive voltage.

830 .

– Install propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;

– Install wheel spoiler and wheel housing liner ⇒ General body
Wheels, tyres .
Function “0001 - Adapt learnt values - after component re‐
placement” ⇒ Vehicle diagnostic tester.
Caution

– Bleed fuel system ⇒ Servicing 6-cylinder TDI engine, common

rail; Rep. gr. 23 ; Injection system; Filling and bleeding fuel
system .
– Install engine cover panel ⇒ page 45 .
Note

– Check ATF level ⇒ Rep. gr. 34 ; ATF; Checking ATF level .
insulation .


Engine mounting
1 - Subframe
2 - Bolt
❑ 20 Nm
3 - Bolt
❑ 10 Nm
⇒ page 42
⇒ page 36
5 - Bolt
❑ 55 Nm
6 - Engine support
⇒ page 50
7 - Heat shield
8 - Bolt
❑ 10 Nm
9 - Bolt
❑ 55 Nm
❑ with
valve - N144-
valve - N145-
⇒ page 39
11 - Bolt
❑ 90 Nm +90°
12 - Bolt
❑ 30 Nm

support mounting.
Gearbox mounting
1 - Bolt
mountings
speed automatic gear‐
mountings
Assembly mountings;
bly mountings
⇒ 8-speed automatic
Assembly mountings;
bly mountings
3 - Stop plate
Assembly mountings;
bly mountings
⇒ 8-speed automatic gearbox; Rep. gr. 37 ; Assembly mountings; Exploded view - assembly mountings
5 - Gearbox
6 - Nut
❑ Tightening torques ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; Assembly mountings; Exploded view -
assembly mountings

7 - Gearbox support
❑ Removing and installing ⇒ 7-speed dual clutch gearbox; Rep. gr. 34 ; Assembly mountings; Exploded
view - assembly mountings
❑ Removing and installing ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; Assembly mountings; Exploded
view - assembly mountings
8 - Bolt
assembly mountings
9 - Bolt
assembly mountings
10 - Nut
assembly mountings

tion
♦ Engine support (basic set) - T40091-
♦ Engine support bracket (supplementary set) - T40093-
Procedure
WARNING
Risk of accident when weight of engine is shifted.

♦ In order to support the engine as described below, the
gearbox and tunnel cross members must be installed.


G505- .

– Press release tabs on both sides and disconnect crankcase

breather hose -2-.
– Unscrew bolts -arrows- and detach intake connecting pipe
-1-.
Note
Disregard -item 3-.
– Set up support bracket - 10-222A- on longitudinal members

(left and right), as shown.
– Engage spindles -10-222A/11- at engine lifting eyes (left and
right).
– Tighten spindles slightly to take up weight of engine, but do
not lift.
Attaching
Note
Secure all hose connections with correct type of hose clips (as

Tightening torques
Turbocharger; Exploded view - turbocharger
charge air system
♦ ⇒ Fig. ““Bracket with pressure differential sender -G505- -
tightening torque”“ , page 158

ings
⇒ “2.3.1 Removing and installing engine mounting (left-side)”,
page 39
⇒ “2.3.2 Removing and installing engine mounting (right-side)”,
page 41

ing (left-side)
Removing
ing is relieved.
Caution


noise insulation .
– Remove front left wheel spoiler ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liners; Removing and
belt .
– Remove air conditioner compressor from bracket and tie up to
left side ⇒ Heating, air conditioning; Rep. gr. 87 ; Air condi‐
tioner compressor; Detaching and attaching air conditioner
compressor at bracket .
– Unplug electrical connector -arrow- for left electrohydraulic
engine mounting solenoid valve - N144- .


Installing
Note

angle.

Tightening torques

ing (right-side)
Removing
– Remove bolts -arrows- and detach engine mounting (right-
side) -1-.
Installing
Note

angle.

Tightening torques
2.4 Removing and installing support mount‐

ing
⇒ “2.4.1 Removing and installing support mounting (left-side)”,
page 42
⇒ “2.4.2 Removing and installing support mounting (right-side)”,
page 42

ing (left-side)
Removing
noise insulation .
– Remove bolts -arrows- and detach support mounting (left-
side) -2-.
Installing
Note

angle.
• Installation position ⇒ page 36 .

Tightening torques

ing (right-side)
Removing
noise insulation .
– Remove bolt -1- for support mounting (left-side).

– Remove bolts -arrows- for support mounting (right-side) -1-.

– Raise engine slightly with spindle - 10-222A/11- and detach
support mounting towards left.
Installing
Tightening torques

mounting
⇒ “2.5.1 Removing and installing gearbox support with gearbox
mounting”, page 43
⇒ “2.5.2 Removing and installing gearbox mounting”, page 44
2.5.1 Removing and installing gearbox sup‐

port with gearbox mounting
Removing
– Remove tunnel cross member ⇒ 7-speed dual clutch gearbox;
mountings , or ⇒ 8-speed automatic gearbox; Rep. gr. 37 ;
Installing
Tightening torques
♦ ⇒ 8-speed automatic gearbox; Rep. gr. 37 ; Assembly mount‐
2.5.2 Removing and installing gearbox

mounting
Removing
– Remove gearbox support with gearbox mounting ⇒ page 43 .
box support -4-.
Installing
– Install gearbox support with gearbox mounting ⇒ page 43 .
Tightening torques



panel
Removing
Installing
– When fitting engine cover panel, take care not to damage oil
filler neck.
– First press engine cover panel onto rear retaining pins and
then onto front retaining pins with both hands.

page 49
page 50
51
1.1 Exploded view - cylinder block (pulley end)
1 - Poly V-belt
TDI engine, common
rail; Rep. gr. 13 ; Cylin‐
der block (pulley end);
Exploded view - cylinder
block (pulley end)
⇒ page 49
❑ With poly V-belt pulley
⇒ page 49
3 - Bolt
Servicing 6-cylinder TDI
engine, common rail;
Rep. gr. 13 ; Cylinder
block (pulley end); Ex‐
ploded view - cylinder
block (pulley end)
4 - Idler roller
❑ For poly V-belt
5 - Bolt
ploded view - cylinder
block (pulley end)
6 - Cover
❑ For idler roller

7 - Cover
8 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 13 ; Cylinder block (pulley
end); Exploded view - cylinder block (pulley end)
9 - Idler roller
❑ For poly V-belt
10 - Bolt
❑ Tightening torques ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
11 - Alternator
12 - Bracket
❑ For alternator
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 13 ; Cylinder block
(pulley end); Removing and installing bracket for ancillaries
13 - Bolt
14 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 19 ; Coolant pump/ther‐
mostat assembly; Exploded view - coolant pump
15 - Pulley
16 - Bolt
(pulley end); Removing and installing tensioner for poly V-belt
18 - Gasket
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 13 ; Cylinder block
(pulley end); Exploded view - cylinder block (pulley end)
19 - Bracket
20 - Bolt
21 - Dowel sleeves
23 - Bolt
❑ Tightening torques ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Exploded view

1 - Oil seal
end)
❑ Renewing ⇒ Servicing
6-cylinder TDI engine,
13 ; Cylinder block (pul‐
ley end); Renewing
crankshaft oil seal (pul‐
ley end)
⇒ page 51
3 - Bracket
❑ For intake manifold flap
motor - V157-
4 - Bolt
ploded view - sealing
flange (pulley end)
5 - O-rings
TDI engine, common
der block (pulley end);
Exploded view - cylinder
block (pulley end)
6 - Oil temperature sender 2 -
G664-
⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switch ; Removing
and installing oil temperature sender 2 - G664-
7 - Bolt
end); Exploded view - sealing flange (pulley end)
8 - Gasket
9 - Bolt
mostat assembly; Exploded view - coolant pump
11 - O-ring

12 - Gasket
13 - Dowel pin
❑ 2x
14 - Bolt
end); Exploded view - sealing flange (pulley end)

Removing
noise insulation .
Tightening torques

poly V-belt

er
Removing
– Unclip air duct (bottom) -2-.

Installing
Additional work:
Tightening torques

cillaries

Removing
– Remove engine mounting ⇒ page 39 .
Engine support (left-side):
– Unscrew bolts -arrows- and remove engine support.
Engine support (right-side):

– Remove bolts -arrows- and press coolant pipe (right-side)
Note
Disregard items -1 and 2-.


Installing
Tightening torques
Coolant pipes; Exploded view - coolant pipes

end)
Renewing crankshaft oil seal (pulley end) .

(pulley end)
Removing
– Drain off engine oil ⇒ Maintenance ; Booklet 830 .
– Remove oil filter element ⇒ Maintenance ; Booklet 830 .
– Remove intake manifold flap motor ⇒ Servicing 6-cylinder TDI
and installing intake manifold flap motor - V157- .
Installing
Additional work:
– Install intake manifold flap motor ⇒ Servicing 6-cylinder TDI
and installing intake manifold flap motor - V157- .
– Install oil filter element and fill up with engine oil ⇒ Mainte‐
nance ; Booklet 830 .


(gearbox end) .

3 Crankshaft
3. Crankshaft 53
4 Balance shaft
cylinder TDI engine, common rail; Rep. gr. 13 ; Balance shaft .


conrods .


1 - Bolt
2 - Sender wheel
❑ For engine speed send‐
er - G28-
TDI engine, common
rail; Rep. gr. 13 ; Crank‐
shaft; Removing and in‐
stalling sender wheel
3 - Oil seal
❑ For crankshaft (gearbox
end)
13 ; Cylinder block
(gearbox end); Renew‐
ing crankshaft oil seal
(gearbox end)
4 - Timing chain cover (bottom)
⇒ page 58
5 - Dowel sleeve
❑ 2x
6 - Gasket
7 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 15 ; Timing chain cover;
Exploded view - timing chain cover
8 - Timing chain cover (left-side)
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 15 ; Timing chain
cover; Removing and installing timing chain cover
9 - Bolt
10 - Reed valve

11 - Bolt
12 - Reed valve
13 - Bolt
14 - Cover
15 - Bolt
16 - O-ring
17 - Bolt
18 - Line
19 - O-ring
20 - Line
21 - O-ring
22 - Line
23 - Bolt
24 - O-ring
25 - Gasket
26 - Clamping sleeve
❑ 3x
❑ Prevents ingress of lubricant into threaded hole
27 - Bolt
28 - Timing chain cover (right-side)
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 15 ; Timing chain
29 - Bolt
30 - Reed valve
1. Timing chain cover 57

31 - Bolt
32 - Gasket
33 - Bolt
34 - Reed valve
35 - Dowel sleeve
37 - Not fitted
38 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 28 ; Glow plug system;
Exploded view - glow plug system

cover
page 58
⇒ “1.2.2 Removing and installing timing chain cover (bottom)”,
page 58

cover (top)
gine, common rail; Rep. gr. 15 ; Timing chain cover; Removing

cover (bottom)
Removing
• Gearbox removed ⇒ 7-speed dual clutch gearbox; Rep. gr.
34 ; Removing and installing gearbox; Removing gearbox
• Gearbox removed ⇒ 8-speed automatic gearbox; Rep. gr.
37 ; Removing and installing gearbox
• Steering rack secured to subframe with original bolts (bolts
should be tightened to specified torque but not turned through
specified angle).

– Lower engine evenly using spindles -10-222/11- until spindle

at engine lifting eye at rear right is loosened.
– Disengage spindle from engine lifting eye at rear right and
move clear to one side.
WARNING
Risk of injury
♦ The engine must be secured with the spindle at the engine
lifting eye (front left) to keep it from tipping.

engine, common rail; Rep. gr. 15 ; Timing chain cover; Removing

2 Chain drive
cylinder TDI engine, common rail; Rep. gr. 15 ; Chain drive .

3 Cylinder head
Note
Illustration shows the cylinder head for cylinder bank 2 (left-side) as an example.

15 ; Cylinder head; Re‐
moving and installing
cylinder head .
TDI engine, common
der head; Exploded
view - cylinder head
2 - Bolt
head; Exploded view -
cylinder head
3 - Bracket
4 - O-ring
TDI engine, common
der head; Exploded
5 - Coolant pipe
6 - Bolt
cylinder head
7 - Seal
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 15 ; Cylinder head;
Exploded view - cylinder head
3. Cylinder head 61
8 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 15 ; Cylinder head; Ex‐
ploded view - cylinder head
9 - Engine lifting eye
10 - O-ring
11 - Coolant pipe
12 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 19 ; Coolant pipes; Ex‐
ploded view - coolant pipes
13 - Bolt
15 - Bolt
16 - Cylinder head
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 15 ; Cylinder head;
Removing and installing cylinder head

Note
Illustration shows the cylinder head cover for cylinder bank 2 (left-side) as an example.
1 - Gasket
TDI engine, common
der head; Exploded
cover
2 - O-ring
TDI engine, common
der head; Exploded
cover
3 - Cylinder head cover
⇒ page 65
4 - O-ring
TDI engine, common
der head; Exploded
cover
5 - Bolt
cylinder head cover
6 - Oil filler neck
7 - Nut
ploded view - cylinder head cover
8 - Not fitted
9 - Not fitted
10 - Grommet
11 - Seal
❑ For sealing cap
Exploded view - cylinder head cover
3. Cylinder head 63
12 - Filler cap
❑ Installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Injectors/high-pressure reservoir
(rail); Removing and installing high-pressure pipes
14 - High-pressure reservoir (rail)
15 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Injectors/high-pressure
reservoir (rail); Exploded view - injectors
16 - Clamping piece
❑ Removing and installing ⇒ “5.8 Removing and installing injectors”, page 146
17 - Bolt
18 - Fuel return hose
19 - O-ring
20 - Injector
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Injectors/high-
pressure reservoir (rail); Removing and installing injectors ⇒ page 146
21 - Bolt
22 - Bracket
23 - O-ring
24 - Copper seal
25 - Seal
❑ For injector
❑ Renewing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 15 ; Cylinder head; Removing and
installing seals for injectors
26 - Grommets
27 - Bolt
❑ With seal
28 - Ball stud


Removing
Installing
Additional work:
– Change engine oil ⇒ Maintenance ; Booklet 830 .

cover
⇒ “3.4.1 Removing and installing cylinder head cover - bank 1
(left-side)”, page 66
3.4.1 Removing and installing cylinder head

cover - bank 1 (right-side)
3. Cylinder head 65
Removing
G505- .
– Clamp off coolant hose -1- with hose clamp up to 25 mm -

3094- and move it clear.
– Clamp off coolant hose using -3094- , release hose clip -2- and
disconnect hose.
– Remove nut -3- and bolt -4- and pivot coolant pipe (right-side)
at longitudinal member towards rear.
Installing
Additional work:
Tightening torques
♦ ⇒ Fig. ““Coolant pipe (right-side) on longitudinal member -
tightening torques”“ , page 99

cover - bank 2 (left-side)

Removing


-item 2-.

– Move coolant line -3- and electrical wiring harness -2- clear.
– Remove bolts -arrows- and detach bracket -1- for engine con‐
trol unit.
Installing
Additional work:
ing battery .
Tightening torques
♦ ⇒ “9.1 Exploded view - engine control unit”, page 161

tors
3. Cylinder head 67

pression .

4 Valve gear
4. Valve gear 69

cylinder TDI engine, common rail; Rep. gr. 15 ; Inlet and exhaust
valves .

17 – Lubrication
1 Sump/oil pump
page 75
er G266 ”, page 75
Note
Oil spray jet for piston cooling ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 13 ; Pistons and
conrods; Exploded view - pistons and conrods
Sump (bottom section)/oil pump
1. Sump/oil pump 71

sender - G266-
TDI engine, common
rail; Rep. gr. 17 ; Sump/
oil pump; Removing and
installing oil level and oil
temperature sender -
G266-
2 - Seal
TDI engine, common
oil pump; Exploded view
- sump/oil pump
3 - Bolt
sump/oil pump
⇒ page 75
5 - Bolt
sump/oil pump
6 - Baffle plate
7 - Suction pipe
8 - Oil pump
❑ With vacuum pump for brake servo
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 17 ; Sump/oil pump;
Removing and installing oil pump
9 - Chain sprocket
❑ For oil pump
10 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 17 ; Sump/oil pump; Ex‐
ploded view - sump/oil pump
11 - Dowel sleeves
12 - Seal
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 17 ; Sump/oil pump;
13 - Bolt
14 - O-ring

15 - Bolt
16 - Seal
17 - Oil drain plug
18 - Bolt
Sump (top section)
1 - Bolt
sump/oil pump
trol - N428-
TDI engine, common
rail; Rep. gr. 17 ; Oil fil‐
ter/oil pressure switch;
valve for oil pressure
control - N428-
3 - O-ring
TDI engine, common
- sump/oil pump
4 - O-ring
TDI engine, common
- sump/oil pump
TDI engine, common
oil pump; Removing and
installing sump (top section)
6 - Dowel sleeve
7 - Guide tube
❑ For oil dipstick
1. Sump/oil pump 73
8 - Bolt
9 - O-rings
10 - Sealing plug
11 - Bolt
12 - Gasket
13 - Bolt
14 - Vacuum line
❑ Leading from vacuum pump
15 - Bolt
16 - O-ring
17 - Dowel sleeve
18 - Seal
19 - Plug
❑ For “TDC” marking
20 - Bolt
1.2 Engine oil

tenance tables .
Caution
Risk of damage to catalytic converter.

♦ The oil level must not be above the “MAX” mark on the
dipstick.


section)
Removing
– Lower subframe cross brace (do not press off joint pin of guide
link) ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe;
Removing and installing subframe cross brace .
Tightening torques
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Ex‐
ploded view - subframe

tion)


1. Sump/oil pump 75
2 Engine oil cooler

cylinder TDI engine, common rail; Rep. gr. 17 ; Engine oil cooler .


page 78
”, page 79
⇒ “3.6 Removing and installing oil temperature sender 2 G664 ”,
page 79
1 - Bolt
pressure switch; Explo‐
ded view - oil filter
2 - Oil filter housing
❑ With map-controlled en‐
gine cooling system
thermostat - F265-
⇒ page 78
3 - Seal
agnostic tester
⇒ page 78
pressure switch; Explo‐
5 - Oil filter element
let 830
6 - O-ring
TDI engine, common
rail; Rep. gr. 17 ; Oil fil‐
ter/oil pressure switch;
Exploded view - oil filter
7 - Sealing cap
❑ With oil filter bypass valve
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure
switch; Exploded view - oil filter

8 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure
9 - Coolant temperature sender 2 - G802-
10 - O-rings
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure
11 - Gasket
12 - O-ring

sender - G10-
Removing
Note
Disregard -item 1-.

engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switch;
Installing
Additional work:
Tightening torques


Removing

Note
Disregard -item 1-.

Installing
Additional work:
Tightening torques

3.6 Removing and installing oil temperature

sender 2 - G664-
gine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switch ;
Removing and installing oil temperature sender 2 - G664- .

19 – Cooling


heater
Note

♦ Orange = Coolant circuit for cylinder block.

1 - Radiator
2 - Restrictor
er 2 - G802-
4 - Map-controlled engine cool‐
ing system thermostat - F265-
V50-
7 - Cylinder block
❑ Cylinder bank 1 (right-
side)
8 - Cylinder head
side)
er - G62-
cooler
11 - Turbocharger
14 - Thermostat
gearbox
15 - Injector for reducing agent
- N474-
16 - ATF cooler
17 - Filler cap
❑ Checking pressure relief valve ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 19 ; Cooling
21 - Restrictor
22 - Cylinder head
❑ Cylinder bank 2 (left-side)
24 - Cylinder block
25 - Restrictor
27 - Temperature sender for engine temperature regulation - G694-
29 - Coolant pump
30 - Auxiliary radiator
❑ Optional equipment

er
Note

1 - Radiator
2 - Restrictor
er 2 - G802-
valve - N279-
V55-
9 - Cylinder block
side)
10 - Cylinder head
side)
11 - Coolant temperature
sender - G62-
cooler
14 - Turbocharger
15 - Thermostat
gearbox
16 - Injector for reducing agent
- N474-
17 - ATF cooler
18 - Filler cap
❑ Checking pressure relief valve ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 19 ; Cooling

22 - Restrictor
23 - Cylinder head
25 - Cylinder block
26 - Restrictor
30 - Coolant pump

Procedure
engine, common rail; Rep. gr. 19 ; Cooling system/coolant;


♦ Safety goggles
Draining coolant
WARNING

WARNING


expansion tank.
noise insulation .

Note
Disregard -item 1-.

Note
Disregard -item 1-.

Preparing coolant mixture and filling cooling system
– Prepare coolant mixture and fill cooling system ⇒ Servicing 6-
cylinder TDI engine, common rail; Rep. gr. 19 ; Cooling
system/coolant; Draining and filling cooling system .
chamber cover .

hose.
clip.

engages).
– On vehicles with auxiliary/supplementary heater, switch heat‐
er on for about 30 seconds.
– Start engine.


2 minutes 2500 rpm • Air conditioning system “OFF”, LED in AC button
not lit
• Heating at “HI”, select lowest possible blower
speed (= 0)
3 minutes Idling speed • Air conditioning system “OFF”

2 minutes 2500 rpm • Heating at “HI”
3 minutes Idling speed
2 minutes 2500 rpm
1 minute Switch off engine
2 minutes 2500 rpm
Until both large coolant Idling
hoses at radiator be‐
come warm
1 minute 2500 rpm

chamber cover .
the engine is cold.
perature.
Tightening torques

⇒ “2.1 Exploded view - coolant pump”, page 88
⇒ “2.3 Exploded view - thermostat”, page 91
page 93
page 94
⇒ “2.8 Removing and installing map-controlled engine cooling

system thermostat F265 ”, page 95
”, page 95
⇒ “2.10 Removing and installing temperature sender for engine
temperature regulation G694 ”, page 95
⇒ “2.11 Removing and installing coolant temperature sender 2
G802 ”, page 96
2.1 Exploded view - coolant pump

1 - Bolt
coolant pump
2 - Bolt
coolant pump
3 - Poly V-belt pulley for cool‐
ant pump
❑ Installation position:
marking “vorne” (front)
faces in direction of trav‐
el
4 - Coolant pump
TDI engine, common
rail; Rep. gr. 19 ; Cool‐
ant pump/thermostat
assembly; Removing
and installing coolant
pump


Coolant circulation pump - V50-
1 - Bolt
❑ 1.5 Nm
2 - Retaining lug
3 - Bracket
❑ For coolant circulation
pump - V50-
4 - Nut
❑ 8 Nm
5 - Coolant hose
6 - Coolant hose
V50-
⇒ page 94

2.3 Exploded view - thermostat

⇒ “2.3.1 Exploded view - thermostat, map-controlled engine cool‐
ing system thermostat F265 ”, page 91
⇒ “2.3.2 Exploded view - thermostat, coolant shut-off valve”, page
92
2.3.1 Exploded view - thermostat, map-controlled engine cooling system ther‐

mostat - F265-
1 - Bolt
pipes; Exploded view -
coolant pipes
2 - Coolant pipe (front)
❑ Exploded view
⇒ page 97
3 - O-ring
TDI engine, common
ant pump/thermostat
assembly; Exploded
view - thermostat
4 - Bolt
thermostat
TDI engine, common
ant pump/thermostat
assembly; Removing
and installing map-con‐
trolled engine cooling
system thermostat -
F265-
6 - Gasket
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 19 ; Coolant pump/
thermostat assembly; Exploded view - thermostat
7 - Gasket
8 - Bolt
mostat assembly; Exploded view - thermostat

❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 19 ; Coolant pump/
10 - O-ring
11 - Compression spring
thermostat assembly; Removing and installing map-controlled engine cooling system thermostat - F265-
12 - Valve
❑ For coolant flap
thermostat assembly; Removing and installing map-controlled engine cooling system thermostat - F265-
13 - O-ring
2.3.2 Exploded view - thermostat, coolant shut-off valve
1 - Seal
TDI engine, common
ant pump/thermostat
assembly; Exploded
view - thermostat
2 - Bolt
thermostat
3 - Coolant connection
4 - Coolant hose
5 - Bolt
thermostat
TDI engine, common
ant pump/thermostat
assembly; Removing
and installing coolant
valves

7 - Gasket
1 - Bolt
coolant temperature
senders
er - G62-
⇒ page 95
3 - O-rings
TDI engine, common
ant pump/thermostat
assembly; Exploded
ture senders
4 - O-rings
TDI engine, common
ant pump/thermostat
assembly; Exploded
ture senders
er 2 - G802-
⇒ page 96
6 - Bolt
mostat assembly; Exploded view - coolant temperature senders
7 - O-rings
thermostat assembly; Exploded view - coolant temperature senders
9 - Bolt
mostat assembly; Exploded view - coolant temperature senders


pump
Removing
– Remove bolts -1- and detach coolant circulation pump - V50-
-item 2-.
Installing
Note

Tightening torques



housing
gine, common rail (EA 897 Gen I); Rep. gr. 19 ; Coolant pump/
thermostat assembly; Removing and installing thermostat hous‐
ing .
2.8 Removing and installing map-controlled

engine cooling system thermostat -
F265-
sembly; Removing and installing map-controlled engine cooling
system thermostat - F265- .

ature sender - G62-
Removing
G62- .
Installing
Additional work:

sender for engine temperature regula‐
tion - G694-
Removing
sembly; Removing and installing temperature sender for engine
temperature regulation - G694- .
Installing
Additional work:


Removing
sembly ; Removing and installing coolant temperature sender 2 -
G802- .
Installing
Additional work:

sembly; Removing and installing coolant valves .

3 Coolant pipes
page 108
Note
The arrow markings on coolant pipes and on ends of hoses must align.
1 - Bolt
❑ 9 Nm
(front)”, page 101
3 - Bolt
❑ 9 Nm
4 - O-ring
5 - O-ring
6 - Coolant pipe (top)
❑ Different versions de‐
pending on equipment
version
(top)”, page 100
7 - Seal
8 - Seal
❑ Only fitted on versions
with auxiliary cooler for
exhaust gas recircula‐
tion
9 - O-ring
10 - Bolt
❑ 9 Nm
11 - Coolant pipe (front) for turbocharger
⇒ “3.2.5 Removing and installing coolant pipe (front) for turbocharger”, page 106
3. Coolant pipes 97
12 - O-ring
13 - Bolt
❑ 9 Nm
14 - O-ring
15 - Bolt
❑ 9 Nm
16 - Coolant pipe (rear) for turbocharger
❑ Removing and installing ⇒ “3.2.4 Removing and installing coolant pipe (right-side)”, page 104
17 - Bolt
❑ 9 Nm
18 - Bolt
❑ 9 Nm
19 - O-ring
20 - Coolant pipe
❑ For cylinder head
21 - O-ring
22 - Bolt
❑ 9 Nm
23 - Sealing plug
❑ For cylinder block
24 - Seal
25 - Bolt
❑ 9 Nm
26 - Housing cover
27 - Bolt
❑ 9 Nm
28 - Bolt
❑ 9 Nm
29 - Bolt
❑ 9 Nm
30 - Connection
❑ For coolant hose
31 - O-ring
32 - Bracket
❑ Exploded view ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 13 ; Cylinder block (pulley end);
Exploded view - cylinder block (pulley end)

33 - O-ring
❑ Removing and installing ⇒ “3.2.3 Removing and installing coolant pipe (left-side)”, page 103
Coolant pipe (right-side) on longitudinal member - tightening tor‐

ques
– Tighten nuts -arrows- to 9 Nm.
Coolant pipe (right-side) - tightening torques

Coolant pipe for gearbox
3. Coolant pipes 99
1 - Coolant hose
2 - Coolant pipe for gearbox
⇒ page 108
3 - Coolant hose
4 - Bolts
❑ 4 Nm

⇒ “3.2.1 Removing and installing coolant pipe (top)”, page 100
⇒ “3.2.2 Removing and installing coolant pipe (front)”,
page 101
page 103
page 104
⇒ “3.2.5 Removing and installing coolant pipe (front) for turbo‐
charger”, page 106
⇒ “3.2.6 Removing and installing coolant pipe (rear) for turbo‐
charger”, page 107

(top)
Removing
– Remove exhaust gas recirculation cooler ⇒ page 190 .

– Unscrew bolts -arrows- and remove coolant pipe (top) -1-.

Installing
Note
Renew seal and O-ring after removing.
– Clean and smoothen sealing surface for O-ring.

– Lubricate O-ring with coolant and slide onto coolant pipe.
– Install exhaust gas recirculation cooler ⇒ page 190 .
Tightening torques

(front)
Removing

Note
Disregard -item 1-.
WARNING


sion tank.
noise insulation .

Note
Disregard -item 1-.


– Remove bolts -arrows- and detach coolant pipe (front) -3- from
map-controlled engine cooling system thermostat - F265- .
Installing
Note


Note

Tightening torques

(left-side)
Removing


noise insulation .
– Unscrew nuts -1, 3- and remove cover -2- for drive shaft.
– Release hose clip -2- and detach coolant hose from coolant
pipe.
– Detach coolant pipe (left-side) -1-.
Note
For illustration purposes, the installation position is shown with

the engine support removed.
Installing
Note

Tightening torques

(right-side)

Removing
– Unscrew bolts -arrows- and remove coolant pipe (right-side).
Installing
Note


Note

Tightening torques


(front) for turbocharger
Removing
– Clamp off coolant hose -arrow- with hose clamp, up to 25 mm
-3094- .

Note
– Clamp off coolant hose using hose clamp up to 25 mm -3094- ,

release hose clip -3- and disconnect hose.
– Unscrew bolt -2- and detach coolant pipe -1- from turbocharg‐
er.
Installing
Note

Note

Tightening torques

(rear) for turbocharger
Removing
– Remove emission control module ⇒ page 175 .

– Clamp off coolant hose -1- with hose clamp, up to 25 mm

-3094- .
Note
– Clamp off coolant hose using hose clamp up to 25 mm -3094- ,

lift retaining clip -3- and disconnect hose.
– Unscrew bolts -arrows- and detach coolant pipe -2-.
Installing
Note
Renew O-ring after removal.
– Install emission control module ⇒ page 175 .

Note

Tightening torques

for gearbox

Removing
noise insulation .
– Unscrew bolts -arrows- and remove coolant pipe for gearbox.
Installing
Note
Note

Tightening torques


Radiator
1 - Coolant hose
tach
❑ Connecting
⇒ page 111
2 - Radiator
⇒ page 112
condensers
3 - O-ring
4 - Sealing plug
tach
❑ Connecting
⇒ page 111
5 - O-ring
6 - Coolant hose
tach
❑ Connecting
⇒ page 111
7 - Coolant pipe
tank
❑ Lift retaining clip to detach
8 - O-ring
9 - Rubber bush
❑ For radiator

10 - Sleeve
11 - Retaining pin
12 - Air duct
13 - Rubber bush
❑ For radiator
15 - Bolt
❑ 5 Nm
16 - Washer
17 - Bolt
❑ 4.5 Nm
18 - O-ring
19 - Drain plug
❑ 1.5 … 3 Nm
20 - O-ring
Note

ant hose.
bly.

1 - Radiator cowl
⇒ page 116
2 - Bolt
❑ 5 Nm
unit - J293-
⇒ page 118
4 - Air flow flap
catalogue
Note
diator cowl.


Removing
WARNING


noise insulation .
– Remove bracket for bumper cover ⇒ General body repairs,
exterior; Rep. gr. 50 ; Lock carrier; Exploded view - lock car‐
rier .
(bottom right).
Note
Disregard -item 2-.


Note
Disregard -item 2-.


G65- .
Caution

aged.




Installing
Note

cylinder TDI engine, common rail; Rep. gr. 00 ; Repair instruc‐
tions; Installing radiators and condensers .

Note

Tightening torques
charge air system


Removing
WARNING

radiator cowl.

noise insulation .
(bottom right).
Note
Disregard -item 2-.
– Lift retaining clip -arrow- and remove sealing plug (bottom left)
on radiator.

from below.
Installing
Note

– Attach connection with plug-in connector ⇒ page 111 .
Note

Tightening torques
charge air system

V7-
Removing
Note
Secure all cable ties in the same locations when re-installing.


Caution

Installing
Tightening torques

1 Turbocharger
1 - Gasket
TDI engine, common
rail; Rep. gr. 21 ; Tur‐
bocharger; Exploded
view - turbocharger
3 - Bolt
- turbocharger
4 - Studs
- turbocharger
5 - Gasket
TDI engine, common
bocharger; Exploded
view - turbocharger
6 - Gasket
TDI engine, common
bocharger; Exploded
view - turbocharger
7 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 21 ; Turbocharger; Explo‐
ded view - turbocharger
8 - Pipe
❑ To exhaust gas recirculation cooler
9 - Air pipe
10 - Bolt

11 - O-ring
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 21 ; Turbocharger;
12 - Bolt
13 - Connection
❑ For air hose
14 - Hose
15 - O-ring
16 - Seal
17 - Nut
18 - Retaining clip
20 - Turbocharger
❑ With turbocharger 1 control unit - J724-
Caution
Risk of further damage if
the turbocharger has
suffered mechanical
damage.
Check
♦ entire charge air
system for foreign matter
TDI engine, common rail;
Rep. gr. 21 ; Turbocharg‐
er; Removing and instal‐
ling turbocharger .

21 - Seal
22 - Screw-type clip
23 - Emission control module
24 - Seal
1. Turbocharger 121
27 - Bolt
28 - Bracket
❑ For turbocharger
29 - Bolt
30 - Bracket
31 - Bolt

Removing
Note
Observe rules for cleanliness ⇒ Servicing 6-cylinder TDI engine,

common rail; Rep. gr. 00 ; Repair instructions; Rules for cleanli‐
ness .

Installing
Additional work:
Note

Tightening torques
charge air system

2 Charge air system

page 124
page 125

⇒ page 124
condensers
2 - Air hose
3 - Bolt
❑ 9 Nm
4 - Spacer sleeve
5 - Grommet
6 - Air pipe
7 - Bolt
❑ 9 Nm
8 - O-ring
11 - Seal
sender - G42-
⇒ page 149
13 - Bolt
❑ Repair method if fastener breaks off
❑ Thread-forming
❑ 7 Nm
14 - O-ring

15 - Air pipe
16 - Seal

charge air system

er
Removing
Note

ness .
Note
Disregard -item 2-.

charge air cooler.
Caution

damaged.

Installing
Note

Tightening torques
charge air system

sure sender - G31-
Removing
– Unscrew bolt -1- and remove charge pressure sender - G31- .
Installing
Note

Tightening torques


gine, common rail (EA 897 Gen I); Rep. gr. 21 ; Charge air


1 Injection system
page 128
Note

1 - Injector
(rail)
❑ For cylinder bank 1
(right-side)
G81-
4 - Fuel filter
5 - Fuel tank
G247-
(rail)
❑ For cylinder bank 2 (left-
side)
10 - Injector
11 - Restrictor
❑ Maintains a residual
pressure in fuel return
hoses
valve - N276-


Engine compartment

❑ Exploded view
⇒ page 135
- G505-
❑ Exploded view
⇒ page 157
sender 2 - G185-
⇒ page 129
⇒ page 129
❑ Exploded view
⇒ page 161
sender - G42-
❑ Exploded view
⇒ page 123
7 - Left electrohydraulic engine
mounting solenoid valve -
N144-
⇒ page 129
N145-
⇒ page 129
V50-



inder

valves -N144- / -N145-

Fitting location of coolant circulation pump - V50-

♦ At bottom on longitudinal member (right-side).
Engine (top view)

valve - N276-
⇒ page 153
❑ Checking ⇒ page 151
2 - Injectors for cylinder bank 1
(right-side)
♦ Injector, cylinder 1 - N30-
❑ Exploded view
⇒ page 143
er 1 - J724-
❑ On turbocharger
❑ Exploded view
⇒ page 120
G212-
❑ Exploded view
⇒ page 189
G247-
⇒ page 150
7 - Injectors for cylinder bank 2
(left-side)


8 - Glow plugs for cylinder bank 2 (left-side)
♦ Glow plug 6 - Q15-
9 - Exhaust gas recirculation temperature sensor - G98-
10 - Coolant temperature sender - G62-
12 - Glow plugs for cylinder bank 1 (right-side)
Engine (front view)


G664-
❑ Exploded view
⇒ page 48
er 2 - G802-
❑ Exploded view
⇒ page 93
5 - Intake manifold flap motor -
V157-
❑ Exploded view
⇒ page 139
G31-
❑ Exploded view
⇒ page 139
J338-
❑ Exploded view
⇒ page 139
8 - Coolant valve for cylinder
head - N489-
cooler change-over valve -
N345-
10 - Temperature sender for
engine temperature regulation
- G694-
trol - N428-
Engine (side view, right-side)

1 - Engine speed sender -

G28-
❑ Exploded view
⇒ page 196
❑ Exploded view
⇒ page 196
sender - G266-
❑ Exploded view
⇒ page 71


system for leaks .

2 Vacuum system

N345-
2 - Vacuum hose
❑ From exhaust gas recir‐
culation cooler change-
over valve - N345- to
vacuum unit at exhaust
gas recirculation cooler
3 - Vacuum unit
❑ At exhaust gas recircu‐
lation cooler
4 - Vacuum unit
❑ At coolant shut-off valve
5 - Vacuum line
❑ From coolant valve for
cylinder head - N489- to
vacuum unit at coolant
shut-off valve
head - N489-
7 - Vacuum supply hose
❑ With non-return valve
❑ Leading from vacuum
pump to brake servo
8 - Vacuum supply hose
❑ To coolant valve for cyl‐
inder head - N489- and
exhaust gas recircula‐
tion cooler change-over
valve - N345-

gine, common rail; Rep. gr. 23 ; Vacuum system; Checking
vacuum system .

3 Air cleaner
1 - Mounting
2 - Water drain
❑ Clean
its or dirt
ing”, page 136
4 - Air pipe
markings
❑ Only installed on vehi‐
cles with air filter bypass
flap valve - N275-
its or dirt
let 830
6 - Bolt
❑ Thread-forming
hand so that it is
que
❑ 3.5 Nm
7 - Bolt
❑ Thread-forming
❑ 3.5 Nm
9 - Air pipe
❑ Tightening torques for hose clips ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 21 ; Charge
air system; Exploded view - hose connections for charge air system
3. Air cleaner 135

11 - Air duct
❑ On lock carrier
12 - Air duct
❑ On lock carrier
13 - Bolt
❑ Thread-forming
❑ 2.5 Nm
14 - Snow screen

housing
Removing
– Depending on vehicle version, electrical connector -2- for air
filter bypass flap valve - N275- must be unplugged and vac‐
uum line must be disconnected.

Note
Disregard -item 1-.
3. Air cleaner 137


Installing
Note
♦ If a new air cleaner housing without air filter bypass flap valve
- N275- is being fitted, the electrical connector at the wiring
harness must be tied back.
♦ To prevent malfunctions, cover critical parts of the engine air
♦ Use silicone-free lubricant when fitting air hoses.
– Check for salt residue and dirt in air pipe (engine intake side).
Tightening torques
charge air system

4 Intake manifold
⇒ “4.2 Removing and installing intake manifold (top section)”,
page 141
⇒ “4.3 Removing and installing intake manifold (bottom section)”,
page 142
⇒ “4.4 Removing and installing intake manifold flap motor V157
”, page 142
142
1 - Bolt
Rep. gr. 23 ; Intake
manifold; Exploded
2 - Pipe
❑ For exhaust gas recircu‐
lation
3 - Gasket
TDI engine, common
rail; Rep. gr. 23 ; Intake
manifold; Exploded
4 - Bolt
manifold; Exploded
5 - Bolt
manifold; Exploded
6 - Bracket
❑ For air pipe
V157-
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Intake manifold;
Removing and installing intake manifold flap motor - V157-
8 - Gasket
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Intake manifold;

9 - Intake manifold (top section)

10 - Bracket
❑ For high-pressure pipe
11 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Intake manifold;
12 - Cable guide
13 - Bolt
14 - Mounting pin
15 - Bolt
16 - Seal
17 - Bolt
18 - Seal
19 - Intake manifold (bottom section)
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Intake manifold;
Removing and installing intake manifold (bottom section)
20 - Bolt
21 - Air pipe
22 - Seal
23 - Bolt
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 21 ; Charge air system;
Exploded view - hose connections for charge air system
25 - Air hose
27 - Bracket
❑ For air pipe

28 - Bolt
29 - Bolt
30 - O-ring
32 - Bolt
33 - Seal

(top section)
Removing
Caution

♦ Observe rules for cleanliness ⇒ Servicing 6-cylinder TDI
engine, common rail; Rep. gr. 00 ; Repair instructions;

and installing intake manifold (top section) .
Installing
Additional work:
Note

Tightening torques
charge air system


(bottom section)
gine, common rail; Rep. gr. 23 ; Intake manifold; Removing and
installing intake manifold (bottom section) .

flap motor - V157-
installing intake manifold flap motor - V157- .

module - J338-
Removing
– Unplug electrical connector -2- for intake air temperature
sender - G42- .
Installing
Additional work:
Note

Tightening torques
charge air system

(rail)
⇒ “5.3 Performing adaption of correction values for injectors”,
page 145
⇒ “5.4 Checking for injectors sticking open”, page 145
⇒ “5.5 Checking return flow rate of injectors with engine running”,
page 145
⇒ “5.6 Checking return flow rate of injectors at starter cranking
speed”, page 145
⇒ “5.7 Checking restrictor in fuel return line”, page 145
page 147
Caution


1 - Support bracket
❑ For clamping piece
Rep. gr. 23 ; Injectors/
high-pressure reservoir
(rail); Exploded view -
injectors
2 - Clamping piece
TDI engine, common
rail; Rep. gr. 23 ; Injec‐
tors/high-pressure res‐
ervoir (rail); Exploded
view - injectors
3 - Bolt
Rep. gr. 23 ; Injectors/
high-pressure reservoir
(rail); Exploded view -
injectors
❑ From injectors
TDI engine, common
rail; Rep. gr. 23 ; Injec‐
tors/high-pressure res‐
ervoir (rail); Exploded
view - injectors
❑ From high-pressure res‐
ervoir (rail) to injector
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Injectors/high-
pressure reservoir (rail); Exploded view - injectors
❑ From high-pressure reservoir (rail) on opposite side
8 - Retaining clamp
9 - Bolt
❑ From high-pressure pump to high-pressure reservoir (rail)

11 - Bolt
13 - O-ring
14 - Injector
15 - O-ring
16 - Copper seal

5.3 Performing adaption of correction val‐

ues for injectors
(rail); Performing adaption of correction values for injectors .
5.4 Checking for injectors sticking open

(rail); Checking for injectors sticking open .
5.5 Checking return flow rate of injectors

with engine running
(rail); Checking return flow rate of injectors with engine running .
5.6 Checking return flow rate of injectors at

starter cranking speed
(rail); Checking return flow rate of injectors at starter cranking
speed .
5.7 Checking restrictor in fuel return line

(rail); Checking restrictor in fuel return line .


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

Cylinder bank 1 (right-side):
Cylinder bank 1 (right-side), injector for cylinders 1 and 2:
Caution


Cylinder bank 2 (left-side), injector for cylinder 5:
– Detach engine control unit - J623- from bracket and move
aside ⇒ page 162 .


– Move electrical connector -1- for injector for reducing agent -
N474- clear at bracket -2-.
– Unscrew bolts -arrows- and detach bracket.
ervoir (rail); Removing and installing injectors .
Installing
Additional work:
Note

Tightening torques
Cylinder head; Exploded view - cylinder head cover
♦ ⇒ Rep. gr. 21 ; Charge air system; Exploded view - hose
connections for charge air system

pipes

reservoir (rail)
Removing

Caution


(rail) .
Installing
Additional work:
Note

nectors .
Tightening torques
charge air system


⇒ “6.1 Removing and installing intake air temperature sender G42
”, page 149
page 150
150
N276 ”, page 153
page 151
”, page 153

Removing
– Release fastener -arrow A-, turn intake air temperature sender
- G42- in anti-clockwise direction -arrow B- and detach.
Installing
Note

♦ If fastener on air pipe has broken off, secure intake air tem‐
perature sender - G42- with a bolt, refer to ⇒ Electronic parts
catalogue .

- G70-
Removing


Installing
Note

Tightening torques
charge air system

ture sender - G81-

sender - G247-

Removing
Caution



– Unscrew fuel pressure sender for low pressure - G410-
-item 2- (counterhold at connection -3-).
Installing
Note
– Screw in fuel pressure sender for low pressure - G410- by

hand until it makes contact and then tighten.
Tightening torques
High-pressure pump; Exploded view - high-pressure pump
charge air system

- N276-

♦ Test lead - VAS 6551/3- from pressure tester (diesel) - VAS

6551-
♦ Fuel-resistant measuring container

♦ Test hose for return line connection
Procedure
• Fuel temperature above 15 °C.
Caution

Procedure
– Seal fuel return hose -arrow- with hose clamp up to 25 mm
-3094- and disconnect hose ⇒ Fuel supply system; Rep. gr.
20 ; Plug-in connectors; Disconnecting plug-in connectors .
– Move fuel return hose clear to one side.

– Connect test lead - VAS 6551/3- to return hose -arrow- and

hold into measuring container, as shown in illustration.
– Start engine and run at idling speed for one minute.
• Return flow rate (engine start): 0 ml
– Leave engine running at idling speed.
– While engine is running, empty measuring container, or ex‐
change it for an empty container and begin measurement.
– Leave engine running at idling speed for two minutes and
measure return flow rate.
• Return flow rate after 2 minutes: 0 ... 60 ml
Note
If specified values are obtained, fuel pressure regulating valve -

N276- is OK.
If values do not match specifications:
Note
♦ The fuel pressure regulating valve - N276- and injectors were

checked during the preceding measuring process.
♦ To determine which component is defective, you must check
the return flow rate of the injectors.
– Measure return flow rate of injectors with engine running

⇒ page 145 .
– If return flow rate of injectors is OK, renew fuel pressure reg‐
ulating valve - N276- .
– If return flow rate of injectors is not OK, renew defective injec‐
tor.
Attaching
– Connect fuel hose ⇒ Fuel supply system, diesel engines; Rep.



Removing

G505- .

breather hose -2-.
-1-.

– Detach retaining clip -3-.

– Release catches -arrows- and detach bracket for pressure dif‐
ferential sender - G505- -item 2-.
– Release hose clips -1-.
– Spray hoses on pressure differential sender - G505- with sili‐
cone-free lubricant.
– To prevent hose connections from breaking off, carefully dis‐
connect hoses and keep them straight when pulling them off.
Installing
Note
♦ Blow through hose (towards emission control module) with

compressed air to remove dirt or ice (frozen condensation).
♦ Make sure that hoses are securely fitted and seal properly.
♦ If pressure pipes have been detached from emission control
module, tighten them to specified torque.

– If pressure differential sender - G505- has been renewed, per‐
form adaptions listed in Guided Function “0001 - Adapt learnt
values - after component replacement” ⇒ Vehicle diagnostic
tester.
Tightening torques

pump .

8 Lambda probe
1 - Not fitted
2 - NOx sender 2 - G687- with
control unit for NOx sender 2 -
J881-
⇒ page 159
Lambda probe
3 - Not fitted
- G505-
⇒ page 153
❑ Tightening torques and
installation instructions
TDI engine, common
rail; Rep. gr. 23 ; Lamb‐
da probe; Exploded
view - Lambda probe
sender 3 - G495-
⇒ page 186
6 - NOx sender - G295- with
control unit for NOx sender -
J583-
⇒ page 158
engine, common rail; Rep. gr. 23 ; Lambda probe; Exploded view - Lambda probe
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas
temperature control; Removing and installing exhaust gas temperature sender
8. Lambda probe 157

Bracket with pressure differential sender - G505- - tightening tor‐

que
– Tighten bolt -arrow- to 4.5 Nm.
Bracket with NOx sender 2 - G687- - tightening torque

– Tighten nut -4- to 9 Nm.
– Fit nuts -arrows-.

gine, common rail; Rep. gr. 23 ; Lambda probe; Removing and

page 158
page 159

G295-

Removing
WARNING
When working on all parts of the exhaust system:

♦ Observe safety precautions when working on the exhaust
system ⇒ Servicing 6-cylinder TDI engine, common rail;
Rep. gr. 00 ; Safety precautions; Safety precautions when
working on the exhaust system .


Installing
Note
Coat thread with high-temperature paste ⇒ Electronic parts cata‐

logue .
– Move control unit for NOx sender - J583- into installation po‐
sition and secure.
Tightening torques
Lambda probe; Exploded view - Lambda probe

G687-
8. Lambda probe 159


Removing
– Detach bracket and move control unit for NOx sender 2 - J881-
clear.
Note
Disregard -item 2-.
– Unscrew NOx sender 2 - G687- -arrow- using a tool from

Installing
Note

logue .

Tightening torques
♦ ⇒ Fig. ““Bracket with NOx sender 2 -G687- - tightening tor‐
que”“ , page 158


page 162
2 - Mounting
J623-
❑ After renewing, perform
ded Function “0001 -
Adapt learnt values -
after component re‐
placement” ⇒ Vehicle
diagnostic tester
⇒ page 162
4 - Bolt
❑ 4.5 Nm
5 - Bolts
❑ 9 Nm


Removing
Note
♦ If renewing the engine control unit, perform the adaptions lis‐

ted in the Guided Function “0001 - Adapt learnt values - after
component replacement” ⇒ Vehicle diagnostic tester.
♦ If the adaption values of the injectors cannot be read out of the
old (defective) engine control unit, they must be entered into
the new engine control unit manually and the adaption proce‐
dure must be performed accordingly.
– Remove bolts -arrows- and take out engine control unit - J623-
-item 2-.
Note
Disregard -item 1-.
– Unplug electrical connectors -arrows- and remove engine con‐

trol unit - J623- .
Installing
– If engine control unit - J623- has been renewed, perform adap‐
tions listed in Guided Function “0001 - Adapt learnt values -
after component replacement” ⇒ Vehicle diagnostic tester.
Tightening torques


drive”, page 163
drive”, page 166
1.1.1 Exploded view - silencers, vehicles with

front-wheel drive
WARNING


1 - Rear silencer
⇒ page 171
❑ Combined as one unit
original equipment
❑ Centre silencer and rear
silencer can be renewed
separately
❑ Cutting point
⇒ page 169
⇒ page 172
2 - Clamp (front)
free of stress
⇒ page 172
⇒ page 165
3 - Centre silencer
⇒ page 171
❑ Supplied as one unit
with silencer as original
equipment
separately
❑ Cutting point
⇒ page 169
it is free of stress ⇒ page 172
4 - Rubber mounting
5 - Clamp (rear)
6 - Rubber mounting
7 - Bracket
❑ For rubber mounting
8 - Bolt
❑ 20 Nm
9 - Bracket

10 - Bolt
❑ 20 Nm
12 - Trim
❑ For tailpipes
Clamps - installation position

• Bolt connections face outwards.

1 - Clamp (front)
free of stress
⇒ page 172
⇒ page 167
2 - Centre silencer
⇒ page 171
separately
for repair purposes
⇒ page 172
3 - Rubber mounting
4 - Clamp (rear)
❑ For separate replace‐
ment of centre and rear
silencers
free of stress
⇒ page 172
5 - Rear silencer
❑ Centre silencer and rear silencer can be renewed separately
purposes
❑ Cutting point between centre silencer and rear silencer ⇒ page 169
6 - Bolt
❑ 23 Nm
7 - Mounting
8 - Rubber mounting

9 - Bracket
10 - Bolt
❑ 23 Nm


pipe
Note
The SCR catalytic converter is integrated in the front exhaust

pipe.
Removing
WARNING


noise insulation .



shield (right-side) -1- to the side.
Note
♦ The illustration shows the subframe shield (left-side); the right

side is similar.
♦ Disregard -item 2-.
Caution
Risk of damage to flexible joint in front exhaust pipe.

♦ Do NOT bend flexible joint in front exhaust pipe more than
10°.
– Remove bolt -2- and nuts -1-.

– Bring subframe shield (right-side) back into installation posi‐
tion.


– Detach front exhaust pipe.
Installing
Note
Renew gaskets and self-locking nuts after removal.

Tightening torques
♦ ⇒ “2.1 Exploded view - emission control system”, page 173

Procedure
WARNING


Version 1:
– Cut through exhaust pipes at a right angle at cutting point
– Position centre of clamp over cutting point ⇒ page 165 and

tighten nuts -arrows-.
Version 2:

Tightening torques


Removing
WARNING


body trim; Exploded view - underbody trim .
WARNING

lencer.
– Disengage mountings -arrows- at exhaust system (rear).

Installing
Tightening torques


Procedure
WARNING



mounting for exhaust pipe is preloaded by -a- = 10 ± 2 mm.
nections evenly.

Tightening torques



⇒ “2.2 Removing and installing emission control module”,
page 175

tem
WARNING


❑ With integrated SCR
catalytic converter
❑ With flexible joint; do not
bend flexible joint more
than 10° – otherwise it
can be damaged
and impact
⇒ page 167
⇒ page 172
2 - Nut
❑ 25 Nm
3 - Bolt
❑ 9 Nm
4 - Heat shield
❑ With pressure line for
pressure differential
sender - G505-
⇒ page 175
diagnostic tester
6 - Screw-type clip

❑ 15 Nm
7 - Seal
8 - Turbocharger
9 - Gasket
Components of mountings (front) for front exhaust pipe on gear‐

box
1- Spacer sleeve
3- Washer
4- Bolt, 23 Nm
5- Bolt, 23 Nm
6- Spacer sleeve
7- Rubber buffer
8- Bracket
9- Spacer sleeve
Installation position of screw-type clip for emission control module

• Angle -α- = 90° ± 15°.

Mounting components for emission control module

1- Cage nut (integrated in emission control module)
2- Spacer sleeve
4- Washer
5- Bolt, 23 Nm
6- Bolt, 23 Nm
7- Spacer sleeve
8- Rubber buffer
9- Bracket
10 - Spacer sleeve
2.2 Removing and installing emission con‐

trol module
Removing
WARNING


noise insulation .
shield (right-side) -1- to the side.
Note
♦ The illustration shows the subframe shield (left-side); the right

side is similar.
♦ Disregard -item 2-.

– Remove nuts -1-.
Note
Disregard -item 2-.


G505- .
Note
Disregard -item 2-.

– Detach electrical connectors -1, 2, 3- from bracket, unplug

connectors and move electrical wiring clear.

– Detach injector for reducing agent - N474- -item 1- and place
to one side.



sion control module.
– Remove emission control module -2- (pay attention to brake
servo pressure sensor - G294- ).
Installing
Note

– Install injector for reducing agent - N474- ⇒ page 183 .
– If emission control module has been renewed, perform adap‐
Tightening torques
Exhaust gas temperature control; Exploded view - exhaust
charge air system


system
”, page 183
1 - Supply line
WARNING
Safety risk due to escap‐
ing reducing agent.
Observe
♦ safety meas‐
ures when handling re‐
ducing agent ⇒ Servicing
00 ; Safety precautions;
Safety precautions when
working on the SCR sys‐
tem .
2 - Sealing plug
❑ For drain pipe
system - GX19-
system - GX19- :
♦ Filter
agent - G684-
- G686-
♦ Reducing agent quality sensor - G849- (country-specific version)
♦ Pump for reducing agent - V437-
♦ Heater for reducing agent tank - Z102-
♦ Heater 2 for reducing agent tank (heater circuit 3) - Z167-


❑ Adapt learnt value after filling or renewing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 00 ;
Repair notes; Adapting learnt values for SCR system
4 - Nut
❑ 20 Nm
5 - Spacer sleeve
6 - Grommet
7 - Spacer sleeve
8 - Filler neck
❑ For fuel tank
9 - Filler cap
10 - Bolt
❑ 8 Nm
11 - Filler neck
12 - Spacer sleeve
13 - Grommet
14 - Spacer sleeve
15 - Bolt
❑ 20 Nm
❑ Before tightening the four bolts, slide reducing agent tank towards rear of vehicle (with bolts in bolt holes)
❑ Adapt learnt value after renewing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 00 ; Repair
notes; Adapting learnt values for SCR system
17 - Bolt
❑ 3 Nm

line

Procedure
Note
Re-install all cable ties in the same locations when installing.

WARNING

on the SCR system .
Safety risk due to escaping reducing agent.
♦ To prevent large amounts of reducing agent from escap‐
ing when the supply line is opened, wait until the reducing
agent has been drawn back automatically ⇒ Servicing 6-
cylinder TDI engine, common rail; Rep. gr. 00 ; Safety
precautions; Safety precautions when working on the
SCR system .

– Open tank flap.
derbody trim .

Attaching
– Adapt learnt value after filling with reducing agent or renewing
components ⇒ Servicing 6-cylinder TDI engine, common rail;
Rep. gr. 00 ; Repair notes; Adapting learnt values for SCR
system .
Tightening torques

tank

Removing
WARNING

on the SCR system .

agent supply line .
harness clear.

Caution

♦ Reducing agent tank must be empty when it is removed.

Installing
-arrows-.
system .
Tightening torques

- N474- .


Removing
derbody trim .
Installing
– If control unit for reducing agent metering system - J880- is
renewed, adapt “learnt value” ⇒ Servicing 6-cylinder TDI en‐
gine, common rail; Rep. gr. 00 ; Repair notes; Adapting learnt
values for SCR system .
Tightening torques


page 185
⇒ “4.2 Removing and installing exhaust gas temperature sender”,
page 186
4.1 Exploded view - exhaust gas tempera‐

ture control
WARNING

1 - Not fitted
J881-
⇒ page 158
3 - Not fitted
- G505-
⇒ page 153
sender 3 - G495-
⇒ page 186
Rep. gr. 26 ; Exhaust
gas temperature con‐
trol; Exploded view - ex‐
haust gas temperature
control
J583-
⇒ page 158
sender 2 - G448-
⇒ page 186
engine, common rail; Rep. gr. 26 ; Exhaust gas temperature control; Exploded view - exhaust gas
temperature control


temperature control; Removing and installing exhaust gas temperature sender
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas temper‐
ature control; Exploded view - exhaust gas temperature control

temperature sender
⇒ “4.2.1 Removing and installing exhaust gas temperature send‐
er 1 G235 ”, page 186
er 2 G448 ”, page 186
er 3 G495 ”, page 186
er 4 G648 ”, page 186
4.2.1 Removing and installing exhaust gas

gine, common rail; Rep. gr. 26 ; Exhaust gas temperature control;
Removing and installing exhaust gas temperature sender .




Removing
WARNING

Note

♦ When removing, the electrical wiring must not be cut, other‐
wise a fault diagnosis would no longer be possible.



G505- .
Installing
Note
♦ Take care to protect exhaust gas temperature sender from

♦ Coat thread with high-temperature paste; for high-temperature
paste refer to ⇒ Electronic parts catalogue .
– Move exhaust gas temperature sender 4 - G648- into instal‐

lation position, screw in by hand and then tighten from above.
Tightening torques
♦
charge air system


page 189
page 190
⇒ “5.3 Removing and installing exhaust gas recirculation temper‐
ature sensor G98 ”, page 190
5.1 Exploded view - exhaust gas recirculation system

pipe
❑ To intake manifold
2 - Bolt
gas recirculation; Explo‐
ded view - exhaust gas
recirculation
3 - Gasket
TDI engine, common
rail; Rep. gr. 26 ; Ex‐
haust gas recirculation;
Exploded view - exhaust
gas recirculation
4 - Bolt
gas recirculation; Explo‐
ded view - exhaust gas
recirculation
er - G62-
❑ Exploded view
⇒ page 93
6 - O-rings
TDI engine, common
rail; Rep. gr. 26 ; Exhaust gas recirculation; Exploded view - exhaust gas recirculation
7 - Exhaust gas recirculation cooler
❑ With exhaust gas recirculation control motor - V338-
recirculation; Removing and installing exhaust gas recirculation cooler
8 - Nut
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas recircu‐
lation; Exploded view - exhaust gas recirculation

9 - Gasket
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas
recirculation; Exploded view - exhaust gas recirculation
10 - Exhaust gas recirculation pipe
❑ From turbocharger
12 - Coolant hose
13 - Bolt
14 - Coolant hose
15 - Bolt
16 - Vacuum hose
17 - O-ring
❑ Installation instructions ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas
recirculation; Exploded view - exhaust gas recirculation
19 - Bolt

circulation cooler

circulation temperature sensor - G98-
Removing and installing exhaust gas recirculation temperature
sensor - G98- .

6 Exhaust manifolds
⇒ “6.1 Exploded view - exhaust manifold”, page 191
⇒ “6.2 Removing and installing exhaust manifolds”, page 192
6.1 Exploded view - exhaust manifold
WARNING

Note
Illustration shows the exhaust manifold for cylinder bank 2 (left-side) as an example.
1 - Nut
TDI engine, common
haust manifolds; Explo‐
ded view - exhaust
manifold
⇒ page 192
3 - Gasket
TDI engine, common
ded view - exhaust
manifold
4 - Gasket
TDI engine, common
ded view - exhaust
manifold
5 - Clamp
- turbocharger
6. Exhaust manifolds 191

❑ Mark position of screw-

type clip prior to removal
6.2 Removing and installing exhaust mani‐

folds
⇒ “6.2.1 Removing and installing exhaust manifold (left-side)”,
page 192
⇒ “6.2.2 Removing and installing exhaust manifold (right-side)”,
page 193
6.2.1 Removing and installing exhaust mani‐

fold (left-side)
Removing
WARNING

– Remove front wheel (left-side) ⇒ Running gear, axles, steer‐

ing; Rep. gr. 44 ; Wheels, tyres .
⇒ page 49 .

– Use a felt-tip pen to mark installation position of screw-type

clip -1-.
– Release clip -1- and slide it onto intake funnel of turbocharger.
Note
Disregard -item 2-.
– Remove nuts -arrows- and detach exhaust manifold towards

rear.
Installing
Note
♦ Renew gaskets, seals, self-locking nuts and screw-type clip

after removal.
♦ If installation positions have been marked, pay attention to
these when installing parts.

– Install poly V-belt ⇒ page 49 .
Tightening torques
Exhaust manifolds; Exploded view - exhaust manifold

fold (right-side)
Removing
WARNING


– Unbolt coolant pipe (front) and detach from map-controlled
engine cooling system thermostat - F265- ⇒ page 101 .


breather hose -2-.
-1-.
– Remove bolts -1, 3- and press air pipe -2- to one side.
Note
Disregard -item 4-.
– Use a felt-tip pen to mark installation position of screw-type

clip -2-.
Note
Disregard -item 1-.
– Remove engine support (right-side) ⇒ page 50 .


rear.
Installing
Note
♦ Renew O-ring, bolts and screw-type clips after removal.

♦ If installation positions have been marked, pay attention to
these when installing parts.
– Install engine support ⇒ page 50 .

– Install coolant pipe (front) ⇒ page 101 .
Tightening torques


1 Glow plug system
J179 ”, page 197
198
1 - Sender wheel
er - G28-
TDI engine, common
rail; Rep. gr. 13 ; Crank‐
shaft; Removing and in‐
stalling sender wheel
2 - Glow plug
side):
❑ Cylinder bank 2 (left-
side):
⇒ page 197
Rep. gr. 28 ; Glow plug
glow plug system
3 - Electrical connector
4 - O-ring
TDI engine, common rail; Rep. gr. 28 ; Glow plug system; Exploded view - glow plug system
6 - Bolt


8 - Bolt
9 - Cover
Automatic glow period control unit - J179- - tightening torque

– Tighten bolt -2- to 4.5 Nm.


Removing
Installing
Tightening torques
♦ ⇒ Fig. ““ Automatic glow period control unit -J179- - tightening
torque”“ , page 197
1. Glow plug system 197


G40-
Removing
– Unscrew bolt -1- and remove Hall sender - G40- .
Installing
Note

Tightening torques
Glow plug system; Exploded view - glow plug system

sender - G28-
Removing
noise insulation .
– Unscrew bolt -1- and detach engine speed sender - G28- .
Installing
Tightening torques
Glow plug system; Exploded view - glow plug system

Service
Workshop Manual
Audi A4 2015 ➤
Audi A5 2016 ➤
897 - Gen. II, S4, S5)
Engine ID
DEW DEW
A B
Edition 02.2019

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system

Copyright © 2019 Audi AG, Ingolstadt D4B80900E6E

Audi A4 2015 ➤ , Audi A5 2016 ➤
6-cylinder TDI engine, 3.0 ltr. 4-valve common rail (EA 897 - Gen. II, S4, S5) - Edition 02.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.3 Removing and installing poly V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Contents i
Audi A4 2015 ➤ , Audi A5 2016 ➤

1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4 Radiators/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.1 Exploded view - radiator/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.2 Exploded view - electric compressor with control unit for electric compressor J1123 . . . . 121
1.4 Removing and installing electric compressor with control unit for electric compressor J1123
...................................................................... 123
1.5 Removing and installing sender 1 for turbocharger speed G688 . . . . . . . . . . . . . . . . . . . . 125
2.5 Removing and installing charge air temperature sender before charge air cooler G810 . . 131
ii Contents
Audi A4 2015 ➤ , Audi A5 2016 ➤
2.6 Removing and installing charge air temperature sender after charge air cooler G811 . . . . 132

2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.7 Checking pressure retention valve in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
6.1 Removing and installing actuator for engine sound generator . . . . . . . . . . . . . . . . . . . . . . 159
6.8 Removing and installing pressure differential sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
8.4 Removing and installing particulate sensor G784 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Contents iii
Audi A4 2015 ➤ , Audi A5 2016 ➤

1.4 Removing and installing silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3.3 Releasing pressure in SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
iv Contents
Audi A4 2015 ➤ , Audi A5 2016 ➤
1 Identification
(ARL005114; Edition 02.2019)
1. Identification 1
Audi A4 2015 ➤ , Audi A5 2016 ➤

Audi A4 2015 ➤ , Audi A5 2016 ➤
Audi A4 2015 ➤ , Audi A5 2016 ➤

page 26
1.1 Removing engine



Audi A4 2015 ➤ , Audi A5 2016 ➤

>2005 - VAS 6131/13-


Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Ball joint ejector - VAS 251 805-
♦ Tensioning strap - T10038-

Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Wrench, 21 mm - T40263-

Procedure
• The engine is removed from underneath together with the
• Fit cable ties in the same locations when installing.
cleanliness .
• All bolts on running gear components with bonded rubber
(vehicle unladen).
• The electromechanical parking brake must be released before
during removal.
– De-energise 48 V electrical system and disconnect battery ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .

Audi A4 2015 ➤ , Audi A5 2016 ➤
CAUTION

expansion tank.
– Remove wheel spoilers (both sides), wheel housing liner (front
right) and drive shaft cover (left-side) ⇒ General body repairs,
tion .
– Remove propshaft ⇒ Final drive; Rep. gr. 39 ; Propshaft; Re‐
moving and installing propshaft .

– Release hose clip -1-, disconnect coolant hose from ATF cool‐
er and drain off coolant.

Audi A4 2015 ➤ , Audi A5 2016 ➤

off coolant.

off coolant.

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Move fuel hoses -3- clear and press to one side.

– Move coolant hoses clear and tie up to right side.
– Open electronics box -2- for 48 Volt system -arrow-.

– Remove nut -1- and move electrical wire clear.

Audi A4 2015 ➤ , Audi A5 2016 ➤

-arrow A-.

– Unscrew bolts -arrows-, detach connection upwards and tie

up to left side.
– Detach electrical connectors -1- from bracket, unplug and

-item 2-.

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Remove bolts -arrows- and move wiring duct -1- clear.
– Unplug electrical connectors -2- at electric compressor and

move wiring clear.

– Move wiring harness clear if engine and gearbox are to be
separated later.

Audi A4 2015 ➤ , Audi A5 2016 ➤

and unplug.
– Detach electrical connector -2- from bracket, unplug and move

electrical wire clear.
– Vehicles with auxiliary/supplementary heater: Remove ex‐
haust system ⇒ Auxiliary heater, supplementary heater; Rep.
gr. 82 ; Auxiliary/supplementary heater; Removing and instal‐
ling auxiliary/supplementary heater exhaust system .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Release hose clip -1- and detach air hose from air pipe.
2 - For starter-alternator coolant pump - V621-
3 - For starter-alternator - C29-

– If you intend to secure engine to engine and gearbox support
in a later step, unscrew bolt -1- for support mounting on both
sides.
NOTICE
Risk of damage if joints of upper suspension links are over‐
strained.
– Support wheel bearing housing.

do so).

Audi A4 2015 ➤ , Audi A5 2016 ➤

• To prevent damage to ball joint puller, make sure the two lever
arms of the puller are parallel when maximum force is exerted.
CAUTION
Track rod ball joint is released abruptly when it is pressed out -
risk of injury.
Risk of contusions.
– Secure tools by placing engine and gearbox jack under‐
neath.
joint ejector - VAS 251 805- .
– Then unscrew nut; if necessary, counterhold at joint pin with
a 6 mm hexagon socket.

if necessary.
CAUTION
Swivel joint is released abruptly when it is pressed out - risk of
injury.
Risk of contusions.
– Secure tools by placing engine and gearbox jack under‐
neath.
wrench.

Note:

Audi A4 2015 ➤ , Audi A5 2016 ➤
rod -2-.

belt .
NOTICE
Risk of irreparable damage due to electrostatic discharge.
– Do not touch connector contacts with your hands.
– Touch the lifting platform or other earthed object to discharge
static electricity.
– Turn retainer catch anti-clockwise -arrow- and unplug electri‐

cal connector -1- at gearbox.
– Unplug electrical connector -2- on right side of gearbox and

move electrical wiring clear:
– Remove underbody trim (front left and centre left) ⇒ General
body repairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded
view - underbody trim .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Unplug electrical connectors -1, 2- and move them clear.

exhaust pipe.
– Unplug electrical connector -1- for exhaust flap control unit -

J883- .

line .
parking lock clear.

Audi A4 2015 ➤ , Audi A5 2016 ➤
Setting up scissor-type assembly platform:

lows:
C4 /10-1 /10-4 /10-5 /10-11
E4 /10-1 /10-4 /10-5 /10-11
E10 /10-1 /10-2 /10-5 /13-2
B15 /10-1 /10-3 /10-5 /11-1
F15 /10-1 /10-2 /10-5 /10-6
F17 /10-1 /10-2 /10-5 /13-2
assembly platform.
zontally.


Note:

Audi A4 2015 ➤ , Audi A5 2016 ➤


NOTICE
– Carefully guide out engine/gearbox assembly with subframe
from engine compartment when lowering.



Audi A4 2015 ➤ , Audi A5 2016 ➤

Procedure
wiring harness.
CAUTION
Risk of accident caused by high weight of subframe.
mechanic.

side (remove support elements); shown with engine installed.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Vehicles with flexible ATF hoses: Remove bolts -arrows- and

push ATF cooler slightly to one side with hoses -1, 2, 4- at‐
tached.
– Vehicles with inflexible ATF lines: Remove ATF cooler ⇒
Gearbox; Rep. gr. 37 ; ATF circuit: Removing and installing
ATF cooler .
NOTICE
– To slacken bolts, counterhold crankshaft at vibration damper

using wrench, 21 mm - T40263- and adapter -T40314- .
– Remove 6 bolts -arrow- from drive plate -1-. Turn crankshaft

60° in direction of engine rotation each time.

Audi A4 2015 ➤ , Audi A5 2016 ➤

to one side.

ing clear.

– Move bracket -2- with pressure differential sender - G505-
clear.
– Remove nuts -1- at bracket for front exhaust pipe.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove bolt -3- on bracket.
CAUTION


– Release hose clip -arrow- and detach coolant hose.

– Release screw-type clip -1- and detach exhaust gas recircu‐
lation pipe -2-.

– Remove bolt -2- and move pressure differential sender 2 -
G524- clear.

Audi A4 2015 ➤ , Audi A5 2016 ➤

1- Continued coolant circulation pump - V51-
2- Exhaust gas recirculation control motor 2 - V339-
– Remove bolts -arrows- and move coolant pipes (rear) to one

side.

one side.

Audi A4 2015 ➤ , Audi A5 2016 ➤

lows:
VAS 6131/12-2-
C7 /10-1 /12-2 /10-5 /10-12
E7 /10-1 /10-4 /10-5 /10-12
C10 /10-1 /10-4 /10-5 /10-12
F10 /10-1 /10-4 /10-5 /11-1

– Position support elements from -VAS 6131/10- at left of gear‐

box.

Audi A4 2015 ➤ , Audi A5 2016 ➤

VAS 6131/11-1- at right of gearbox.



support

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gine - VAS 6095/1-14-

Audi A4 2015 ➤ , Audi A5 2016 ➤
Procedure
from gearbox)
VAS 6100- .

-1-.


Audi A4 2015 ➤ , Audi A5 2016 ➤



Procedure
angle.
The suspension mountings must therefore only be tightened
when the suspension is in the unladen position.
– Install coolant pipe (left-side) ⇒ page 91 .

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Fit gearbox to engine ⇒ Gearbox; Rep. gr. 37 ; Removing and
– Install coolant pipes (rear) and coolant pipe (right-side)
– Install front exhaust pipe ⇒ page 176 .
– Install pressure differential sender ⇒ page 163 .
– Install exhaust gas recirculation pipe ⇒ page 193 .
– Install ATF cooler ⇒ Gearbox; Rep. gr. 37 ; ATF circuit; Re‐
moving and installing ATF cooler .
note the following:
– Remove locating pins ⇒ Running gear, axles, steering; Rep.
– Install tunnel cross member ⇒ Gearbox; Rep. gr. 37 ; As‐
– Install bracket for NOx sender 2 - G687- / particulate sensor -
G784- ⇒ page 168 .
– Install subframe shield and coupling rod ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Subframe; Exploded view - sub‐
frame .
– Vehicles with auxiliary/supplementary heater: Install exhaust
system ⇒ Auxiliary heater, supplementary heater; Rep. gr.
82 ; Auxiliary/supplementary heater; Removing and installing
auxiliary/supplementary heater exhaust system .

Audi A4 2015 ➤ , Audi A5 2016 ➤

nectors .
ing battery .
NOTICE
sive voltage.

Wheels, tyres .
– After renewing engine, perform required adaptions using
system .
– Check ATF level ⇒ Gearbox; Rep. gr. 37 ; ATF; Checking
ATF level .
insulation .
Tightening torques
• Tightening torques apply only to lightly greased, oiled,
• Additional lubricant such as engine oil or gearbox oil may be
• Do not use degreased parts.
• Tolerance for tightening torques: ± 15 %.
Component Nm
Bolts/nuts M6 9

Audi A4 2015 ➤ , Audi A5 2016 ➤
Component Nm
M7 15
M8 20
M10 40
M12 65
♦ Gearbox to engine ⇒ Gearbox; Rep. gr. 37 ; Removing and
installing gearbox; Tightening torques for gearbox

Audi A4 2015 ➤ , Audi A5 2016 ➤
⇒ “2.3 Removing and installing engine mounting”, page 38

♦ Engine mounting ⇒ page 33
♦ Installation position of support mounting ⇒ page 34
♦ Gearbox mounting ⇒ page 34
Engine mounting
1 - Subframe
2 - Bolt
❑ 20 Nm
3 - Bolt
❑ 10 Nm
⇒ page 39
⇒ page 34
5 - Bolt
❑ 55 Nm
6 - Engine support
⇒ page 47
7 - Heat shield
8 - Bolt
❑ 10 Nm
9 - Bolt
❑ 55 Nm
❑ with
valve - N144-
valve - N145-
⇒ page 38
11 - Bolt
❑ 90 Nm +90°
Audi A4 2015 ➤ , Audi A5 2016 ➤
12 - Bolt
❑ 30 Nm

support mounting.
Gearbox mounting
1 - Bolt
Assembly mountings;
bly mountings
⇒ Gearbox; Rep. gr.
37 ; Assembly mount‐
ings; Exploded view -
assembly mountings
3 - Nut
Assembly mountings;
bly mountings
4 - Gearbox support
⇒ page 41
5 - Bolt
Assembly mountings;
bly mountings
⇒ page 41
7 - Stop
8 - Bolt

Audi A4 2015 ➤ , Audi A5 2016 ➤
❑ Tightening torques ⇒ Gearbox; Rep. gr. 37 ; Assembly mountings; Exploded view - assembly mountings
9 - Nut
❑ Tightening torques ⇒ Gearbox; Rep. gr. 37 ; Assembly mountings; Exploded view - assembly mountings

tion
Procedure
CAUTION
Risk of injury when weight of engine is shifted.
– Only support engine with gearbox and tunnel cross member
installed.
Audi A4 2015 ➤ , Audi A5 2016 ➤


to one side.
and longitudinal members, as shown.

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Spindle - 10-222A/11-
2 - Adapter - T40093/3-5-
3 - Adapter - 10-222A/31-3-
4 - Adapter - T40091/1-
5 - Support - 10-222A/1-
6 - Adapter - T40091/3-
7 - Adapter - 10-222A/4-
8 - Adapter - T40093/6-
9 - Support - 10-222A/1-
10 - Spindle - 10-222A/11-

right).
not lift.
Assembling
– Install injector for reducing agent - N474- ⇒ Servicing 6-cyl‐
inder TDI engine, common rail; Rep. gr. 26 ; SCR (selective
catalytic reduction) system; Removing and installing injector
for reducing agent - N474- .
Tightening torques
Audi A4 2015 ➤ , Audi A5 2016 ➤

ing
page 38
page 39
⇒ “2.3.3 Removing and installing support mounting (left-side)”,
page 39
⇒ “2.3.4 Removing and installing support mounting (right-side)”,
page 40

ing (left-side)
Removing
ing is relieved.
NOTICE
Risk of damage to the drive shafts if they are allowed to knock
against the suspension struts.
– Lift the engine so that the drive shafts do not touch the sus‐
pension struts.

belt .

Audi A4 2015 ➤ , Audi A5 2016 ➤

engine mounting -1-.
Installing
angle.
Tightening torques

ing (right-side)
Removing
side) -1-.
Installing
angle.
Tightening torques

ing (left-side)
Removing
noise insulation .
Audi A4 2015 ➤ , Audi A5 2016 ➤

side) -2-.
Installing
angle.
Tightening torques

ing (right-side)
Removing
noise insulation .

Installing
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

mounting
Removing and installing gearbox mounting

box support -4-.
Installing
Tightening torques
Audi A4 2015 ➤ , Audi A5 2016 ➤


Audi A4 2015 ➤ , Audi A5 2016 ➤
⇒ “1.3 Removing and installing poly V-belts”, page 43
page 43
page 44
48

end)

end)
1.3 Removing and installing poly V-belts


poly V-belt

er
Removing
cover .

Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
Additional work:
cover .
Tightening torques
♦ ⇒ “4.1 Exploded view - radiator/radiator fans”, page 111

cillaries
⇒ “1.6.1 Removing and installing bracket for alternator”,
page 44
⇒ “1.6.2 Removing and installing bracket for air conditioner com‐
pressor”, page 45
1.6.1 Removing and installing bracket for al‐

ternator
Removing
– Remove bolts -arrows- and press coolant pipes slightly to one
side.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Move electrical wiring harness clear -arrows-.

– Remove bolts -2, 3- and detach bracket -1-.
Installing
Tightening torques
Cylinder block (pulley end); Exploded view - cylinder block
(pulley end)
- alternator
1.6.2 Removing and installing bracket for air

conditioner compressor
Removing
– Remove coolant pipe (bottom front)
⇒ “3.2.3 Removing and installing coolant pipe (bottom front)”,
page 98 .
– Remove poly V-belt tensioner for air conditioner compressor
Cylinder block (pulley end); Removing and installing tensioner
for poly V-belt .
– Remove drive shaft cover (left-side) and wheel spoiler (front
left) ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Detach coolant pipe (left-side) -1- from bracket for air condi‐
tioner compressor (but leave it in installation position). (Shown
with engine support removed.)
– Remove bolts -arrows- and push vacuum line to the side.

– Unscrew bolts -arrows- and detach bracket -1- for air condi‐
tioner compressor.
Installing
• Renew gasket and O-ring after removal.
– Install poly V-belt tensioner for air conditioner compressor ⇒
for poly V-belt .
– Install coolant pipe (bottom front)
page 98 .
Tightening torques
(pulley end)

Audi A4 2015 ➤ , Audi A5 2016 ➤

Removing

– Remove drive shaft cover ⇒ General body repairs, exterior;

Installing
Tightening torques

end)

Audi A4 2015 ➤ , Audi A5 2016 ➤

(pulley end)
Removing
– Remove coolant pipe (front)
page 95 .
– Remove intake manifold flap control unit - GX14-
⇒ page 150 .
– Release fastener -arrow-, detach changeover valve down‐
wards from bracket and press to one side.
– Remove vibration damper ⇒ page 43 .
– Remove bracket for air conditioner compressor
⇒ “1.6.2 Removing and installing bracket for air conditioner
compressor”, page 45 .
Installing
Additional work:
– Install bracket for air conditioner compressor
– Install vibration damper ⇒ page 43 .
– Install coolant pipe (front)
page 95 .

Audi A4 2015 ➤ , Audi A5 2016 ➤

(gearbox end) .

Audi A4 2015 ➤ , Audi A5 2016 ➤
3 Crankshaft

Audi A4 2015 ➤ , Audi A5 2016 ➤
4 Balance shaft
4. Balance shaft 51
Audi A4 2015 ➤ , Audi A5 2016 ➤

conrods .

Audi A4 2015 ➤ , Audi A5 2016 ➤


gine, common rail; Rep. gr. 15 ; Timing chain cover; Exploded

cover
⇒ “1.2.1 Removing and installing timing chain cover (top left)”,
page 53
page 54

cover (top left)
Removing
– Remove coolant pipe 5 for turbocharger
⇒ “3.2.12 Removing and installing coolant pipe 5 for turbo‐
charger”, page 108 .
Installing
Additional work:
– Install coolant pipe 5 for turbocharger
⇒ “3.2.12 Removing and installing coolant pipe 5 for turbo‐
charger”, page 108 .

cover (top right)
Removing
⇒ “3.2.10 Removing and installing coolant pipes 2 and 3 for
turbocharger”, page 106 .
Installing
Additional work:

Audi A4 2015 ➤ , Audi A5 2016 ➤

cover (bottom)
Removing
specified angle).
CAUTION
– Secure engine with spindle at engine lifting eye (front left) to
keep it from tipping.


Audi A4 2015 ➤ , Audi A5 2016 ➤
2 Chain drive
2. Chain drive 55
Audi A4 2015 ➤ , Audi A5 2016 ➤
3 Cylinder head

cylinder head .



cover
⇒ “3.4.1 Removing cylinder head cover - bank 1 (right-side)”, page
56
⇒ “3.4.2 Removing cylinder head cover - bank 2 (left-side)”, page
57
3.4.1 Removing cylinder head cover - bank 1

(right-side)
Removing
– Unplug electrical connector -arrow- for charge air temperature
sender before charge air cooler - G810- .

Audi A4 2015 ➤ , Audi A5 2016 ➤

clear.
– Unplug electrical connector -1- and remove bolts -arrows-.

– Move sender 1 for turbocharger speed - G688- -item 2- clear
and place it to one side.
– Disconnect vacuum hose -arrow-, taking care not to damage

it.
Installing
Additional work:
Tightening torques
3.4.2 Removing cylinder head cover - bank 2

(left-side)
Removing
3. Cylinder head 57
Audi A4 2015 ➤ , Audi A5 2016 ➤
– Detach electrical connectors -1- from bracket, unplug and

-item 2-.

trol unit.
belt .
– Remove intake manifold flap control unit - GX14-
⇒ page 150 .
– Remove banjo bolt -1- and bolt -3-.

– Unplug electrical connector -2- and detach exhaust gas pres‐
sure sensor 1 - G450- .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove bolts -arrows-, detach coolant line -2- from electric

compressor and press it to one side.
– Remove bolts -arrows- and press vacuum line -2- slightly to

left side.
Installing
Additional work:
– Install intake manifold flap control unit - GX14- ⇒ page 150 .
installing poly V-belt ⇒ page 43 .
ing battery .
Tightening torques
♦ ⇒ Brake system; Rep. gr. 47 ; Vacuum system; Exploded view
- vacuum pump
Exhaust gas recirculation; Exploded view - exhaust gas recir‐
culation

tors

pression .
3. Cylinder head 59
Audi A4 2015 ➤ , Audi A5 2016 ➤
4 Valve gear

Audi A4 2015 ➤ , Audi A5 2016 ➤


Audi A4 2015 ➤ , Audi A5 2016 ➤
17 – Lubrication
1 Sump/oil pump
page 62
er G266 ”, page 64

- sump/oil pump .
1.2 Engine oil

sary
tenance tables .

section)
Removing
noise insulation .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Using spindle -10-222A/11- -item 1-, raise engine through dis‐

tance -a-.
• Dimension -a- = 30 mm
Tightening torques

tion)
Removing
• Engine secured to engine and gearbox support
26
1. Sump/oil pump 63
Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove bolts -arrows- and move vacuum line -2- clear.

– Move vacuum hose clear and detach dipstick guide tube -1-.
Tightening torques
(pulley end)
Sump/oil pump; Exploded view - sump/oil pump



Audi A4 2015 ➤ , Audi A5 2016 ➤
2 Engine oil cooler


Audi A4 2015 ➤ , Audi A5 2016 ➤
cylinder TDI engine, common rail (EA 897 Gen II); Rep. gr. 17 ;

Audi A4 2015 ➤ , Audi A5 2016 ➤

page 68
”, page 69
page 69


Removing
– Remove oil filter element ⇒ Maintenance ; Booklet 830 ; Main‐
tenance; Engine oil: renewing oil filter .
– Remove oil pressure sender - G10- ⇒ page 68 .
– Unbolt coolant pipe (front) and detach from thermostat
⇒ page 95 .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Unplug electrical connector -1- for exhaust gas recirculation

cooler changeover valve - N345- .
– Remove bolts -2- and place changeover valve to one side to‐
gether with bracket -1-.

– Detach retaining plate -1-, pull off connections -2, 3- and press
to side.
Installing
Additional work:
– Install oil pressure sender - G10- ⇒ Servicing 6-cylinder TDI
engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure
switches ; Removing and installing oil pressure sender - G10- .
– Install oil filter element ⇒ Maintenance ; Booklet 830 ; Main‐
Tightening torques

sender - G10-
Removing
engine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switches ;
Installing
Additional work:
Tightening torques


Audi A4 2015 ➤ , Audi A5 2016 ➤

Removing
– Remove coolant pipe (bottom front)
page 98 .
Installing
Additional work:
– Install coolant pipe (bottom front)
page 98 .

sender 2 - G664-
Removing
noise insulation .

Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
Additional work:
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤
19 – Cooling

auxiliary/supplementary heater”, page 71
iliary/supplementary heater”, page 73

vehicles without auxiliary/supplementa‐
ry heater
♦ Orange = Coolant circuit for cylinder block
Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Radiator
er 2 - G802-
3 - Thermostat
cooler
6 - Starter-alternator coolant
pump - V621-
8 - Cylinder block
side)
9 - Cylinder head
side)
10 - Turbocharger
12 - Filler cap
V50-
16 - Thermostat
❑ Low pressure
18 - ATF cooler
20 - Restrictor
22 - Thermostat
❑ For turbocharger coolant circuit
23 - Restrictor
24 - Cylinder head
25 - Cylinder block

Audi A4 2015 ➤ , Audi A5 2016 ➤

31 - Electric compressor
32 - Restrictor
36 - Coolant pump

vehicles with auxiliary/supplementary
heater
Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Radiator
er 2 - G802-
3 - Thermostat
cooler
valve - N279-
V55-
pump - V621-
11 - Cylinder block
side)
12 - Cylinder head
side)
13 - Turbocharger
15 - Filler cap
coolant; Checking cooling system for leaks
19 - Thermostat
❑ Low pressure
21 - ATF cooler
23 - Restrictor
25 - Thermostat
❑ For turbocharger coolant circuit
26 - Restrictor
27 - Cylinder block

Audi A4 2015 ➤ , Audi A5 2016 ➤
28 - Cylinder head
34 - Electric compressor
35 - Restrictor
39 - Coolant pump

Procedure

Audi A4 2015 ➤ , Audi A5 2016 ➤


Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Safety goggles
Draining coolant
CAUTION

expansion tank.
noise insulation .
CAUTION
Audi A4 2015 ➤ , Audi A5 2016 ➤

– Release hose clip -arrow-.

– Disconnect coolant hose from ATF cooler, hold end of hose
downwards and drain off coolant.

off coolant.

off coolant.

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Disconnect coolant hose from exhaust gas recirculation cool‐
er, hold end of hose downwards and drain off coolant.
common rail; Rep. gr. 19 ; Cooling system/coolant; Draining and
filling cooling system .
NOTICE
Danger of corrosion damage if unsuitable mixtures of water and
coolant additives are used.
– Always use distilled water as this ensures optimum corrosion
protection.

to -25 °C
to -36 °C

⇒ page 79 ).
and gearbox jack.
V.A.G 1274/8- .
Note:
rection of flow).
Audi A4 2015 ➤ , Audi A5 2016 ➤

zone.
in the green zone.
sequent filling.
ess.
tained.
– Open valve -A-.
is then filled.

cedure.
chamber cover .

Audi A4 2015 ➤ , Audi A5 2016 ➤

hose.
clip.

engages).
– Start engine.

not lit
speed (= 0)
3 minutes Idle • Air conditioning system “OFF”

3 minutes Idle
2 minutes 2500 rpm
3 minutes Idle
1 minutes Switch off engine
2 minutes 2500 rpm
Until both large coolant Idle
come warm
1 minutes 2500 rpm

chamber cover .
Audi A4 2015 ➤ , Audi A5 2016 ➤
CAUTION
the engine is cold.
perature.
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

page 85
page 85
”, page 89

sembly; Exploded view - coolant pump .

♦ Coolant circulation pump - V50- ⇒ page 83
♦ Starter-alternator coolant pump - V621- ⇒ page 84
Coolant circulation pump - V50-

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Coolant pipes (rear)

⇒ page 103
V50-
⇒ page 85
3 - Coolant hoses
4 - Bolt
❑ 1.5 Nm
Starter-alternator coolant pump - V621-

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Coolant hose
pump - V621-
installing starter-alter‐
nator coolant pump
V621 ”, page 87
3 - Coolant hose
4 - Bolt
❑ 9 Nm
5 - Bracket
❑ For starter-alternator
coolant pump - V621-
6 - Bolt
❑ 1.5 Nm
7 - Bolt
❑ 9 Nm

sembly; Exploded view - thermostat .

senders
sembly; Exploded view - coolant temperature sender .

pump
page 85
⇒ “2.5.2 Removing and installing starter-alternator coolant pump
V621 ”, page 87

tion pump - V50-

Audi A4 2015 ➤ , Audi A5 2016 ➤

Removing
– Remove subframe shield (left-side) ⇒ Running gear, axles,
subframe shield .
ling steering column .

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Remove bolt -1- and push coolant hose to one side.
– Release hose clips -arrows-, detach coolant circulation pump
- V50- and remove coolant hoses.
Installing
Tightening torques
♦ ⇒ , page 83
2.5.2 Removing and installing starter-alterna‐

tor coolant pump - V621-

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
noise insulation .
– Remove bolts -arrows- and detach starter-alternator coolant
pump - V621- with bracket.
– Unscrew bolts -3- and detach coolant pump from bracket.
Installing
Tightening torques
♦ ⇒ , page 84

Removing
for poly V-belt .
– Remove bolt -arrow- and detach retaining plate -1-.
– Detach connection -3- from oil filter housing.

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Press coolant hoses (front) to side.

cooler changeover valve - N345- .
– Release fastener -arrow- and move changeover valve to one
side.
Installing
Additional work:
for poly V-belt .
Tightening torques

sembly; Removing and installing thermostat .

ature sender - G62-
Removing
G62- .

Audi A4 2015 ➤ , Audi A5 2016 ➤

tion - G694-
Procedure
• Engine cold.

for poly V-belt .

– Unscrew bolt -2- and detach temperature sender for engine
– To avoid loss of coolant, insert new temperature sender im‐
mediately.
note the following:
for poly V-belt .
Tightening torques
Coolant pump/thermostat assembly; Exploded view - coolant
temperature senders


Audi A4 2015 ➤ , Audi A5 2016 ➤
3 Coolant pipes

♦ Part I ⇒ page 91
♦ Part II ⇒ page 92
♦ Part III ⇒ page 93
align.
Part I
1 - O-rings
2 - Retaining plate
3 - Bolt
❑ 9 Nm
4 - O-ring
⇒ page 101
6 - Seal
7 - O-ring
8 - Bolt
❑ 9 Nm
9 - O-ring
10 - Bolts
❑ 9 Nm
11 - Coolant pipe (top right)
⇒ page 101
12 - Coolant pipe 4 for turbo‐
charger
⇒ page 107
13 - O-ring
14 - Bolt
❑ 9 Nm
15 - Bolt
❑ 9 Nm
3. Coolant pipes 91
Audi A4 2015 ➤ , Audi A5 2016 ➤
17 - O-ring
18 - O-ring
19 - Coolant pipe 5 for turbocharger
❑ Removing and installing ⇒ “3.2.12 Removing and installing coolant pipe 5 for turbocharger”, page 108
20 - Bolt
❑ 9 Nm
21 - Bolt
❑ 9 Nm
22 - Bolt
❑ 9 Nm
23 - O-ring
24 - Bolts
❑ 9 Nm
26 - Bolt
❑ 9 Nm
27 - Housing cover
28 - Gasket
Part II

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Bolt
❑ 9 Nm
2 - Coolant pipe (bottom front)
(bottom front)”,
page 98
3 - Bolt
❑ 9 Nm
4 - O-ring
5 - Bracket
❑ For air conditioner com‐
pressor
⇒ page 45
6 - Bolt
❑ 9 Nm
7 - Coolant pipes (front)
installing coolant pipes
(front)”, page 97
8 - Bolt
❑ 9 Nm
9 - Bolt
❑ 9 Nm
10 - Bolt
❑ 9 Nm
11 - Coolant pipe at electric compressor
⇒ “3.2.13 Removing and installing coolant pipe at electric compressor”, page 109
12 - Bolt
❑ 9 Nm
13 - O-ring
14 - Bolt
❑ 20 Nm
16 - Bolt
❑ 9 Nm
17 - O-ring
Part III
3. Coolant pipes 93
Audi A4 2015 ➤ , Audi A5 2016 ➤

⇒ page 103
2 - Bolt
❑ 9 Nm
3 - Coolant pipe 1 for turbo‐
charger
⇒ page 105
4 - O-ring
5 - Bolt
❑ 9 Nm
6 - O-ring
7 - Bolt
❑ 9 Nm
⇒ page 95
9 - Bolt
❑ 9 Nm
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 9 Nm
installing coolant pipe (right-side)”, page 101
13 - Bolt
❑ 9 Nm
14 - Bolt
❑ 9 Nm
15 - Bolt
❑ 9 Nm
16 - O-ring
17 - Bolts
❑ 9 Nm
18 - O-ring

Audi A4 2015 ➤ , Audi A5 2016 ➤
21 - Bolt
❑ 9 Nm
22 - Bolt
❑ 20 Nm
23 - Bolt
❑ 20 Nm

page 95
⇒ “3.2.2 Removing and installing coolant pipes (front)”,
page 97
page 98
page 99
⇒ “3.2.6 Removing and installing coolant pipe (top right)”,
page 101
page 101
⇒ “3.2.8 Removing and installing coolant pipes (rear)”,
page 103
⇒ “3.2.9 Removing and installing coolant pipe 1 for turbocharger”,
page 105
⇒ “3.2.10 Removing and installing coolant pipes 2 and 3 for tur‐
bocharger”, page 106
⇒ “3.2.11 Removing and installing coolant pipe 4 for turbocharg‐
er”, page 107
⇒ “3.2.12 Removing and installing coolant pipe 5 for turbocharg‐
er”, page 108
⇒ “3.2.13 Removing and installing coolant pipe at electric com‐
pressor”, page 109

(front)
3. Coolant pipes 95
Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
CAUTION

sion tank.
noise insulation .


Audi A4 2015 ➤ , Audi A5 2016 ➤

thermostat housing.
Installing
Tightening torques

(front)
3. Coolant pipes 97
Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
• Reinstall heat insulation sleeves in the same locations when
installing.
– Remove coolant pipe (front) ⇒ page 95 .
– Detach retaining plate -1- and pull connection -3- off oil filter
housing.

– Fold heat insulation sleeve to side.
– Release hose clips -1, 2, 3-, disconnect coolant hoses and
detach coolant pipes.
Installing
Tightening torques

(bottom front)

Audi A4 2015 ➤ , Audi A5 2016 ➤

Removing
noise insulation .
– Remove bolts -1- and detach coolant pipe -2- from bracket for
air conditioner compressor.
Installing
Tightening torques

(left-side)
3. Coolant pipes 99
Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
noise insulation .
belt .
– Remove drive shaft cover (left-side) ⇒ General body repairs,
pipe.
– Detach coolant pipe (left-side) -1-. (Shown with engine support
removed.)
Installing
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

(top)
Removing
Installing
• Renew seal and O-ring after removing.
Tightening torques

(top right)
Removing
– Remove coolant pipe 4 for turbocharger ⇒ page 107 .
– Remove coolant pipe (top) ⇒ page 101 .
– Remove oil filter element ⇒ Maintenance ; Booklet 830 ; Main‐
– Loosen hose clip -2- and detach coolant hose.
– Detach coolant pipe (top right).
Installing
– Install coolant pipe (top) ⇒ page 101 .
– Install coolant pipe 4 for turbocharger ⇒ page 107 .
Tightening torques

(right-side)

Audi A4 2015 ➤ , Audi A5 2016 ➤

Removing
– Vehicles with auxiliary/supplementary heater: Remove ex‐
haust system ⇒ Auxiliary heater, supplementary heater; Rep.
gr. 82 ; Auxiliary/supplementary heater; Removing and instal‐
ling auxiliary/supplementary heater exhaust system .
noise insulation .
– Remove wheel spoiler (front right) and drive shaft cover (right-
side) ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove bolt -arrow- and press bracket -1- with electrical wir‐
ing harness to one side.

– Unscrew bolts -arrows- using socket Torx T30 - T10405- and
detach coolant pipe (right-side).
Installing
– Vehicles with auxiliary/supplementary heater: Install exhaust
system ⇒ Auxiliary heater, supplementary heater; Rep. gr.
82 ; Auxiliary/supplementary heater; Removing and installing
auxiliary/supplementary heater exhaust system .
ing battery .
Tightening torques

(rear)

Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Bit XZN 10 - T10501-
Removing
G524- clear.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Unplug electrical connector -2- for coolant circulation pump -

V50- .

– Unscrew bolts -arrows- and detach coolant pipes -1-.
Installing
– Install pressure differential sender 2 - G524- ⇒ page 193 .
Tightening torques
3.2.9 Removing and installing coolant pipe 1

for turbocharger
Removing
installing.

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Fold heat insulation sleeve back slightly.
– Unscrew bolt -arrow- and detach coolant pipe -1- from turbo‐
charger.
– Loosen hose clip -2- and detach coolant pipe.
Installing
Tightening torques
3.2.10 Removing and installing coolant pipes 2

and 3 for turbocharger
Removing coolant pipe 2 for turbocharger


Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove exhaust gas temperature sender 2 - G448- -item 2-

Exhaust gas temperature control; Removing and installing ex‐
haust gas temperature sender 2 - G448- .
– Release hose clips -arrows-, pull coolant pipe 2 off turbo‐
charger and remove it.
Removing coolant pipe 3 for turbocharger

• Coolant pipe 2 for turbocharger removed
– Pull coolant pipe -1- off cylinder block and detach it.
Installing
Tightening torques

for turbocharger

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
installing.
– Remove spreader rivets -arrows- and press wiring duct -1- to
side.
– Unscrew bolt -3- and detach coolant pipe -2- from turbocharg‐
er.
– Push heat insulation sleeve slightly to side.
– Release hose clip -1- and detach coolant pipe.
Installing
Tightening torques

for turbocharger

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
installing.
– Remove bolt -2- and detach bracket for emission control mod‐
ule.
charger.
– Push heat insulation sleeve slightly to side.
Installing
Tightening torques
3.2.13 Removing and installing coolant pipe at

electric compressor
Removing
– Remove throttle valve module ⇒ page 152 .

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Remove bolts -arrows- and pull coolant pipe -1- off electric
compressor.
Installing
– Install throttle valve module ⇒ page 152 .
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤
4 Radiators/radiator fans
⇒ “4.1 Exploded view - radiator/radiator fans”, page 111
4.1 Exploded view - radiator/radiator fans

♦ Radiator ⇒ page 111
♦ Connecting coolant hose with plug-in connector ⇒ page 112
♦ Radiator cowl and radiator fan ⇒ page 112
Radiator
1 - Coolant hose
tach
❑ Connecting
⇒ page 112
2 - Radiator
⇒ page 113
condensers
❑ Radiator must be re‐
newed if fasteners are
damaged
3 - O-ring
4 - Plug
tach
❑ Connecting
⇒ page 112
5 - O-ring
6 - Coolant hose
tach
❑ Connecting
⇒ page 112
7 - Coolant pipe
4. Radiators/radiator fans 111

Audi A4 2015 ➤ , Audi A5 2016 ➤
8 - O-ring
9 - Rubber bush
❑ For radiator
10 - Sleeve
11 - Retaining pin
12 - Air duct
13 - Rubber bush
❑ For radiator
15 - Bolt
❑ 5 Nm
16 - Support
17 - Bolt
❑ 4.5 Nm
18 - O-ring
19 - Drain plug
❑ 1.5 … 3 Nm
20 - O-ring

ant hose.
bly.

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Bolt
❑ 5 Nm
2 - Radiator cowl
⇒ page 117
3 - Bolt
❑ 5 Nm
4 - Radiator fan - VX57-
❑ With radiator fan - V7-
and radiator fan control
unit - J293-
⇒ page 119
5 - Radiator fan 2 - V177-
unit 2 - J671-
⇒ page 119

• The radiator must be removed and installed together with the
radiator cowl.

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
noise insulation .
ploded view - lock carrier / ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front); Removing and installing impact
bar .
CAUTION
(bottom right).
– Unplug electrical connectors -1, 2- for radiator fan.

Audi A4 2015 ➤ , Audi A5 2016 ➤



G65- .
NOTICE
Danger of damage to refrigerant lines and hoses when detach‐
ing and pivoting condenser.
– Do NOT stretch, kink or bend refrigerant lines and hoses.
NOTICE


Audi A4 2015 ➤ , Audi A5 2016 ➤


Audi A4 2015 ➤ , Audi A5 2016 ➤
Installing
Tightening torques
charge air system

Removing
noise insulation .

Audi A4 2015 ➤ , Audi A5 2016 ➤

CAUTION
(bottom right).
on radiator.

Audi A4 2015 ➤ , Audi A5 2016 ➤
from below.
Installing
Tightening torques
charge air system

V7-
Designation in current flow diagram: radiator fan - VX57-
Description applies to radiator fan - V7- and radiator fan 2 - V177- .
Removing
• Use correct type of fasteners for electrical wiring (as original
equipment) ⇒ Electronic parts catalogue .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Unscrew bolts -1- or -2- and remove the corresponding radi‐

ator fan.
Note:
Do not remove balancing clamps from fan wheel. This can cause
noise due to imbalance in fan wheel.
Installing
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 Turbocharger
⇒ “1.2 Exploded view - electric compressor with control unit for
electric compressor J1123 ”, page 121
⇒ “1.4 Removing and installing electric compressor with control
unit for electric compressor J1123 ”, page 123
⇒ “1.5 Removing and installing sender 1 for turbocharger speed
G688 ”, page 125

turbocharger .
1.2 Exploded view - electric compressor with control unit for electric compressor
- J1123-
1 - Vacuum hose
2 - Electric compressor/ control
unit for electric compressor -
J1123-
stalling electric com‐
pressor with control unit
for electric compressor
J1123 ”, page 123
3 - Bolt
❑ 9 Nm
4 - Guard plate
❑ For electrical connec‐
tors
5 - Bolt
❑ 23 Nm
6 - Noise insulation
7 - Bolt
❑ 9 Nm
10 - Bolt
❑ 9 Nm
11 - O-rings
12 - Bolt
1. Turbocharger 121
Audi A4 2015 ➤ , Audi A5 2016 ➤
13 - Coolant pipe at electric compressor

⇒ “3.2.13 Removing and installing coolant pipe at electric compressor”, page 109
14 - Connection
15 - Connection
16 - Not fitted
18 - Clip

Removing
– Unscrew bolt -3-, detach coolant pipe 4 from turbocharger and
press to one side.

– Remove bolts -arrows-, detach coolant pipe 5 from turbo‐
charger and press to one side.
– Disconnect vacuum hose -arrow-.

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Move sender 1 for turbocharger speed - G688- -item 2- clear.
Installing
Additional work:
Tightening torques
Exhaust gas recirculation; Exploded view - exhaust gas recir‐
culation
1.4 Removing and installing electric com‐

pressor with control unit for electric com‐
pressor - J1123-
Removing
– De-energise 48 V electrical system ⇒ Electrical system; Rep.
gr. 27 ; Battery; Disconnecting and connecting battery .
– Remove coolant pipe at electric compressor
⇒ “3.2.13 Removing and installing coolant pipe at electric
– Remove bracket for air conditioner compressor ⇒ Servicing
6-cylinder TDI engine, common rail; Rep. gr. 13 ; Cylinder
block (pulley end); Removing and installing bracket for ancil‐
laries .
– Detach retaining plate -1-, pull connection -2- off oil filter hous‐
ing and press to side.
1. Turbocharger 123
Audi A4 2015 ➤ , Audi A5 2016 ➤

– Move vacuum hose clear.
– Detach guide tube -1- for oil dipstick.
– Remove bolts -arrows- and detach guard plate -1-.

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Unscrew bolt -1- and detach coolant connection.
– Unscrew bolts -arrows- and detach electric compressor.
Installing
CAUTION
Risk of irreparable damage to electric compressor if vacuum
hose is loose, damaged or blocked.
– Check for damage on vacuum hose to electric compressor,
and ensure that it is routed correctly.
– Install bracket for air conditioner compressor ⇒ Servicing 6-

(pulley end); Removing and installing bracket for ancillaries .
– Install coolant pipe at electric compressor
⇒ “3.2.13 Removing and installing coolant pipe at electric
ing battery .
Tightening torques
♦ ⇒ “1.2 Exploded view - electric compressor with control unit
for electric compressor J1123 ”, page 121
charge air system
1.5 Removing and installing sender 1 for tur‐

bocharger speed - G688-
Removing
1. Turbocharger 125
Audi A4 2015 ➤ , Audi A5 2016 ➤

clear.

it.

breather hose -2-.
– Remove bolts -arrows- and detach resonator -1-.
– Unplug electrical connector -1- and remove bolts -arrows-.

– Move sender 1 for turbocharger speed - G688- -item 2- clear.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove bolt -arrow- and detach sender 1 for turbocharger

speed - G688- -item 1-.
Installing
Tightening torques
charge air system
1. Turbocharger 127
Audi A4 2015 ➤ , Audi A5 2016 ➤
2 Charge air system

page 129
page 130
⇒ “2.5 Removing and installing charge air temperature sender
before charge air cooler G810 ”, page 131
⇒ “2.6 Removing and installing charge air temperature sender af‐
ter charge air cooler G811 ”, page 132

⇒ page 129
condensers
❑ Radiator must be re‐
newed if fasteners are
damaged
2 - Air hose
3 - Bolt
sequence ⇒ page 129
4 - Spacer sleeve
5 - Rubber bush
6 - Air pipe
7 - Seal
8 - Charge air temperature
sender before charge air cool‐
er - G810-
⇒ page 131
❑ 22 Nm
9 - Bolt
10 - Seal

Audi A4 2015 ➤ , Audi A5 2016 ➤
11 - Air hose
12 - Connection
❑ For air duct
13 - O-ring
15 - Bolt
❑ 5 Nm
16 - Spacer sleeve
17 - Bolt
❑ 9 Nm
18 - Rubber bush
19 - Air hose
Air pipe - tightening torque and sequence

– Tighten bolts in stages as follows:
1. -1, 3- Screw in by hand until contact is made
2. -3- 8 Nm
3. -1- 8 Nm

charge air system

er
Removing
cleanliness .
cover .

Audi A4 2015 ➤ , Audi A5 2016 ➤
charge air cooler.
NOTICE

Installing
cover .
Tightening torques
charge air system

sure sender - G31-
Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
Tightening torques

perature sender before charge air cooler
- G810-
Removing

– Unscrew charge air temperature sender before charge air
cooler - G810- .
Installing
Tightening torques
charge air system

Audi A4 2015 ➤ , Audi A5 2016 ➤

perature sender after charge air cooler -
G811-
Removing
– Remove bolt -1- and detach charge air temperature sender
after charge air cooler - G811- .
Installing
Tightening torques

gine, common rail; Rep. gr. 21 ; Charge air system; Checking

Audi A4 2015 ➤ , Audi A5 2016 ➤

1 Injection system
page 134

1 - Injector
(rail)
(right-side)
G81-
4 - Fuel filter
5 - Fuel tank
G247-
(rail)
side)
10 - Injector
11 - Restrictor
hoses
valve - N276-

Audi A4 2015 ➤ , Audi A5 2016 ➤

system
⇒ page 134
⇒ page 136
♦ Overview of fitting locations - engine (from front)
⇒ page 138
♦ Overview of fitting locations - engine (left-side) ⇒ page 139
♦ Overview of fitting locations - engine (right-side) ⇒ page 140

❑ Exploded view
air cleaner housing”,
page 143
er - G810-
❑ Exploded view
charge air system”,
page 128
- G505-
da probe
J883-
⇒ page 136
GX2-
❑ With:
- G79-
2 - G185-
⇒ page 135
valve 2 - GX6-
❑ With:
♦ Exhaust gas recirculation potentiometer 2 - G466-
♦ Exhaust gas recirculation control motor 2 - V339-

Audi A4 2015 ➤ , Audi A5 2016 ➤

9 - Pressure differential sender 2 - G524-
❑ Exploded view ⇒ “2.1 Exploded view - charge air system”, page 128
13 - Automatic glow period control unit - J179-


inder

Audi A4 2015 ➤ , Audi A5 2016 ➤

valves -N144- / -N145-
⇒ “2.3 Removing and installing engine mounting”, page 38

♦ At coolant pipes (rear)
Exploded view
Fitting location of exhaust gas recirculation valve 2 - GX6-

♦ On left of gearbox
Exploded view
⇒ “5.1.2 Exploded view - exhaust gas recirculation system, low-
pressure side (rear)”, page 193 .

♦ At trap catalytic converter
Exploded view
⇒ “2.1 Exploded view - emission control system”, page 182 .
Overview of fitting locations - engine (from above)

Audi A4 2015 ➤ , Audi A5 2016 ➤

valve - N276-
TDI engine, common
rail; Rep. gr. 23 ; Send‐
ers and sensors; Re‐
fuel pressure regulating
valve - N276-
glow plug system
3 - Sender 1 for turbocharger
speed - G688-
charger
glow plug system
gine, common rail; Rep. gr. 28 ; Glow plug system; Exploded view - glow plug system
6 - Control unit for turbocharger 1 - J724-
❑ On turbocharger
❑ Exploded view ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 21 ; Turbocharger; Exploded
view - turbocharger
❑ With:
10 - Glow plug 6 - Q15-

Audi A4 2015 ➤ , Audi A5 2016 ➤
11 - Glow plug 5 - Q14-

12 - Pressure sender for exhaust gas recirculation - G691-
13 - Glow plug 4 - Q13-
assembly; Exploded view - coolant temperature senders
❑ Exploded view ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; High-pressure pump;
Exploded view - high-pressure pump
Overview of fitting locations - engine (from front)
pump - V621-
❑ Exploded view
electric coolant pump”,
page 83
N345-
G664-
gr. 13 ; Cylinder block
(pulley end); Exploded
view - sealing flange
(pulley end)
gr. 17 ; Oil filter/oil pres‐
sure switches; Explo‐
5 - Intake manifold flap control
unit - GX14-
❑ With intake manifold
flap motor - V157-
gr. 23 ; Intake manifold;
Exploded view - intake
manifold

Audi A4 2015 ➤ , Audi A5 2016 ➤

❑ With:
♦ Throttle valve potentiometer - G69-
♦ Throttle valve module - J338-
9 - Electric compressor with control unit for electric compressor - J1123-
❑ Exploded view
⇒ “1.2 Exploded view - electric compressor with control unit for electric compressor J1123 ”, page 121
assembly; Exploded view - coolant temperature senders
❑ Exploded view ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 17 ; Sump/oil pump; Exploded
view - sump/oil pump
Overview of fitting locations - engine (left-side)

Audi A4 2015 ➤ , Audi A5 2016 ➤

sender - G266-
TDI engine, common
- sump/oil pump
tors
tors
tors
Overview of fitting locations - engine (right-side)

Audi A4 2015 ➤ , Audi A5 2016 ➤

G28-
glow plug system
er - G810-
❑ Exploded view
page 128
tors
tors
gine, common rail; Rep. gr. 23 ; Injectors/high-pressure reservoir (rail); Exploded view - injectors


system for leaks .

Audi A4 2015 ➤ , Audi A5 2016 ➤
2 Vacuum system
cylinder TDI engine, common rail; Rep. gr. 23 ; Vacuum system .

Audi A4 2015 ➤ , Audi A5 2016 ➤
3 Air cleaner
1 - Mounting
2 - Water drain
❑ Clean
its or dirt
ing”, page 144
4 - Not fitted
its or dirt
ing housing
6 - Bolt
❑ Thread-forming
hand so that it is
que
❑ 3.5 Nm
7 - Bolt
❑ Thread-forming
hand so that it is
❑ 3.5 Nm
9 - Air pipe
3. Air cleaner 143

Audi A4 2015 ➤ , Audi A5 2016 ➤
11 - Air duct
❑ On lock carrier
12 - Air duct
❑ On lock carrier
13 - Bolt
❑ Thread-forming
❑ 2.5 Nm
14 - Snow screen

housing
Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Move fuel hoses -3- clear and press to one side.
Installing
Tightening torques
charge air system
3. Air cleaner 145

Audi A4 2015 ➤ , Audi A5 2016 ➤
4 Intake manifold
page 146
page 150
”, page 150
152

- intake manifold .

(top section)
Removing
cleanliness .
– Remove throttle valve module - GX3- ⇒ page 152 .

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Unplug electrical connector -1- for fuel pressure sender for low
pressure - G410- .
– Move clear electrical connector -4- for exhaust gas tempera‐
ture sender 4 - G648- .
– Move electrical wiring harnesses -2- and fuel hose -arrow-
clear at bracket -3-.
– Unclip bracket from high-pressure lines and push to one side.
– Unplug electrical connectors on glow plugs.
– Move fuel hose -3- clear.

– Move electrical wiring harness -4- clear at wiring duct -2-.
– Unscrew bolt -1- (left and right) and detach wiring duct.
– Move fuel return hose -5- clear at intake manifold and high-
pressure pipe.
– If fitted, disconnect vacuum hose -4- and move hose clear at

bracket.
– Detach electrical connectors -1 and 2- from bracket, unplug
– Unclip bracket -3- from high-pressure lines and detach.
– Unclip bracket -5- from high-pressure pipes and move to one
side together with SCR line.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Unscrew bolts -arrows- and remove retaining clips.
CAUTION
– Unscrew union nuts -1, 2- and detach high-pressure pipe.

valve 1 - GX5- .
– Unscrew union nuts -arrows- and detach high-pressure pipe
-1-.
– Unplug electrical connectors -1- for electric compressor and

move wiring clear.

– Disconnect vacuum hose -2- from actuator for exhaust gas
recirculation.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Detach changeover valve -4- from bracket and move clear to

side.
side.
1 - For intake manifold flap control unit - GX14-
3 - For charge pressure sender - G31-
– Remove bolts -1- for exhaust gas recirculation pipe and bolts
-2- on bracket for air pipe.
– Remove bolts -arrows- and detach oil filler neck -1-.

– Seal off opening with plug from engine bung set - VAS 6122-
(clean plug thoroughly).
– Move electrical wiring -1- clear.

– Remove bolts -arrows- and move bracket with automatic glow
period control unit - J179- to one side.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Move coolant hose leading to injector for reducing agent -

N474- clear at intake manifold.
– If necessary, move electrical wiring clear.
– Loosen and remove bolts in the sequence -14 ... 1- and detach
intake manifold (top section).
Installing
• Renew gaskets/seals after removing.
– Install high-pressure pipes ⇒ page 157 .
– Install throttle valve module - GX3- ⇒ page 152 .
Tightening torques
Intake manifold; Exploded view - intake manifold
charge air system

(bottom section)

flap motor - V157-
Designation in current flow diagram: intake manifold flap control
unit - GX14-
Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤
– If necessary, release exhaust gas recirculation temperature

sensor - G98- and rotate it to one side ⇒ page 198 .
– Disconnect vacuum hose -2- from actuator for exhaust gas

recirculation.
side.
1 - For intake manifold flap control unit - GX14-
– Remove bolts -1- for exhaust gas recirculation pipe and bolts
-2- on bracket for air pipe.

detach air pipe -2- with intake manifold flap control unit - GX14-
-item 1-.
Installing
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

module - J338-
Designation in current flow diagram: throttle valve module - GX3-
Removing
– Unscrew bolts -arrows-, detach connection upwards and tie
up to left side.
– Remove bolts -arrows- and push wiring duct -1- to the side.

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Remove bolts -arrows-, pull off throttle valve module upwards
and remove it.
Installing
common rail; Rep. gr. 00 ; Repair notes .
Tightening torques
charge air system

Audi A4 2015 ➤ , Audi A5 2016 ➤
(rail)
page 154
page 155
speed”, page 155
⇒ “5.7 Checking pressure retention valve in fuel return line”, page
156
page 157



ues for injectors

Procedure
Cylinder bank 1 (right-side)

Audi A4 2015 ➤ , Audi A5 2016 ➤

ervoir (rail); Checking for injectors sticking open .
Assembling
Additional work:
Tightening torques
charge air system

with engine running
Procedure
ervoir (rail); Checking return flow rate of injectors with engine
running .
Assembling
Additional work:
Tightening torques
charge air system

Procedure

Audi A4 2015 ➤ , Audi A5 2016 ➤

ervoir (rail); Checking return flow rate of injectors at starter crank‐
ing speed .
Assembling
Additional work:
Tightening torques
charge air system
5.7 Checking pressure retention valve in

fuel return line
(rail); Checking pressure retention valve in fuel return line .

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

Cylinder bank 2 (left-side):

Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
Additional work:
Tightening torques

pipes

reservoir (rail)
Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤

(rail) .
Installing
Additional work:
nectors .
Tightening torques
charge air system

Audi A4 2015 ➤ , Audi A5 2016 ➤

⇒ “6.1 Removing and installing actuator for engine sound gener‐
ator”, page 159
page 160
160
page 161
N276 ”, page 162
⇒ “6.8 Removing and installing pressure differential sender”, page
163

gine sound generator
Removing
– Detach battery tray -1- from actuator 1 for engine sound gen‐
erator - R257- -item 2-.
Installing

- G70-
Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
ing housing .
Tightening torques
charge air system

ture sender - G81-

sender - G247-

Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤

engine, common rail; Rep. gr. 23 ; Senders and sensors; Re‐
moving and installing fuel pressure sender for low pressure -
G410- .
Installing
Additional work:
Tightening torques
charge air system

- N276-

6551-

Procedure
cleanliness .

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Move fuel return hose clear and place it on one side.

Note:
N276- is OK.
⇒ page 155 .
tor.
Assembling


Audi A4 2015 ➤ , Audi A5 2016 ➤

ential sender
⇒ “6.8.1 Removing and installing pressure differential sender
G505 ”, page 163
⇒ “6.8.2 Removing and installing pressure differential sender 2
G524 ”, page 164
6.8.1 Removing and installing pressure differ‐

♦ Silicone-free lubricant (commercially available)

Removing

clear.

Audi A4 2015 ➤ , Audi A5 2016 ➤

breather hose -2-.

ferential sender -2-.
– Spray hoses on pressure differential sender with silicone-free
lubricant.
Installing
• Blow through hose (towards emission control module) with
• Make sure that hoses are securely fitted and seal properly.
• If pressure pipes have been detached from emission control
– After renewing component, perform required adaptions using
Tightening torques
♦ ⇒ “5.1.2 Exploded view - exhaust gas recirculation system,
low-pressure side (rear)”, page 193
charge air system
6.8.2 Removing and installing pressure differ‐

ential sender 2 - G524-

Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Silicone-free lubricant (commercially available)

Removing
– Remove body brace (left-side) ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Suspension strut, upper links; Removing and
installing body brace .
G524- clear.

Audi A4 2015 ➤ , Audi A5 2016 ➤

lubricant.
Installing
Tightening torques
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Suspension
strut, upper links; Exploded view - suspension strut, upper
links

Audi A4 2015 ➤ , Audi A5 2016 ➤

gine, common rail; Rep. gr. 23 ; High-pressure pump; Exploded
view - high-pressure pump .

pump
Removing
– Unbolt coolant pipe 5 from turbocharger and move clear to one
side ⇒ page 108 .
engine, common rail; Rep. gr. 23 ; High-pressure pump; Remov‐
ing and installing high-pressure pump .
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤
8 Lambda probe
⇒ “8.4 Removing and installing particulate sensor G784 ”,
page 171

gine, common rail; Rep. gr. 23 ; Lambda probe; Exploded view -
Lambda probe .
que
Bracket with NOx sender 2 - G687- / particulate sensor - G784- -

tightening torque
Particulate sensor - G784- - tightening torque



Audi A4 2015 ➤ , Audi A5 2016 ➤

page 169
page 170

G295-

Removing
8. Lambda probe 169

Audi A4 2015 ➤ , Audi A5 2016 ➤
CAUTION

Installing
• Coat thread with high-temperature paste ⇒ Electronic parts
catalogue .
sition and secure.
Tightening torques

G687-

Removing
Removing and installing underbody trim .

Audi A4 2015 ➤ , Audi A5 2016 ➤

clear.
CAUTION
– Unscrew NOx sender 2 - G687- -item 2- using a tool from

Installing
• When reusing probe, coat thread with high-temperature paste
⇒ Electronic parts catalogue .
Tightening torques
♦ ⇒ Fig. ““Bracket with NOx sender 2 -G687- / particulate sensor
-G784- - tightening torque”“ , page 168
8.4 Removing and installing particulate sen‐

sor - G784-
Removing
8. Lambda probe 171

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Detach bracket.
– Remove nuts -arrows-, detach particulate sensor - G784- from

bracket and move sensor clear.
CAUTION
– Unscrew particulate sensor - G784- -item 1-.

Installing
Tightening torques
♦ ⇒ Fig. ““ Particulate sensor -G784- - tightening torque”“ , page
168

Audi A4 2015 ➤ , Audi A5 2016 ➤

page 173
2 - Mounting
J623-
❑ After renewing compo‐
nent, perform required
adaptions using ⇒ Vehi‐
cle diagnostic tester ⇒
notes
⇒ page 173
4 - Bolt
❑ 4.5 Nm
5 - Bolts
❑ 9 Nm

unit - J623-
Removing
- J623- is removed.

Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Drive train
♦ 0001 - Replace, further operations
-item 2-.

trol unit - J623- .
Installing
– If engine control unit has been renewed, perform function
0001 - Replace, further operations in Guided Func-
tions mode of ⇒ Vehicle diagnostic tester.
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤
⇒ “1.4 Removing and installing silencer”, page 179
1 - Rear silencer
⇒ page 179
original equipment
separately
❑ Cutting point
⇒ page 178
⇒ page 180
2 - Clamp (front)
free of stress
⇒ page 180
⇒ page 176
❑ Tighten bolted connec‐
3 - Centre silencer
⇒ page 179
original equipment
separately
❑ Cutting point
⇒ page 178
4 - Mounting

Audi A4 2015 ➤ , Audi A5 2016 ➤
5 - Clamp (rear)
❑ For renewing centre and rear silencers separately
❑ Tighten bolted connections evenly to 23 Nm
6 - Mounting
7 - Bracket
8 - Bolt
❑ 20 Nm
9 - Bracket
10 - Bolt
❑ 20 Nm
11 - Mounting
12 - Trim
❑ For tailpipes

• Bolted connections face outwards.

pipe

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
noise insulation .
– Unplug electrical connectors -1, 2- and move them clear.
exhaust pipe.
CAUTION
– Remove nuts -arrows-.

Audi A4 2015 ➤ , Audi A5 2016 ➤
NOTICE

Installing
– Wrap tape around connection ⇒ Servicing 6-cylinder TDI en‐
gine, common rail; Rep. gr. 26 ; Emission control system;
Exploded view - emission control system .
– Slide clamp -arrow- as far as possible onto trap catalytic con‐

verter and tighten, paying attention to aluminium foil/glass
cloth tape.
Tightening torques


Audi A4 2015 ➤ , Audi A5 2016 ➤
Procedure
CAUTION


Tightening torques
1.4 Removing and installing silencer

Removing
body trim; Removing and installing underbody trim .
CAUTION


Audi A4 2015 ➤ , Audi A5 2016 ➤
CAUTION
mechanic.

Installing
Tightening torques

Procedure
CAUTION

nections evenly.

Audi A4 2015 ➤ , Audi A5 2016 ➤

Tightening torques


Audi A4 2015 ➤ , Audi A5 2016 ➤

page 182
page 185
page 185

tem

trol module
Removing
noise insulation .

Audi A4 2015 ➤ , Audi A5 2016 ➤

clear.


to one side.


Audi A4 2015 ➤ , Audi A5 2016 ➤
– Unplug electrical connector -2- for vacuum sender - G608- .

– Carefully pull vacuum line -3- off plenum chamber partition
panel -4- and brake servo -1-.

G524- clear to one side.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove bolt -3- on bracket.

Installing
• Dirt screen ⇒ Item 12 (page 194) must be renewed if emission
control module was renewed.
– After renewing component, perform required adaptions using
Tightening torques
Emission control system; Exploded view - emission control
system
charge air system

converter
gine, common rail; Rep. gr. 26 ; Emission control system ;
Removing and installing trap catalytic converter.

moving and installing exhaust flap control unit - J883- .

Audi A4 2015 ➤ , Audi A5 2016 ➤

system
⇒ “3.3 Releasing pressure in SCR system”, page 188
”, page 190
G849 ”, page 191
1 - Bolt
❑ 2 Nm
sor - G849-
⇒ page 191
❑ After renewing compo‐
nent or draining reduc‐
ing agent (opening a
reducing agent line),
perform required adap‐
tions using ⇒ Vehicle di‐
agnostic tester ⇒ Serv‐
gr. 00 ; Repair instruc‐
tions
3 - Seal
system - GX19-
system - GX19- :
♦ Filter
agent - G684-
♦ Pressure sender for reducing agent metering system - G686-

Audi A4 2015 ➤ , Audi A5 2016 ➤

❑ After renewing component or draining reducing agent (opening a reducing agent line), perform required
adaptions using ⇒ Vehicle diagnostic tester ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr.
00 ; Repair instructions
5 - Nut
❑ 20 Nm
6 - Spacer sleeve
7 - Grommet
8 - Spacer sleeve
9 - Filler neck
❑ For fuel tank
10 - Filler cap
11 - Bolt
❑ 8 Nm
12 - Filler neck
13 - Spacer sleeve
14 - Grommet
15 - Spacer sleeve
16 - Bolt
❑ 20 Nm
❑ After renewing component or draining reducing agent (opening a reducing agent line), perform required
adaptions using ⇒ Vehicle diagnostic tester ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr.
00 ; Repair instructions
18 - Bolt
❑ 3 Nm
20 - Sealing plug
❑ For drain pipe

line

Audi A4 2015 ➤ , Audi A5 2016 ➤
3.3 Releasing pressure in SCR system

tion) system; Releasing pressure in SCR system .

Procedure
– Open tank flap.
derbody trim .

Assembling
After renewing component or draining reducing agent (opening a
reducing agent line), perform required adaptions using ⇒ Vehicle
diagnostic tester ⇒ Servicing 6-cylinder TDI engine, common rail;
Rep. gr. 00 ; Repair instructions .
Tightening torques

tank

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
agent supply line .
harness clear.

• Reducing agent tank must be empty when it is removed.

Installing

Audi A4 2015 ➤ , Audi A5 2016 ➤
of vehicle (with bolts in bolt holes) and finally tighten bolts.
Tightening torques

- N474- .

Removing
derbody trim .
Installing
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

Removing
sensor - G849- .
Installing
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤


Audi A4 2015 ➤ , Audi A5 2016 ➤

page 193
page 195

tion system
⇒ “5.1.1 Exploded view - exhaust gas recirculation system, engine
side (front)”, page 193
pressure side (rear)”, page 193
5.1.1 Exploded view - exhaust gas recircula‐

tion system, engine side (front)
5.1.2 Exploded view - exhaust gas recirculation system, low-pressure side (rear)

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Hoses
❑ To pressure differential
sender 2 - G524-
2 - G524-
⇒ page 164
3 - Bracket
❑ For pressure differential
sender 2 - G524-
4 - Bolt
❑ 9 Nm
5 - Nut
❑ 9 Nm
6 - Connection
7 - Hose
lation
8 - Bolt
❑ 9 Nm
9 - Seal
valve 2 - GX6-
⇒ page 197
11 - Seal
❑ On some vehicle ver‐
sions, seal and dirt
screen -12- are a single component
12 - Dirt screen
❑ On some vehicle versions, seal -11- and dirt screen are a single component
❑ Dirt screen must be renewed if emission control module was renewed
13 - Exhaust gas recirculation cooler (rear)
14 - Bolt
❑ 20 Nm
15 - Resonator
16 - Bolt
❑ 9 Nm
17 - Seal
19 - Bolt
❑ 9 Nm

Audi A4 2015 ➤ , Audi A5 2016 ➤
20 - Seal
❑ 15 Nm
22 - Mounting
23 - Bolt
❑ 23 Nm
24 - Nut
❑ 25 Nm
25 - Gasket
26 - Trap catalytic converter

circulation cooler
⇒ “5.2.1 Removing and installing exhaust gas recirculation cooler
(rear)”, page 195
5.2.1 Removing and installing exhaust gas re‐

circulation cooler (front)

circulation cooler (rear)

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
G524- clear.
subframe shield .
CAUTION
– Loosen screw-type clip -2-.

– Remove bolts -arrows- and detach exhaust pipe -1-.
– Remove tunnel cross member and lower gearbox ⇒ Gearbox;
mountings .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Release hose clip -3- at hose for exhaust gas recirculation.

– Remove bolt -1- from retaining clip.
circulation pump - V50- .
cooler (rear) -5-.
Installing
• Renew seals and O-rings after removal.
– Wrap tape around connection ⇒ Servicing 6-cylinder TDI en‐
gine, common rail; Rep. gr. 26 ; Emission control system;
Exploded view - emission control system .
– Slide clamp -arrow- as far as possible onto trap catalytic con‐

verter and tighten, paying attention to aluminium foil/glass
cloth tape.
Tightening torques

Designation in current flow diagram: exhaust gas recirculation
valve 2 - GX6-
Removing
– Remove exhaust gas recirculation cooler (rear) ⇒ Servicing
recirculation; Removing and installing exhaust gas recircula‐
tion cooler .

Audi A4 2015 ➤ , Audi A5 2016 ➤
CAUTION
– Unscrew bolt -2- and nuts -arrows- and detach exhaust gas
recirculation valve 2 - GX6- -item 1-.
Installing
– Clean and insert dirt screen ⇒ Item 12 (page 194) .
– Install exhaust gas recirculation cooler (rear) ⇒ Servicing 6-
tion cooler .
common rail; Rep. gr. 00 ; Repair notes .
Tightening torques

sensor - G98- .

Audi A4 2015 ➤ , Audi A5 2016 ➤
6 Exhaust manifolds

gine, common rail; Rep. gr. 26 ; Exhaust manifolds; Exploded
view - exhaust manifold .

folds
page 199
page 201

fold (left-side)
Removing
belt .
– Unbolt electric compressor, move it towards front and secure
it (bracket for air conditioner compressor remains installed) ⇒
Turbocharger ; Removing and installing electric compressor.
– Move coolant line -3- and electrical wiring harness clear.
trol unit.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove bolts -arrows- for vacuum line -2-.
CAUTION

rear.
Installing
• Renew gaskets, seals, self-locking nuts and screw-type clip
after removal.
– Install electric compressor ⇒ Servicing 6-cylinder TDI engine,
common rail; Rep. gr. 21 ; Turbocharger ; Removing and in‐
stalling electric compressor.
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

fold (right-side)
Removing
– Remove coolant pipes (front) ⇒ page 97 .
lation pipe -2-.

breather hose -2-.

Audi A4 2015 ➤ , Audi A5 2016 ➤
CAUTION


rear.
Installing
• Renew O-ring, bolts and screw-type clips after removal.
– Install coolant pipes (rear) ⇒ page 103 .
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

1 Glow plug system
cylinder TDI engine, common rail; Rep. gr. 28 ; Glow plug
system .

Service
Workshop Manual
Audi A4 2015 ➤
Audi A5 2016 ➤
897 - Gen. II)
Engine ID
DCP DCP
C E
Edition 08.2018

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system

Copyright © 2018 Audi AG, Ingolstadt D4B80674178

Audi A4 2015 ➤ , Audi A5 2016 ➤
6-cylinder TDI engine, 3.0 ltr. 4-valve common rail (EA 897 - Gen. II) - Edition 08.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.2 Removing and installing cam actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.4 Measuring radial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Contents i
Audi A4 2015 ➤ , Audi A5 2016 ➤

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.5 Removing and installing oil temperature sender G8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4 Radiator/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
ii Contents
Audi A4 2015 ➤ , Audi A5 2016 ➤

2.5 Removing and installing charge air temperature sender after charge air cooler G811 . . . . 115

2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.7 Checking restrictor in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8.4 Removing and installing particulate sensor G784 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Contents iii
Audi A4 2015 ➤ , Audi A5 2016 ➤

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
iv Contents
Audi A4 2015 ➤ , Audi A5 2016 ➤
1 Identification
(ARL005933; Edition 08.2018)
1. Identification 1
Audi A4 2015 ➤ , Audi A5 2016 ➤

Audi A4 2015 ➤ , Audi A5 2016 ➤
Audi A4 2015 ➤ , Audi A5 2016 ➤

page 26
1.1 Removing engine


Audi A4 2015 ➤ , Audi A5 2016 ➤

>2005 - VAS 6131/13-


Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Wrench, 21 mm - T40263-

Audi A4 2015 ➤ , Audi A5 2016 ➤

Procedure
Note

♦ Observe rules for cleanliness ⇒ Servicing 6-cylinder TDI en‐
cleanliness .
(vehicle unladen).

Note
The electromechanical parking brake must be released before

during removal.


Audi A4 2015 ➤ , Audi A5 2016 ➤
WARNING


expansion tank.
liner (front) .
noise insulation .

– Release hose clip -1-, disconnect coolant hose from ATF cool‐
er and drain off coolant.

Audi A4 2015 ➤ , Audi A5 2016 ➤


Audi A4 2015 ➤ , Audi A5 2016 ➤


-arrow A-.


Audi A4 2015 ➤ , Audi A5 2016 ➤
– Lift retaining clip -2- and disconnect coolant hose (top left) from
radiator.

– Move wiring harness clear if engine and gearbox are to be
separated later.

-item 2-.

Audi A4 2015 ➤ , Audi A5 2016 ➤


and unplug.


Audi A4 2015 ➤ , Audi A5 2016 ➤

– If you intend to secure engine to engine and gearbox support
in a later step, unscrew bolt -1- for support mounting.
Caution

ported.

do so).

Audi A4 2015 ➤ , Audi A5 2016 ➤

WARNING

Caution

socket.

if necessary.
WARNING

wrench.

Note

Audi A4 2015 ➤ , Audi A5 2016 ➤
rod -2-.

belt .
Caution

hand.
with your hands.

– Remove underbody trim (front left and centre left) ⇒ General
body repairs, exterior; Rep. gr. 66 ; Underbody trim; Removing
and installing underbody trim .
– Unplug electrical connectors -1, 2- and move clear.

exhaust pipe.

Audi A4 2015 ➤ , Audi A5 2016 ➤

J883- .
Note

line .
parking lock clear.

Audi A4 2015 ➤ , Audi A5 2016 ➤

and adapters -VAS 6131/13-2- as follows:
C4 /10-1 /10-4 /10-5 /10-11
E4 /10-1 /10-4 /10-5 /10-11
E10 /10-1 /10-2 /10-5 /13-2
B15 /10-1 /10-3 /10-5 /11-1
F15 /10-1 /10-2 /10-5 /10-6
F17 /10-1 /10-2 /10-5 /13-2
assembly platform.
zontally.


Note

Audi A4 2015 ➤ , Audi A5 2016 ➤


Caution




Audi A4 2015 ➤ , Audi A5 2016 ➤

Procedure
wiring harness.

Audi A4 2015 ➤ , Audi A5 2016 ➤
WARNING
Risk of accident caused by weight of subframe.

♦ A second mechanic is required for removal of the sub‐
frame.

side (remove support elements).
Note
stalled.
– Remove bolts -arrows- and push ATF cooler slightly to one

side with hoses -1, 2, 4- attached.
Caution

slips.
-arrow-.
– To slacken bolts for flywheel, counterhold crankshaft at vibra‐

tion damper using wrench, 21 mm - T40263- and adapter -
T40314- .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove 6 bolts -arrow- for flywheel from drive plate -1-. Turn
crankshaft 60° in direction of engine rotation each time.

to one side.

ing clear.

Audi A4 2015 ➤ , Audi A5 2016 ➤

G505- .
– Remove nuts -1- at bracket for front exhaust pipe.
WARNING
Please note the following warnings when working on all parts

of the exhaust system:
♦ Wear gloves (e.g. rubber, not textile) and safety goggles
to avoid contact with eyes and skin - risk of injury.



Audi A4 2015 ➤ , Audi A5 2016 ➤

lation pipe -2-.

G524- clear.

1- Continued coolant circulation pump - V51-
2- Exhaust gas recirculation control motor 2 - V339-
– Remove bolts -arrows- and move coolant pipes (rear) to one

side.

Audi A4 2015 ➤ , Audi A5 2016 ➤

one side.

Note
The other support elements remain unchanged.

VAS 6131/12-2-
C7 /10-1 /12-2 /10-5 /10-12
E7 /10-1 /10-4 /10-5 /10-12
C10 /10-1 /10-4 /10-5 /10-12
F10 /10-1 /10-4 /10-5 /11-1


Audi A4 2015 ➤ , Audi A5 2016 ➤

box.



Audi A4 2015 ➤ , Audi A5 2016 ➤


support

gine - VAS 6095/1-14-

Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Lift arm extension (workshop hoist) - VAS 6101-
Procedure
from gearbox)
VAS 6100- .

-1-.

Audi A4 2015 ➤ , Audi A5 2016 ➤





Audi A4 2015 ➤ , Audi A5 2016 ➤


Audi A4 2015 ➤ , Audi A5 2016 ➤
Procedure
Note

angle.
position.
– Install coolant pipe (left-side) ⇒ page 86 .

– Before installing gearbox, remove residue from threaded holes
for engine/gearbox bolts in cylinder block using a thread tap.
and gearbox:
– Clean contact surface -1- on timing chain cover (bottom) and
on sealing element -2- with cleaning fluid - D 009 401 04- .
– Bond sealing element to timing chain cover (bottom).

Audi A4 2015 ➤ , Audi A5 2016 ➤


gearbox are fitted in cylinder block.
can be reused; if so, apply marking ⇒ 8-speed automatic
gearbox; Rep. gr. 37 ; Removing and installing gearbox;
Tightening torques for gearbox .
• When joining the engine and the gearbox, make sure that the
end seal is seated correctly.
– Bring gearbox into position on engine and at the same time
screw in bolt -1- for starter.
– Screw in bolts -2 … 11- by hand until they make contact.
– Tighten bolts -1 ... 11- ⇒ 8-speed automatic gearbox; Rep. gr.
gearbox .
– Remove transport lock - T40170- .
• The following step is necessary to ensure that the torque con‐

verter is straight and that it makes even contact with the drive
plate.
– Use assembly lever -1- to press torque converter -2- slightly
against drive plate -3- -arrow-.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Bolt torque converter onto drive plate as follows:

– Turn torque converter until hole is visible next to notch
-arrow- in recess in bottom of gearbox housing.
Note
There is only one notch on the circumference; turn the torque

converter accordingly.
– Tighten bolt -arrow- for torque converter -1- accessible in this

position ⇒ 8-speed automatic gearbox; Rep. gr. 32 ; Torque
converter; Exploded view - torque converter .
Note

Audi A4 2015 ➤ , Audi A5 2016 ➤
Caution

slips.
-arrow-.
– Then tighten remaining 5 bolts to specified torque (turn crank‐

shaft by 60° each time -arrow-) ⇒ 8-speed automatic gearbox;
Rep. gr. 32 ; Torque converter; Exploded view - torque con‐
verter .
– Install coolant pipes (rear) and coolant pipe (right-side)
⇒ page 86 .
– Install front exhaust pipe ⇒ page 152 .
– Install pressure differential sender - G505- ⇒ page 143 .
– Install pressure differential sender 2 - G524- and exhaust gas
recirculation pipe ⇒ page 172 .
temperature control; Exploded view - exhaust gas temperature
control .
– Install ATF cooler ⇒ 8-speed automatic gearbox; Rep. gr. 37 ;
ATF circuit; Removing and installing ATF cooler .
note the following:
– Remove locating pins ⇒ Running gear, axles, steering; Rep.
– Install tunnel cross member ⇒ 8-speed automatic gearbox;
mountings .
– Install bracket for NOx sender 2 - G687- / particulate sensor -
G784- ⇒ page 143 .
gr. 40 ; Subframe; Removing and installing subframe shield .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Install coupling rod ⇒ Running gear, axles, steering; Rep. gr.

40 ; Subframe; Exploded view - subframe .
nectors .
ing battery .
Caution

sive voltage.

830 .
Wheels, tyres .
Function “0001 - Adapt learnt values - after component re‐
placement” ⇒ Vehicle diagnostic tester.
Caution


system .

Audi A4 2015 ➤ , Audi A5 2016 ➤
Note

– Check ATF level ⇒ Automatic gearbox; Rep. gr. 37 ; ATF;
Checking ATF level .
insulation .
Tightening torques
Note

Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65
♦ Engine to gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Tightening torques for gearbox

Audi A4 2015 ➤ , Audi A5 2016 ➤

Engine mounting
1 - Subframe
2 - Bolt
❑ 20 Nm
3 - Bolt
❑ 10 Nm
⇒ page 41
⇒ page 37
5 - Bolt
❑ 55 Nm
6 - Engine support
⇒ page 46
7 - Heat shield
8 - Bolt
❑ 10 Nm
9 - Bolt
❑ 55 Nm
❑ with
valve - N144-
valve - N145-
⇒ page 39
11 - Bolt
❑ 90 Nm +90°
12 - Bolt
❑ 30 Nm

Audi A4 2015 ➤ , Audi A5 2016 ➤

support mounting.
Gearbox mounting
1 - Bolt
mountings
Assembly mountings;
bly mountings
3 - Nut
mountings
4 - Gearbox support
⇒ page 42
5 - Bolt
mountings
7 - Stop plate
8 - Bolt
assembly mountings
Audi A4 2015 ➤ , Audi A5 2016 ➤
9 - Nut
assembly mountings

tion
Procedure
WARNING
Risk of accident when weight of engine is shifted.

♦ In order to support the engine as described below, the
gearbox and tunnel cross members must be installed.

Audi A4 2015 ➤ , Audi A5 2016 ➤

(left and right), as shown.
right).
not lift.
Attaching
Note

Tightening torques
charge air system

ings
page 39
page 41
⇒ “2.3.3 Removing and installing engine mounting - support
mounting (left-side)”, page 41
⇒ “2.3.4 Removing and installing engine mounting - support
mounting (right-side)”, page 42

ing (left-side)
Removing
ing is relieved.
Caution

Audi A4 2015 ➤ , Audi A5 2016 ➤

terior; Rep. gr. 66 ; Wheel housing liners; Removing and
belt .

engine mounting -1-.
Installing
Note

angle.

Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

ing (right-side)
Removing
side) -1-.
Installing
Note

angle.

Tightening torques

ing - support mounting (left-side)
Removing
noise insulation .
side) -2-.
Installing
Note

angle.

Tightening torques
Audi A4 2015 ➤ , Audi A5 2016 ➤

ing - support mounting (right-side)
Removing
noise insulation .

Installing
Tightening torques

mounting
– Remove tunnel cross member ⇒ 8-speed automatic gearbox;
mountings .

Audi A4 2015 ➤ , Audi A5 2016 ➤

box support -4-.
Installing
Tightening torques
Audi A4 2015 ➤ , Audi A5 2016 ➤

gine, common rail; Rep. gr. 10 ; Engine cover panel; Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤
page 45
page 46
47

end)

end)


poly V-belt

er
Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
Additional work:
Tightening torques

cillaries

Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Remove drive shaft cover ⇒ General body repairs, exterior;

Installing
Tightening torques

end)

(pulley end)
Removing
– Remove intake manifold flap motor - V157- ⇒ Servicing 6-
cylinder TDI engine, common rail; Rep. gr. 23 ; Intake mani‐
fold; Removing and installing intake manifold flap motor -
V157- .
– Remove tensioner for poly V-belt ⇒ Servicing 6-cylinder TDI
– Remove coolant pipe (front) ⇒ page 89 .
Installing

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Install vibration damper ⇒ Servicing 6-cylinder TDI engine,

common rail; Rep. gr. 13 ; Cylinder block (pulley end); Re‐
moving and installing vibration damper .
– Install tensioner for poly V-belt ⇒ Servicing 6-cylinder TDI en‐
– Install intake manifold flap motor - V157- ⇒ Servicing 6-cylin‐
der TDI engine, common rail; Rep. gr. 23 ; Intake manifold;
Removing and installing intake manifold flap motor - V157- .

Audi A4 2015 ➤ , Audi A5 2016 ➤

(gearbox end) .

Audi A4 2015 ➤ , Audi A5 2016 ➤
3 Crankshaft

Audi A4 2015 ➤ , Audi A5 2016 ➤
4 Balance shaft
4. Balance shaft 51
Audi A4 2015 ➤ , Audi A5 2016 ➤

conrods .

Audi A4 2015 ➤ , Audi A5 2016 ➤


gine, common rail; Rep. gr. 15 ; Timing chain cover; Exploded

cover
⇒ “1.2.1 Removing and installing timing chain cover (top left)”,
page 53
⇒ “1.2.2 Removing and installing timing chain cover (top right)”,
page 53
page 53

cover (top left)

cover (top right)
Removing
– Remove coolant pipe (bottom front) for turbocharger ⇒ 6-cyl‐
inder TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr. 19 ;
Coolant pipes; Removing and installing coolant pipes .

cover (bottom)
Removing
• Gearbox removed ⇒ 8-speed automatic gearbox; Rep. gr.
37 ; Removing and installing gearbox; Removing gearbox .
specified angle).

Audi A4 2015 ➤ , Audi A5 2016 ➤

WARNING
Risk of injury.
♦ The engine must be secured with the spindle at the engine
lifting eye (front left) to keep it from tipping.


Audi A4 2015 ➤ , Audi A5 2016 ➤
2 Chain drive
2. Chain drive 55
Audi A4 2015 ➤ , Audi A5 2016 ➤
3 Cylinder head

cylinder head .



cover
(left-side)”, page 57

cover - bank 1 (right-side)
Removing
G505- .
Installing
Additional work:
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

cover - bank 2 (left-side)

Removing
-item 2-.

3. Cylinder head 57
Audi A4 2015 ➤ , Audi A5 2016 ➤
trol unit.
Installing
Additional work:
ing battery .
Tightening torques

tors

pression .

Audi A4 2015 ➤ , Audi A5 2016 ➤
4 Valve gear
⇒ “4.2 Removing and installing cam actuators”, page 59
⇒ “4.4 Measuring radial clearance of camshaft”, page 59

gine, common rail; Rep. gr. 15 ; Valve gear; Exploded view - valve
gear .
4.2 Removing and installing cam actuators

Removing
engine, common rail; Rep. gr. 15 ; Valve gear; Removing and
installing cam actuators .
Installing
Additional work:
Tightening torques

gine, common rail; Rep. gr. 15 ; Valve gear; Measuring axial
clearance of camshaft .
4.4 Measuring radial clearance of camshaft

gine, common rail; Rep. gr. 15 ; Valve gear; Measuring radial
clearance of camshaft .

installing camshaft .

seals
4. Valve gear 59
Audi A4 2015 ➤ , Audi A5 2016 ➤


Audi A4 2015 ➤ , Audi A5 2016 ➤
17 – Lubrication
1 Sump/oil pump
page 61
er G266 ”, page 62

- sump/oil pump .
1.2 Engine oil


section)
Removing
– Lower subframe cross brace (do not press off joint pin of guide
link) ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe;
Removing and installing subframe cross brace .
Tightening torques

tion)
Removing
– Remove bolt -2- and disconnect vacuum hose -1-.
1. Sump/oil pump 61
Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove bolts -1, 3- and pull out guide tube -2- for oil dipstick.
Tightening torques
(pulley end)



Audi A4 2015 ➤ , Audi A5 2016 ➤
2 Engine oil cooler


Audi A4 2015 ➤ , Audi A5 2016 ➤
cylinder TDI engine, common rail (EA 897 Gen II); Rep. gr. 17 ;

Audi A4 2015 ➤ , Audi A5 2016 ➤

page 65
page 66
⇒ “4.5 Removing and installing oil temperature sender G8 ”, page
66
page 66
”, page 66
page 67


pressure control

Removing
– Remove oil filter element ⇒ page 61 .
– Remove poly V-belt ⇒ page 45 .
– Drain coolant ⇒ 6-cylinder TDI engine, 3.0 ltr. 4-valve common
rail; Rep. gr. 19 ; Cooling system/coolant; Draining and filling
cooling system .
– Unbolt coolant pipe (front) and disconnect from thermostat ⇒
6-cylinder TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr.
19 ; Coolant pipes; Removing and installing coolant pipes .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Unplug electrical connector -2- for oil pressure sender - G10- .

Installing
Additional work:

switch - F22-
gine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switch;
Removing and installing oil pressure switch - F22- .

sender - G8-
gine, common rail; Rep. gr. 17 ; Oil filter/oil pressure switches ;
Removing and installing oil temperature sender - G8- .

sender - G10-
Removing
Installing
Additional work:
Tightening torques


Removing
noise insulation .

Audi A4 2015 ➤ , Audi A5 2016 ➤

Tightening torques

sender 2 - G664-
Removing
noise insulation .
Installing
Additional work:
Note

Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤
19 – Cooling


heater
Note


Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Radiator
2 - Restrictor
3 - Thermostat
5 - Cylinder block
side)
er - G62-
7 - Cylinder head
side)
cooler
9 - Turbocharger
10 - Siphon
12 - Filler cap
V50-
cooler
❑ Low pressure
17 - Thermostat
19 - ATF cooler
22 - Restrictor
23 - Cylinder head
25 - Cylinder block
Audi A4 2015 ➤ , Audi A5 2016 ➤
26 - Restrictor
29 - Coolant pump

Audi A4 2015 ➤ , Audi A5 2016 ➤
er
Note

1 - Radiator
2 - Restrictor
3 - Thermostat
valve - N279-
7 - Cylinder block
side)
V55-
er - G62-
10 - Cylinder head
side)
cooler
12 - Turbocharger
13 - Siphon
15 - Filler cap
Audi A4 2015 ➤ , Audi A5 2016 ➤
❑ Low pressure
20 - Thermostat
22 - ATF cooler
25 - Restrictor
26 - Cylinder head
28 - Cylinder block
29 - Restrictor
32 - Coolant pump

Procedure


Audi A4 2015 ➤ , Audi A5 2016 ➤

Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Safety goggles
Draining coolant
WARNING

WARNING


Audi A4 2015 ➤ , Audi A5 2016 ➤

expansion tank.
noise insulation .



– Disconnect coolant hose from exhaust gas recirculation cool‐
er, hold end of hose downwards and drain off coolant.
common rail; Rep. gr. 19 ; Cooling system/coolant; Draining and
to -25 °C
to -36 °C
Audi A4 2015 ➤ , Audi A5 2016 ➤

⇒ page 75 ).
V.A.G 1274/8- .
Note:
rection of flow).

zone.
in the green zone.
sequent filling.
ess.
tained.
– Open valve -A-.
is then filled.

Audi A4 2015 ➤ , Audi A5 2016 ➤

cedure.
chamber cover .

hose.
clip.

engages).
– Start engine.

not lit
speed (= 0)
3 minutes Idling speed • Air conditioning system “OFF”

2 minutes 2500 rpm
1 minute Switch off engine
Audi A4 2015 ➤ , Audi A5 2016 ➤

2 minutes 2500 rpm
Until both large coolant Idling
come warm
1 minute 2500 rpm

chamber cover .
WARNING

the engine is cold.
perature.
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

page 81
page 82
”, page 85

sembly; Exploded view - coolant pump .

⇒ “2.2.1 Exploded view - continued coolant circulation pump V50
”, page 79
⇒ “2.2.2 Exploded view - starter-alternator coolant pump V621 ”,
page 81
2.2.1 Exploded view - continued coolant circulation pump - V50-

Audi A4 2015 ➤ , Audi A5 2016 ➤

V50-
⇒ page 82
2 - Bolt
❑ 1.5 Nm
⇒ page 97
4 - Coolant hose
5 - Coolant hose

Audi A4 2015 ➤ , Audi A5 2016 ➤
2.2.2 Exploded view - starter-alternator coolant pump - V621-
1 - Coolant hose
pump - V621-
⇒ page 83
3 - Coolant hose
4 - Bolt
❑ 9 Nm
5 - Bracket
coolant pump - V621-
6 - Bolt
❑ 1.5 Nm
7 - Bolt
❑ 9 Nm

sembly; Exploded view - thermostat .

senders

Audi A4 2015 ➤ , Audi A5 2016 ➤

pump
page 82
⇒ “2.5.2 Removing and installing starter-alternator coolant pump
V621 ”, page 83

tion pump - V50-
Removing
subframe shield .

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Remove bolt -1- and push coolant hose to one side.
– Release hose clips -arrows-, detach coolant circulation pump
- V50- and remove coolant hoses.
Installing
Note

Tightening torques
2.5.2 Removing and installing starter-alterna‐

tor coolant pump - V621-

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
noise insulation .
– Remove bolts -arrows- and detach starter-alternator coolant
pump - V621- .
– Unscrew bolts -3- and detach coolant pump from bracket.
Installing
Tightening torques
♦ ⇒ “2.2.2 Exploded view - starter-alternator coolant pump V621
”, page 81


gine, common rail (EA 897 Gen. II); Rep. gr. 19 ; Coolant pump/
thermostat assembly; Removing and installing thermostat .

Audi A4 2015 ➤ , Audi A5 2016 ➤

ature sender - G62-
Removing
G62- .

tion - G694-
Removing

side.
sembly; Removing and installing temperature sender for engine
Installing
Additional work:


Audi A4 2015 ➤ , Audi A5 2016 ➤
3 Coolant pipes
Note

align.
Part I
Part II ⇒ page 87
1 - O-ring
2 - Bolt
❑ 9 Nm
3 - Bolt
❑ 9 Nm
4 - Bolt
❑ 9 Nm
⇒ page 89
6 - O-ring
7 - Seal
8 - O-ring
9 - Coolant pipe (top right)
⇒ page 94
10 - Bolts
❑ 9 Nm
11 - O-ring
⇒ page 89
13 - Bolt
❑ 9 Nm
14 - Bolt
❑ 9 Nm
15 - Coolant pipe

Audi A4 2015 ➤ , Audi A5 2016 ➤
16 - O-ring
17 - O-ring
18 - Sealing plug
19 - Bolt
❑ 9 Nm
20 - Gasket
21 - Bolt
❑ 9 Nm
22 - Housing cover
24 - Bolt
❑ 20 Nm
25 - Bolt
❑ 9 Nm
26 - O-ring
27 - Bolt
❑ 9 Nm
28 - Connection
29 - O-ring
30 - Bracket
❑ Removing and installing ⇒ 6-cylinder TDI engine, 3.0 ltr. 4-valve common rail; Rep. gr. 13 ; Cylinder
block (pulley end); Removing and installing bracket for ancillaries
Part II
Part I ⇒ page 86
3. Coolant pipes 87
Audi A4 2015 ➤ , Audi A5 2016 ➤

⇒ page 97
2 - Bolt
❑ 9 Nm
3 - Coolant pipe (rear) for tur‐
bocharger
⇒ page 93
4 - O-ring
5 - Bolt
❑ 9 Nm
6 - O-ring
7 - Bolt
❑ 9 Nm
8 - Coolant pipe (top front) for
turbocharger
⇒ page 96
9 - Bolt
❑ 9 Nm
10 - O-ring
11 - Bolts
❑ 9 Nm
for turbocharger
13 - Bolt
❑ 9 Nm
15 - Bolt
❑ 9 Nm
16 - Bolt
❑ 9 Nm
17 - Bolt
❑ 20 Nm
18 - Bolt
❑ 20 Nm

Audi A4 2015 ➤ , Audi A5 2016 ➤

page 89
page 92
⇒ “3.2.4 Removing and installing coolant pipe (rear) for turbo‐
charger”, page 93
⇒ “3.2.5 Removing and installing coolant pipe (top right)”,
page 94
page 95
⇒ “3.2.7 Removing and installing coolant pipes (front) for turbo‐
charger”, page 96
⇒ “3.2.8 Removing and installing coolant pipes (rear)”,
page 97

(top)
Removing
Installing
Note
Renew seal and O-ring after removing.

Tightening torques

(front)
3. Coolant pipes 89
Audi A4 2015 ➤ , Audi A5 2016 ➤

Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤
WARNING


sion tank.
noise insulation .

3. Coolant pipes 91
Audi A4 2015 ➤ , Audi A5 2016 ➤

map-controlled engine cooling system thermostat - F265- .
Installing
Note


Note

Tightening torques

(left-side)
Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤

noise insulation .
pipe.
– Detach coolant pipe (left-side) -1-.
Note
For illustration purposes, the installation position is shown with

the engine support removed.
Installing
Note

Tightening torques

(rear) for turbocharger
3. Coolant pipes 93
Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
Note
Reinstall heat insulation sleeves in the same locations when in‐

stalling.

– Fold heat insulation sleeve back slightly.
charger.
Installing
Note

Note

Tightening torques

(top right)
Removing
– Remove exhaust gas recirculation cooler ⇒ Servicing 6-cyl‐
inder TDI engine, common rail; Rep. gr. 26 ; Exhaust gas
tion cooler .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Detach coolant pipe (top right).

Installing

(right-side)
Removing
battery .
noise insulation .
– Remove cover for drive shaft (right-side) and wheel spoiler
(front) .
– Remove bolt -arrow- and move bracket -1- with electrical wir‐
3. Coolant pipes 95
Audi A4 2015 ➤ , Audi A5 2016 ➤

detach coolant pipe (right-side).
Installing
Note

ing battery .
Tightening torques

(front) for turbocharger
Removing coolant pipe (top front) for turbocharger


Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove exhaust gas temperature sender 2 - G448- -item 2-

Exhaust gas temperature control; Removing and installing ex‐
haust gas temperature sender 2 - G448- .
– Release hose clips -arrows-, detach coolant pipe (top front)
from turbocharger and remove.
Removing coolant pipe (bottom front) for turbocharger

• Coolant pipe (top front) for turbocharger removed
– Detach coolant pipe (bottom front) -1- from cylinder block and
remove.
Installing
Note


Note

Tightening torques

(rear)
3. Coolant pipes 97
Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Bit XZN 10 - T10501-
Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤

G524- clear.
– Unplug electrical connector -2- for coolant circulation pump -

V50- .

– Unscrew bolts -arrows- and detach coolant pipes -1-.
Installing
Note


– Install pressure differential sender 2 - G524- ⇒ page 172 .
Note

Tightening torques
3. Coolant pipes 99
Audi A4 2015 ➤ , Audi A5 2016 ➤
4 Radiator/radiator fans

Radiator
1 - Coolant hose
tach
❑ Connecting
⇒ page 101
2 - Radiator
⇒ page 102
condensers
3 - O-ring
4 - Sealing plug
tach
❑ Connecting
⇒ page 101
5 - O-ring
6 - Coolant hose
tach
❑ Connecting
⇒ page 101
7 - Coolant pipe
tank
8 - O-ring
9 - Rubber bush
❑ For radiator

Audi A4 2015 ➤ , Audi A5 2016 ➤
10 - Sleeve
11 - Retaining pin
12 - Air duct
13 - Rubber bush
❑ For radiator
15 - Bolt
❑ 5 Nm
16 - Washer
17 - Bolt
❑ 4.5 Nm
18 - O-ring
19 - Drain plug
❑ 1.5 … 3 Nm
20 - O-ring
Note

ant hose.
bly.
4. Radiator/radiator fans 101

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Bolt
❑ 5 Nm
2 - Radiator cowl
⇒ page 106
3 - Bolt
❑ 5 Nm
unit - J293-
⇒ page 108
unit 2 - J671-
⇒ page 108
Note
diator cowl.


Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
WARNING


noise insulation .
ploded view - lock carrier , ⇒ General body repairs, exterior;
Rep. gr. 63 ; Bumper (front); Removing and installing impact
bar .
(bottom right).

Audi A4 2015 ➤ , Audi A5 2016 ➤



Audi A4 2015 ➤ , Audi A5 2016 ➤

G65- .
Caution

aged.



Audi A4 2015 ➤ , Audi A5 2016 ➤
Installing
Note

cylinder TDI engine, common rail; Rep. gr. 00 ; Repair instruc‐
tions; Installing radiators and condensers .

Note

Tightening torques
charge air system


Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
WARNING

radiator cowl.

noise insulation .
(bottom right).
on radiator.

Audi A4 2015 ➤ , Audi A5 2016 ➤
from below.
Installing
Note

Tightening torques
charge air system

V7-
Description applies to radiator fan - V7- and radiator fan 2 - V177- .

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
• Use correct type of fasteners for electrical wiring (as original
equipment) ⇒ Electronic parts catalogue .
ator fan.
Caution

Installing
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 Turbocharger

turbocharger .

Removing

– Release hose clip -1- and detach exhaust gas recirculation
pipe -2-.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove bolts -1- and pull air pipe -2- off turbocharger (leave
in installation position).
Installing
Additional work:
Note

Tightening torques
charge air system
1. Turbocharger 111
Audi A4 2015 ➤ , Audi A5 2016 ➤
2 Charge air system

page 113
page 114
⇒ “2.5 Removing and installing charge air temperature sender af‐
ter charge air cooler G811 ”, page 115

⇒ page 113
condensers
2 - Air hose
3 - Bolt
❑ 9 Nm
4 - Spacer sleeve
5 - Rubber bush
6 - Air pipe
7 - Bolt
❑ 9 Nm
8 - Seal
9 - Air hose
10 - Rubber bush
11 - Spacer sleeve
12 - Bolt
❑ 9 Nm
13 - Connection
❑ For air duct
14 - Bolt
❑ 5 Nm

Audi A4 2015 ➤ , Audi A5 2016 ➤
16 - O-ring
17 - Air hose

charge air system

er
Removing
Note

ness .

Audi A4 2015 ➤ , Audi A5 2016 ➤
charge air cooler.
Caution

damaged.

Installing
Note

Tightening torques
charge air system

sure sender - G31-
gine, common rail; Rep. gr. 21 ; Charge air system; Removing
and installing charge pressure sender - G31- .

Audi A4 2015 ➤ , Audi A5 2016 ➤

perature sender after charge air cooler -
G811-
Removing
– Remove bolt -1- and detach charge air temperature sender
after charge air cooler - G811- .
Installing
Note
Tightening torques

gine, common rail; Rep. gr. 21 ; Charge air system; Checking

Audi A4 2015 ➤ , Audi A5 2016 ➤

1 Injection system
page 117
Note

1 - Injector
(rail)
(right-side)
G81-
4 - Fuel filter
5 - Fuel tank
G247-
(rail)
side)
10 - Injector
11 - Restrictor
hoses
valve - N276-

Audi A4 2015 ➤ , Audi A5 2016 ➤

Engine compartment

❑ Exploded view
⇒ page 125
- G505-
❑ Exploded view
⇒ page 142
J883-
⇒ page 119
GX2-
❑ With:
- G79-
2 - G185-
⇒ page 118
valve 2 - GX6-
❑ With:
potentiometer 2 - G466-
⇒ page 119
V50-
⇒ page 118
8 - Pressure differential sender 2 - G524-

Audi A4 2015 ➤ , Audi A5 2016 ➤


inder

valves -N144- / -N145-

♦ At coolant pipes (rear)

Audi A4 2015 ➤ , Audi A5 2016 ➤
Fitting location of exhaust gas recirculation control motor 2 -

V339-
♦ On left of gearbox
2 - Exhaust gas recirculation control motor 2 - V339-
Exploded view ⇒ Servicing 6-cylinder TDI engine, common rail;
Rep. gr. 26 ; Exhaust gas recirculation; Exploded view - exhaust
gas recirculation

♦ At trap catalytic converter
Engine (top view)

Audi A4 2015 ➤ , Audi A5 2016 ➤

valve - N276-
⇒ page 138
glow plug system
glow plug system
glow plug system
er 1 - J724-
❑ On turbocharger
❑ Exploded view
⇒ page 110
❑ At high-pressure pump
valve 1 - GX5-
❑ With:
10 - Glow plug 5 - Q14-
11 - Glow plug 4 - Q13-

Audi A4 2015 ➤ , Audi A5 2016 ➤

Engine (front view)

G664-
❑ Exploded view
⇒ page 45
N345-
V157-
❑ Exploded view
⇒ page 128
head - N489-
G31-
❑ Exploded view
⇒ page 128
GX3-
❑ With:
♦ Throttle valve potentiome‐
ter - G69-
♦ Throttle valve module -
J338-
♦ Exploded view
⇒ page 128
8 - Temperature sender for en‐
gine temperature regulation -
G694-
trol - N428-
Engine (side view, left-side)

Audi A4 2015 ➤ , Audi A5 2016 ➤

tors
tors
tors
Engine (side view, right-side)

Audi A4 2015 ➤ , Audi A5 2016 ➤

G28-
glow plug system
tors
tors
tors
icing 6-cylinder TDI engine, common rail; Rep. gr. 28 ; Glow plug system; Exploded view - glow plug
system
7 - Starter-alternator coolant pump - V621-
❑ Exploded view ⇒ “2.2.2 Exploded view - starter-alternator coolant pump V621 ”, page 81
❑ Exploded view ⇒ Servicing 6-cylinder TDI engine, common rail (EA 897 Gen II); Rep. gr. 17 ; Sump/oil
pump; Exploded view - sump/oil pump


system for leaks .

Audi A4 2015 ➤ , Audi A5 2016 ➤
2 Vacuum system
All procedures and components are described in ⇒ 6-cylinder TDI
engine, 3.0 ltr. 4-valve common rail; Rep. gr. 23 ; Vacuum sys‐
tem .

Audi A4 2015 ➤ , Audi A5 2016 ➤
3 Air cleaner
1 - Mounting
2 - Water drain
❑ Clean
its or dirt
ing”, page 126
4 - Not fitted
its or dirt
let 830
6 - Bolt
❑ Thread-forming
hand so that it is
que
❑ 3.5 Nm
7 - Bolt
❑ Thread-forming
hand so that it is
que
❑ 3.5 Nm
9 - Air pipe
3. Air cleaner 125

Audi A4 2015 ➤ , Audi A5 2016 ➤
11 - Air duct
❑ On lock carrier
12 - Air duct
❑ On lock carrier
13 - Bolt
❑ Thread-forming
❑ 2.5 Nm
14 - Snow screen

housing
Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
Note

♦ To prevent malfunctions, cover critical parts of the engine air
♦ Use silicone-free lubricant when fitting air hoses.
Tightening torques
charge air system
3. Air cleaner 127

Audi A4 2015 ➤ , Audi A5 2016 ➤
4 Intake manifold
page 128
page 129
”, page 129
129

- intake manifold .

(top section)
Removing
Caution


and installing intake manifold (top section) .
Installing
Additional work:
Note

Tightening torques
charge air system

Audi A4 2015 ➤ , Audi A5 2016 ➤

(bottom section)

flap motor - V157-
installing intake manifold flap motor - V157- .

module - J338-
Removing
– Release hose clip -arrow-, detach air hose and tie up to left
side.
Installing
Additional work:
Note

Tightening torques
charge air system

Audi A4 2015 ➤ , Audi A5 2016 ➤
(rail)
page 130
page 130
speed”, page 130
⇒ “5.7 Checking restrictor in fuel return line”, page 131
page 132



ues for injectors

(rail); Checking for injectors sticking open .

with engine running
(rail); Checking return flow rate of injectors with engine running .

(rail); Checking return flow rate of injectors at starter cranking
speed .

Audi A4 2015 ➤ , Audi A5 2016 ➤
5.7 Checking restrictor in fuel return line

(rail); Checking restrictor in fuel return line .

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



Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
Additional work:
Note

Tightening torques

pipes

reservoir (rail)
Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤


(rail) .
Installing
Additional work:
Note

nectors .
Tightening torques
charge air system

Audi A4 2015 ➤ , Audi A5 2016 ➤

page 135
135
page 136
N276 ”, page 138
”, page 138

- G70-
Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
Note
Tightening torques
charge air system

ture sender - G81-

sender - G247-

Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤

engine, common rail; Rep. gr. 23 ; Senders and sensors ; Re‐
moving and installing fuel pressure sender for low pressure -
G410- .
Installing
Additional work:
Tightening torques
charge air system

- N276-

6551-

Procedure

Audi A4 2015 ➤ , Audi A5 2016 ➤
Caution

Procedure
– Move fuel return hose clear to one side.

Audi A4 2015 ➤ , Audi A5 2016 ➤

Note

N276- is OK.
Note


⇒ page 130 .
tor.
Attaching


Description for removal applies to pressure differential sender -
G505- and pressure differential sender 2 - G524- .

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
Pressure differential sender - G505- :

G505- .

breather hose -2-.
-1-.

Audi A4 2015 ➤ , Audi A5 2016 ➤
Pressure differential sender 2 - G524- :

– Remove body brace (left-side) ⇒ Running gear, axles, steer‐
ing; Rep. gr. 40 ; Suspension strut, upper links; Removing and
installing body brace .
G524- clear.
Continued for both pressure differential senders:

lubricant.
Installing
Note


– If pressure differential sender was renewed, perform adap‐
Tightening torques
♦ ⇒ Running gear, axles, steering; Rep. gr. 40 ; Suspension
strut, upper links; Exploded view - suspension strut, upper
links

Audi A4 2015 ➤ , Audi A5 2016 ➤
pump .

Audi A4 2015 ➤ , Audi A5 2016 ➤
8 Lambda probe

J881-
⇒ page 145
Lambda probe
2 - Particulate sensor - G784-
⇒ page 146
Lambda probe
❑ Tightening torques for
control units
⇒ page 143 and
⇒ page 143
- G505-
⇒ page 138
TDI engine, common
rail; Rep. gr. 23 ; Lamb‐
da probe; Exploded
view - Lambda probe
sender 3 - G495-
temperature control; Removing and installing exhaust gas temperature sender 3 - G495-
5 - NOx sender - G295- with control unit for NOx sender - J583-
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Lambda probe; Ex‐
ploded view - Lambda probe
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Lambda probe;
Removing and installing Lambda probe

Audi A4 2015 ➤ , Audi A5 2016 ➤
❑ Tightening torques ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Lambda probe; Ex‐
ploded view - Lambda probe

que
Bracket with NOx sender 2 - G687- / particulate sensor - G784- -

tightening torque
Particulate sensor - G784- - tightening torque


8. Lambda probe 143

Audi A4 2015 ➤ , Audi A5 2016 ➤

page 144
page 145

G295-

Removing
WARNING

Note


Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
Note

logue .
sition and secure.
Tightening torques

G687-

Removing
WARNING

Note
8. Lambda probe 145

Audi A4 2015 ➤ , Audi A5 2016 ➤

clear.
– Unscrew NOx sender 2 - G687- -item 2- using a tool from

Installing
Note

logue .

Tightening torques
♦ ⇒ Fig. ““Bracket with NOx sender 2 -G687- / particulate sensor
-G784- - tightening torque”“ , page 143
8.4 Removing and installing particulate sen‐

sor - G784-
Removing
WARNING

Note

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Detach bracket.
– Remove nuts -arrows-, detach particulate sensor - G784- from

bracket and move sensor clear.
– Unscrew particulate sensor - G784- -item 1-.

Installing
Tightening torques
♦ ⇒ Fig. ““ Particulate sensor -G784- - tightening torque”“ , page
143
8. Lambda probe 147

Audi A4 2015 ➤ , Audi A5 2016 ➤

page 148
J623-
diagnostic tester
⇒ page 148
4 - Bolt
❑ 4.5 Nm
5 - Bolts
❑ 9 Nm

Removing
- J623- is removed.

Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Drive train
placement
-item 2-.

trol unit - J623- .
Installing
– If engine control unit has been renewed, perform adaptions
listed in Guided Function “0001 - Adapt learnt values - after
component replacement” ⇒ Vehicle diagnostic tester.
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤
WARNING


Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Rear silencer
⇒ page 155
original equipment
separately
❑ Cutting point
⇒ page 154
⇒ page 156
2 - Clamp (front)
free of stress
⇒ page 156
⇒ page 152
3 - Centre silencer
⇒ page 155
❑ Supplied as one unit
with silencer as original
equipment
separately
❑ Cutting point
⇒ page 154
4 - Rubber mounting
5 - Clamp (rear)
6 - Rubber mounting
7 - Retainer
8 - Bolt
❑ 20 Nm
9 - Bracket

Audi A4 2015 ➤ , Audi A5 2016 ➤
10 - Bolt
❑ 20 Nm
12 - Trim
❑ For tailpipes


pipe
Note
The SCR catalytic converter is integrated in the front exhaust

pipe.
Removing
WARNING


Audi A4 2015 ➤ , Audi A5 2016 ➤

noise insulation .
– Unplug electrical connectors -1, 2- and move clear.
exhaust pipe.

Audi A4 2015 ➤ , Audi A5 2016 ➤
Caution
Risk of damage to flexible joint in front exhaust pipe.

♦ Do NOT bend flexible joint in front exhaust pipe more than
10°.

Installing
Note

Tightening torques


Audi A4 2015 ➤ , Audi A5 2016 ➤
Procedure
WARNING



Tightening torques

Removing
WARNING


body trim; Removing and installing underbody trim .

Audi A4 2015 ➤ , Audi A5 2016 ➤

WARNING

lencer.

Installing
Tightening torques

Procedure
WARNING


Audi A4 2015 ➤ , Audi A5 2016 ➤

nections evenly.

Tightening torques


Audi A4 2015 ➤ , Audi A5 2016 ➤

page 158
page 161
page 161

tem

trol module
Removing
WARNING


noise insulation .

Audi A4 2015 ➤ , Audi A5 2016 ➤

G505- .


Audi A4 2015 ➤ , Audi A5 2016 ➤

to one side.


Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
Note
♦ Renew gaskets and self-locking nuts after removal.

♦ Dirt screen ⇒ Item 12 (page 173) must be renewed if emission
control module was renewed.

– If emission control module has been renewed, perform adap‐
Tightening torques
charge air system

converter
gine, common rail (EA 897 Gen. II) ; Rep. gr. 26 ; Emission control
system; Exploded view - emission control system .

gine, common rail (EA 897 Gen. II) ; Rep. gr. 26 ; Emission control
system; Exploded view - emission control system .

Audi A4 2015 ➤ , Audi A5 2016 ➤

system
”, page 166
1 - Supply line
WARNING
Safety risk due to escap‐
ing reducing agent.
Observe
♦ safety meas‐
ures when handling re‐
ducing agent ⇒ Servicing
00 ; Safety precautions;
Safety precautions when
working on the SCR sys‐
tem .
2 - Sealing plug
❑ For drain pipe
system - GX19-
system - GX19- :
♦ Filter
agent - G684-
- G686-
♦ Reducing agent quality sensor - G849- (country-specific version)

Audi A4 2015 ➤ , Audi A5 2016 ➤

❑ Adapt learnt value after filling or renewing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 00 ;
Repair notes; Adapting learnt values for SCR system
4 - Nut
❑ 20 Nm
5 - Spacer sleeve
6 - Grommet
7 - Spacer sleeve
8 - Filler neck
❑ For fuel tank
9 - Filler cap
10 - Bolt
❑ 8 Nm
11 - Filler neck
12 - Spacer sleeve
13 - Grommet
14 - Spacer sleeve
15 - Bolt
❑ 20 Nm
❑ Adapt learnt value after renewing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 00 ; Repair
notes; Adapting learnt values for SCR system
17 - Bolt
❑ 3 Nm

line

Procedure
Note

Audi A4 2015 ➤ , Audi A5 2016 ➤
WARNING

on the SCR system .
♦ To prevent large amounts of reducing agent from escap‐
ing when the supply line is opened, wait until the reducing
agent has been drawn back automatically ⇒ Servicing 6-
cylinder TDI engine, common rail; Rep. gr. 00 ; Safety
precautions; Safety precautions when working on the
SCR system .

– Open tank flap.

Attaching
system .
Tightening torques

tank

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
WARNING

on the SCR system .

agent supply line .
harness clear.

Audi A4 2015 ➤ , Audi A5 2016 ➤
Caution

♦ Reducing agent tank must be empty when it is removed.

Installing
system .
Tightening torques

- N474- .

Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
– If control unit for reducing agent metering system - J880- is
renewed, adapt “learnt value” ⇒ Servicing 6-cylinder TDI en‐
gine, common rail; Rep. gr. 00 ; Repair notes; Adapting learnt
values for SCR system .
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

page 168
G235 ”, page 170
G448 ”, page 170
G495 ”, page 170
G648 ”, page 170
4.1 Exploded view - exhaust gas tempera‐

ture control
WARNING


Audi A4 2015 ➤ , Audi A5 2016 ➤

J881-
⇒ page 144
2 - Particulate sensor - G784-
⇒ page 146
- G505-
⇒ page 138
sender 3 - G495-
TDI engine, common
control; Removing and
installing exhaust gas
temperature sender 3 -
G495-
gas temperature con‐
trol; Exploded view - ex‐
control
J583-
⇒ page 144
❑ Removing and installing ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 23 ; Lambda probe;

Audi A4 2015 ➤ , Audi A5 2016 ➤

Removing and installing exhaust gas temperature sender 1 -
G235- .

G448- .

G495- .

Removing
WARNING

Note


Audi A4 2015 ➤ , Audi A5 2016 ➤

G505- .

breather hose -2-.
– Unscrew bolts -arrows- and remove resonator -1-.
engine, common rail; Rep. gr. 26 ; Exhaust gas temperature con‐
trol; Removing and installing exhaust gas temperature sender 4
- G648- .
Installing
Additional work:
Note

Tightening torques
charge air system

Audi A4 2015 ➤ , Audi A5 2016 ➤

page 172
page 174

tion system
⇒ “5.1.1 Exploded view - exhaust gas recirculation system, engine
side (front)”, page 172
pressure side (rear)”, page 172
5.1.1 Exploded view - exhaust gas recircula‐

tion system, engine side (front)
gine, common rail; Rep. gr. 26 ; Exhaust gas recirculation system;
5.1.2 Exploded view - exhaust gas recirculation system, low-pressure side (rear)

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Hoses
sender 2 - G524-
2 - G524-
⇒ page 138
3 - Bracket
❑ For pressure differential
sender 2 - G524-
4 - Bolt
❑ 9 Nm
5 - Nut
❑ 9 Nm
6 - Connection
7 - Hose
lation
8 - Bolt
❑ 9 Nm
9 - Seal
⇒ page 176
11 - Gasket
❑ On some vehicle ver‐
sions, gasket and dirt
screen -12- are a single component
12 - Dirt screen
❑ On some vehicle versions, gasket -11- and dirt screen are a single component
❑ Dirt screen must be renewed if emission control module was renewed
13 - Bolt
❑ 20 Nm
14 - Bolt
❑ Tightening torque ⇒ Servicing 6-cylinder TDI engine, common rail; Rep. gr. 21 ; Turbocharger; Exploded
view - turbocharger
15 - Resonator
16 - Seal
18 - Exhaust gas recirculation cooler (rear)
19 - Bolt
❑ 9 Nm

Audi A4 2015 ➤ , Audi A5 2016 ➤
20 - Gasket
❑ 15 Nm
22 - Mounting
23 - Bolt
❑ 23 Nm
25 - Clamp

circulation cooler
(rear)”, page 174

circulation cooler (front)

circulation cooler (rear)

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
G524- clear.
subframe shield .
– Release clamp -arrow- on exhaust gas recirculation pipe.

– Remove bolts -arrows- and detach exhaust pipe -1-.
– Remove tunnel cross member and lower gearbox ⇒ 8-speed
automatic gearbox; Rep. gr. 37 ; Assembly mountings; Ex‐
ploded view - assembly mountings .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Release hose clip -3- at hose for exhaust gas recirculation.

– Remove bolt -1- from retaining clip.
circulation pump - V50- .
cooler (rear) -5-.
Installing
Note
♦ Renew seals and O-rings after removal.

Note

Tightening torques

Removing
– Remove exhaust gas recirculation cooler (rear) ⇒ Servicing
tion cooler .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Unscrew bolt -2- and nuts -arrows- and detach exhaust gas
recirculation control motor 2 - V339- -item 1-.
Installing
Note
Renew seals and O-rings after removal.
– Clean and insert dirt screen ⇒ Item 12 (page 173) .

– Install exhaust gas recirculation cooler (rear) ⇒ Servicing 6-
tion cooler .
Tightening torques

sensor - G98- .

Audi A4 2015 ➤ , Audi A5 2016 ➤
6 Exhaust manifolds
WARNING

1 - Nut
TDI engine, common
ded view - exhaust
manifold
❑ Shown for cylinder bank
2 (left-side)
⇒ page 179
3 - Gasket
TDI engine, common
ded view - exhaust
manifold
4 - Gasket
TDI engine, common
ded view - exhaust
manifold
5 - Clamp
- turbocharger

Audi A4 2015 ➤ , Audi A5 2016 ➤

folds
page 179
page 180

fold (left-side)
Removing
WARNING


⇒ page 45 .

Audi A4 2015 ➤ , Audi A5 2016 ➤

rear.
Installing
Note
Renew gaskets, seals, self-locking nuts and screw-type clip after

removal.

Tightening torques

fold (right-side)
Removing
WARNING


– Unbolt coolant pipe (front) and detach from thermostat
⇒ page 89 .
lation pipe -2-.

Audi A4 2015 ➤ , Audi A5 2016 ➤

breather hose -2-.
– Unscrew bolts -arrows- and remove resonator -1-.


Audi A4 2015 ➤ , Audi A5 2016 ➤

rear.
Installing
Note
Renew O-ring, bolts and screw-type clips after removal.

Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

1 Glow plug system
cylinder TDI engine, common rail; Rep. gr. 28 ; Glow plug
system .

Service
Workshop Manual
Audi A4 2015 ➤
Audi A5 2016 ➤
6-cylinder direct injection engine (2.9 ltr., 3.0 ltr. 4-
valve TFSI EA 839)
Engine ID
CWG DEC
D A
Edition 02.2019

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system

Copyright © 2019 Audi AG, Ingolstadt D4B8063F1EB

Audi A4 2015 ➤ , Audi A5 2016 ➤
6-cylinder direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI EA 839) - Edition 02.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.1 Exploded view - camshaft timing chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.2 Exploded view - drive chain for oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.3 Removing camshaft timing chain from camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.4 Removing and installing camshaft timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Contents i
Audi A4 2015 ➤ , Audi A5 2016 ➤

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.3 Removing and installing spray nozzle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.8 Removing and installing engine outlet coolant temperature sender G82 . . . . . . . . . . . . . . 150
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4 Radiator/radiator fan(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.2 Exploded view - radiator blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4.3 Exploded view - auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
ii Contents
Audi A4 2015 ➤ , Audi A5 2016 ➤

4.7 Removing and installing radiator blind . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.8 Removing and installing radiator blind control motor V544 . . . . . . . . . . . . . . . . . . . . . . . . 194
4.9 Removing and installing auxiliary radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
1 Turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.1 Exploded view - turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.3 Renewing vacuum unit for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.4 Removing and installing temperature sender for engine cover panel G765 . . . . . . . . . . . . 207
2.3 Removing and installing air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
2.7 Removing and installing overrun air recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
4.4 Cleaning throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
5 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
6.1 Exploded view - actuator for structure-borne sound and control unit for structure-borne
sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.2 Removing and installing actuator for structure-borne sound R214 . . . . . . . . . . . . . . . . . . 252
6.3 Removing and installing control unit for structure-borne sound J869 . . . . . . . . . . . . . . . . 252
G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Contents iii
Audi A4 2015 ➤ , Audi A5 2016 ➤

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
iv Contents
Audi A4 2015 ➤ , Audi A5 2016 ➤
1 Identification
(ARL006255; Edition 02.2019)
ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Identification .
1. Identification 1
Audi A4 2015 ➤ , Audi A5 2016 ➤
ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Safety precautions .

Audi A4 2015 ➤ , Audi A5 2016 ➤
ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Repair instructions .
Audi A4 2015 ➤ , Audi A5 2016 ➤

page 69
page 72
1.1 Removing engine

⇒ “1.1.1 Removing engine - 2.9 ltr. engine without particulate fil‐
ter”, page 4
⇒ “1.1.2 Removing engine - 2.9 ltr. engine with particulate filter”,
page 18
⇒ “1.1.3 Removing engine - 3.0 ltr. engine without particulate fil‐
ter”, page 33
⇒ “1.1.4 Removing engine - 3.0 ltr. engine with particulate filter”,
page 46
1.1.1 Removing engine - 2.9 ltr. engine with‐

out particulate filter

Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Supplementary kit - VAS 6131/11- (not illustrated)

♦ Supplementary set, Audi Q7 >2005 - VAS 6131/13-


Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Universal wedge no. 7 from scraper set - VAS 6845-

Audi A4 2015 ➤ , Audi A5 2016 ➤

Procedure
♦ Observe rules for cleanliness ⇒ Servicing 6-cylinder engine,
2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 00 ; Repair notes; Rules
for cleanliness .
(vehicle unladen) on vehicles with coil springs or in reference
position on vehicles with air suspension.
(unladen position/reference position). Otherwise, the bush
would be subject to torsion loading and its service life short‐
ened.
gear, axles, steering; Rep. gr. 00 ; Repair notes; Lifting sus‐
pension to unladen position (vehicles with coil springs) or
determine reference position ⇒ Running gear, axles, steering;
Rep. gr. 00 ; Repair notes; Lifting suspension to unladen po‐
sition (vehicles with air suspension) .
during removal.

Audi A4 2015 ➤ , Audi A5 2016 ➤

battery .
WARNING


expansion tank.
– Remove wheel spoiler on both sides and unfasten front sec‐
tion of front right wheel housing liner ⇒ General body repairs,
noise insulation .

– Lift retaining clip -arrow-, disconnect coolant hose (bottom
right) from radiator and drain off coolant.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Release hose clips -2, 3-, disconnect coolant hoses and drain
off coolant.
– Unscrew bolts -1- on both sides and tie up coolant pipes to
right side.

– Disconnect coolant hose at T-piece and drain off coolant.

– Disconnect coolant hose from gear oil cooler, hold end of hose

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove ball stud -arrows- and detach heat shield -1-.


coal filter system.

Audi A4 2015 ➤ , Audi A5 2016 ➤

-arrow A-.
– Lift retaining clip -2- and disconnect coolant bleeder line.

– Release hose clip -1-, detach air hose and tie up to left side.


Audi A4 2015 ➤ , Audi A5 2016 ➤
– Unplug electrical connectors -1- on engine control unit - J623-

-item 2- and move connectors clear.
electrical wiring clear.
– Detach electrical connector -arrow- from bracket and unplug.

and unplug.

– Remove refrigerant lines from air conditioner compressor ⇒
pressor; Detaching and attaching refrigerant lines at air con‐
ditioner compressor .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Release hose clip -1- and detach coolant hose from connec‐
tion.
– Using assembly tool - T10118- , unplug electrical connector

-arrow- for electrohydraulic engine mounting solenoid valve on
both sides and move wiring clear.
Caution

ported.

strap - T10038- (use the handle of a hammer -2- to do so).

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Unplug electrical connector -3- for front vehicle level sender

on both sides and move electrical wire clear.
Note
For the following work on the running gear, check the latest ver‐
sions ⇒ Running gear, axles, steering; Rep. gr. 48 ; Steering
rack; Removing and installing track rod ball joint , and ⇒ Running
gear, axles, steering; Rep. gr. 40 ; Lower suspension links, swivel
joint; Removing and installing guide link .

WARNING

Caution

socket.

if necessary.
WARNING

wrench.

Audi A4 2015 ➤ , Audi A5 2016 ➤

Note
rod -2-.

Caution

hand.
with your hands.


Audi A4 2015 ➤ , Audi A5 2016 ➤
parking lock clear.
Caution

♦ Do NOT bend the flexible joint in the front silencer more
than 10°.
– Remove bolt -2- and nuts -1- and -arrows- for front silencer
(left-side).
– Detach front silencer (left-side).
– Remove bolt -1- and nuts -arrows- for front silencer (right-
side).
– Detach front silencer (right-side).

Audi A4 2015 ➤ , Audi A5 2016 ➤

C4 /10-1 /10-4 /10-5 /10-11
E4 /10-1 /10-4 /10-5 /10-11
E10 /10-1 /10-2 /10-5 /13-2
B15 /10-1 /10-2 /10-5 /11-1
F15 /10-1 /10-3 /10-5 /11-1
assembly platform.
zontally.

of engine.
– Support subframe using support elements from -

Note

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Position support elements from -VAS 6131/10- and adapters

-VAS 6131/11-1- at tunnel cross member.
Caution


1.1.2 Removing engine - 2.9 ltr. engine with

particulate filter

Audi A4 2015 ➤ , Audi A5 2016 ➤



Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Universal wedge no. 7 from scraper set - VAS 6845-

Audi A4 2015 ➤ , Audi A5 2016 ➤

Procedure
for cleanliness .
ened.

Audi A4 2015 ➤ , Audi A5 2016 ➤

during removal.
battery .
WARNING


expansion tank.
– Remove body brace (right-side) ⇒ Running gear, front-wheel
drive and four-wheel drive; Rep. gr. 40 ; Suspension strut,
upper links; Removing and installing body brace .
noise insulation .

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Lift retaining clip -arrow-, disconnect coolant hose (bottom
right) from radiator and drain off coolant.
off coolant.
– Unscrew bolts -1- on both sides and tie up coolant pipes to
right side.

– Disconnect coolant hose at T-piece and drain off coolant.

– Disconnect coolant hose from gear oil cooler, hold end of hose

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove ball stud -arrows- and detach heat shield -1-.


Audi A4 2015 ➤ , Audi A5 2016 ➤

coal filter system.

-arrow A-.

– If engine is to be separated from gearbox: Remove bolts -1-
and move bracket clear together with pressure differential
sender for particulate filter - G1037- .

Audi A4 2015 ➤ , Audi A5 2016 ➤

sender 3 - G495- .
– If engine is to be separated from gearbox: Detach electrical
connector from bracket and move clear.




Audi A4 2015 ➤ , Audi A5 2016 ➤
– Detach electrical connector -arrow- from bracket and unplug.

2 for particulate filter - G1038- .
– If engine is to be separated from gearbox: Remove bolts -2-
and move bracket -3- clear together with pressure differential
sender 2 for particulate filter - G1038- .

sender 3 for bank 2 - G497- .
– If engine is to be separated from gearbox: Detach electrical
connector from bracket and move clear.

and unplug.

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Remove refrigerant lines from air conditioner compressor ⇒
pressor; Detaching and attaching refrigerant lines at air con‐
ditioner compressor .
– Release hose clip -1- and detach coolant hose from connec‐
tion.
– Using assembly tool - T10118- , unplug electrical connector

-arrow- for electrohydraulic engine mounting solenoid valve on
both sides and move wiring clear.

Audi A4 2015 ➤ , Audi A5 2016 ➤
Caution

ported.


Note

WARNING

Caution

socket.

Audi A4 2015 ➤ , Audi A5 2016 ➤

if necessary.
WARNING

wrench.

Note
rod -2-.


Audi A4 2015 ➤ , Audi A5 2016 ➤
Caution

hand.
with your hands.

parking lock clear.
Caution

than 10°.
– Remove bolt -1- and nuts -arrows- for front silencer (left and
right).

Audi A4 2015 ➤ , Audi A5 2016 ➤
Setting up scissor-type assembly platform:

C4 /10-1 /10-4 /10-5 /10-11
E4 /10-1 /10-4 /10-5 /10-11
E10 /10-1 /10-2 /10-5 /13-2
B15 /10-1 /10-2 /10-5 /11-1
F15 /10-1 /10-3 /10-5 /11-1
assembly platform.
zontally.

of engine.

Note

Audi A4 2015 ➤ , Audi A5 2016 ➤

Caution


1.1.3 Removing engine - 3.0 ltr. engine with‐


Audi A4 2015 ➤ , Audi A5 2016 ➤



Audi A4 2015 ➤ , Audi A5 2016 ➤

Audi A4 2015 ➤ , Audi A5 2016 ➤

Procedure
for cleanliness .
ened.
during removal.

Audi A4 2015 ➤ , Audi A5 2016 ➤

battery .
WARNING


expansion tank.
noise insulation .

– Lift retaining clip -arrow-, disconnect coolant hose from radia‐
tor and drain off coolant.

Audi A4 2015 ➤ , Audi A5 2016 ➤



Audi A4 2015 ➤ , Audi A5 2016 ➤

coal filter system.

-arrow A-.

– Release fastener -arrow- and press coolant circulation pump
- V50- to one side.

G31- .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Lift retaining clip -arrow- and disconnect coolant hose (top left)
from radiator.



and unplug.

Audi A4 2015 ➤ , Audi A5 2016 ➤



Audi A4 2015 ➤ , Audi A5 2016 ➤
Caution

ported.


Note

WARNING

Caution

socket.

Audi A4 2015 ➤ , Audi A5 2016 ➤

if necessary.
WARNING

wrench.

Note
rod -2-.

Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep.
gr. 13 ; Cylinder block (pulley end); Removing and installing
poly V-belts .

Audi A4 2015 ➤ , Audi A5 2016 ➤
Caution

hand.
with your hands.

parking lock clear.

C4 /10-1 /10-4 /10-5 /10-12
E4 /10-1 /10-4 /10-5 /10-11
E10 /10-1 /10-2 /10-5 /13-2
B15 /10-1 /10-2 /10-5 /11-1
F15 /10-1 /10-3 /10-5 /11-1
assembly platform.
zontally.

Audi A4 2015 ➤ , Audi A5 2016 ➤

of engine.

Note

Caution



Audi A4 2015 ➤ , Audi A5 2016 ➤
1.1.4 Removing engine - 3.0 ltr. engine with

particulate filter


Audi A4 2015 ➤ , Audi A5 2016 ➤


Audi A4 2015 ➤ , Audi A5 2016 ➤

Procedure
for cleanliness .
ened.

Audi A4 2015 ➤ , Audi A5 2016 ➤

during removal.
battery .
WARNING


expansion tank.
noise insulation .


Audi A4 2015 ➤ , Audi A5 2016 ➤



Audi A4 2015 ➤ , Audi A5 2016 ➤

coal filter system.

-arrow A-.

sender 3 - G495- .
– If engine is to be separated from gearbox: Remove electrical
connector from bracket and move electrical wiring clear.

Audi A4 2015 ➤ , Audi A5 2016 ➤

G31- .
– Lift retaining clip -arrow- and disconnect coolant hose (top left)
from radiator.



Audi A4 2015 ➤ , Audi A5 2016 ➤

– If engine is to be separated from gearbox at a later stage: Re‐
move bolts -2- and move bracket -3- clear together with pres‐
sure differential sender 2 for particulate filter - G1038- .

and unplug.


Audi A4 2015 ➤ , Audi A5 2016 ➤

Caution

ported.


Note

Audi A4 2015 ➤ , Audi A5 2016 ➤

WARNING

Caution

socket.

if necessary.
WARNING

wrench.

Note

Audi A4 2015 ➤ , Audi A5 2016 ➤
rod -2-.

poly V-belts .
Caution

hand.
with your hands.

parking lock clear.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Use tensioning strap - T10038- to secure front silencers as

shown.

C4 /10-1 /10-4 /10-5 /10-12
E4 /10-1 /10-4 /10-5 /10-11
E10 /10-1 /10-2 /10-5 /13-2
B15 /10-1 /10-2 /10-5 /11-1
F15 /10-1 /10-3 /10-5 /11-1
assembly platform.
zontally.

of engine.

Audi A4 2015 ➤ , Audi A5 2016 ➤

Note

Caution



⇒ “1.2.1 Separating engine and gearbox - vehicles with 2.9 ltr.
engine”, page 58
engine”, page 63
1.2.1 Separating engine and gearbox - vehi‐

cles with 2.9 ltr. engine

Audi A4 2015 ➤ , Audi A5 2016 ➤

♦ Wrench, 21 mm - T40263-

Audi A4 2015 ➤ , Audi A5 2016 ➤
Procedure
– Remove bolt -bottom arrow- for support mounting (right-side)
-1-.
wiring harness.
WARNING

• Perform the following work with the assistance of a second
mechanic.

side (remove support elements). Shown with engine installed.

side with hoses -1, 4- attached.

Audi A4 2015 ➤ , Audi A5 2016 ➤
Caution

slips.
-arrow-.
– To slacken bolts for torque converter, counterhold crankshaft

at vibration damper using wrench, 21 mm - T40263- and
adapter -T40314- .
– Remove 6 bolts -arrow- for torque converter from drive plate

-1-. Turn crankshaft 60° in direction of engine rotation each
time.

one side.

Audi A4 2015 ➤ , Audi A5 2016 ➤

VAS 6131/12-2-
C7 /10-1 /12-2 /10-5 /10-12
E7 /10-1 /12-2 /10-5 /10-12
C10 /10-1 /10-4 /10-5 /10-12
F10 /10-1 /10-4 /10-5 /11-3

VAS 6131/12-2- at both sides of engine.

box.

Audi A4 2015 ➤ , Audi A5 2016 ➤



1.2.2 Separating engine and gearbox - vehi‐


Audi A4 2015 ➤ , Audi A5 2016 ➤

♦ Wrench, 21 mm - T40263-

Audi A4 2015 ➤ , Audi A5 2016 ➤
Procedure
wiring harness.
WARNING

mechanic.

side (remove support elements). Shown with engine installed.

side with hoses -1, 4- attached.

Audi A4 2015 ➤ , Audi A5 2016 ➤
Caution

slips.
-arrow-.
– To slacken bolts for torque converter, counterhold crankshaft

at vibration damper using wrench, 21 mm - T40263- and
adapter -T40314- .
– Remove 6 bolts -arrow- for torque converter from drive plate

-1-. Turn crankshaft 60° in direction of engine rotation each
time.
(left-side).
side).

Audi A4 2015 ➤ , Audi A5 2016 ➤
Caution

than 10°.
– Remove bolts -arrows- on both sides and detach correspond‐

ing front silencer.

one side.

VAS 6131/12-2-
C7 /10-1 /12-2 /10-5 /10-12
E7 /10-1 /12-2 /10-5 /10-12
C10 /10-1 /10-4 /10-5 /10-12
F10 /10-1 /10-4 /10-5 /11-3

Audi A4 2015 ➤ , Audi A5 2016 ➤

VAS 6131/12-2- at both sides of engine.

box.


Audi A4 2015 ➤ , Audi A5 2016 ➤



sembly platform
⇒ “1.3.1 Removing engine from scissor-type assembly platform -
vehicles with 2.9 ltr. engine”, page 69
⇒ “1.3.2 Removing engine from scissor-type assembly platform -
1.3.1 Removing engine from scissor-type as‐

sembly platform - vehicles with 2.9 ltr.
engine

Audi A4 2015 ➤ , Audi A5 2016 ➤
Procedure
from gearbox)
engine”, page 58 .
WARNING
Risk of accident!
♦ The engine can only be transported with the gearbox re‐
moved using the method described.

VAS 6100- .
– Raise engine using workshop hoist.
1.3.2 Removing engine from scissor-type as‐

sembly platform - vehicles with 3.0 ltr.
engine

Audi A4 2015 ➤ , Audi A5 2016 ➤
Procedure
from gearbox)

Audi A4 2015 ➤ , Audi A5 2016 ➤
WARNING
Risk of accident!
♦ The engine can only be transported with the gearbox re‐
moved using the method described.

VAS 6100- .

support
♦ Universal mounting - VAS 6095/1- and bracket for V6 TFSI

engine - VAS 6095/1-15-

Audi A4 2015 ➤ , Audi A5 2016 ➤
Procedure
– Unscrew bolts -arrows- and remove engine support (left-side).
If work is subsequently required on chain drive:

– Remove nuts -4- and bolt -5-.
– Detach vacuum reservoir -1-.
– Unscrew plug -1- for “TDC” hole and detach bracket -2-.
Continued:
– Remove nut -arrow- for earth wire.

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter;
Removing and installing starter .

TFSI engine - VAS 6095/1-15- , secure engine to engine and
gearbox support - VAS 6095A- (40 Nm).

Procedure
angle.
♦ Before fitting, check vacuum hoses for damage and renew if
necessary.
position.
– Move starter into installation position.
– Install engine supports, engine mountings and, if applicable,
support mountings
⇒ “2.1 Exploded view - assembly mountings”, page 78 .

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Fit gearbox to engine ⇒ 8-speed automatic gearbox; Rep. gr.
37 ; Removing and installing gearbox; Installing gearbox .
– Fit plug for “OT” hole ⇒ Servicing 6-cylinder engine, 2.9 ltr.,
3.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Crankshaft; Exploded view
- crankshaft .
⇒ “3.1 Exploded view - coolant pipes”, page 152 .
– Install exhaust system
⇒ “1.1 Exploded view - silencers”, page 259 .
– Install ATF cooler ⇒ 8-speed automatic gearbox; Rep. gr. 37 ;
ATF circuit; Removing and installing ATF cooler .
– Carefully guide engine/gearbox assembly into body using
scissor-type assembly platform - VAS 6131 B- .
– Remove locating pins and install subframe ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Subframe; Fixing position of
subframe .
– Tighten bolts for tunnel cross member ⇒ 8-speed automatic
gearbox; Rep. gr. 37 ; Assembly mountings; Exploded view -
assembly mountings .
note the following:
– Install manual release cable for parking lock ⇒ 8-speed au‐
tomatic gearbox; Rep. gr. 37 ; Selector mechanism .
– If removed previously, install air conditioner compressor ⇒
pressor; Exploded view - air conditioner compressor drive
unit .
– If removed previously, install poly V-belt
⇒ “1.3 Removing and installing poly V-belts”, page 85 and
⇒ Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI;
Rep. gr. 13 ; Cylinder block (pulley end); Removing and in‐
stalling poly V-belts .
– If removed previously, fit refrigerant lines at air conditioner
compressor ⇒ Heating, air conditioning; Rep. gr. 87 ; Air con‐
ditioner compressor; Detaching and attaching refrigerant lines
at air conditioner compressor .
– Install anti-roll bar and coupling rod ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Subframe; Exploded view - subframe .
gr. 40 ; Subframe; Exploded view - subframe .
– If previously removed, install body brace (right-side) ⇒ Run‐
ning gear, front-wheel drive and four-wheel drive; Rep. gr. 40 ;

Audi A4 2015 ➤ , Audi A5 2016 ➤
Suspension strut, upper links; Removing and installing body

brace .
– Install pressure differential sender together with bracket ⇒
Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI EA
839; Rep. gr. 24 ; Senders and sensors; Exploded view -
pressure differential sender .
– Install engine control unit - J623-
⇒ “9.2 Removing and installing engine/motor control unit J623
”, page 257 .
– Electrical wiring and connections ⇒ Electrical system; Rep.
gr. 97 ; Relay carriers, fuse carriers, electronics boxes; Over‐
view of fitting locations - relay carriers, fuse carriers, electron‐
ics boxes and ⇒ Current flow diagrams, Electrical fault finding
page 245 .
– Install heat shield and engine cover panel ⇒ Servicing 6-cyl‐
inder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 10 ; Engine
cover panel; Removing and installing engine cover panel .
– Install bumper cover ⇒ General body repairs, exterior; Rep.
gr. 63 ; Bumper (front); Removing and installing bumper cov‐
er .
Wheels, tyres .
ing battery .
Caution

sive voltage.
– If engine and gearbox have been separated or engine has

been renewed, perform corresponding adaptions listed in Gui‐
ded Function “0001 - Functions, engine mechanics” ⇒ Vehicle
diagnostic tester.

Audi A4 2015 ➤ , Audi A5 2016 ➤
Caution


page 176 .
– Check ATF level ⇒ 8-speed automatic gearbox; Rep. gr. 37 ;
ATF; Checking ATF level .
insulation .
Tightening torques
Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65
♦ Bolts securing engine to gearbox ⇒ 8-speed automatic gear‐
box; Rep. gr. 37 ; Removing and installing gearbox; Tighten‐
ing torques for gearbox

Audi A4 2015 ➤ , Audi A5 2016 ➤

Engine mounting
1 - Subframe
2 - Bolt
❑ For 2.9 ltr. engine
❑ 20 Nm
3 - Bolt
❑ For 2.9 ltr. engine
❑ 10 Nm
❑ For 2.9 ltr. engine, right
side only
installing support
mounting”, page 82
⇒ Fig. ““Support mount‐
ing - installation posi‐
tion”“ , page 79
5 - Bolt
❑ 55 Nm
6 - Engine support
stalling engine support”,
page 91
7 - Not fitted
8 - Not fitted
9 - Bolt
❑ 55 Nm
❑ With:
♦ Left electrohydraulic engine mounting solenoid valve - N144-
♦ Right electrohydraulic engine mounting solenoid valve - N145-
❑ Removing and installing ⇒ “2.3.1 Removing and installing engine mountings”, page 81
11 - Bolt
❑ 90 Nm +90°
12 - Bolt
❑ 30 Nm

Audi A4 2015 ➤ , Audi A5 2016 ➤
Support mounting - installation position

• Projection -2- on engine support must engage in recess -1- on
support mounting.
Gearbox mounting
1 - Bolt
mountings
Assembly mountings;
bly mountings
3 - Nut
mountings
4 - Gearbox support
ing”, page 83
5 - Bolt
mountings
7 - Stop plate
8 - Bolt
Audi A4 2015 ➤ , Audi A5 2016 ➤
assembly mountings
9 - Nut
assembly mountings

tion
Procedure
– Remove engine cover panel and heat shield ⇒ Servicing 6-
Engine cover panel; Removing and installing engine cover
panel .
(left and right).
right).
– Tighten spindles slightly to take up weight of engine until en‐
gine mountings are no longer supporting engine.
Attaching

Audi A4 2015 ➤ , Audi A5 2016 ➤

ings

ings
Removing
⇒ “2.2 Supporting engine in installation position”, page 80 and
take up weight with spindle - 10-222A/11- until load on engine
mounting is relieved.
noise insulation .
– Unfasten front section of wheel housing liner and press to one
side ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel
poly V-belts .
– Remove poly V-belt from alternator pulley ⇒ Servicing 6-cyl‐
inder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 13 ;
belts .
– Vehicles with 2.9 ltr. engine: Remove support mounting (right-
side)
⇒ “2.3.2 Removing and installing support mounting”,
page 82 .
Audi A4 2015 ➤ , Audi A5 2016 ➤

– Unplug electrical connector affected -arrow- for electrohy‐
draulic engine mounting solenoid valve.
– Remove bolts -arrows- and detach engine mounting -1-

(shown on left).
Installing
angle.
– Vehicles with 2.9 ltr. engine: Install support mounting (right-
side)
⇒ “2.3.2 Removing and installing support mounting”,
page 82 .
⇒ “1.3 Removing and installing poly V-belts”, page 85 and
Tightening torques
- alternator
Fitting locations

ing
Removing
noise insulation .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove bolts -arrows- for support mounting -1-.

Installing
• Installation position
⇒ Fig. ““Support mounting - installation position”“ , page 79 .
Tightening torques

mounting
– Remove tunnel cross member ⇒ 8-speed automatic gearbox;
mountings .
– Remove bolts -arrows- and detach gearbox support -1- and
gearbox mounting from gearbox.

box support -4- (gearbox support in vehicle does not corre‐
spond to illustration).
Installing
– Install gearbox support with gearbox mounting.
Tightening torques
Audi A4 2015 ➤ , Audi A5 2016 ➤

ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 10 ; Engine cover panel .

Audi A4 2015 ➤ , Audi A5 2016 ➤
page 89
page 91
92

end)
end); Exploded view - cylinder block (pulley end) .

end)
end); Exploded view - sealing flange (pulley end) .

⇒ “1.3.1 Removing and installing poly V-belt for alternator/coolant
pump - vehicles with 2.9 ltr. engine”, page 85
⇒ “1.3.2 Removing and installing poly V-belt for air conditioner
compressor (with radiator fitted) - vehicles with 2.9 ltr. engine”,
page 86
compressor (with radiator removed) - vehicles with 2.9 ltr. en‐
gine”, page 88
⇒ “1.3.4 Removing and installing poly V-belts for alternator/cool‐
ant pump and air conditioner compressor - vehicles with 3.0 ltr.
engine”, page 89
1.3.1 Removing and installing poly V-belt for

alternator/coolant pump - vehicles with
2.9 ltr. engine
end); Removing and installing poly V-belts .

Audi A4 2015 ➤ , Audi A5 2016 ➤

air conditioner compressor (with radiator
fitted) - vehicles with 2.9 ltr. engine
Complete procedure if radiator has NOT been removed during
preparatory work

Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Flat-nose pliers, straight and long version (commercially avail‐

able)
♦ Socket (30 mm)
♦ M10x40 bolt
♦ M10x60 bolt
♦ Nuts M10 (3x)
Preparing counterhold tool - 3145-
– Secure socket (30 mm) -item 1- to counterhold tool - 3145-
with M10x40 bolt -item 2- and M10x60 bolt -item 3-, as shown
in illustration.
– Tighten nuts -arrows-.
Removing
noise insulation .
If poly V-belt for air conditioner compressor is being removed

completely:
– Clamp off coolant hose -2- with hose clamp, up to 25 mm -
3094- .
– Clamp off coolant hose using hose clamp up to 25 mm - 3094- ,
Continued:
– Remove bolts -arrows- and push coolant pipes at lock carrier
slightly upwards.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Apply counterhold tool - 3145- at poly V-belt and sump flange,

as shown.
– Turn counterhold tool anti-clockwise only until tensioner -1-
can be locked with locking pin - T10060A- .
Note:
Fit locking pin - T10060A- with flat-nose pliers (long version).
Installing
– Fit poly V-belt ⇒ Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-
valve TFSI; Rep. gr. 13 ; Cylinder block (pulley end); Exploded
view - cylinder block (pulley end) .
– Apply counterhold tool - 3145- on poly V-belt, swivel slightly

anti-clockwise and pull out locking pin - T10060A- .
– Detach counterhold tool.
– Check that poly V-belts are properly seated.
– Start engine and check that poly V-belt(s) run properly.
– Check coolant level
Tightening torques

air conditioner compressor (with radiator
removed) - vehicles with 2.9 ltr. engine
Simplified procedure if radiator has been removed during prepar‐
atory work

Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Socket Torx T60 - 40087-
Removing
– Slacken poly V-belt by turning tensioner clockwise -arrow- us‐
ing socket Torx T 60 - 40087- .
– Lock tensioner with locking pin - T10060A- and take off poly
V-belt.
– If removing poly V-belt for air conditioner compressor com‐
pletely: Release hose clip -1- and detach coolant hose.
Installing
– Fit poly V-belt ⇒ Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-
valve TFSI; Rep. gr. 13 ; Cylinder block (pulley end); Exploded
view - cylinder block (pulley end) .
– Turn poly V-belt tensioner slightly clockwise using socket Torx
T 60 - 40087- and pull out locking pin - T10060A- .
– Release tensioner to slacken poly V-belt.
1.3.4 Removing and installing poly V-belts for

alternator/coolant pump and air condi‐
tioner compressor - vehicles with 3.0 ltr.
engine

poly V-belt
end); Removing and installing tensioner for poly V-belt .

Audi A4 2015 ➤ , Audi A5 2016 ➤

er
⇒ “1.5.1 Removing and installing vibration damper - vehicles with
2.9 ltr. engine”, page 90
1.5.1 Removing and installing vibration damp‐

er - vehicles with 2.9 ltr. engine
Removing
– Remove radiator with radiator cowl
⇒ “4.4.1 Removing and installing radiator - vehicles with 2.9
ltr. engine”, page 181 .
– Release hose clip -1-, disconnect coolant hose and push front
coolant pipe (bottom left) slightly to one side.
Installing
Additional work:
– Install radiator with radiator cowl
Tightening torques
♦ ⇒ “3.1.1 Exploded view - coolant pipes (engine end), vehicles
with 2.9 ltr. engine”, page 152

Removing

Audi A4 2015 ➤ , Audi A5 2016 ➤
Installing
Additional work:
Tightening torques

cillaries

Removing
– Remove engine mounting
page 81 .

noise insulation .
– Remove cover for drive shaft (right-side) ⇒ General body re‐
slightly to one side (shown on vehicle with 3.0 ltr. engine).

Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
– Install engine mountings
page 81 .
Tightening torques

end)
end); Renewing crankshaft oil seal (pulley end) .

(pulley end)
⇒ “1.9.1 Removing and installing sealing flange (pulley end) - ve‐
hicles with 2.9 ltr. engine”, page 92
⇒ “1.9.2 Removing and installing sealing flange (pulley end) - ve‐
1.9.1 Removing and installing sealing flange

(pulley end) - vehicles with 2.9 ltr. engine
Removing
⇒ “1.5.1 Removing and installing vibration damper - vehicles
with 2.9 ltr. engine”, page 90 .
– Remove air pipe (top)
⇒ “2.3.1 Removing and installing air pipe (top) with radiator
fitted - vehicles with 2.9 ltr. engine”, page 211 .
– Remove coolant pipe (front left)
⇒ “3.2.3 Removing and installing coolant pipe (front left) - ve‐
hicles with 2.9 ltr. engine”, page 160 .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Unplug electrical connector -3- and pull coolant valve for cyl‐
inder head - N489- slightly off from bracket -2-.
– Remove bolts -arrows-, pull bracket off coolant valve and tie
to one side.
(pulley end); Removing and installing sealing flange (pulley end) .
Installing
Additional work:
– Install coolant pipe (front left)
⇒ “3.2.3 Removing and installing coolant pipe (front left) - ve‐
hicles with 2.9 ltr. engine”, page 160 .
– Install air pipe (top)
– Install vibration damper ⇒ Servicing 6-cylinder engine, 2.9 ltr.,
1.9.2 Removing and installing sealing flange

(pulley end) - vehicles with 3.0 ltr. engine
Removing
⇒ “1.5.2 Removing and installing vibration damper - vehicles
– Remove air pipe
⇒ “2.3.4 Removing and installing air pipe (top) - vehicles with
3.0 ltr. engine”, page 219 .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Unplug electrical connector -3- and detach coolant valve for

cylinder head - N489- from bracket -2-.
– Remove bolts -arrows- and tie up bracket to one side.
(pulley end); Removing and installing sealing flange (pulley end) .
Installing
Additional work:
– Install air pipe
– Install vibration damper ⇒ Servicing 6-cylinder engine, 2.9 ltr.,

Audi A4 2015 ➤ , Audi A5 2016 ➤

cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder
block (gearbox end) .

Audi A4 2015 ➤ , Audi A5 2016 ➤
3 Crankshaft
Crankshaft .

Audi A4 2015 ➤ , Audi A5 2016 ➤
4 Balance shaft
cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Balance
shaft .
4. Balance shaft 97
Audi A4 2015 ➤ , Audi A5 2016 ➤

cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Pistons
and conrods .

Audi A4 2015 ➤ , Audi A5 2016 ➤

cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Timing
chain cover .

Audi A4 2015 ➤ , Audi A5 2016 ➤
2 Chain drive
⇒ “2.1 Exploded view - camshaft timing chains”, page 100
⇒ “2.2 Exploded view - drive chain for oil pump”, page 100
⇒ “2.3 Removing camshaft timing chain from camshafts”,
page 100
⇒ “2.4 Removing and installing camshaft timing chain”,
page 101
2.1 Exploded view - camshaft timing chains

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Chain drive; Exploded
view - camshaft timing chains .
2.2 Exploded view - drive chain for oil pump

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Chain drive; Exploded
view - drive chain for oil pump .
2.3 Removing camshaft timing chain from

camshafts
⇒ “2.3.1 Removing camshaft timing chain from camshafts - vehi‐
cles with 2.9 ltr. engine”, page 100
⇒ “2.3.2 Removing camshaft timing chain from camshafts - vehi‐
2.3.1 Removing camshaft timing chain from

camshafts - vehicles with 2.9 ltr. engine
Removing
If performing this work with the engine installed:
engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Chain drive;
Removing camshaft timing chain from camshafts .
Installing
Additional work:

camshafts - vehicles with 3.0 ltr. engine
Removing
If performing this work with the engine installed:

Audi A4 2015 ➤ , Audi A5 2016 ➤

engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Chain drive;
Removing camshaft timing chain from camshafts .
Installing
Additional work:
Tightening torques
2.4 Removing and installing camshaft tim‐

ing chain
2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Chain drive; Removing
and installing camshaft timing chain .
2. Chain drive 101

Audi A4 2015 ➤ , Audi A5 2016 ➤
3 Cylinder head

view - cylinder head .

view - camshaft housing .

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head; Re‐

ing
⇒ “3.4.1 Removing and installing camshaft housing - cylinder
bank 1 (right-side)”, page 102
bank 2 (left-side)”, page 103
3.4.1 Removing and installing camshaft hous‐

ing - cylinder bank 1 (right-side)

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
coal filter system.
Removing and installing camshaft housing .
Installing
Additional work:

ing - cylinder bank 2 (left-side)
2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head; Re‐
moving and installing camshaft housing .

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head; Checking
compression .

Audi A4 2015 ➤ , Audi A5 2016 ➤
4 Valve gear
page 105

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Exploded
view - valve gear .

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Measuring
axial clearance of camshaft .

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Valve gear; Measuring
radial clearance of camshaft .

and installing camshaft .

Removing cam actuators for cylinder bank 1 (right-side)
page 245 .
Removing and installing cam actuators .

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing cam actuators for cylinder bank 2 (left-side)

– Detach engine control unit - J623- from bracket and move to
one side
”, page 257 .
trol unit.
Installing
Additional work:
page 245 .
Tightening torques

This procedure applies to camshaft control valves -N205- , -
N208- , -N318- and -N319- .
Removing camshaft control valve 1 - N205- on vehicles with 2.9
ltr. engine with particulate filter:
– Remove body brace (right-side) ⇒ Running gear, front-wheel
– Drain coolant

ltr. engine with coolant circulation pump - V50- :
– Release fastener -arrow- and move coolant circulation pump
- V50- to one side.
4. Valve gear 105

Audi A4 2015 ➤ , Audi A5 2016 ➤

ltr. engine with particulate filter:
– Remove body brace (left-side) ⇒ Running gear, front-wheel
Installing
Additional work:
– Install body brace (right-side) ⇒ Running gear, front-wheel

seals
and installing valve stem oil seals .

Audi A4 2015 ➤ , Audi A5 2016 ➤

ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Inlet and exhaust valves .

Audi A4 2015 ➤ , Audi A5 2016 ➤
17 – Lubrication
1 Sump/oil pump
page 108
er G266 ”, page 109

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump; Ex‐
ploded view - sump/oil pump .
1.2 Engine oil

♦ Check oil level ⇒ Maintenance ; Booklet 830 ; Maintenance;
Engine oil: checking oil level and correcting if necessary .
tenance tables .

section)
moving and installing sump (bottom section) .

tion)
moving and installing sump (top section) .

moving and installing oil pump .

Audi A4 2015 ➤ , Audi A5 2016 ➤

moving and installing oil level and oil temperature sender - G266- .

Audi A4 2015 ➤ , Audi A5 2016 ➤
2 Engine oil cooler

⇒ “2.3 Removing and installing spray nozzle valve”, page 111

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Engine oil cooler; Ex‐
ploded view - engine oil cooler .

er
⇒ “2.2.1 Removing and installing engine oil cooler - vehicles with
⇒ “2.2.2 Removing and installing engine oil cooler - vehicles with
2.2.1 Removing and installing engine oil cool‐

Removing
– Remove turbocharger, cylinder bank 1 (right-side)
⇒ “1.2.1 Removing and installing turbocharger, cylinder bank
1 (right-side) - vehicles with 2.9 ltr. engine”, page 205 .
engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Engine oil cool‐
er; Removing and installing engine oil cooler .
Installing
Additional work:
– Install turbocharger, cylinder bank 1 (right-side)
⇒ “1.2.1 Removing and installing turbocharger, cylinder bank
1 (right-side) - vehicles with 2.9 ltr. engine”, page 205 .
2.2.2 Removing and installing engine oil cool‐

Removing
installing.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Open heat insulation sleeve.

1 - For tank breather pressure sensor 1 - G950-
3 - For activated charcoal filter solenoid valve 1 - N80-
coal filter system.
– Detach activated charcoal filter solenoid valve 1 - N80- from
bracket.
engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Engine oil cool‐
er; Removing and installing engine oil cooler .
Installing
Additional work:
2.3 Removing and installing spray nozzle

valve
2.9 ltr., 3.0 ltr. TFSI, 4-valve; Rep. gr. 17 ; Engine oil cooler; Re‐
moving and installing spray nozzle valve .

Audi A4 2015 ➤ , Audi A5 2016 ➤

Audi A4 2015 ➤ , Audi A5 2016 ➤

page 113
page 114
114
page 114
”, page 115

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Oil filter/oil pressure
switches; Exploded view - oil filter .

pressure control
switches; Exploded view - oil pressure switches/oil pressure con‐
trol .

⇒ “4.3.1 Removing and installing oil filter housing - vehicles with
4.3.1 Removing and installing oil filter housing

- vehicles with 2.9 ltr. engine
2.9 ltr., 3.0 ltr. TFSI, 4-valve; Rep. gr. 17 ; Oil filter/oil pressure
switches; Removing and installing oil filter housing .

Removing
panel .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Press release tabs on both sides and detach hose -arrow- for

engine, 2.9 ltr., 3.0 ltr. TFSI, 4-valve; Rep. gr. 17 ; Oil filter/oil
pressure switches; Removing and installing oil filter housing .
Installing
Additional work:

switch - F22-
switches; Removing and installing oil pressure switch - F22- .

sender - G8-
switches ; Removing and installing oil temperature sender - G8- .

sender - G10-
⇒ “4.6.1 Removing and installing oil pressure sender G10 - vehi‐
4.6.1 Removing and installing oil pressure

sender - G10- - vehicles with 2.9 ltr. en‐
gine
switches ; Removing and installing oil pressure sender - G10- .

Audi A4 2015 ➤ , Audi A5 2016 ➤

gine
Removing
– Remove poly V-belt for alternator
⇒ “1.3 Removing and installing poly V-belts”, page 85 .
stalling tensioner for poly V-belt , and detach poly V-belt.
pressure switches ; Removing and installing oil pressure sender
- G10- .
Installing
Additional work:
tensioner for poly V-belt .
– Install poly V-belt for alternator

switches; Checking oil pressure .

⇒ “4.8.1 Removing and installing valve for oil pressure control
N428 - vehicles with 2.9 ltr. engine”, page 115
4.8.1 Removing and installing valve for oil

pressure control - N428- - vehicles with
2.9 ltr. engine
switches; Removing and installing valve for oil pressure control -
N428- .

3.0 ltr. engine
Removing
icing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr.
13 ; Cylinder block (pulley end); Removing and installing poly
V-belts .

Audi A4 2015 ➤ , Audi A5 2016 ➤

pressure switches; Removing and installing valve for oil pressure
control - N428- .
Installing
Additional work:
– Install poly V-belt for air conditioner compressor ⇒ Servicing
belts .
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤
19 – Cooling

⇒ “1.1.1 Connection diagram - coolant hoses, vehicles with 2.9
ltr. engine”, page 117
ltr. engine without auxiliary heater”, page 119
ltr. engine with auxiliary heater”, page 121
1.1.1 Connection diagram - coolant hoses, vehicles with 2.9 ltr. engine
♦ Pink = Coolant circuit for charge air cooler.

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Radiator
gearbox
2 - Auxiliary radiator (right-
side)
4 - Thermostat
❑ For auxiliary radiator
(right-side)
6 - Engine outlet coolant tem‐
❑ Vacuum-controlled
G694-
9 - Cylinder head
side)
10 - Cylinder block
11 - Turbocharger
side)
13 - Restrictor
14 - Bleeder hole
18 - Filler cap
21 - Thermostat
22 - Radiator
❑ For gear oil
23 - ATF cooler
24 - Turbocharger
26 - Cylinder head

Audi A4 2015 ➤ , Audi A5 2016 ➤

28 - Cylinder block
30 - Restrictor
31 - Restrictor
32 - Coolant pump
❑ Actuated by switch valve for mechanical coolant pump - N649-
36 - Bleeder screw
37 - Auxiliary radiator (bottom front)
38 - Auxiliary radiator (front)
39 - Radiator
41 - Bleeder screw
1.1.2 Connection diagram - coolant hoses, vehicles with 3.0 ltr. engine without
auxiliary heater

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Radiator
G694-
6 - Cylinder head
side)
7 - Cylinder block
8 - Bleeder hole
V50-
tion pump - V51-
12 - Filler cap
Rep. gr. 19 ; Cooling
system/coolant; Check‐
ing cooling system for
leaks
14 - Thermostat
❑ For ATF coolant circuit
15 - ATF cooler
17 - Turbocharger
18 - Restrictor
20 - Cylinder block
21 - Cylinder head
23 - Restrictor
24 - Restrictor
25 - Map-controlled engine cooling system thermostat - F265-
26 - Coolant pump

Audi A4 2015 ➤ , Audi A5 2016 ➤
1.1.3 Connection diagram - coolant hoses, vehicles with 3.0 ltr. engine with aux‐
iliary heater
1 - Radiator
G694-
V55-
7 - Cylinder head
side)
valve - N279-
9 - Cylinder block
10 - Bleeder hole
tion pump - V51-
13 - Filler cap
Rep. gr. 19 ; Cooling
system/coolant; Check‐
ing cooling system for
leaks
15 - Thermostat
❑ For ATF coolant circuit

Audi A4 2015 ➤ , Audi A5 2016 ➤
16 - ATF cooler
18 - Turbocharger
19 - Restrictor
21 - Cylinder block
22 - Cylinder head
24 - Restrictor
25 - Restrictor
26 - Map-controlled engine cooling system thermostat - F265-
27 - Coolant pump

Procedure
engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Cooling system/
coolant; Checking cooling system for leaks .

⇒ “1.3.1 Draining and filling cooling system - vehicles with 2.9 ltr.
engine”, page 122
⇒ “1.3.2 Draining and filling cooling system - vehicles with 3.0 ltr.
engine”, page 128
1.3.1 Draining and filling cooling system - ve‐

hicles with 2.9 ltr. engine

Audi A4 2015 ➤ , Audi A5 2016 ➤


Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Safety goggles
Draining coolant
WARNING


expansion tank.
noise insulation .

Audi A4 2015 ➤ , Audi A5 2016 ➤
WARNING


off coolant.

– Reconnect coolant hoses (version with plug-in connector)
page 176 .
to -25 °C
to -36 °C
Caution

♦ Always use distilled water as this ensures optimum cor‐
rosion protection.

Audi A4 2015 ➤ , Audi A5 2016 ➤

⇒ page 125 ).
and gearbox jack.
V.A.G 1274/8- .
Note:
rection of flow).

zone.
in the green zone.
sequent filling.
ess.
tained.
– Open valve -A-.
is then filled.

Audi A4 2015 ➤ , Audi A5 2016 ➤

cedure.
chamber cover .

– Open bleeder screw -arrow- until coolant flows out.

– Open bleeder screw -arrow- until coolant flows out.

Audi A4 2015 ➤ , Audi A5 2016 ➤

hose.
clip.
gages).
• Vehicles with auxiliary heater/supplementary heater: Set heat‐
ing to “HI” and select lowest possible blower speed (= 0).
– Open valves in coolant circuit ⇒ Vehicle diagnostic tester 01
19 Coolant circuit vent routine .
– Follow instructions shown on vehicle diagnostic tester .

chamber cover .
WARNING

the engine is cold.
perature.
Tightening torques
1.3.2 Draining and filling cooling system - ve‐


Audi A4 2015 ➤ , Audi A5 2016 ➤


Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Safety goggles
Draining coolant
WARNING


expansion tank.
noise insulation .

Audi A4 2015 ➤ , Audi A5 2016 ➤
WARNING



– Reconnect coolant hoses (version with plug-in connector)
page 176 .
to -25 °C
to -36 °C
Caution

♦ Always use distilled water as this ensures optimum cor‐
rosion protection.

Audi A4 2015 ➤ , Audi A5 2016 ➤

⇒ page 131 ).
and gearbox jack.
V.A.G 1274/8- .
Note:
rection of flow).

zone.
in the green zone.
sequent filling.
ess.
tained.
– Open valve -A-.
is then filled.

Audi A4 2015 ➤ , Audi A5 2016 ➤

cedure.
chamber cover .

hose.
clip.
gages).
If bleeding routine is NOT stored in engine control unit:
– Start engine.

not lit
speed (= 0)
Until radiator fan starts Idling speed • Air conditioning system “OFF”
running
2 minutes 2500 rpm • Air conditioning system “OFF”


If bleeding routine is stored in engine control unit:
• Vehicles with auxiliary heater/supplementary heater: Set heat‐
ing to “HI” and select lowest possible blower speed (= 0).
– Open valves in coolant circuit ⇒ Vehicle diagnostic tester 01
19 Coolant circuit vent routine .
– Follow instructions shown on vehicle diagnostic tester .

Audi A4 2015 ➤ , Audi A5 2016 ➤

chamber cover .
WARNING

the engine is cold.
perature.
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

page 139
page 139
”, page 150
⇒ “2.8 Removing and installing engine outlet coolant temperature
sender G82 ”, page 150

stat
stat assembly; Exploded view - coolant pump/thermostat .

⇒ “2.2.1 Exploded view - electric coolant pump, vehicles with 2.9
ltr. engine without particulate filter”, page 137
ltr. engine with particulate filter”, page 138
2.2.1 Exploded view - electric coolant pump, vehicles with 2.9 ltr. engine

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Bolt
❑ 1.5 Nm
2 - Spacer sleeve
3 - Grommet
4 - Bracket
❑ For continued coolant
circulation pump - V51-
❑ Some versions are fitted
with damping elements
5 - Bolt
❑ 9 Nm
6 - Bolt
❑ 1.5 Nm
7 - Bolt
❑ 20 Nm
8 - Bracket
pump - V50-
V50-
without auxiliary heater
installing coolant circu‐
lation pump V50 - vehi‐
cles with 2.9 ltr. engine”,
page 139
11 - Bolt
❑ 9 Nm
⇒ “2.4.3 Removing and installing charge air cooling pump V188 - vehicles with 2.9 ltr. engine”,
page 142
13 - Bolt
❑ 9 Nm
14 - Bracket
❑ For charge air cooling pump - V188-
15 - Bolt
❑ 9 Nm
16 - O-ring
17 - Connection
18 - Coolant hose
⇒ “2.4.2 Removing and installing continued coolant circulation pump V51 - vehicles with 2.9 ltr. engine”,
page 140

Audi A4 2015 ➤ , Audi A5 2016 ➤
2.2.2 Exploded view - electric coolant pump, vehicles with 3.0 ltr. engine without
particulate filter
1 - Bolt
❑ 1.5 Nm
2 - Bracket
❑ Some versions are fitted
with damping elements
3 - Bolt
❑ 9 Nm
4 - Nut
❑ 9 Nm
5 - Bracket
pump - V50-
6 - Bolt
❑ 1.5 Nm
7 - Bracket
pump - V50-
V50-
without auxiliary heater
without particulate fil‐
ter”, page 143
9 - Coolant hose
10 - Bolt
❑ 9 Nm
11 - O-ring
12 - Connection
⇒ “2.4.6 Removing and installing continued coolant circulation pump V51 - vehicles with 3.0 ltr. engine

Audi A4 2015 ➤ , Audi A5 2016 ➤
2.2.3 Exploded view - electric coolant pump, vehicles with 3.0 ltr. engine with
particulate filter
1 - Coolant hose
❑ For specific equipment
version
2 - O-ring
3 - Connection
4 - Bolt
❑ 1.5 Nm
5 - Rubber bush
6 - Bracket
pump - V50-
7 - Nut
❑ 20 Nm
8 - Coolant hose
V50-
with particulate filter”,
page 144
10 - Coolant hose
11 - Bolt
❑ 9 Nm
12 - Bracket
13 - Spacer bush
14 - Bolt
❑ 1.5 Nm
15 - Rubber bush
16 - Coolant hose
⇒ “2.4.7 Removing and installing continued coolant circulation pump V51 - vehicles with 3.0 ltr. engine
18 - Coolant hose
19 - Bolt
❑ 9 Nm

Audi A4 2015 ➤ , Audi A5 2016 ➤

senders
stat assembly; Exploded view - coolant temperature senders .

pump
pump V51 - vehicles with 2.9 ltr. engine”, page 140
⇒ “2.4.3 Removing and installing charge air cooling pump V188 -
vehicles with 3.0 ltr. engine without particulate filter”, page 143
vehicles with 3.0 ltr. engine with particulate filter”, page 144
pump V51 - vehicles with 3.0 ltr. engine without particulate filter”,
page 146
pump V51 - vehicles with 3.0 ltr. engine with particulate filter”,
page 147

tion pump - V50- - vehicles with 2.9 ltr.
engine

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
– Remove front silencer (right-side)
– Push heat shield slightly upwards.
– Remove bolt -arrow- and detach coolant circulation pump -
V50- with bracket.
– Unscrew bolts -arrows- and detach coolant pump -2- from

bracket -1-.
Installing
– Install front silencer (right-side)
⇒ “1.3.1 Draining and filling cooling system - vehicles with 2.9
Tightening torques
♦ ⇒ “2.2.1 Exploded view - electric coolant pump, vehicles with

with 2.9 ltr. engine

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
– Remove catalytic converter (right-side)
page 275 , place it to one side with Lambda probe connected
and secure (move wiring clear).
– Drain coolant
– Remove centre hex studs -2- and bolts -1-, then detach brack‐
et for continued coolant circulation pump - V51- .

– Unscrew bolt -arrow- using socket Torx T30 - T10405- .
– Release hose clip -1- and detach continued coolant circulation
pump - V51- -item 2-.
Installing
– Install catalytic converter (right-side)
page 275 .
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

ing pump - V188- - vehicles with 2.9 ltr.
engine
Removing
– Drain coolant
– Release bumper cover (bottom) at lock carrier ⇒ General body
repairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded view
- bumper cover .

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Remove bolt -arrow- and detach retaining bracket.
Installing
Tightening torques
♦ ⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper (front);
Exploded view - bumper cover

engine without particulate filter

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
– Release fastener -arrow- and detach coolant circulation pump
- V50- .
Installing
Tightening torques
3.0 ltr. engine without particulate filter”, page 137

engine with particulate filter

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
page 245 .
– Remove bolts -arrows- and detach coolant circulation pump -
V50- from bracket.
Installing
page 245 .
Tightening torques
3.0 ltr. engine with particulate filter”, page 138

Audi A4 2015 ➤ , Audi A5 2016 ➤

with 3.0 ltr. engine without particulate fil‐
ter
Removing
– Drain coolant
Vehicle without auxiliary heater:
- V50- to one side.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove nuts -arrows- and detach bracket -1- for coolant cir‐
culation pump - V50- .


Installing
Tightening torques
3.0 ltr. engine without particulate filter”, page 137

with 3.0 ltr. engine with particulate filter

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
– Remove catalytic converter
with 3.0 ltr. engine with particulate filter”, page 282 .
– Drain coolant

Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
Tightening torques
3.0 ltr. engine with particulate filter”, page 138

stat assembly; Removing and installing coolant pump .

F265-
Removing
⇒ “4.4 Removing and installing radiator”, page 181 .
thermostat assembly; Removing and installing map-controlled
engine cooling system thermostat - F265- .
Installing
Additional work:
⇒ “4.4 Removing and installing radiator”, page 181 .

Audi A4 2015 ➤ , Audi A5 2016 ➤

ature sender - G62-
Removing
2.8 Removing and installing engine outlet

thermostat assembly ; Removing and installing engine outlet
coolant temperature sender - G82- .

Procedure
• Engine cold.
sion tank.
– Close filler cap again (make sure it engages).
– Vehicles with 2.9 ltr. engine: Remove front wheel spoiler (right-
side) ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel
– Vehicles with 3.0 ltr. engine: Remove air intake grille (right-
side) ⇒ General body repairs, exterior; Rep. gr. 63 ; Bumper
(front) .

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Unscrew bolt -2- and pull off radiator outlet coolant tempera‐
ture sender - G83- . (Shown on vehicles with 3.0 ltr. engine)
Note:
If an O-ring remains lodged in cylinder block, lift out O-ring with a
piece of wire.
– Vehicles with 3.0 ltr. engine: Install air intake grille ⇒ General
body repairs, exterior; Rep. gr. 63 ; Bumper (front) .
– Check coolant level
Tightening torques
Rep. gr. 19 ; Coolant pump/thermostat assembly; Exploded
view - coolant temperature senders

tion - G694-
Removing
thermostat assembly; Removing and installing temperature send‐
er for engine temperature regulation - G694- .

stat assembly; Removing and installing coolant valves .

Audi A4 2015 ➤ , Audi A5 2016 ➤
3 Coolant pipes

⇒ “3.1.1 Exploded view - coolant pipes (engine end), vehicles with
⇒ “3.1.2 Exploded view - coolant pipes (engine end), vehicles with
⇒ “3.1.3 Exploded view - coolant pipes (gearbox end)”,
page 156
3.1.1 Exploded view - coolant pipes (engine end), vehicles with 2.9 ltr. engine
• Markings on coolant pipes and on ends of hoses must align.
1 - O-ring
2 - Bolt
❑ 9 Nm
3 - Coolant pipe (front left)
(front left) - vehicles with
2.9 ltr. engine”,
page 160
4 - Bolt
❑ 9 Nm
5 - O-ring
6 - Bolt
❑ 9 Nm
(front) - vehicles with 2.9
8 - Bolt
❑ 9 Nm
9 - O-rings
10 - Bolt
❑ 9 Nm
11 - Connection
12 - O-ring

Audi A4 2015 ➤ , Audi A5 2016 ➤
13 - Bolt
❑ 9 Nm
14 - Bolt
❑ 9 Nm
15 - O-ring
16 - Large coolant pipe (rear right)
⇒ “3.2.12 Removing and installing large coolant pipe (rear right) - vehicles with 2.9 ltr. engine”,
page 171
17 - Retaining clamp
18 - Bolt
❑ 9 Nm
19 - O-rings
20 - Bolt
❑ 9 Nm
22 - Bolt
❑ 9 Nm
23 - Small coolant pipe (rear right)
⇒ “3.2.10 Removing and installing small coolant pipe (rear right) - vehicles with 2.9 ltr. engine”,
page 169
24 - Bolt
❑ 9 Nm
25 - Coolant pipe (rear left)
⇒ “3.2.8 Removing and installing coolant pipe (rear left) - vehicles with 2.9 ltr. engine”, page 167
26 - Bolt
❑ 9 Nm
27 - O-rings
28 - Bolt
❑ 9 Nm
29 - Connection
30 - Nut
❑ 9 Nm
⇒ “3.2.6 Removing and installing coolant pipe (left-side) - vehicles with 2.9 ltr. engine”, page 163
32 - Nut
❑ 9 Nm
33 - Nut
❑ 9 Nm
34 - Bolt
❑ 20 Nm

Audi A4 2015 ➤ , Audi A5 2016 ➤

⇒ “3.2.5 Removing and installing coolant pipe (bottom front) - vehicles with 2.9 ltr. engine”, page 162
Coolant pipes at lock carrier (bottom) - tightening torque

– Tighten bolts -arrows- to 4.5 Nm.
3.1.2 Exploded view - coolant pipes (engine end), vehicles with 3.0 ltr. engine
must align.
1 - Coolant pipe (front left)

(front left) - vehicles with
3.0 ltr. engine”,
page 161
2 - Bolt
❑ 9 Nm
3 - O-ring
4 - Bolt
❑ 9 Nm
(front) - vehicles with 3.0
6 - Bolt
❑ 9 Nm
7 - O-ring
8 - O-ring
9 - Bolt
❑ 9 Nm
10 - Connection
11 - O-ring

Audi A4 2015 ➤ , Audi A5 2016 ➤
12 - Bolt
❑ 9 Nm
13 - Large coolant pipe (rear right)
❑ Removing and installing:
♦ ⇒ “3.2.13 Removing and installing large coolant pipe (rear right) - vehicles with 3.0 ltr. engine without par‐
♦ ⇒ “3.2.14 Removing and installing large coolant pipe (rear right) - vehicles with 3.0 ltr. engine with particulate
filter”, page 173
15 - Bolt
❑ 9 Nm
17 - Bolt
❑ 9 Nm
18 - O-ring
20 - Bolt
❑ 9 Nm
21 - Small coolant pipe (rear right)
⇒ “3.2.11 Removing and installing small coolant pipe (rear right) - vehicles with 3.0 ltr. engine”,
page 170
22 - Bolt
❑ 9 Nm
23 - Bolt
❑ 9 Nm
24 - Coolant pipe (rear left)
⇒ “3.2.9 Removing and installing coolant pipe (rear left) - vehicles with 3.0 ltr. engine”, page 168
25 - Seal
26 - Bolt
❑ 9 Nm
27 - O-ring
28 - O-ring
29 - Bolt
❑ 9 Nm
30 - Connection
31 - Seal
32 - Bolt
❑ 9 Nm

Audi A4 2015 ➤ , Audi A5 2016 ➤
3.1.3 Exploded view - coolant pipes (gearbox end)
1 - Coolant hose
3 - Coolant hose
4 - Bolts
❑ 9 Nm
5 - Bolt
❑ 9 Nm

Audi A4 2015 ➤ , Audi A5 2016 ➤

⇒ “3.2.1 Removing and installing coolant pipe (front) - vehicles
⇒ “3.2.3 Removing and installing coolant pipe (front left) - vehicles
⇒ “3.2.4 Removing and installing coolant pipe (front left) - vehicles
⇒ “3.2.5 Removing and installing coolant pipe (bottom front) - ve‐
⇒ “3.2.6 Removing and installing coolant pipe (left-side) - vehicles
page 165
⇒ “3.2.8 Removing and installing coolant pipe (rear left) - vehicles
⇒ “3.2.9 Removing and installing coolant pipe (rear left) - vehicles
⇒ “3.2.10 Removing and installing small coolant pipe (rear right)
- vehicles with 2.9 ltr. engine”, page 169
⇒ “3.2.11 Removing and installing small coolant pipe (rear right)
⇒ “3.2.12 Removing and installing large coolant pipe (rear right)
- vehicles with 3.0 ltr. engine without particulate filter”,
page 172
- vehicles with 3.0 ltr. engine with particulate filter”, page 173

(front) - vehicles with 2.9 ltr. engine
Removing
– Unbolt air pipe (top) and swivel it to left side
fitted - vehicles with 2.9 ltr. engine”, page 211 . (If radiator has
been removed during preparatory work, this step is not nec‐
essary.)

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove poly V-belt from coolant pump pulley ⇒ Servicing 6-

belts .
– Fit counterhold tool - T10172- with adapters -T10172/10- on
pulley -1- and remove bolts -2-.
– Detach pulley.
– Remove bolts -arrows- and pull coolant pipe (front) -1- off cyl‐
inder head (right-side) and shut-off valve.
Installing
• Renew coolant pipe and O-ring after removal.
– Lubricate O-ring with coolant and fit O-ring.
– If removed previously, install coolant pipe (top)
Tightening torques
♦ ⇒ “2.1.1 Exploded view - charge air system, vehicles with 2.9
view - coolant pump/thermostat

(front) - vehicles with 3.0 ltr. engine

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
– Drain coolant
– Install poly V-belt for alternator ⇒ Servicing 6-cylinder engine,
– Fit counterhold tool - T10172- with adapters -T10172/10- on
pulley -1- and remove bolts -2-.
– Detach pulley.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove bolts -arrows- and pull coolant pipe (front) -1- off cyl‐
inder head (right-side) and shut-off valve.
Installing
• Renew coolant pipe and O-ring after removal.
Tightening torques
view - coolant pump/thermostat

(front left) - vehicles with 2.9 ltr. engine

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
– Remove air pipe (bottom)
⇒ “2.3.3 Removing and installing air pipe (bottom) - vehicles
– Remove bolts -arrows- and detach coolant pipe (front left)
-2- from coolant pump.
Installing
• Renew seal and O-ring after removal.
– Install air pipe (bottom)
⇒ “2.3.3 Removing and installing air pipe (bottom) - vehicles
Tightening torques

(front left) - vehicles with 3.0 ltr. engine
Removing
– Drain coolant
icing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr.
V-belts .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove bolts -arrows- and detach coolant pipe (front left) from
coolant pump.
Installing
– Install poly V-belt for air conditioner compressor ⇒ Servicing
belts .
Tightening torques

(bottom front) - vehicles with 2.9 ltr. en‐
gine

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
– Unscrew bolt -arrow- and detach coolant pipe.
Installing
poly V-belts .
Tightening torques

(left-side) - vehicles with 2.9 ltr. engine

Audi A4 2015 ➤ , Audi A5 2016 ➤

Removing
⇒ “2.2 Supporting engine in installation position”, page 80 and
take up weight with spindle - 10-222A/11- until load on engine
mounting (left-side) is relieved.
noise insulation .

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Clamp off coolant hose -3- with hose clamp, up to 25 mm -
3094- .
– Clamp off coolant hose using hose clamp up to 25 mm - 3094- ,
– Unscrew nuts -arrows-, lift engine slightly and detach coolant
pipe towards front.
Installing
– Remove engine support bracket ⇒ page 80 .
Tightening torques

(right-side)

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
battery .
noise insulation .
– Drain coolant
– Remove cover for drive shaft (right-side) and wheel spoiler
(front) .
– Remove bolt -arrow- and move bracket -1- with electrical wir‐

Audi A4 2015 ➤ , Audi A5 2016 ➤

detach coolant pipe. (Shown on vehicles with 3.0 ltr. engine)
Installing
ing battery .
Tightening torques
♦ ⇒ “3.1.3 Exploded view - coolant pipes (gearbox end)”,
page 156
- alternator

(rear left) - vehicles with 2.9 ltr. engine
Removing
– Drain coolant
noise insulation .
– Vehicles with particulate filter: Remove catalytic converter
(left-side)

Audi A4 2015 ➤ , Audi A5 2016 ➤

panel .
– Unscrew bolts -arrows- and remove coolant pipe -2-.
Installing
– Lubricate gasket and O-ring with coolant and fit.
– Vehicles with particulate filter: Install catalytic converter (left-
side)
Tightening torques

(rear left) - vehicles with 3.0 ltr. engine
Removing
– Drain coolant
panel .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Vehicles with particulate filter: Remove noise insulation (rear)

⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Removing and installing noise insulation .
– Release hose clip -1- and detach coolant pipe -2-.
Installing
– Lubricate gasket and O-ring with coolant and fit.
Tightening torques
3.2.10 Removing and installing small coolant

pipe (rear right) - vehicles with 2.9 ltr.
engine
Removing
– Drain coolant
cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI EA 839; Rep. gr.
10 ; Engine cover panel; Removing and installing engine cover
panel .
– Vehicles without particulate filter: Loosen screw-type clip -1-
and press catalytic converter slightly to side.
(right-side)

Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
page 275 .
page 176 .
Tightening torques
3.2.11 Removing and installing small coolant

engine
Removing
– Drain coolant
panel .

Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
page 176 .
Tightening torques
3.2.12 Removing and installing large coolant

engine
Removing
– Drain coolant
page 275 , place it to one side with Lambda probe connected
and secure (move wiring clear).

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Unscrew bolts -1, 2- and detach coolant pipes from turbo‐

chargers.

Installing
– Lubricate O-rings with coolant.
– Install catalytic converter (right-side)
page 275 .
Tightening torques

engine without particulate filter

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
– Drain coolant
panel .
- V50- to one side.
– Remove nuts -arrows- and detach bracket -1- for coolant cir‐
culation pump - V50- .

Installing
– Lubricate O-ring with coolant.
Tightening torques

engine with particulate filter

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
– Drain coolant
Installing
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤
4 Radiator/radiator fan(s)
⇒ “4.2 Exploded view - radiator blind”, page 179
⇒ “4.3 Exploded view - auxiliary radiator”, page 180
⇒ “4.7 Removing and installing radiator blind”, page 193
⇒ “4.8 Removing and installing radiator blind control motor V544
”, page 194
⇒ “4.9 Removing and installing auxiliary radiator”, page 195

Radiator
Radiator cowl with one radiator fan ⇒ page 176
Radiator cowl with two radiator fans ⇒ page 177
1 - Coolant hose
tach
❑ Connecting
page 176
2 - Radiator
stalling radiator”,
page 181
tors and condensers
❑ Renew radiator if fas‐
teners on condenser,
charge air cooler or aux‐
iliary radiator are dam‐
aged
3 - O-ring
4 - Sealing plug
tach
❑ Connecting
page 176
4. Radiator/radiator fan(s) 175

Audi A4 2015 ➤ , Audi A5 2016 ➤
5 - O-ring
6 - Coolant hose
7 - Coolant pipe
8 - O-ring
9 - Rubber bush
❑ For radiator
10 - Sleeve
11 - Retaining pin
12 - Air duct
13 - Rubber bush
❑ For radiator
15 - Bolt
❑ 5 Nm
16 - Support
17 - Bolt
❑ 4.5 Nm
18 - O-ring
19 - Not fitted
20 - Not fitted

– If damaged, renew retaining clip -4-.
– If damaged, renew O-ring -2-. To do so, remove O-ring from
plug-in connector -3- using a suitable tool (do not use a sharp
tool). Take care not to damage the plug-in connector or the
surface on which the O-ring is seated.
ant hose.
bly.
Radiator cowl with one radiator fan

Radiator ⇒ page 175
Radiator cowl with two radiator fans ⇒ page 177

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Radiator cowl
page 189
2 - Bolt
❑ 5 Nm
unit - J293-
page 192
4 - Air flap
catalogue
Radiator cowl with two radiator fans

Radiator ⇒ page 175
Radiator cowl with one radiator fan ⇒ page 176

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Bolt
❑ 5 Nm
2 - Radiator cowl
page 189
3 - Bolt
❑ 5 Nm
unit - J293-
page 192
unit 2 - J671-
page 192

Audi A4 2015 ➤ , Audi A5 2016 ➤
4.2 Exploded view - radiator blind
1 - Air guide
2 - Radiator blind
stalling radiator blind”,
page 193
3 - Bolt
❑ 5 Nm
4 - Fin
5 - Bracket
6 - Bolt
❑ 8 Nm
7 - Carrier
8 - Bolt
❑ 2.5 Nm
tor - V544-
stalling radiator blind
control motor V544 ”,
page 194
11 - Speed nut
12 - Air guide
13 - Spring element
14 - Bolt
❑ 8 Nm

Audi A4 2015 ➤ , Audi A5 2016 ➤
4.3 Exploded view - auxiliary radiator
1 - Air duct
2 - Auxiliary radiator (bottom
front)
installing auxiliary radia‐
tor (bottom front) - vehi‐
page 195
3 - Grommet
4 - Bolt
❑ Tightening torque:
♦ Radiator with cast cham‐
ber: 6 Nm
♦ Radiator with plastic cham‐
ber: 3.4 Nm
5 - Air duct
6 - Cooler for gearbox coolant
circuit
7 - Grommet
8 - Coolant hose
9 - Nut
❑ 9 Nm
10 - O-ring
11 - Bleeder screw
❑ Screw in by hand until
contact is made
12 - Air duct
13 - Auxiliary radiator (front
right)
⇒ “4.9.4 Removing and installing auxiliary radiator (right-side) - vehicles with 2.9 ltr. engine”, page 202
14 - Nut
❑ 20 Nm
15 - Grommet
16 - Bracket
❑ For auxiliary radiator
17 - Nut
❑ 9 Nm
18 - Thermostat
19 - Grommet
20 - Coolant hose
21 - Auxiliary radiator (front)
⇒ “4.9.2 Removing and installing auxiliary radiator (front) - vehicles with 2.9 ltr. engine”, page 198

Audi A4 2015 ➤ , Audi A5 2016 ➤
❑ Renew auxiliary radiator if fasteners for condenser are damaged

22 - Bleeder screw
❑ 2 Nm
23 - O-ring
24 - Bolt
❑ 5 Nm

⇒ “4.4.1 Removing and installing radiator - vehicles with 2.9 ltr.
engine”, page 181
engine”, page 185
4.4.1 Removing and installing radiator - vehi‐

diator cowl.


Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
noise insulation .
WARNING
Your hands can be injured if the radiator fan starts up auto‐

matically.
• Do not reach into the radiator fan when unplugging the
connector.

– Release hose clip -1- on both sides and detach coolant hose.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Release fasteners -arrow-.

– Detach air duct -1- and unfasten air duct -3-, leaving it in in‐
stallation position.


Audi A4 2015 ➤ , Audi A5 2016 ➤

G65- .
Caution
Risk of irreparable damage to auxiliary radiator (front).

♦ The auxiliary radiator (front) must be renewed if the fas‐
teners are damaged.


– If necessary, detach auxiliary radiators (front and bottom
front).

Audi A4 2015 ➤ , Audi A5 2016 ➤
Installing
• Renew radiator if fasteners are damaged.
– Install condenser ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit .
– Connect coolant hose and coolant connection with plug-in
connector
page 176 .
Tightening torques
4.4.2 Removing and installing radiator - vehi‐

diator cowl.

Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
noise insulation .
– Equipment version without radiator blind: Remove bracket for
bumper cover together with impact bar ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Lock carrier; Exploded view - lock
carrier .
– Equipment version with radiator blind: Remove impact bar to‐
gether with radiator blind ⇒ General body repairs, exterior;
Rep. gr. 50 ; Lock carrier; Exploded view - lock carrier .
WARNING

matically.
connector.

Audi A4 2015 ➤ , Audi A5 2016 ➤


– Remove charge air cooler
⇒ “2.4.2 Removing and installing charge air cooler - vehicles

Audi A4 2015 ➤ , Audi A5 2016 ➤

G65- .
Caution

aged.



Audi A4 2015 ➤ , Audi A5 2016 ➤
Installing
– Install charge air cooler
– Connect coolant hose and coolant connection with plug-in
connector
page 176 .
Tightening torques

⇒ “4.5.1 Removing and installing radiator cowl - vehicles with 2.9
⇒ “4.5.2 Removing and installing radiator cowl - vehicles with 3.0
4.5.1 Removing and installing radiator cowl -

vehicles with 2.9 ltr. engine
The radiator cowl is removed and installed together with the ra‐
diator
4.5.2 Removing and installing radiator cowl -


Audi A4 2015 ➤ , Audi A5 2016 ➤

Removing
noise insulation .
– Remove charge air cooler
G65- .
Caution

aged.
Risk of damage to refrigerant lines and hoses.

– Release catches -2- and detach air duct (bottom) -1- for radi‐
ator.

Audi A4 2015 ➤ , Audi A5 2016 ➤

on radiator.
WARNING

matically.
connector.

Audi A4 2015 ➤ , Audi A5 2016 ➤
suitable tool -3-.
-arrow-.
Note:

possible.
Installing
– Install charge air cooler
– Connect sealing plug with plug-in connector
page 176 .
Tightening torques

V7-
⇒ “4.6.1 Removing and installing radiator fan V7 / V177 - vehicles
⇒ “4.6.2 Removing and installing radiator fan V7 - vehicles with
4.6.1 Removing and installing radiator fan -

V7- / -V177- - vehicles with 2.9 ltr. en‐
gine
Removing
– Remove radiator

Audi A4 2015 ➤ , Audi A5 2016 ➤

ator fan.
Installing
– Install radiator
4.6.2 Removing and installing radiator fan -

V7- - vehicles with 3.0 ltr. engine
Removing
⇒ “4.5.2 Removing and installing radiator cowl - vehicles with
Note:
Missing balancing clamps on fan wheel can cause noises due to
imbalances.
Installing
⇒ “4.5.2 Removing and installing radiator cowl - vehicles with
Tightening torques

Removing
WARNING
Risk of injury if components are triggered inadvertently.

♦ Before handling pyrotechnic components (e.g. plugging in
the electrical connector) the mechanic must discharge any
static electricity. This can be done by briefly touching the
door striker plate, or similar.
– Equipment version with pedestrian protection: Unplug electri‐

cal connector -1- at crash sensor for pedestrian protection and
move electrical wiring harness -2- clear.

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Detach radiator blind -1- towards front.
Installing
Tightening torques
♦ ⇒ “4.2 Exploded view - radiator blind”, page 179

Removing
– Take electrical connector -1- for radiator blind control motor -

V544- out of bracket and unplug it.
– Carefully press connecting piece -3- upwards/downwards and
unscrew bolts -arrows-.
– Detach control motor with bracket -2- and fins.

Audi A4 2015 ➤ , Audi A5 2016 ➤

- V544- -item 3-.
– Carefully unclip coupling -1- -arrow A- and at the same time,
detach it from bracket -5- together with control motor
-arrow B-.
– Pull off and detach control motor from coupling.
Installing
– Bring radiator blind control motor - V544- with bracket and fins
into installation position:
– Insert fins -1- one after another on both sides into holes on
radiator blind -2- -left arrows-.
– On both sides, guide fins into recesses on radiator blind
-right arrows-.
note the following:
– If radiator blind control motor - V544- was renewed, perform
corresponding adaptions listed in Guided Function “0001 -
Functions, engine mechanics” ⇒ Vehicle diagnostic tester.
Tightening torques
♦ ⇒ “4.2 Exploded view - radiator blind”, page 179
4.9 Removing and installing auxiliary radia‐

tor
⇒ “4.9.1 Removing and installing auxiliary radiator (bottom front)
⇒ “4.9.2 Removing and installing auxiliary radiator (front) - vehi‐
⇒ “4.9.3 Removing and installing cooler for gearbox coolant circuit
⇒ “4.9.4 Removing and installing auxiliary radiator (right-side) -
4.9.1 Removing and installing auxiliary radia‐

tor (bottom front) - vehicles with 2.9 ltr.
engine

Audi A4 2015 ➤ , Audi A5 2016 ➤

Removing
(left-side)

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Clamp off and detach coolant hoses using hose clamps up to
25 mm - 3094- on both sides (release hose clip -1- to do so).
– Release fasteners -arrow-.

– Detach air duct -1- and unfasten air duct -3-, leaving it in in‐
stallation position.

G65- .
Caution
Risk of irreparable damage to auxiliary radiator (front).

♦ The auxiliary radiator (front) must be renewed if the fas‐
teners are damaged.

denser from radiator and tie up to one side.

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Disengage left side of auxiliary radiator -1-upwards -arrow A-
and detach it towards left side -arrow B-.
Installing
– Install condenser ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit .
– If removed previously, install catalytic converter
Tightening torques
♦ ⇒ “4.3 Exploded view - auxiliary radiator”, page 180

tor (front) - vehicles with 2.9 ltr. engine

Audi A4 2015 ➤ , Audi A5 2016 ➤


Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
– Remove auxiliary radiator (bottom front)
⇒ “4.9.1 Removing and installing auxiliary radiator (bottom
front) - vehicles with 2.9 ltr. engine”, page 195 .
Caution

aged.
– Release fastener -arrow- on both sides, disengage auxiliary

radiator -1- from radiator and detach.
Installing
– Install auxiliary radiator (bottom front)
⇒ “4.9.1 Removing and installing auxiliary radiator (bottom
front) - vehicles with 2.9 ltr. engine”, page 195 .
4.9.3 Removing and installing cooler for gear‐

box coolant circuit - vehicles with 2.9 ltr.
engine

Audi A4 2015 ➤ , Audi A5 2016 ➤

Removing
– Remove bumper cover ⇒ General body repairs, exterior; Rep.
er .
– Release fasteners -arrows- on both sides and detach air duct
-1-.

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Unscrew bolt -arrow-, disengage bottom of cooler -1- towards
front and then upwards and detach it.
Installing
er .
Tightening torques
♦ ⇒ “4.3 Exploded view - auxiliary radiator”, page 180

tor (right-side) - vehicles with 2.9 ltr. en‐
gine

Audi A4 2015 ➤ , Audi A5 2016 ➤

Removing
– Remove cooler for gearbox coolant circuit
⇒ “4.9.3 Removing and installing cooler for gearbox coolant
circuit - vehicles with 2.9 ltr. engine”, page 200 .
– Release fasteners -arrows- on both sides and detach air duct
-1-.

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Disengage top of auxiliary radiator -1- forwards and then up‐
wards and detach it.
Installing
– Install cooler for gearbox coolant circuit
⇒ “4.9.3 Removing and installing cooler for gearbox coolant
circuit - vehicles with 2.9 ltr. engine”, page 200 .

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 Turbochargers
⇒ “1.1 Exploded view - turbochargers”, page 205
⇒ “1.3 Renewing vacuum unit for turbocharger”, page 207
cover panel G765 ”, page 207
1.1 Exploded view - turbochargers

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbochargers; Explo‐
ded view - turbocharger .

⇒ “1.2.1 Removing and installing turbocharger, cylinder bank 1
(right-side) - vehicles with 2.9 ltr. engine”, page 205
⇒ “1.2.2 Removing and installing turbocharger, cylinder bank 2
(left-side) - vehicles with 2.9 ltr. engine”, page 205
⇒ “1.2.3 Removing and installing turbocharger - vehicles with 3.0
1.2.1 Removing and installing turbocharger,

cylinder bank 1 (right-side) - vehicles
Removing
– Unbolt air pipe (top)
⇒ “2.3 Removing and installing air pipe”, page 211 and swivel
it to left side.
engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbochargers;
Removing and installing turbochargers .
Installing
Additional work:
⇒ “2.3 Removing and installing air pipe”, page 211 .
1.2.2 Removing and installing turbocharger,

cylinder bank 2 (left-side) - vehicles with
2.9 ltr. engine
Removing
– Unbolt air pipe (top)
⇒ “2.3 Removing and installing air pipe”, page 211 and swivel
it to left side.
– Remove engine control unit - J623-
”, page 257 .
1. Turbochargers 205
Audi A4 2015 ➤ , Audi A5 2016 ➤
– Move electrical connector -arrow- clear.

trol unit.
Installing
Additional work:
Tightening torques

Removing
panel .
page 245 .
– Press release tabs on both sides and disconnect hose
-arrow- for activated charcoal filter system.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove bolts -arrows- for air pipe -1-.

– Unscrew bolt -3-, detach line -2- for activated charcoal filter
system and move it to one side.
Installing
Additional work:
page 245 .
1.3 Renewing vacuum unit for turbocharger

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbochargers; Re‐
newing vacuum unit for turbocharger .

sender for engine cover panel - G765-
engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbochargers ;
Removing and installing temperature sender for engine cover
panel - G765- .
Audi A4 2015 ➤ , Audi A5 2016 ➤
2 Charge air system

page 211
⇒ “2.3 Removing and installing air pipe”, page 211
page 225
page 226
⇒ “2.7 Removing and installing overrun air recirculation valve”,
page 226

⇒ “2.1.1 Exploded view - charge air system, vehicles with 2.9 ltr.
engine”, page 208
⇒ “2.1.2 Exploded view - charge air system, vehicles with 3.0 ltr.
engine”, page 210
⇒ “2.1.3 Exploded view - charge air system (engine end)”,
page 210
2.1.1 Exploded view - charge air system, vehicles with 2.9 ltr. engine

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Coolant pipes
2 - Bolt
❑ 9 Nm
3 - Bolt
❑ 9 Nm
4 - Washer
5 - Grommet
6 - Bracket
For charge air cooler
7 - Air hose
8 - Nut
❑ 9 Nm
9 - Grommet
11 - Nut
❑ 9 Nm
12 - Bracket
❑ For air pipe
13 - Air hose
14 - Bolt
❑ 9 Nm
15 - O-ring
16 - Bolt
er breaks off
❑ Thread-forming
❑ 7 Nm
❑ Removing and installing ⇒ “2.5 Removing and installing charge pressure sender G31 ”, page 225
18 - Air pipe
19 - Air hose
⇒ “2.4.1 Removing and installing charge air cooler - vehicles with 2.9 ltr. engine”, page 221

Audi A4 2015 ➤ , Audi A5 2016 ➤
2.1.2 Exploded view - charge air system, vehicles with 3.0 ltr. engine

installing charge air
cooler - vehicles with 3.0
tors and condensers
2 - Air hose
5 - Seal
G31-
sender G31 ”,
page 225
7 - Bolt
er breaks off
❑ Thread-forming
hand so that it is
❑ 7 Nm
8 - O-ring
9 - Air pipe
10 - Seal
2.1.3 Exploded view - charge air system (en‐

gine end)
Exploded view - charge air system .

Audi A4 2015 ➤ , Audi A5 2016 ➤

charge air system
Exploded view - hose connections for charge air system .
2.3 Removing and installing air pipe

⇒ “2.3.1 Removing and installing air pipe (top) with radiator fitted
⇒ “2.3.2 Removing and installing air pipe (top) with radiator re‐
moved - vehicles with 2.9 ltr. engine”, page 215
⇒ “2.3.3 Removing and installing air pipe (bottom) - vehicles with
⇒ “2.3.4 Removing and installing air pipe (top) - vehicles with 3.0
2.3.1 Removing and installing air pipe (top)

with radiator fitted - vehicles with 2.9 ltr.
engine
Complete procedure if radiator has NOT been removed during
preparatory work
♦ Insert tool, 8 mm - T10572-

Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Locking tool - T40098-
♦ Angled screwdriver - T40398- (not illustrated)

Removing
for cleanliness .
– Detach poly V-belt from air conditioner compressor using -
T40098-
– Remove tensioner for air conditioner compressor and move it
to one side ⇒ Heating, air conditioning; Rep. gr. 87 ; Air con‐
ditioner compressor; Detaching and attaching air conditioner
page 245 .
– Unplug electrical connectors and move electrical wiring har‐
ness clear:
1- For temperature sender 2 for charge air cooler - G764-
– Remove oil filter element (⇒ Maintenance ; Booklet 830 ;
Maintenance; Engine oil: renewing oil filter ) and cover open‐
ing with a clean cloth.

breather hose -2-.
– Move air pipe -1- to one side.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove cover.
– Unscrew bolt -arrow- and remove idler roller.
– Move coolant line -2- clear.

– Release hose clips -1, 2- and detach air hose.

breather hose -1-.

Audi A4 2015 ➤ , Audi A5 2016 ➤

ness -2- clear:
4 - For intake manifold pressure sender - G71-
5 - For throttle valve module - GX3-
– Press release tabs on both sides and unplug vacuum hose
-6- and crankcase breather hose -3-.
– Unscrew bolts -arrows-; use angled screwdriver - T40398- if
necessary.
– Carefully swivel air pipe -1- to left side.
– Release screw-type clip -2- and detach air hose.

– Unscrew bolts -arrows-; use -T10572- if necessary.
– Remove air pipe (bottom) -1-.
– Remove air pipe (top).
Installing
• Check O-rings for damage ⇒ Servicing 6-cylinder engine, 2.9
ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Charge air system; Ex‐
ploded view - charge air system .
• Renew seals and O-ring after removal.
angle.
page 245 .
Tightening torques
system

Audi A4 2015 ➤ , Audi A5 2016 ➤
2.3.2 Removing and installing air pipe (top)

with radiator removed - vehicles with 2.9
ltr. engine
Simplified procedure if radiator has been removed during prepar‐
atory work
Removing
for cleanliness .
– Release hose clips -arrows- and detach air hose -1-.

Audi A4 2015 ➤ , Audi A5 2016 ➤

ness clear:
– Remove oil filter element (⇒ Maintenance ; Booklet 830 ;
Maintenance; Engine oil: renewing oil filter ) and cover open‐
ing with a clean cloth.

breather hose -2-.
– Move coolant line -2- clear.


Audi A4 2015 ➤ , Audi A5 2016 ➤

breather hose -1-.

ness -2- clear:
– Carefully swivel air pipe -1- to left side and detach.
Installing
• Check O-rings for damage ⇒ Servicing 6-cylinder engine, 2.9
ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Charge air system; Ex‐
ploded view - charge air system .
angle.
Tightening torques
system
2.3.3 Removing and installing air pipe (bot‐

tom) - vehicles with 2.9 ltr. engine

Audi A4 2015 ➤ , Audi A5 2016 ➤
♦ Bit - T10573-
Removing
for cleanliness .
Procedure if radiator has NOT been removed during preparatory
work:
– Remove bolts -arrows-. Detach air pipe (bottom).

Procedure if radiator has been removed during preparatory work:
– Remove temperature senders for charge air cooler -G763-
and -G764- ⇒ Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-
valve TFSI; Rep. gr. 21 ; Charge air system; Removing and
installing charge air temperature sender .
– Remove coolant pipe (front)

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Remove bolts -arrows-. Detach air pipe (bottom) -1-.
Installing
angle.
– If removed previously, install coolant pipe (front)
– If removed previously, install engine cover panel ⇒ Servicing
panel .
– If removed previously, install coolant pipe (top)
Tightening torques
system
2.3.4 Removing and installing air pipe (top) -

♦ Bit - T10573-
Removing
for cleanliness .
noise insulation .

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Detach connection and remove crankcase breather hose -1-.
To do so, press release tabs on both sides.
– Move connection to side.

G31- .
– Move clear coolant bleeder line -2-.

breather hose -1-.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– If fitted, disconnect hose -arrow- for activated charcoal filter

system by pressing release tabs on both sides.

ness -2- clear:
– Detach air pipe -1-.
Installing
• Renew gaskets and O-rings after removal.
angle.
Tightening torques
system

er
⇒ “2.4.1 Removing and installing charge air cooler - vehicles with
⇒ “2.4.2 Removing and installing charge air cooler - vehicles with


Audi A4 2015 ➤ , Audi A5 2016 ➤
Removing
for cleanliness .
– Remove bumper cover ⇒ General body repairs, exterior; Rep.
er .
– Drain coolant
ltr. engine”, page 122 (leave collector tank from coolant col‐
lecting system -VAS 5014- or drip tray for workshop hoist -
VAS 6208- underneath).

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Release hose clips -2, 3, 4- and disconnect coolant hoses.
– Release hose clip -5- securing air hose.

– Release hose clip -2- securing air hose.
– Disengage charge air cooler -1- upwards and detach it to‐
wards rear; detach air hoses at the same time.
Installing
er .
Tightening torques

Removing
for cleanliness .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Release catches -arrow- and detach air ducts -1, 3- from ra‐
diator; fold air ducts inwards and leave in this position.
Note:
Bottom catches can be accessed via openings for air intake grille
in bumper cover.
charge air cooler.
– Tilt charge air cooler slightly (right side upwards) and in this
position detach it downwards.
Installing
• The charge air cooler must be renewed if the fasteners are
damaged.
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

sure sender - G31-
⇒ “2.5.1 Removing and installing charge pressure sender G31 -
⇒ “2.5.2 Removing and installing charge pressure sender G31 -
2.5.1 Removing and installing charge pres‐

sure sender - G31- - vehicles with 2.9 ltr.
engine
Removing

Installing
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤
2.5.2 Removing and installing charge pres‐

sure sender - G31- - vehicles with 3.0 ltr.
engine
Removing
Installing
• If fastener on air pipe has broken off, secure charge pressure
sender - G31- with a bolt, refer to ⇒ Electronic parts cata‐
logue .
Tightening torques

perature sender
Procedure applies for vehicles with 2.9 ltr. engine only.
Removing and installing charge air temperature sender .
2.7 Removing and installing overrun air re‐

circulation valve
⇒ “2.7.1 Removing and installing overrun air recirculation valve -
2.7.1 Removing and installing overrun air re‐

circulation valve - vehicles with 2.9 ltr.
engine
Removing
system; Removing and installing overrun air recirculation valve .
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

engine
Removing and installing overrun air recirculation valve .

♦ Adapters -V.A.G 1687/11- and -V.A.G 1687/14-
Procedure
for cleanliness .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Connect adapters -V.A.G 1687/11- and -V.A.G 1687/14- to

connection.
– Connect hose -arrow- of charge air system tester -V.A.G 1687-
to adapter.
Attaching
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

1 Injection system
page 229

system
Fitting locations in engine compartment - vehicles with 2.9 ltr. en‐
gine ⇒ page 229
gine ⇒ page 233
Fitting locations on engine (from above), part 1 - vehicles with 2.9
ltr. engine ⇒ page 234
ltr. engine ⇒ page 236
Fitting locations on engine (from above), part 2 ⇒ page 236
Fitting locations on engine (from front) - shown on 3.0 ltr. engine
⇒ page 237
Fitting locations on engine (from right side) ⇒ page 238
Fitting locations on engine (from left side) ⇒ page 240
Fitting locations on engine (from rear) - shown on 3.0 ltr. engine
⇒ page 241
gine

Audi A4 2015 ➤ , Audi A5 2016 ➤

N145-
valves -N144- / -N145-
”“ , page 232
V50-
of coolant circulation
pump -V50- - vehicles
with 2.9 ltr. engine”“ ,
page 232
TFSI; Rep. gr. 24 ;
ded view - Lambda
probe
lytic converter - G131-
TFSI; Rep. gr. 24 ;
ded view - Lambda
probe
GX2-
❑ Comprises:
♦ Accelerator position sender - G79-
♦ Accelerator position sender 2 - G185-
♦ Active accelerator pedal motor - V592-
❑ Fitting location ⇒ Fig. ““Fitting location of accelerator pedal module -GX2- ”“ , page 231
❑ Fitting location ⇒ Fig. ““Fitting location of brake light switch -F- ”“ , page 231
page 232
❑ Removing and installing ⇒ “9.2 Removing and installing engine/motor control unit J623 ”, page 257
⇒ Fig. ““Fitting location of charge air cooling pump -V188- - vehicles with 2.9 ltr. engine”“ , page 232
⇒ Fig. ““Fitting location of charge pressure sender -G31- - vehicles with 2.9 ltr. engine”“ , page 233

Audi A4 2015 ➤ , Audi A5 2016 ➤
11 - Pressure differential sender 2 for particulate filter - G1038-

❑ Exploded view ⇒ Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and
sensors; Exploded view - pressure differential sender
12 - Lambda probe 2 - G108-
13 - Lambda probe - G39-
14 - Pressure differential sender for particulate filter - G1037-


inder

Audi A4 2015 ➤ , Audi A5 2016 ➤

valves -N144- / -N145-

G83-
♦ At bottom right of radiator
1- Electrical connector for radiator outlet coolant temperature
sender - G83-
Exploded view ⇒ Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-
valve TFSI; Rep. gr. 19 ; Coolant pump/thermostat assembly;
Exploded view - coolant temperature senders
Fitting location of coolant circulation pump - V50- - vehicles with

2.9 ltr. engine
♦ -Item 1- at rear right of engine
Exploded view
Fitting location of charge air cooling pump - V188- - vehicles with

2.9 ltr. engine
♦ -Item 1- at front left of charge air cooler
Exploded view

Audi A4 2015 ➤ , Audi A5 2016 ➤
Fitting location of charge pressure sender - G31- - vehicles with

2.9 ltr. engine
♦ At air pipe (left-side) in engine compartment
1- Connect electrical connector for charge pressure sender -
G31-
Exploded view
⇒ “2.1 Exploded view - charge air system”, page 208 .

gine

N145-
valves -N144- / -N145-
”“ , page 232
V50-
❑ Exploded view
electric coolant pump”,
page 135
❑ Fitting location on vehi‐
cles with particulate fil‐
ter
of coolant circulation
pump -V50- - vehicles
with 3.0 ltr. engine with
particulate filter”“ ,
page 234
TFSI; Rep. gr. 24 ;
ded view - Lambda
probe
sender 2 - G185-
⇒ Fig. ““Fitting location of accelerator pedal module -GX2- ”“ , page 231
❑ Fitting location ⇒ Fig. ““Fitting location of brake light switch -F- ”“ , page 231
page 232

Audi A4 2015 ➤ , Audi A5 2016 ➤

❑ Removing and installing ⇒ “9.2 Removing and installing engine/motor control unit J623 ”, page 257
❑ Exploded view ⇒ “2.1 Exploded view - charge air system”, page 208
9 - Pressure differential sender for particulate filter - G1037-
Fitting location of coolant circulation pump - V50- - vehicles with

3.0 ltr. engine with particulate filter
♦ In wheel housing (front right)
2 - Electrical connector for coolant circulation pump - V50-
Exploded view

ltr. engine

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Overrun air recirculation

valve for bank 1 - N625-
TFSI; Rep. gr. 21 ; Tur‐
bochargers; Exploded
view - turbocharger
2 - Switch valve for mechanical
coolant pump - N649-
❑ Connection diagram ⇒
gine, 2.9 ltr., 3.0 ltr. 4-
Vacuum system; Con‐
nection diagram - vac‐
uum system
3 - Tank breather pressure
sensor 1 - G950-
4 - Activated charcoal filter sol‐
enoid valve 1 - N80-
sure pump
sure pump
❑ Connection diagram ⇒ Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Vacuum
system; Connection diagram - vacuum system
8 - Temperature sender for engine cover panel - G765-
❑ With throttle valve module - J338- , throttle valve drive for electric throttle - G186- , throttle valve drive
angle sender 1 for electric throttle - G187- and throttle valve drive angle sender 2 for electric throttle -
G188-
❑ Exploded view ⇒ Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Charge air
system; Exploded view - charge air system
11 - Overrun air recirculation valve for bank 2 - N626-
❑ Exploded view ⇒ Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Turbochargers;
12 - Temperature sender 2 for charge air cooler - G764-

Audi A4 2015 ➤ , Audi A5 2016 ➤

ltr. engine

view - turbocharger
❑ Connection diagram ⇒
gine, 2.9 ltr., 3.0 ltr. 4-
Vacuum system; Con‐
nection diagram - vac‐
uum system
3 - Tank breather pressure
sensor 1 - G950-
4 - Activated charcoal filter sol‐
enoid valve 1 - N80-
sure pump
sure pump
❑ Connection diagram ⇒ Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Vacuum
system; Connection diagram - vacuum system
8 - Temperature sender for engine cover panel - G765-
❑ With throttle valve module - J338- , throttle valve drive for electric throttle - G186- , throttle valve drive
angle sender 1 for electric throttle - G187- and throttle valve drive angle sender 2 for electric throttle -
G188-
Fitting locations on engine (from above), part 2

Audi A4 2015 ➤ , Audi A5 2016 ➤

G694-
ant pump/thermostat
assembly; Exploded
ture senders
filter/oil pressure
switches; Exploded
view - oil pressure
control
3 - Oil temperature sender -
G8-
filter/oil pressure
switches; Exploded
view - oil pressure
control
er - G62-
ant pump/thermostat assembly; Exploded view - coolant temperature senders
5 - Engine outlet coolant temperature sender - G82-
❑ Exploded view ⇒ Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 19 ; Coolant pump/
thermostat assembly; Exploded view - coolant temperature senders
Fitting locations on engine (from front) - shown on 3.0 ltr. engine

Audi A4 2015 ➤ , Audi A5 2016 ➤

filter/oil pressure
switches; Exploded
view - oil pressure
control
ant pump/thermostat
assembly; Exploded
view - coolant pump/
thermostat
head - N489-
ant pump/thermostat
assembly; Exploded
ture senders
Fitting locations on engine (from right side)

Audi A4 2015 ➤ , Audi A5 2016 ➤

tion pump - V51-
ant pump/thermostat
assembly; Exploded
view - electric coolant
pump
3 - Inlet cam actuator 1 for cyl‐
inder 2 - F452-
TFSI; Rep. gr. 15 ; Cyl‐
inder head; Exploded
view - camshaft housing
inder 3 - F456-
TFSI; Rep. gr. 28 ; Ignition system; Exploded view - ignition system
8 - Ignition coil 3 with output stage - N291-

Audi A4 2015 ➤ , Audi A5 2016 ➤

15 - Inlet cam actuator 1 for cylinder 1 - F448-
❑ Exploded view ⇒ Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 15 ; Cylinder head;
Exploded view - camshaft housing
Fitting locations on engine (from left side)

trol - N428-
filter/oil pressure
switches; Exploded
view - oil pressure
control
inder 4 - F460-
stage - N292-
2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition system; Exploded view - ignition system

Audi A4 2015 ➤ , Audi A5 2016 ➤

8 - Ignition coil 6 - N324-
Fitting locations on engine (from rear) - shown on 3.0 ltr. engine

Audi A4 2015 ➤ , Audi A5 2016 ➤

N208-
cover
valve 2 - N319-
cover
valve 1 - N318-
cover
N205-
cover
sender - G266-
❑ Exploded view ⇒ Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 17 ; Sump/oil pump;

Audi A4 2015 ➤ , Audi A5 2016 ➤
2 Vacuum system
cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Vacuum
system .

Audi A4 2015 ➤ , Audi A5 2016 ➤
3 Air cleaner
1 - Mounting
2 - Water drain
❑ Clean
its or dirt
ing”, page 245
its or dirt
ing housing
5 - Bolt
❑ Thread-forming
hand so that it is
que
❑ 3.5 Nm
6 - Air pipe
markings
❑ Tightening torques for
hose clips ⇒ Servicing
6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 21 ; Charge air system; Exploded view - hose
8 - Air duct
❑ On lock carrier
9 - Air duct
❑ On lock carrier

Audi A4 2015 ➤ , Audi A5 2016 ➤
10 - Bolt
❑ Thread-forming
❑ 2.5 Nm
11 - Snow screen

housing
♦ Silicone-free lubricant
Removing
3. Air cleaner 245

Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤
4 Intake manifold
248
⇒ “4.4 Cleaning throttle valve module GX3 ”, page 249

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Ex‐
ploded view - intake manifold .

Removing
– Drain coolant
Intake manifold (cylinder bank 1, right-side):
– Remove engine support (right-side)
⇒ “1.7 Removing and installing engine support”, page 91 .
page 245 .
– Remove bracket for alternator ⇒ Servicing 6-cylinder engine,
Intake manifold (cylinder bank 2, left-side):
– Remove ABS control unit with hydraulic unit ⇒ Brake system;
Rep. gr. 45 ; Control unit and hydraulic unit; Removing and
installing ABS control unit - J104- / ABS hydraulic unit - N55- .
page 81 .

Audi A4 2015 ➤ , Audi A5 2016 ➤

– Remove bolts -arrows- and detach connection -2-.
– Detach connection.
Installing
Additional work:
– Install bracket for alternator ⇒ Servicing 6-cylinder engine, 2.9
ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 13 ; Cylinder block (pulley
page 245 .
– Install engine support (right-side)
– Install ABS control unit with hydraulic unit ⇒ Brake system;
Rep. gr. 45 ; Control unit and hydraulic unit; Removing and
installing ABS control unit - J104- / ABS hydraulic unit - N55- .
– Install engine mounting (left-side)
page 81 .

module - GX3-
Removing
2.9 ltr. engine:

Audi A4 2015 ➤ , Audi A5 2016 ➤
3.0 ltr. engine:

G31- .

GX3- .
Installing
– If throttle valve module - GX3- was renewed, perform corre‐
sponding adaptions listed in Guided Function “0001 - Func‐
tions, engine mechanics” ⇒ Vehicle diagnostic tester.
Tightening torques
system
4.4 Cleaning throttle valve module - GX3-

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Intake manifold; Clean‐
ing throttle valve module .

Audi A4 2015 ➤ , Audi A5 2016 ➤
5 Injectors

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Exploded view
- fuel rail with injectors .

Removing fuel rail for cylinder bank 2 (left-side)
– Detach engine control unit - J623- from bracket and move to
one side
”, page 257 .
– If fitted, move electrical connector -arrow- clear.
– Remove throttle valve module - GX3-
⇒ “4.3 Removing and installing throttle valve module GX3 ”,
page 248 .

– Remove bolts -arrows- and detach bracket for engine control
unit - J623- .
engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Injectors; Re‐
moving and installing fuel rail .
Tightening torques



Audi A4 2015 ➤ , Audi A5 2016 ➤

⇒ “6.1 Exploded view - actuator for structure-borne sound and
control unit for structure-borne sound”, page 251
⇒ “6.2 Removing and installing actuator for structure-borne sound
R214 ”, page 252
⇒ “6.3 Removing and installing control unit for structure-borne
sound J869 ”, page 252
253
6.1 Exploded view - actuator for structure-borne sound and control unit for
structure-borne sound
1 - Plenum chamber
2 - Control unit for structure-
borne sound - J869-
stalling control unit for
J869 ”, page 252
3 - Nut
❑ 3 Nm
4 - Nut
❑ 5 Nm
5 - Actuator for structure-borne
sound - R214-
stalling actuator for
R214 ”, page 252

Audi A4 2015 ➤ , Audi A5 2016 ➤
6.2 Removing and installing actuator for

structure-borne sound - R214-
Removing
chamber cover .
– Remove nut -arrow- and detach actuator for structure-borne
sound - R214- -item 2-.
Installing
chamber cover .
Tightening torques
♦ ⇒ “6.1 Exploded view - actuator for structure-borne sound and

structure-borne sound - J869-
Removing
chamber cover .
– Remove nuts -arrows- and unclip control unit for structure-
borne sound - J869- -item 2-.
Installing
chamber cover .
Tightening torques
♦ ⇒ “6.1 Exploded view - actuator for structure-borne sound and

Audi A4 2015 ➤ , Audi A5 2016 ➤

Removing
– Unscrew bolt -1- and pull intake air temperature sender -
G42- / intake manifold pressure sender - G71- out of air pipe.
Installing
Tightening torques
system

sender - G247-

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Senders and sensors ;
G410- .

Audi A4 2015 ➤ , Audi A5 2016 ➤


pump

pipe
⇒ “7.3.1 Removing high-pressure pipe (right-side)”, page 254
⇒ “7.3.2 Removing high-pressure pipe (rear)”, page 254
⇒ “7.3.3 Installing high-pressure pipe”, page 254
7.3.1 Removing high-pressure pipe (right-

side)
Removing
panel .
engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 24 ; High-pressure
pump; Removing and installing high-pressure pipe .
7.3.2 Removing high-pressure pipe (rear)

Removing and installing high-pressure pipe .
7.3.3 Installing high-pressure pipe

Removing and installing high-pressure pipe .

Audi A4 2015 ➤ , Audi A5 2016 ➤
8 Lambda probe

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Lambda probe; Explo‐
ded view - Lambda probe .

⇒ “8.2.1 Removing and installing Lambda probe - vehicles with
⇒ “8.2.2 Removing and installing Lambda probe - vehicles with
8.2.1 Removing and installing Lambda probe

Removing Lambda probe - G39- / Lambda probe after catalytic
converter - G130-
page 245 .
Removing Lambda probe 2 - G108- / Lambda probe 2 after cat‐
alytic converter - G131-
– Remove engine control unit - J623-
”, page 257 .
– Move electrical connector -arrow- clear.

– Remove bolts -arrows- and detach bracket for engine control
unit - J623- .
8. Lambda probe 255

Audi A4 2015 ➤ , Audi A5 2016 ➤
Lambda probe 2 - G108- :

engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Lambda probe;
Removing and installing Lambda probe .
Installing
Additional work:
page 245 .
Tightening torques

Removing
page 245 .
engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 24 ; Lambda probe;
Removing and installing Lambda probe .
Installing
Additional work:
page 245 .

Audi A4 2015 ➤ , Audi A5 2016 ➤

page 257
1 - Bolt
❑ 7.5 Nm
2 - Bracket
J623-
3 - Bolt
❑ 7.5 Nm
stalling engine/motor
control unit J623 ”, page
257
corresponding adap‐
tions listed in Guided
Function “0001 - Func‐
tic tester
5 - Bolt
❑ 7.5 Nm

Removing
If engine control unit - J623- is to be renewed, adaption values
must be read out:
– Connect vehicle diagnostic tester , switch on ignition and se‐
lect Replace engine control module in Guided func-
tions mode.

Audi A4 2015 ➤ , Audi A5 2016 ➤

J623- -item 2-.
Installing
– If engine control unit - J623- was renewed, perform corre‐
sponding adaptions listed in Guided Function “0001 - Func‐
tions, engine mechanics” ⇒ Vehicle diagnostic tester.
Tightening torques

Audi A4 2015 ➤ , Audi A5 2016 ➤

⇒ “1.1.1 Exploded view - silencers, vehicles with 2.9 ltr. engine”,
page 259
⇒ “1.1.2 Exploded view - silencers, vehicles with 3.0 ltr. engine”,
page 261
1.1.1 Exploded view - silencers, vehicles with 2.9 ltr. engine
1 - Bolt
❑ 20 Nm
2 - Bracket
3 - Rubber mounting
tem”, page 271
4 - Clamps (front)
sition of front clamps”“ ,
page 261
❑ Push onto front silencer
as far as stop
free of stress
tem”, page 271
5 - Centre silencer
for repair purposes

Audi A4 2015 ➤ , Audi A5 2016 ➤
stalling silencers”,
page 270
❑ Cutting point ⇒ “1.3 Separating exhaust pipes/silencers”, page 269
6 - Rubber mounting
7 - Not fitted
8 - Not fitted
9 - Nut
❑ Coat threads with high-temperature paste; for high-temperature paste refer to ⇒ Electronic parts cata‐
logue
❑ 23 Nm
10 - Gasket
11 - Front silencer
❑ With flexible joint; do not bend flexible joint more than 10° – otherwise it can be damaged
12 - Clamp (rear)
❑ Installation position ⇒ Fig. ““Installation position of rear clamps”“ , page 261
13 - Mounting
❑ Check preload ⇒ “1.5 Stress-free alignment of exhaust system”, page 271
14 - Bolt
❑ 20 Nm
15 - Bolt
❑ 9 Nm
16 - Exhaust flap control unit
♦ On right side: exhaust flap control unit - J883-
♦ On left side: exhaust flap control unit 2 - J945-
❑ Removing and installing ⇒ “2.3 Removing and installing exhaust flap control unit J883 ”, page 284
17 - Rear silencer
purposes

Audi A4 2015 ➤ , Audi A5 2016 ➤
Installation position of front clamps

– Install clamps so that the bolt ends do not protrude beyond
bottom of clamp.
• Installation position: bolted connections face outwards.
• Angle -α- = 45°
Installation position of rear clamps

– Install clamps so that the bolt ends do not protrude beyond
bottom of clamp.
• Installation position: bolted connections face forwards.
Mounting components
1- Spacer sleeve
3- Washer
4- Bolt, 23 Nm
5- Bolt, 23 Nm
6- Spacer sleeve
7- Buffer
8- Retainer
9- Spacer sleeve
1.1.2 Exploded view - silencers, vehicles with 3.0 ltr. engine

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 - Bolt
❑ 20 Nm
2 - Bracket
3 - Rubber mounting
tem”, page 271
4 - Clamps (front)
sition of front clamps”“ ,
page 261
❑ Push onto front silencer
as far as stop
free of stress
tem”, page 271
5 - Centre silencer
for repair purposes
stalling silencers”,
page 270
6 - Rubber mounting
7 - Bolt
❑ 20 Nm
8 - Mounting
9 - Nut
logue
❑ 23 Nm
10 - Gasket

Audi A4 2015 ➤ , Audi A5 2016 ➤
11 - Nut
logue
❑ 23 Nm
12 - Front silencer
❑ With flexible joint; do not bend flexible joint more than 10° – otherwise it can be damaged
13 - Mounting
14 - Bolt
❑ 20 Nm
15 - Exhaust flap control unit
♦ On right side: exhaust flap control unit - J883-
♦ On left side: exhaust flap control unit 2 - J945-
❑ Removing and installing ⇒ “2.3 Removing and installing exhaust flap control unit J883 ”, page 284
16 - Nut
❑ 3 Nm
17 - Rear silencer
purposes
18 - Clamp (rear)
❑ Installation position ⇒ Fig. ““Installation position of rear clamps”“ , page 261

Audi A4 2015 ➤ , Audi A5 2016 ➤

⇒ “1.2.1 Removing and installing front silencers - vehicles with 2.9
1.2.1 Removing and installing front silencers -

vehicles with 2.9 ltr. engine without par‐
ticulate filter
Removing
noise insulation .
Front silencer (left-side):
panel .
(left-side).
Front silencer (right-side):

side).

Audi A4 2015 ➤ , Audi A5 2016 ➤
Both sides:
Caution

than 10°.
– Release relevant clamp -1 or 2- and push to rear.

Installing
– If removed previously, install heat shield and engine cover
panel ⇒ Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve
TFSI; Rep. gr. 10 ; Engine cover panel; Removing and instal‐
ling engine cover panel .
Tightening torques
♦ ⇒ “1.1.1 Exploded view - silencers, vehicles with 2.9 ltr. en‐
gine”, page 259

vehicles with 2.9 ltr. engine with partic‐
ulate filter
Removing
noise insulation .
Front silencer (right-side):
– Remove heat shield ⇒ Servicing 6-cylinder engine, 2.9 ltr., 3.0
– Loosen bolt -1-, lift catalytic converter slightly and secure it.

Audi A4 2015 ➤ , Audi A5 2016 ➤
Both sides:
– Remove bolt -1- and nuts -arrows- for relevant front silencer.
Caution

than 10°.
– Release relevant clamp -1 or 2- and push to rear.

Installing
– If removed previously, install heat shield and engine cover
panel ⇒ Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve
TFSI; Rep. gr. 10 ; Engine cover panel; Removing and instal‐
ling engine cover panel .
Tightening torques
gine”, page 259

vehicles with 3.0 ltr. engine without par‐
ticulate filter
Removing
panel .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove nuts -arrows- (illustration shows silencer on left side).

– Front silencer (right-side): Remove noise insulation (rear) ⇒
General body repairs, exterior; Rep. gr. 66 ; Noise insulation;
Removing and installing noise insulation .
– Loosen clamp -arrow- and push towards rear.
Caution

than 10°.

Installing
Tightening torques
gine”, page 261

Audi A4 2015 ➤ , Audi A5 2016 ➤

vehicles with 3.0 ltr. engine with partic‐
ulate filter
Removing
panel .
– Unscrew nut -1- (illustration shows silencer on left side).
– Remove bolt -2- and nuts -arrows-.
– Front silencer (right-side): Remove noise insulation (rear) ⇒

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Loosen clamp -arrow- and push towards rear.
Caution

than 10°.

Installing
Tightening torques
gine”, page 261

♦ Shown on vehicle with 3.0 ltr. engine as an example

Audi A4 2015 ➤ , Audi A5 2016 ➤
Procedure
– Cut through exhaust pipes at right angles at the positions
marked -arrows- using chain pipe cutter - VAS 6254- .
– Position centre of clamps -arrows- over cutting point and tight‐

en nuts ⇒ page 261 .
Tightening torques

Removing
– Remove tunnel cross-piece and diagonal struts (optional
equipment) ⇒ General body repairs, exterior; Rep. gr. 66 ;
Underbody trim; Exploded view - underbody struts .
– Release clamps -1 and 2- and push to rear.
– Lower front silencer slightly and detach clamps.
– Unplug electrical connector -2- for exhaust flap control unit

-1- on both sides. (Shown on vehicles with 3.0 ltr. engine)

Audi A4 2015 ➤ , Audi A5 2016 ➤
WARNING

mechanic.

Installing
Tightening torques

Procedure
– Unfasten clamps -1, 2-.

nections evenly.

Audi A4 2015 ➤ , Audi A5 2016 ➤
Vehicles with 2.9 ltr. engine:

Vehicles with 3.0 ltr. engine:

Tightening torques

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 26 ; Exhaust pipes/silencers;

Audi A4 2015 ➤ , Audi A5 2016 ➤

page 284

tem
⇒ “2.1.1 Exploded view - emission control system, vehicles with
2.9 ltr. engine, with or without particulate filter (depending on ver‐
sion)”, page 273
3.0 ltr. engine, with or without particulate filter (depending on ver‐
sion)”, page 274
2.1.1 Exploded view - emission control system, vehicles with 2.9 ltr. engine, with
or without particulate filter (depending on version)
1 - Turbocharger
view - turbocharger
TFSI; Rep. gr. 24 ;
ded view - Lambda
probe
3 - Seal
4 - Screw-type clip
sition of screw-type clips
for catalytic convert‐
ers”“ , page 274
❑ 7 Nm
TFSI; Rep. gr. 24 ;
ded view - Lambda
probe

Audi A4 2015 ➤ , Audi A5 2016 ➤
❑ Removing and installing ⇒ “2.2 Removing and installing catalytic converter”, page 275
Installation position of screw-type clips for catalytic converters

• Angle -α- = 90° ± 15°.
2.1.2 Exploded view - emission control system, vehicles with 3.0 ltr. engine, with
or without particulate filter (depending on version)
1 - Turbocharger
view - turbocharger
TFSI; Rep. gr. 24 ;
ded view - Lambda
probe
3 - Seal
4 - Screw-type clip
sition of screw-type clip
for catalytic converter”“ ,
page 275
❑ 7 Nm
TFSI; Rep. gr. 24 ;
ded view - Lambda
probe
❑ Removing and installing ⇒ “2.2 Removing and installing catalytic converter”, page 275

Audi A4 2015 ➤ , Audi A5 2016 ➤
Installation position of screw-type clip for catalytic converter

• Angle -α- = 90° ± 15°.

verter
with 2.9 ltr. engine without particulate filter”, page 275
with 2.9 ltr. engine with particulate filter”, page 277
with 3.0 ltr. engine without particulate filter”, page 280
with 3.0 ltr. engine with particulate filter”, page 282

verter - vehicles with 2.9 ltr. engine with‐
Removing
panel .
noise insulation .
Catalytic converter (left-side):
– Remove nuts -1- and -arrows- for front silencer (left-side).

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Loosen Lambda probe 2 after catalytic converter - G131-

-item 2- half a turn and move electrical wire clear at cylinder
head.
– Release screw-type clip -2-, detach catalytic converter care‐

fully and remove it from Lambda probe.
• Electrical wire for Lambda probe must not be twisted.
Catalytic converter (right-side):

– Unscrew nuts -arrows- for front silencer (right-side).
– Loosen Lambda probe after catalytic converter - G130-

head.

Audi A4 2015 ➤ , Audi A5 2016 ➤

Installing
• Renew seals and screw-type clips after removing.
Tightening torques
gine”, page 259
♦ ⇒ “2.1.1 Exploded view - emission control system, vehicles
with 2.9 ltr. engine, with or without particulate filter (depending
on version)”, page 273
Rep. gr. 24 ; Lambda probe; Exploded view - Lambda probe

verter - vehicles with 2.9 ltr. engine with
particulate filter
Removing
panel .
noise insulation .

Audi A4 2015 ➤ , Audi A5 2016 ➤
Catalytic converter (left-side):

– Remove bolt -1- and nuts -arrows- for front silencer. (Illustra‐
tion shows silencer on right side.)

– Remove bolts -2- and move bracket -3- clear together with
pressure differential sender 2 for particulate filter - G1038- .
– Detach electrical connector -1- for exhaust gas temperature

sender 3, bank 2 - G497- from bracket, unplug connector and
– Loosen Lambda probe 2 after catalytic converter - G131-

head.

Audi A4 2015 ➤ , Audi A5 2016 ➤

Catalytic converter (right-side):

– Remove bolts -1- and move bracket clear together with pres‐
sure differential sender for particulate filter - G1037- .

sender 3 - G495- from bracket, unplug it and move wiring clear.
– Loosen Lambda probe after catalytic converter - G130-

head.

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Release screw-type clip -1-, lift catalytic converter slightly and

secure it.
– Unscrew nuts -arrows- for front silencer (right-side), detach

catalytic converter carefully and remove it from Lambda probe.
Installing
• Renew seals and screw-type clips after removing.
– If catalytic converter with particulate filter was renewed, per‐
form corresponding adaptions listed in Guided Function “0001
- Functions, engine mechanics” ⇒ Vehicle diagnostic tester.
Tightening torques
gine”, page 259
Rep. gr. 24 ; Lambda probe; Exploded view - Lambda probe

verter - vehicles with 3.0 ltr. engine with‐
Removing
panel .
page 245 .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Remove nuts -arrows- on both sides.

noise insulation .
– Unscrew bolt -1- and detach front silencer (left-side) from cat‐
alytic converter.

lytic converter - G130- and move wiring clear.
– Unfasten and detach screw-type clip -3-.

– Pull catalytic converter -2- off front silencer -1- and remove.
Installing
• Renew gasket and screw-type clip after removing.
page 245 .
Tightening torques
gine”, page 261

Audi A4 2015 ➤ , Audi A5 2016 ➤

verter - vehicles with 3.0 ltr. engine with
particulate filter
Removing
panel .
page 245 .
noise insulation .
– Remove nuts -arrows- and -1- (left and right) for front silencer
(left-side).

clear.

Audi A4 2015 ➤ , Audi A5 2016 ➤


– Remove bolts -2- and move bracket -3- clear together with
pressure differential sender for particulate filter - G1037- .
– Unfasten and detach screw-type clip -2-.

– Detach catalytic converter -1-.
Installing
• Renew gasket and screw-type clip after removing.
page 245 .
– If catalytic converter with particulate filter was renewed, per‐
form corresponding adaptions listed in Guided Function “0001
- Functions, engine mechanics” ⇒ Vehicle diagnostic tester.
Tightening torques
gine”, page 261

Audi A4 2015 ➤ , Audi A5 2016 ➤

⇒ “2.3.1 Removing and installing exhaust flap control unit J883 -
⇒ “2.3.2 Removing and installing exhaust flap control unit J883 -
2.3.1 Removing and installing exhaust flap

control unit - J883- - vehicles with 2.9 ltr.
engine
Procedure applies to exhaust flap control unit - J883- and exhaust
flap control unit 2 - J945- .
Removing
– Lower exhaust system (rear)
⇒ “1.4 Removing and installing silencers”, page 270 .
– Remove bolts -arrows- and detach exhaust flap control unit
-2-.
Installing
– Move exhaust flap control unit into installation position.
• Spring -2- must engage in groove on exhaust flap control unit
-1-.
Tightening torques
gine”, page 259
2.3.2 Removing and installing exhaust flap

control unit - J883- - vehicles with 3.0 ltr.
engine
Procedure applies to exhaust flap control unit - J883- and exhaust
flap control unit 2 - J945- .
Removing
– Lower exhaust system (rear)
⇒ “1.4 Removing and installing silencers”, page 270 .
– Remove nuts -arrows- and detach exhaust flap control unit
-1-.

Audi A4 2015 ➤ , Audi A5 2016 ➤
Installing
• Renew nuts after removing.
– Move exhaust flap control unit into installation position.
• Spring -2- must engage in grooves on exhaust flap -1-.
Tightening torques
gine”, page 261

Audi A4 2015 ➤ , Audi A5 2016 ➤

cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 26 ; Exhaust
gas temperature control .

Audi A4 2015 ➤ , Audi A5 2016 ➤
1 Ignition system
⇒ “1.2 Removing and installing ignition coils with output stages”,
page 287
page 289
290

2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition system; Ex‐
ploded view - ignition system .

with output stages
Removing ignition coil for cylinder 1
Removing ignition coils for cylinders 2 and 3

page 245 .
– Unplug electrical connectors -1, 2- for Lambda probes and

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Vehicles with particulate filter: Detach electrical connector

-1- from bracket, unplug and move clear. (Shown on vehicle
with 3.0 ltr. engine.)

1 - For camshaft control valve 1 - N205-
3 - For ignition coils
5 - For Hall sender - G40-
– Remove bolts -4- and move earth wire clear.
– Detach wiring duct -2- from ball studs and press to one side.
Removing ignition coils for cylinders 4, 5, 6

– Detach engine control unit - J623- from bracket and press
slightly to side
”, page 257 .

Audi A4 2015 ➤ , Audi A5 2016 ➤
– Vehicles with 2.9 ltr. engine and particulate filter: Detach elec‐
trical connector -1- for exhaust gas temperature sender 3 for
bank 2 - G497- from bracket, unplug connector and move
– Release retainer -arrow-, detach wiring duct -1- from ball studs
and press to one side. If necessary, move electrical wiring
harness clear.
engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition system;
Removing and installing ignition coils with output stages .
Installing
Additional work:
– Install engine control unit - J623-
”, page 257 .
page 245 .
Tightening torques
♦ Earth wires ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations

- G61-
Knock sensor 2 - G66- is removed in the same manner.
Removing
– Remove corresponding engine support
Removing and installing knock sensor 1 - G61- .
Installing
Additional work:
– Install engine support

Removing Hall sender - G40- (inlet camshaft)
page 245 .
Removing and installing Hall senders .

Audi A4 2015 ➤ , Audi A5 2016 ➤
Installing
Additional work:
page 245 .

sender - G28-
2.9 ltr., 3.0 ltr. 4-valve TFSI; Rep. gr. 28 ; Ignition system; Re‐
moving and installing engine speed sender - G28- .

Service
Workshop Manual
Audi A4 2008 ➤ , Audi A4 2015 ➤ ,
Audi A4 China 2016 ➤ , Audi A5 2016 ➤ ,
Audi A5 Cabriolet 2009 ➤ ,
Audi A5 Coupé 2008 ➤ , Audi A6 2011 ➤ ,
Audi A6 2019 ➤ , Audi A6 China 2012 ➤ ,
Audi A6 China 2019 ➤ ,
Audi A7 Sportback 2011 ➤ ,
Audi A8 2010 ➤ , Audi Q5 2008 ➤ ,
Audi Q5 2017 ➤ , Audi Q5 China 2010 ➤ ,
Audi Q5 China 2019 ➤ , Audi Q7 2016 ➤ ,
Audi Q8 China 2018 ➤
Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI (EA
888, Gen. III)
CYM CYR CYR CWP DAX DAX CJEB CJED
Engine ID CJEE
C B C B B C
CNC CNC CUH CUJA CNC CUH DAY CYG CYN
D E A B B B A B
CYP CYP CYY CVJA DDW DJYA DKW DNT DKN
A B A A A A A
DLH DLH DMF DKW DLG DPM DKW DDW DMF
A B A B A A C B B
Edition 12.2019

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system

Copyright © 2019 Audi AG, Ingolstadt D4B8065FFD6

Audi A4 2008 ➤ , Audi A4 2015 ➤ , Audi A4 China 2016 ➤ , Audi A5 2016 ➤ ...
Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI (EA 888, Gen. III) - Edition 12.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Safety precautions when working on the high-voltage system . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions when working in the vicinity of high-voltage components . . . . . . . . . . 3
3.4 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.5 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.9 Nuts, bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Contents i
4.1 Exploded view - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.3 Allocation of main bearing shells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.4 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.5 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.6 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.1 Exploded view - balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.2 Removing and installing balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.3 Renewing oil seal for balance shaft (inlet side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

2.3 Renewing oil seal for vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.2 Exploded view - drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.3 Removing and installing bearing saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.5 Checking timing chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.6 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
ii Contents

3.3 Removing and installing mechanical switching valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
5.9 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
2 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
2.3 Removing and installing turbocharger air recirculation valve N249 . . . . . . . . . . . . . . . . . . 230
Contents iii

3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
5 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
5.4 Renewing seals on injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
6.5 Removing and installing pressure differential sender for particulate filter G1037 . . . . . . . . 264
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

5 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
5.1 Exploded view - secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
5.2 Removing and installing secondary air pump motor V101 . . . . . . . . . . . . . . . . . . . . . . . . 287
5.3 Removing and installing secondary air inlet valve N112 . . . . . . . . . . . . . . . . . . . . . . . . . . 288
5.4 Removing and installing sender 1 for secondary air pressure G609 . . . . . . . . . . . . . . . . . . 288
iv Contents
5.5 Removing and installing resonator for secondary air system . . . . . . . . . . . . . . . . . . . . . . . . 288
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

2 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
2.2 Removing and installing ignition coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Contents v
vi Contents
1 Identification
(ARL006772; Edition 12.2019)

Engine number
♦ The engine number (“engine code” and “serial number”) can
be found at the joint between engine and gearbox -arrow-.
ers.
Engine data
♦ For allocation of engine code, refer to ⇒ Technical data for
petrol engines; Rep. gr. 00 ; Overview of engines .
1. Identification 1
⇒ “2.1 Safety precautions when working on the high-voltage sys‐
tem”, page 2
⇒ “2.2 Safety precautions when working in the vicinity of high-
voltage components”, page 3
tem”, page 3
page 4
page 4
page 5
page 6
2.1 Safety precautions when working on the high-voltage system

High voltage can cause fatal injury.
The voltage levels in the high-voltage system constitute a safety
hazard. Danger of severe or fatal injuries from electric shock or
electric arcs.
– The high-voltage system must be de-energised before any
work is performed on the high-voltage system.
– For work that does not affect the high-voltage system directly,
the high-voltage system must also be de-energised in some
cases.
– Please note the work for which the high-voltage system must
be de-energised ⇒ Rep. gr. 00 ; Assessing high-voltage sys‐
tem risk level .
– Have an Audi high-voltage technician (HVT) or an Audi high-
voltage expert (HVE) de-energise the high-voltage system.

It is difficult to determine whether the drive system of an electric
vehicle or hybrid vehicle is active. Moving parts can trap or draw
in parts of the body.
– Deposit the ignition key outside of the vehicle.
Risk of damage to high-voltage wiring

Incorrect handling may result in damage to the insulation of high-
voltage wires or high-voltage connectors.

– Never use high-voltage wiring or high-voltage connectors as

a support.
– Never support tools or equipment on high-voltage wires and
high-voltage connectors.
– High-voltage cables must not be excessively bent or kinked.
– Pay attention to coding when connecting high-voltage con‐
nections.
Risk of injury if auxiliary air conditioner is activated

On electric and hybrid vehicles, the auxiliary air conditioner can
switch itself on if it has been activated. The radiator fans can start
up automatically and trap or draw in parts of the body.
– Deactivate auxiliary air conditioner.
2.2 Safety precautions when working in the vicinity of high-voltage components

hazard. Danger of severe or fatal injuries from electric shock or
electric arcs if high-voltage components or high-voltage wiring are
damaged.
– Carry out a visual check of high-voltage components and high-
voltage wiring.
– Never use cutting/forming tools or other sharp-edged imple‐
ments in the vicinity of high-voltage components and high-
voltage wires.
– Never perform work using welding, brazing, thermal bonding
or hot air in the vicinity of high-voltage components or high-
voltage wires.

may spray out.

fuel pump.

a road test
Or:
seat.

The cooling system is under pressure when the power unit is hot.

incorrectly.


Risk of injury when disconnecting the exhaust system

There is a risk of eye irritation caused by soot particles in the air.

Risk to health due to chemical substances in components of ex‐

haust system
Risk to health if components of system for after-treatment of ex‐
haust gases are dismantled.
– Do NOT cut, saw or open components of system for after-
treatment of exhaust gases.


wiring.

are not fitted as specified.
tached.

⇒ “3.4 General notes”, page 8
⇒ “3.5 General repair instructions”, page 8
9


be used.
Requirements:
speed.
able torque range.
Use:
a torque wrench.

opening.
that have not been stored in their packing (e.g. in tool boxes
etc.).
3.4 General notes

♦ The engine control unit has a self-diagnosis capability. Before
carrying out repairs and fault finding, the event memory must
be interrogated. The vacuum hoses and connections must al‐
so be checked (unmetered air).
♦ A voltage of at least 11.5 V is required for proper operation of
the electrical components.
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and will
damage the Lambda probe.
♦ The vehicles are fitted with a crash fuel shut-off system. This
system is designed to reduce the risk of a vehicle fire after a
crash by deactivating the fuel pump via the fuel pump relay.
♦ At the same time, this system also improves the engine's start‐
ing performance. When the driver's door is opened, the fuel
pump is activated for 2 seconds in order to build up pressure
in the fuel system
⇒ “2.3 Safety precautions when working on the fuel supply
system”, page 3 .
3.5 General repair instructions

♦ Clean tools and workbench etc. before working on the injection
system.
♦ If the high-pressure fuel lines are to be re-used, you must mark
them before removal. High-pressure pipes must always be re-
installed on the same cylinder.
♦ Position high-pressure pipes so they are free of stress. Tighten
all unions lightly to start with before tightening to final torque.

♦ Never attempt to bend high-pressure fuel lines to shape.

♦ When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
♦ All cable ties which are released or cut open when removing
♦ Fuel hoses in engine compartment must only be secured with
spring-type clips. O-type clips or screw-type clips must not be
used.

⇒ page 220

fitted.
Please note:
ranty.

and wiring
ing.
3.9 Nuts, bolts

quence.
quence and method.

bolts.


Procedure
♦ Cracks
– If a fault is stored in the event memory, check the vacuum lines
leading to the corresponding component and also check the
remaining vacuum lines in the system.


Observe safety precautions ⇒ 4-cylinder direct injection engine
(2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep. gr. 00 ; Safety pre‐
cautions .

page 12
2.1 Removing engine

All procedures are described in ⇒ 4-cylinder direct injection en‐
gine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 10 ; Removing and
installing engine; Removing engine .

support
Procedure
tackle - 2024A-
• To adjust to the centre of gravity of the assembly, the perfo‐
rated rails of the support hooks must be positioned as shown.
CAUTION
Risk of injury if engine drops when it is lifted.
– Remove drive plate ⇒ page 46 .

– Secure engine to engine and gearbox support - VAS 6095A-

using universal mounting - VAS 6095/1- .
Tightening torque
Component Nm
Bolts/nuts M6 10
M8 20
M10 45
M12 65
Assembling
– Install drive plate ⇒ page 46 .

gine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 10 ; Removing and
installing engine; Installing engine .

All procedures and components are described in ⇒ 4-cylinder
direct injection engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 10 ;
Assembly mountings .



panel
Some models are not fitted with an engine cover panel.
Removing
the other -arrows- (do not jerk cover panel away, and do not
try to pull on one side only).
Note:
There are variations depending on model and version.
Installing
and dipstick.

cautions .


page 38

end)
⇒ “2.1.1 Exploded view - cylinder block (pulley end), vehicles with
high-voltage system”, page 21
2.1.1 Exploded view - cylinder block (pulley end), vehicles with alternator
1 - Poly V-belt
❑ Check for wear
❑ Do not kink
⇒ page 22
⇒ page 18
on pulleys.
❑ Pivot with wrench to
slacken poly V-belt
❑ Lock in position with
locking pin - T10060A- .
⇒ page 24
3 - Bolt
❑ 8 Nm +45°
4 - Bolt
ing and tightening
❑ Lubricate O-ring with
engine oil
❑ Property class 8.8:

150 Nm + 90°
❑ Property class 10.9: 100 Nm + 180°
❑ The property class of the bolt is visible on the bolt head
5 - O-ring
❑ Not available separately; supplied with ⇒ Item 4 (page 17)
7 - Bracket for ancillaries
❑ With oil filter and engine oil cooler
❑ Removing and installing bracket for ancillaries ⇒ page 38
❑ Removing and installing engine oil cooler ⇒ page 179
8 - Gasket
9 - Bolt
❑ Tightening torques and sequence ⇒ page 19
10 - Bolt
11 - Alternator
12 - Dowel sleeves
14 - Bolt

1- Vibration damper
3- Alternator

Bracket for ancillaries - tightening torques and tightening se‐

quence
angle.
– Fit bracket for ancillaries (first tighten bolt -4-).
Stage Bolts Tightening torques/angle specifica‐
tion
2. -1 … 5- 20 Nm
3. -1 … 5- Turn 90° further
2.1.2 Exploded view - cylinder block (pulley end), vehicles with starter-alternator
1 - Poly V-belt
❑ Check for wear
❑ Do not kink
⇒ page 20
⇒ page 22
on pulleys
2 - Bolt
engine oil
❑ Different versions (de‐
pending on type of gear‐
box and property class
of bolt)
❑ Vehicles with manual
gearbox and property
class 10.9: 240 Nm +
180°
❑ Vehicles with automatic
class 8.8: 150 Nm + 90°
class 10.9: 100 Nm +
180°
❑ The property class of
the bolt is visible on the
bolt head

3 - O-ring
⇒ “2.4.2 Removing and installing vibration damper - vehicles with starter-alternator”, page 30
5 - Bolt
❑ 8 Nm +90° in diagonal sequence in stages
❑ With oil filter housing and engine oil cooler
❑ Removing and installing bracket for ancillaries
⇒ “2.5.2 Removing and installing bracket for ancillaries - vehicles with starter-alternator”, page 40
7 - Gasket
8 - Bolt
10 - Bolt
11 - Tensioner
❑ For poly V-belt
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing starter-
alternator
13 - Bolt
14 - Dowel sleeves
Routing of poly V-belt for starter-alternator - C29-

1- Vibration damper
2- Idler roller
3- Starter-alternator - C29-

Bracket for ancillaries, vehicles with starter-alternator - tightening

torques and tightening sequence
angle.
tion
2. -1 … 5- 20 Nm
2.1.3 Exploded view - cylinder block (pulley end), vehicles with high-voltage sys‐
tem
1 - Bolt
engine oil
150 Nm + 90°
❑ Property class 10.9: 100
Nm + 180°
bolt head
2 - O-ring
❑ Not available separate‐
ly; supplied with
catalogue
installing vibration
damper - vehicles with
starter-alternator”,
page 30
4 - Gasket
❑ With oil filter housing
and engine oil cooler


6 - O-rings
7 - Connection
8 - Bolt
9 - Dowel sleeve
11 - Bolt
12 - Dowel sleeve
13 - Cover
14 - Bolt
❑ 8 Nm +45°

Removing
Preparatory work may be necessary depending on model ⇒ 4-
cylinder direct injection engine (1.8, 2.0 ltr. 4-valve TFSI - gener‐
ation III); Rep. gr. 13 ; Cylinder block (pulley end); Removing and
CAUTION

Vehicles with alternator:
NOTICE
– Turn tensioner clockwise -arrow- and lock in place with locking

pin - T10060A- .

Installing

– Fit poly V-belt ⇒ page 18 .
– Turn tensioner slightly in direction of -arrow- and remove lock‐
ing pin - T10060A- .



sioner
⇒ “2.3.1 Removing and installing poly V-belt tensioner - vehicles
with alternator”, page 24
with starter-alternator”, page 24
2.3.1 Removing and installing poly V-belt ten‐

sioner - vehicles with alternator
Removing
– Detach poly V-belt from tensioner ⇒ page 22 .
– Remove bolts -arrows- and take off tensioner -1- for poly V-
belt from bracket for ancillaries.
Installing
Tightening torques
♦ ⇒ “2.1 Exploded view - cylinder block (pulley end)”, page 17

sioner - vehicles with starter-alternator
Removing
– Remove tensioner -1-.
Installing
Tightening torques
♦ ⇒ “2.1.2 Exploded view - cylinder block (pulley end), vehicles

er
alternator/vehicles with high-voltage system”, page 24

er - vehicles with alternator/vehicles with
high-voltage system

♦ Open end spanner insert, AF 24

Components of assembly tool - T10531- :
♦ Support - T10531/1-
♦ Retaining bolt - T10531/2-
♦ Turning-over tool - T10531/3-

♦ Flange nut - T10531/4-
• The securing bolt for the vibration damper -A- secures the vi‐
bration damper -1-, timing chain sprocket -2- and crankshaft
-3- to each other. Before removing the securing bolt, the timing
chain sprocket must be secured to the crankshaft as described
below.
Removing
cylinder direct injection engine (1.8, 2.0 ltr. 4-valve TFSI); Rep.
gr. 13 ; Cylinder block (pulley end); Removing and installing vi‐
bration damper .
– Vehicles without high-voltage system: Remove pulley without

locking tensioner in place ⇒ page 22 .
NOTICE
– Use ratchet wrench (21 mm) - T40263- , adapter - T40314-

and socket (24 mm) to turn crankshaft in direction of engine
rotation -arrow- until vibration damper is at “TDC” position.
• Notch -1- on vibration damper must align with arrow marking
-2- on cover for timing chains (bottom).
• Marking on timing chain cover (bottom) must be in 4 o'clock
position.
• Do not loosen securing bolt for vibration damper by more than
a half turn at this stage.
– Apply counterhold tool - T10355- and loosen bolt for vibration

damper by approx. 1/2 turn.
– If vibration damper has been twisted out of position, correct
TDC position.
– Remove bolts -arrows- for timing chain cover (bottom).

– Apply support - T10531/1- (as illustrated) to vibration damper

and secure hand-tight with knurled screws -arrows-.
• Arrow marking on support - T10531/1- must point upwards.
– Remove bolt for vibration damper completely.
– Check whether turning-over tool -A- slides easily over clamps

-B-. Turn tensioning bolt -arrow- if necessary.
• Do not turn the tensioning bolt from this stage onwards; oth‐
erwise the clamping pin - T10531/2- will get stuck when it is
screwed into the crankshaft.
– Screw clamping pin - T10531/2- into crankshaft and hand-

tighten with open-end spanner, 12 mm -A-.
– Hand-tighten tensioning bolt -A- to secure chain sprocket to

crankshaft.

– Remove knurled screws -arrows-. Detach support - T10531/1-

and vibration damper -A-.
If crankshaft needs to be rotated without vibration damper:

– Fit turning-over tool - T10531/3- -item A- onto clamping pin -
T10531/2- (pay attention to tooth-shaped profile on chain
sprocket).
• In TDC position, flat surface of tool faces upwards.
– Tighten turning-over tool with flange nut - T10531/4-
-item B-.
– Crankshaft can now be rotated at hexagon flats -arrow-.
Installing
• Renew bolt with O-ring after removal.
– If necessary, detach flange nut - T10531/4- -item B- and turn‐
ing-over tool - T10531/3- -item A- from clamping pin -
T10531/2- .

– Fit vibration damper in TDC position (pay attention to tooth-

shaped profile -arrow- on chain sprocket).

T10531/2- .
• The hexagon flats should face the vibration damper.
– Screw flange nut - T10531/4- -item B- on while moving vibra‐
tion damper back and forth slightly to check whether vibration
damper is seated correctly in tooth-shaped profile.
– Tighten flange nut until vibration damper can no longer be ro‐
tated.

– Unscrew flange nut - T10531/4- -item A- and loosen tensioning

bolt -B-.
– Unscrew clamping pin - T10531/2- and remove with turning-
over tool - T10531/3- .

– Screw in new bolt for vibration damper with lubricated O-ring

-1- hand-tight.
– Remove knurled screws -arrows- and detach support -

T10531/1- .
– Apply counterhold tool - T10355- and tighten bolt for vibration

damper.

note the following:
• Renew bolts -arrows- for timing chain cover after removing.
Additional work depending on model ⇒ 4-cylinder direct injection
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 13 ; Cylinder block
(pulley end); Removing and installing vibration damper
Tightening torques
♦ ⇒ Fig. ““Timing chain cover (bottom) with 15 bolts - tightening
torques and tightening sequence”“ , page 79

er - vehicles with starter-alternator

♦ Counterhold tool - T40378- or

♦ Adapter - T10531/5- , clamping pin - T10531/6-
• The securing bolt for the vibration damper -A- secures the vi‐
bration damper -1-, timing chain sprocket -2- and crankshaft
-3- to each other. Before removing the securing bolt, the timing
chain sprocket must be secured to the crankshaft as described
below.
Removing
cylinder direct injection engine (2.0 ltr. 4-valve TFSI); Rep. gr.
13 ; Cylinder block (pulley end); Removing and installing vibration
damper .
– Remove bolts -arrows- and press wiring duct downwards.

Note:

NOTICE

and socket (24 mm) to turn crankshaft until vibration damper
is at “TDC” position.
position.
• Do not loosen securing bolt for vibration damper by more than
a half turn at this stage.
– Loosen bolt for vibration damper approx. 1/2 a turn; depending

on version, use counterhold tool - T40378- or counterhold tool
- T40379- -1- to do so.
“TDC” position.

– Screw adapter -T10531/5- into cylinder block hand-tight.

and screw knurled screws -1, 3- hand-tight into adapters.
– If necessary, align and counterhold adapters on hexagon flats
-2- using a hexagon socket (4 mm).
– Check whether turning-over tool - T10531/3- -item A- slides

easily over clamps -B-. Unscrew tensioning bolt -arrow- slight‐
ly if necessary.
• Do not turn the tensioning bolt from this stage onwards; oth‐
erwise the clamping pin - T10531/6- will get stuck when it is
screwed into the crankshaft.

tighten with open-end spanner (12 mm) -item A-.

crankshaft.



sprocket).
-item B-.
Installing
• Renew bolt with O-ring after removal.
T10531/6- .



T10531/6- .
tated.

– Unscrew flange nut - T10531/4- -item A- and tensioning bolt

-B-.
over tool - T10531/3- .


-1- hand-tight.
– Remove knurled screws -1, 3- and detach support -

T10531/1- .
– Unscrew adapter - T10531/5- .
– Tighten bolt for vibration damper; depending on version, use

counterhold tool - T40378- or counterhold tool - T40379- -1-
to do so.


note the following:
• Renew bolts -arrows- for timing chain cover after removing.
engine (2.0 ltr. 4-valve TFSI); Rep. gr. 13 ; Cylinder block (pulley
end); Removing and installing vibration damper
Tightening torques

cillaries
⇒ “2.5.1 Removing and installing bracket for ancillaries - vehicles
with high-voltage system”, page 41
2.5.1 Removing and installing bracket for an‐

cillaries - vehicles with alternator
Removing
bracket for ancillaries .
– Unscrew bolts -1, 2- and swivel coolant pipe (left-side) up‐
wards.
– Drain coolant ⇒ 4-cylinder direct injection engine (1.8, 2.0 ltr.
4-valve TFSI); Rep. gr. 19 ; Cooling system/coolant; Draining
– Vehicles without high-voltage system: Detach poly V-belt from
tensioner ⇒ page 22 .
erant lines still attached and tie up to longitudinal member ⇒
at bracket .
– Vehicles without high-voltage system: Remove alternator ⇒
Electrical system; Rep. gr. 27 ; Alternator; Removing and in‐
stalling alternator .


-item 4-
– Place a cloth underneath bracket for ancillaries to catch any

escaping oil.
– Unscrew bolts -1 ... 5- and detach bracket for ancillaries from
coolant pump housing.
Installing
angle.
– Coat new O-rings -4- with coolant additive.

– Insert connection -2- into coolant pump housing -3-.
– Push bracket for ancillaries -1- onto connection, fit bolts and
tighten.
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
– Install oil filter element and check oil level ⇒ page 169 .
– Fill up coolant ⇒ 4-cylinder direct injection engine (1.8, 2.0 ltr.
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 13 ; Cylinder block
Tightening torques
♦ ⇒ Fig. ““Bracket for ancillaries - tightening torques and tight‐
ening sequence”“ , page 19
♦ ⇒ 4-cylinder direct injection engine (1.8, 2.0 ltr. 4-valve TFSI);
Rep. gr. 19 ; Coolant pipes; Exploded view - coolant pipes


cillaries - vehicles with starter-alternator
Removing
wards.
at bracket .
– Remove starter-alternator ⇒ Electrical system; Rep. gr. 27 ;
Alternator; Removing and installing alternator .

1- For oil pressure switch - F22-
2- For oil pressure switch for reduced oil pressure - F378-
3- For piston cooling jet control valve - N522-
Note
Place a cloth underneath bracket for ancillaries to catch any es‐

caping oil.

Installing
Note

angle.

– Moisten new O-rings -4- with coolant.

tighten; tightening sequence ⇒ page 19 .
Note
– Fill up coolant ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-

valve TFSI); Rep. gr. 19 ; Cooling system/coolant; Draining
Tightening torques
♦ ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI); Rep.
gr. 19 ; Coolant pipes; Exploded view - coolant pipes

cillaries - vehicles with high-voltage sys‐
tem
Removing
wards.
– Remove oil filter element ⇒ “2.2 Engine oil”, page 169 .


Note

caping oil.

Installing
Note

angle.

engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep. gr. 13 ; Cyl‐
inder block (pulley end); Removing and installing bracket for
ancillaries
Tightening torques


gine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 13 ; Cylinder block (pulley
end); Removing and installing engine support .


⇒ “3.3 Removing and installing dual-mass flywheel”, page 47
page 48
1 - Cylinder block
2 - Dowel sleeves
end)
❑ With oil seal
⇒ page 48
❑ Do not lubricate oil seal
❑ Before installing, re‐
move 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
4 - Bolt
♦ Steel bolts can be reused
♦ Renew aluminium bolts af‐
ter removing
sequence
♦ Version with 6 bolts
⇒ page 45
♦ Version with 8 bolts
⇒ page 45
5 - Drive plate/dual-mass fly‐
wheel
Drive plate for vehicles without
high-voltage system
❑ A needle bearing must be fitted in the drive plate on vehicles with manual gearbox; install needle bearing
if not yet fitted ⇒ page 51
❑ There should be no needle bearing fitted in the drive plate on vehicles with a dual clutch/automatic
gearbox; remove needle bearing if necessary ⇒ page 51
Dual-mass flywheel for vehicles with high-voltage system

6 - Bolt
❑ 60 Nm +90°
7 - Needle bearing
❑ Renewing ⇒ page 51
❑ Installing ⇒ page 46
Sealing flange (gearbox end) with 6 bolts - tightening torques and

sequence
Note

angle.

tion
2. -1 … 6- Steel bolts: 9 Nm
Aluminium bolts: 4 Nm
3. -1 … 6- Aluminium bolts: Turn 45° further
Note:
Only 6 bolts are fitted; 2 bolt holes remain free.
Sealing flange (gearbox end) with 8 bolts - tightening torques and

sequence
Note

angle.

tion


– Engage intermediate plate on sealing flange -top arrow- and
push onto dowel sleeves -bottom arrows-.

♦ Counterhold tool - 10-201-
♦ Multi-point socket bit (length at least 40 mm)

Removing
installing gearbox; Removing gearbox or ⇒ Gearbox; Rep. gr.

– Insert counterhold tool - 10-201- to slacken bolts.
NOTICE
Risk of damage to drive plate if an unsuitable tool is used.
– Take care not to damage centring flange of drive plate when
loosening and tightening bolts.
– Unscrew bolts for drive plate -1- using a multi-point socket bit
with a length of at least 40 mm.
Installing
angle.
• On vehicles with manual gearbox, a needle bearing is fitted in
the drive plate. Before installing, check that the needle bearing
is fitted. Removing and installing needle bearing in drive plate
(pressing in and out) ⇒ page 51 .
– Fit counterhold tool - 10-201- the other way round to tighten
bolts.
Tightening torques
page 44
3.3 Removing and installing dual-mass fly‐

wheel

Removing
NOTICE
Risk of damage to dual-mass flywheel if handled incorrectly.
– Take care not to damage spline of dual-mass flywheel when
loosening and tightening bolts.
– Unscrew bolts -arrows- and detach dual-mass flywheel -1-.
– To do so, counterhold vibration damper with ratchet wrench,

21 mm - T40263- , adapter - T40314- and socket, 24 mm.
Installing
angle.
Tightening torques
page 44

(gearbox end)
♦ Guide piece - T10122/6- or -T10122/6A- from fitting tool -
T10122B- or -T10122C-
♦ Assembly aid - T10122/1- from fitting tool - T10122B- or -

T10122C-
♦ Electric drill with plastic brush attachment
♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue (ETKA)
Removing
• Vehicles without high-voltage system: Gearbox removed ⇒
Gearbox; Rep. gr. 34 ; Removing and installing gearbox; Re‐
moving gearbox , or ⇒ Gearbox; Rep. gr. 37 ; Removing and
installing gearbox; Removing gearbox

• Vehicles with high-voltage system: Engine removed and se‐

cured to engine and gearbox support ⇒ page 12
– Vehicles without high-voltage system: Remove drive plate
⇒ page 46 .
– Remove bolts -1 ... 8-. (Some versions may only have six
bolts.)
– Release sealing flange from bonded joint.
– Cover exposed parts of the engine.
Installing
• Renew sealing flange after removing.
Place a clean cloth over the open section of the sump to prevent
the lubrication system from being contaminated by sealant resi‐
due.
CAUTION
– Remove sealant residue on cylinder block -1- using rotating

plastic brush or similar.
– Clean sealing surfaces and crankshaft journals; they must be
free of oil and grease.
Note:
Note expiry date of sealant.
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 2
mm).
NOTICE
Risk of engine damage due to excessive sealant in lubrication
system.
– The sealant bead must not be thicker than specified.


• The sealing flange must be installed within 5 minutes after ap‐
plying sealant.
• Check that sealing lip of sealing flange is not bent or damaged.
• Sealing lip must face engine after installation -top arrow-. If the
sealing lip faces outwards after installation this will result in oil
leakage.
– Check guide piece - T10122/6A- -B-; it must not have sharp

edges or be dirty.
– Fit assembly aid - T10122/1- -A- onto guide piece -B-.
– Push sealing flange -C- onto guide piece -B-, starting with out‐
er edge.
– Detach assembly aid -A-.

– Fit guide piece -A- with sealing flange -B- on crankshaft jour‐
nal.
Note:
It is not necessary to tighten bolts -arrows-.
– Push sealing flange -B- over guide piece -A- onto crankshaft
journal.
– Detach guide piece -A-.
– Secure sealing flange with bolts.
• After installing sealing flange, wait about 30 minutes for seal‐
ant to dry. Then (and only then) fill the engine with engine oil.
note the following:
– Vehicles without high-voltage system: Install drive plate
⇒ page 46 .
– Check oil level ⇒ page 169 .
Tightening torques
♦ ⇒ Fig. ““Sealing flange (gearbox end) with 6 bolts - tightening
torques and sequence”“ , page 45
♦ ⇒ Fig. ““Sealing flange (gearbox end) with 8 bolts - tightening
torques and sequence”“ , page 45
page 44

manual gearbox.
♦ Tube - VW 418A-
♦ Tube - VW 421-

♦ Support - 40-103-
Procedure
• Gearbox removed ⇒ 6-speed manual gearbox; Rep. gr. 34 ;
Removing and installing gearbox; Removing gearbox .
– Place support - 40-103- under drive plate when pressing out
bearing.

VW 418A- and workshop press.
gine.

4 Crankshaft
⇒ “4.1 Exploded view - crankshaft”, page 53
⇒ “4.2 Crankshaft dimensions”, page 55
⇒ “4.3 Allocation of main bearing shells”, page 55
⇒ “4.4 Measuring axial clearance of crankshaft”, page 56
⇒ “4.5 Measuring radial clearance of crankshaft”, page 57
⇒ “4.6 Removing and installing sender wheel”, page 58
4.1 Exploded view - crankshaft
1 - Cylinder block
2 - Bearing shell for cylinder
block
❑ With oil groove
shells
❑ Classification of crank‐
shaft bearing shells
⇒ page 55
❑ Lubricate with engine oil
3 - Crankshaft
❑ Secure engine to engine
and gearbox support
when performing as‐
sembly work ⇒ page 12
❑ After removing, place it
down so that the sender
wheel
does not become dam‐
aged
❑ If crankshaft is renewed,
new bearing shells must
be assigned to bearing
caps ⇒ page 55
❑ Measuring axial clear‐
ance ⇒ page 56
❑ Measuring radial clear‐
ance ⇒ page 57
❑ Crankshaft dimensions
⇒ page 55
❑ After removal or renew‐
al, perform adaption
⇒ Vehicle diagnostic
tester 01 - Engine
electronics, functions , 01 - Chain elongation adaption diagnosis
4 - Bearing shell for bearing cap

❑ Without oil groove
❑ Renew used bearing shells
❑ Classification of crankshaft bearing shells ⇒ page 55
5 - Bolt
4. Crankshaft 53
❑ Use old bolts when measuring radial clearance

6 - Bearing caps
❑ Bearing cap 1: Pulley end
❑ Bearing caps 2, 3 and 4 are secured additionally with bolts at side
❑ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side
❑ Mark installation position for re-installation ⇒ page 55
7 - Bolt
❑ Sender wheel ⇒ Item 8 (page 54) must be renewed if bolts are loosened ⇒ page 58
❑ 10 Nm +90°
8 - 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 ⇒ Item 7 (page 54) are loosened
❑ After renewing, perform adaption ⇒ Vehicle diagnostic tester
9 - Thrust washers
❑ For bearing No. 3
10 - Bolt
Crankshaft - tightening torques and sequence

angle.
tion
1. -1 … 10- and Screw in by hand until contact is made
-arrows A-
2. -1 … 10- 65 Nm
3. -1 … 10- Turn 90° further
4. -Arrows A- 15 Nm
5. -Arrows A- Turn 90° further

Markings on crankshaft bearing caps

– Mark position of bearing caps -1 ... 5- for re-installation.
• Lugs -arrows- on bearing caps face crankshaft bearing 3 on
inlet side.
4.2 Crankshaft dimensions

Honing dimension Crankshaft Conrod
1) main bearing journal journal ∅ mm
∅ mm
Basic dimension 52.00 47.80
1) There is currently no provision for machining used crankshafts.
4.3 Allocation of main bearing shells

♦ Bearing shells of the correct thickness are allocated to the cyl‐
inder block at the factory. Coloured dots are used to identify
the thickness of the bearing shells.
♦ Letter codes on lower sealing surface or end of cylinder block
indicate which bearing shell is to be fitted in cylinder block (top
bearing shell) at each location.
♦ Letter codes on crankshaft indicate which bearing shell is to
be fitted in bearing cap (bottom bearing shell).
♦ The first letter stands for bearing cap 1, the second letter for
bearing cap 2, etc.
Marking on bearing shell for cylinder block:
Markings on cylinder block are applied either onto sealing surface
for sump or gearbox end of cylinder block.
4. Crankshaft 55
Marking on cylinder block refers to top bearing shell (bearing shell

for cylinder block).
– Note down letters and select colour coding to be fitted from the
table.
S = Black
R = Red
G = Yellow
B = Blue
V = Violet
W = White
Coloured marking depends on version; for correct type refer to ⇒
Marking on bearing shell for bearing cap:

Marking on crankshaft refers to bottom bearing shell (bearing
shell for bearing cap).
– Note down letters and select colour coding to be fitted from the
table.
R = Red
G = Yellow
B = Blue
W = White
V = Violet
S = Black
Coloured marking depends on version; for correct type refer to ⇒
4.4 Measuring axial clearance of crankshaft


Procedure
– Bolt dial gauge - VAS 6079- with universal dial gauge bracket
- VW 387- onto cylinder block and set it against crank web.
– Press crankshaft against dial gauge by hand and set gauge to
“0”.
– Push crankshaft away from dial gauge and read off value.
Axial clearance:
• New: 0.070 ... 0.231 mm.
4.5 Measuring radial clearance of crank‐

shaft
♦ Plastigauge
Procedure
• Use old bolts when measuring radial clearance.
– Remove crankshaft bearing caps and clean bearing caps and
journals.
bearing on the bearing journal or bearing shell.
• The Plastigauge must be positioned in the centre of the bear‐
ing shell.
4. Crankshaft 57
– Fit crankshaft bearing caps and secure with old bolts

-1 ... 10- ⇒ page 54 without rotating crankshaft.
– Remove crankshaft bearing caps again.
Radial clearance:
• New: 0.017 ... 0.037 mm.
4.6 Removing and installing sender wheel

Removing
• Engine secured to engine and gearbox support ⇒ page 12
– Remove sealing flange (gearbox end) ⇒ page 48 .
– Remove sump (top section) ⇒ page 174 .
– Remove balance shaft timing chain ⇒ page 96 .
– Unbolt conrod bearing caps.
– Remove crankshaft bearing caps.
– Remove crankshaft and unbolt sender wheel.
Installing
– 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 wheel beneath the bolts will be loose.
• Sender wheel can only be fitted in one position because holes
are offset.
– Adaption must be performed after renewing sender wheel
Tightening torques
♦ ⇒ “4.1 Exploded view - crankshaft”, page 53

5 Balance shaft
⇒ “5.1 Exploded view - balance shaft”, page 59
⇒ “5.2 Removing and installing balance shaft”, page 60
⇒ “5.3 Renewing oil seal for balance shaft (inlet side)”,
page 64
5.1 Exploded view - balance shaft
1 - Cylinder block
2 - Bolt
❑ 9 Nm
3 - Balance shaft (inlet side)
❑ Lubricate bearing with
engine oil
❑ Always renew both
sides together
⇒ page 60
4 - Pipe
❑ For balance shaft (ex‐
haust side)
⇒ page 60
5 - Bolt
❑ 9 Nm
6 - Balance shaft (exhaust
side)
engine oil
sides together
⇒ page 63
7 - Needle bearing
❑ Needle bearing is col‐
our-coded; a needle
bearing with the same
colour must be installed
engine oil
8 - Needle bearing
❑ Needle bearing is colour-coded; a needle bearing with the same colour must be installed
❑ Lubricate bearing with engine oil
9 - Pipe
❑ For balance shaft (inlet side)
10 - Seal
5. Balance shaft 59
Tube for balance shaft (inlet side) - installation position

• Lug -arrow A- on balance shaft must engage in notch
-arrow B- on tube.
Tube for balance shaft (exhaust side) - installation position

• Openings -right arrow- must face chain side.
– Insert tube -2- for balance shaft into cylinder block -1-.
• Installation position is correct when dimension -a- = 21 mm.
5.2 Removing and installing balance shaft

⇒ “5.2.1 Removing and installing balance shaft (inlet side)”, page
60
⇒ “5.2.2 Removing and installing balance shaft (exhaust side)”,
page 63
5.2.1 Removing and installing balance shaft

(inlet side)
Removing
– Remove radiator ⇒ 4-cylinder direct injection engine (1.8, 2.0
ltr. 4-valve TFSI); Rep. gr. 19 ; Radiator/radiator fans; Re‐
moving and installing radiator .

– Remove toothed belt for coolant pump ⇒ page 206 .

– Remove camshaft timing chain ⇒ page 96 .
– Detach drive sprocket -1- for toothed belt for coolant pump.
– Unscrew bolt -1- and remove idler gear.
– Detach bearing mounting -1-.
– Remove bolt -2- securing balance shaft (inlet side) and pull out
balance shaft.
5. Balance shaft 61
Installing
• Renew needle bearing after removing balance shaft.
• Needle bearing is colour-coded; a needle bearing with the
same colour must be installed.
– Lubricate balance shaft bearings -arrows- with engine oil.
– Install balance shaft (inlet side) and tighten bolt -2-.
– Renew O-ring -1- and lubricate with engine oil.

– Lubricate bearing mounting with engine oil and install; dowel
pin -arrow- for bearing mounting must engage in bore in cyl‐
inder block.
NOTICE
Risk of damage to engine due to incorrect backlash.
– Always renew idler gear; otherwise the backlash will be in‐
correct.
The new idler gear has a special lubricant coating which wears
off after a short running period and thus automatically creates the
specified backlash.
– Mark faces of gear teeth of idler gear with paint marker

-arrow-.
– Insert idler gear; marking on balance shaft must be positioned
between markings on faces of gear teeth.

– Tighten bolt -1- for idler gear: tightening sequence

⇒ page 91 .
– Check markings on idler gear/balance shaft -arrow-.
note the following:
– Install camshaft timing chain ⇒ page 96 .
– Renew oil seal for balance shaft (inlet side) ⇒ page 64 .
– Install toothed belt for coolant pump ⇒ page 206 .
– Install radiator ⇒ 4-cylinder direct injection engine (1.8, 2.0 ltr.
4-valve TFSI); Rep. gr. 19 ; Radiator/radiator fans; Removing
and installing radiator .
Tightening torques
♦ ⇒ “5.1 Exploded view - balance shaft”, page 59

(exhaust side)
Removing
– Remove radiator ⇒ 4-cylinder direct injection engine (1.8, 2.0
ltr. 4-valve TFSI); Rep. gr. 19 ; Radiator/radiator fans; Re‐
moving and installing radiator .
– Remove bolt -1- securing balance shaft (exhaust side) and pull
out balance shaft.
Installing
• Renew needle bearing after removing balance shaft.
• Needle bearing is colour-coded; a needle bearing with the
– Check installation position of tube for balance shaft; openings
-arrow- must face chain side.
5. Balance shaft 63
– Lubricate balance shaft bearings -arrows- with engine oil.
– Install balance shaft (exhaust side).

– Make sure that balance shaft is in full contact with crankcase
before tightening bolt -1-.
• Insert tube for balance shaft again if balance shaft does not
make full surface contact.
note the following:
– Install radiator ⇒ 4-cylinder direct injection engine (1.8, 2.0 ltr.
Tightening torques
5.3 Renewing oil seal for balance shaft (inlet

side)
♦ Thrust piece - T10353/1-
Procedure

Note:
The drive sprocket bolt has a left-hand thread.
– Unscrew bolt -2- and detach drive sprocket -1- for toothed belt
for coolant pump.
– Press screwdriver -1- firmly onto section -2- of oil seal

-arrow B-.
– Lever out oil seal -arrow A-.
– Lubricate sealing surface of balance shaft -2- with gear oil.

– Fit oil seal -1- onto balance shaft.
• Marking “Inside” -arrow- must face towards engine.
Note:
– Apply thrust piece - T10353/1- to oil seal -1- and press into
cylinder block as far as stop using bolt -2- (take care not to tilt
oil seal).
5. Balance shaft 65

page 74
1 - Bolts
contact surface
ance
❑ Tightening torques:
♦ 1.8 ltr. engine: 30 Nm +90°
♦ 2.0 ltr. engine: 45 Nm +90°
tion
conrod
-A-
Marking -B- faces to‐
wards pulley end
❑ Separating parts of new
conrod ⇒ page 74
3 - Bearing shells
⇒ page 69
shells
❑ Lubricate with engine oil before installing
❑ Axial clearance
♦ New: 0.10 ... 0.35 mm
♦ Wear limit: 0.40 mm
❑ Measuring radial clearance ⇒ page 74
4 - Conrod

❑ Mark cylinder and conrod bearing cap allocation

❑ Installation position: Marking -B- faces towards pulley end
❑ Separating parts of new conrod ⇒ page 74
❑ 27 Nm
6 - Oil spray jet
7 - Circlip
8 - Piston pin
9 - Piston
❑ Arrow on piston crown points to pulley end
❑ Checking pistons and cylinder bores ⇒ page 72
❑ Install using piston ring pliers -VAS 211 003- ⇒ page 68
❑ Installation position in combination with two-part oil scraper ring: “TOP” or “R” must face towards piston
crown
❑ Allocation and installation position in conjunction with three-part oil scraper ring ⇒ page 68
❑ Checking ring gap ⇒ page 73
❑ Check ring-to-groove clearance in combination with two-part oil scraper ring ⇒ page 73
❑ Ring-to-groove clearance cannot be measured in combination with three-part oil scraper ring.
❑ Two-part or three-part, depending on version; allocation ⇒ Electronic parts catalogue
❑ Two-part oil scraper ring:
♦ Install with gap offset by 120° to next compression ring
♦ “TOP” or “R” must face towards piston crown
♦ Checking ring gap ⇒ page 73
♦ Ring-to-groove clearance cannot be checked
❑ Three-part oil scraper ring:
♦ Carefully remove and install by hand
♦ Installation position ⇒ page 68
♦ Allocation ⇒ page 68
♦ Gap cannot be measured
♦ Ring-to-groove clearance cannot be checked

Allocation of piston rings in conjunction with three-part oil scraper

ring
1- Compression ring with chamfer -arrow A- on inside at top.
»TOP« marking or lettering faces upwards
2- Compression ring with shoulder -arrow B- on outside at bot‐
tom. »TOP« marking or lettering faces upwards

• »TOP« marking or lettering faces upwards.
Installing three-part oil scraper ring

• Offset top gap of 3-part oil scraper ring by 120° to next com‐
pression ring.

Installation position of bearing shell

– Position bearing shells in centre of conrod and conrod bearing
cap when fitting.
Oil spray jets - installation position

• Side surface of oil spray jet -1- must be parallel with adjacent
crankshaft bearing -2-.

♦ Pin - VW 222A-

♦ Funnel - T40347-
Removing
– Remove cylinder head ⇒ page 118 .
– Mark installation position and cylinder number of piston.
– Mark installation position and cylinder number of conrod
upwards.
Note:
Installing
angle.
• Arrow on piston crown points to pulley end.
– Install compression rings ⇒ Item 10 (page 67) .
– Install oil scraper ring ⇒ Item 11 (page 67) .
– Oil running surfaces of bearing shells.
– Lubricate running surfaces of bearing shells and cylinder walls

with engine oil.
– Carefully push piston -1- into cylinder by hand -arrow- using
funnel - T40347- .
• Arrow on piston crown points to pulley end.
– Install cylinder head ⇒ page 118 .
– Install sump (upper section) ⇒ page 174 .
Tightening torques


Removing
♦ Socket - T10545-
Removing cylinders 1 to 3:
installing gearbox; Removing gearbox or ⇒ Gearbox; Rep. gr.

NOTICE
– Using ratchet wrench (21 mm) - T40263- , adapter - T40314-

and socket (24 mm), turn crankshaft -arrow- until correspond‐
ing bolt is accessible.
Removing cylinder 4:
• Engine removed and secured to engine and gearbox support
⇒ page 12
– Remove crankshaft.
Continued for all cylinders:

Installing
NOTICE
Risk of damage to oil spray jets due to deformation.
– Never bend oil spray jets.
– Install balance shaft timing chain ⇒ page 96 .

Tightening torques

Checking piston
– Using a micrometer (75 ... 100 mm), measure approx. 15 mm
from the lower edge, perpendicular to the piston pin axis.
♦ Difference between actual and nominal diameter: not more
than 0.04 mm.
Piston ∅
Basic dimension mm 82.421)
• 1)Dimensions not including coating (thickness 0.02 mm).
The coating will wear down in service.

Checking piston ring gap

– Insert piston 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)
Two-part oil scraper rings 0.20 … 0.40 0.80
Three-part oil scraper rings Cannot be measured
Checking ring-to-groove clearance

Piston ring in combination New Wear limit
with two-part oil scraper
ring
Oil scraper rings Cannot be measured
Checking cylinder bore

♦ Cylinder gauge - VAS 6078-
NOTICE
Risk of damage to surface of cylinder bore through incorrect
machining.
– Never machine the cylinder bore (reboring, honing, grinding)
with workshop equipment.

-B-.

♦ Difference between actual and nominal diameter: not more

than 0.08 mm.
Cylinder bore ∅
Basic dimension mm 82.51

separated as intended. If it is not possible to take off the conrod
bearing cap by hand, proceed as follows:
– Mark cylinder number of conrod ⇒ Item 4 (page 66) .
ped lightly.


bearings
♦ Plastigauge
Procedure

Radial clearance:
• New: 0.02 ... 0.06 mm.


cautions .


⇒ “2.3 Renewing oil seal for vibration damper”, page 84
1 - O-ring
❑ Lubricate before instal‐
ling
2 - Dipstick guide tube
❑ Clipped onto timing
chain cover (top)
3 - Bolt
❑ 9 Nm
❑ Exploded view ⇒ 4-cyl‐
inder direct injection en‐
gine (1.8, 2.0 ltr. 4-valve
TFSI); Rep. gr. 19 ;
Coolant pipes; Explo‐
ded view - coolant pipes
5 - Bolt
⇒ page 78
6 - Bolt
❑ Renew aluminium bolt
after removal
♦ Steel bolt: 9 Nm
♦ Aluminium bolt: 4 Nm +45°
valve 1 - N318-
⇒ page 149
❑ Renew O-ring
8 - Camshaft control valve 1 - N205-
❑ Renew O-ring ⇒ Item 16 (page 78)
9 - Seals
❑ Installation position: side with small inner diameter faces outwards
❑ To renew, remove timing chain cover (top) ⇒ Item 10 (page 77)
❑ Lubricate before installing
10 - Timing chain cover (top)
❑ Removing and installing ⇒ “2.2.1 Removing and installing timing chain cover (top)”, page 79

11 - Seal
12 - Filler neck
13 - Seal
14 - Filler cap
15 - Gasket
16 - O-rings
17 - Dowel pin
❑ 2x
❑ For centring cover
18 - Bolt
❑ Tightening torques and sequence, with 15 bolts ⇒ page 79
❑ Tightening torques and sequence, with 8 bolts ⇒ page 79
❑ With oil seal
20 - Oil seal
❑ For vibration damper
21 - Sealing plug
Timing chain cover (top) - tightening torques and tightening se‐

quence
– Tighten bolts -1 ... 6- to 9 Nm in the sequence shown.

Timing chain cover (bottom) with 15 bolts - tightening torques and

tightening sequence
angle.
tion
2. -1 … 15- 8 Nm
3. -1, 2, 4, 5- and Turn 45° further
-7 … 15-
4. -3, 6- Turn 45° further after installing vibra‐
tion damper
Timing chain cover (bottom) with 8 bolts - tightening torques and

tightening sequence
angle.
tion
2. -1 … 8- 8 Nm
3. -2, 3- and Turn 45° further
-5 … 8-
tion damper

cover
page 79

cover (top)
Removing
gr. 15 ; Timing chain cover; Removing and installing timing chain
cover .
– Remove camshaft control valves ⇒ page 149 .

– Version with particulate filter: Take electrical connector -2- for

exhaust gas temperature sender 3 - G495- out of bracket and
unplug.

wards.
– Unclip guide tube -1- for oil dipstick from timing chain cover
(top) -arrow- and pull it out of timing chain cover (bottom).
– Unscrew bolts -1 ... 6- and remove timing chain cover (top).

Installing
• Renew seals and O-rings after removing.
• Installation position of seals: side with small inner diameter
faces outwards
– Install camshaft control valves ⇒ page 149 .
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Timing chain
Tightening torques
♦ ⇒ Fig. ““Timing chain cover (top) - tightening torques and tight‐
♦ ⇒ “2.1 Exploded view - timing chain cover”, page 77


Removing
• Engine oil drained ⇒ page 169 .
– If fitted, remove engine cover panel ⇒ page 15 .
Vehicles with secondary air system:
– Remove secondary air pump motor - V101- ⇒ page 287 .
– Press release tabs on both sides and detach resonator -2-.
Vehicles with particulate filter:

sender 3 - G495- out of bracket.

wards.

– Unclip guide tube -1- for oil dipstick from timing chain cover
(top) -arrow- and pull it out of timing chain cover (bottom).
– Vehicles with alternator: Remove poly V-belt tensioner
⇒ page 24 .
– Remove bolts -1 ... 15-.
Note
Some versions have only 8 bolts.
– Release timing chain cover (bottom) from bonded joint.

Installing
angle.
• Renew timing chain cover (bottom) and seal after removal.
– Check that both dowel pins are fitted in cover -arrows-.

3 mm).
NOTICE
system.

Cover with 15 bolts

– Apply sealant as shown onto clean sealing surface -arrow 1-
and onto edges -arrows 2- of new cover.
• The cover must be installed within 5 minutes after applying
sealant.
– Immediately fit cover and tighten bolts ⇒ page 79 .
Cover with 8 bolts

– Apply sealant as shown onto clean sealing surface -arrow 1-
and onto edges -arrows 2- of new cover.
• The cover must be installed within 5 minutes after applying
sealant.
– Immediately fit cover and tighten bolts ⇒ page 79 .

Continued
• Only tighten bolts -arrows- to final tightening angle after in‐
stalling the vibration damper. The bolts must be unscrewed
again to install the vibration damper.
• After fitting cover, the sealant must dry for approx. 30 minutes.
Then (and only then) fill the engine with engine oil.
note the following:
– Install poly V-belt tensioner ⇒ page 24 .
– Top up engine oil and check oil level ⇒ page 169 .
– If previously removed, install secondary air pump motor -
V101- ⇒ page 287 .
Tightening torques
2.3 Renewing oil seal for vibration damper

♦ Thrust pad - T10375-

♦ Flange nut - 10531/4- from assembly tool - T10531-
♦ Extractor hook - T40274-
Procedure
gr. 15 ; Timing chain cover; Renewing oil seal for vibration damp‐
er .
– Pry out oil seal -arrow- using extractor hook - T40274- .
– Fit oil seal -arrow- onto thrust piece - T10354- .

• Closed side of oil seal faces thrust piece - T10354- .

– Vehicles with alternator: Slide oil seal -arrow- with thrust piece
- T10354- onto clamping pin - T10531/2- -item 1- and position
it on timing chain cover (bottom).
– Vehicles with starter-alternator: Slide oil seal -arrow- with
thrust piece - T10354- onto clamping pin - T10531/6-
-item 1- and position it on timing chain cover (bottom).
– Also fit thrust pad - T10375- and tighten flange nut - 10531/4- .
– Drive oil seal in as far as stop using thrust piece - T10354- .
note the following:
• Renew bolt with O-ring for vibration damper after removal.
• Renew oil seal for vibration damper.
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Timing chain cover

3 Chain drive
⇒ “3.2 Exploded view - drive chain for balance shaft”, page 89
⇒ “3.3 Removing and installing bearing saddle”, page 91
page 96
⇒ “3.5 Checking timing chain”, page 109
⇒ “3.6 Checking valve timing”, page 111

• Learnt values for chain elongation must be re-adapted after
removing or renewing components of the chain drive ⇒ Vehicle
diagnostic tester 01 - Engine electronics, functions ,
01 - Chain elongation adaption diagnosis .
1 - Bolt
❑ For aluminium bolts:
4 Nm + 90°
❑ For steel bolts: 9 Nm
2 - Chain tensioner
❑ Exerts spring pressure
❑ Before removing, lock in
place using locking tool
- T40267-
3 - Tensioning rail for timing
chain
4 - Guide pin
❑ 20 Nm
5 - Bolt
after removal
6 - Clamping sleeve
❑ Not fitted on all bearing
saddle versions
7 - Timing valves
❑ Left-hand thread
❑ Different types depend‐
ing on production ver‐
sion
❑ Use a tool from assem‐
bly tool set - T10352A-
to remove
❑ 35 Nm
8 - Bearing saddle
❑ Fitting instructions ⇒ page 88
3. Chain drive 87
9 - Guide rail for camshaft timing chain

11 - Camshaft timing chain
❑ Before removing, mark running direction with paint
12 - Guide rail for camshaft timing chain
13 - Guide pin
❑ 20 Nm
14 - Three-part chain sprocket assembly
❑ Crankshaft
Checking control valve
Bearing saddle - installation instructions

When installing a new bearing saddle -3- with spring pin -4-:
Check hole -arrow- in cylinder head -1- before installing bearing
saddle.
If hole -arrow- is not suitable for use of spring pin -4-, spring pin
must be removed from bearing saddle. In this case, a shorter bolt
-2- must be used for this hole. For correct type of bolt, refer to ⇒
Electronic parts catalogue (ETKA) .

Bearing saddle - tightening torques and sequence

For steel bolts
Stage Bolts Tightening torques
2. -1 … 6- 9 Nm
For aluminium bolts
angle.
tion
2. -1 … 6- 4 Nm
3. -1 … 6- Turn 180° further
Three-part chain sprocket assembly - installation position

• The two sections -arrows- must be aligned.
3.2 Exploded view - drive chain for balance

shaft
• Learnt values for chain elongation must be re-adapted after
removing or renewing components of the chain drive ⇒ Vehicle
diagnostic tester 01 - Engine electronics, functions ,
01 - Chain elongation adaption diagnosis .
3. Chain drive 89
1 - Guide pin
❑ 20 Nm
2 - Tensioning rail
❑ For timing chain
3 - Balance shaft
❑ Exhaust side
engine oil
sides together
⇒ page 63
4 - Guide pin
❑ 20 Nm
5 - Guide rail
❑ For timing chain
6 - Chain tensioner
logue
❑ 85 Nm
7 - Seal
8 - Cylinder block
9 - O-ring
10 - Bearing mounting
⇒ page 91
11 - Idler gear
❑ If bolt ⇒ Item 13 (page 90) has been loosened, idler gear must be renewed
12 - Thrust washer
13 - Bolt
❑ If bolt has been loosened, idler gear ⇒ Item 11 (page 90) must be renewed
14 - Guide rail
❑ For balance shaft timing chain
15 - Guide pin
❑ 20 Nm
16 - Balance shaft
❑ Inlet side
❑ Always renew both sides together ⇒ page 63
18 - Drive chain for balance shafts
❑ Removing and installing ⇒ “3.4 Removing and installing camshaft timing chain”, page 96

Bearing mounting - installation position

• Renew O-ring -1- and lubricate with oil.
• Dowel pin -arrow- for bearing mounting must engage in bore
in cylinder block.
• Lubricate bearing mounting.
Idler gear - tightening torques and sequence
NOTICE
Risk of damage to engine due to incorrect backlash.
– Always renew idler gear; otherwise the backlash will be in‐
correct.

angle.
– Tighten bolt -1- in stages:
Stage Tightening torques/angle specification
1. 10 Nm
2. – Turn idler gear
• Idler gear must be without play; otherwise loos‐

en bolt and tighten again
3. 25 Nm
3.3 Removing and installing bearing saddle

♦ Assembly tool - T10352A-
♦ Assembly tool - T10352/3-

3. Chain drive 91
♦ Assembly lever - T40243-
Removing
– Remove timing chain cover (top) ⇒ page 79 .
Note:
The timing valves have a left-hand thread.

– Turn assembly tool -1- in direction of -arrow- to remove timing

valve (left and right).
Depending on version of timing valve, use one of the following
tools:
– When doing so, counterhold vibration damper with ratchet

wrench (21 mm) - T40263- , adapter - T40314- and socket (24
mm).

• Detach bearing saddle carefully without tilting it.
– Detach bearing saddle.
– Remove sealing plug -arrow-.
3. Chain drive 93
– Bolt assembly lever - T40243- onto cylinder head

-bottom arrows-.
• A second mechanic is required for the following steps.
– Compress and hold circlip -1- for chain tensioner.
– Push assembly lever - T40243- slowly in direction of -arrow-
and hold in place. This will press the chain tensioner back.
Note:
The chain tensioner is oil-damped and can therefore only be
pressed back slowly by applying constant pressure.
– Lock chain tensioner with locking tool - T40267- .

– Remove assembly lever - T40243- .

Installing
– Fit and tighten bolts -arrows-. Tightening torques
– Lubricate holes -arrows- with engine oil.

– Check whether spring pin -1- is fitted.
• When installing a new bearing saddle -3- with spring pin -4-:
Check hole -arrow- in cylinder head -1- before installing bear‐
ing saddle.
• If hole -arrow- is not suitable for use of spring pin -4-, spring
pin must be removed from bearing saddle. In this case, a
shorter bolt -2- must be used for this hole. Bolt ⇒ Electronic
parts catalogue (ETKA)
3. Chain drive 95
• Carefully attach bearing saddle without tilting it - risk of dam‐

age.
– Fit bearing saddle and screw in bolts -arrows- by hand until
they make contact.
– Remove locking tool - T40267- .
– Tighten bolts for bearing saddle ⇒ page 89 .
note the following:
– Install timing chain cover (top) ⇒ page 79 .
Learnt values for chain elongation must be re-adapted after re‐
moving or renewing components of the chain drive.
♦ Drive train
♦ 01 - Chain elongation adaption diagnosis
Tightening torques
♦ ⇒ Fig. ““Bearing saddle - tightening torques and sequence”“ ,
page 89
♦ ⇒ “3.1 Exploded view - camshaft timing chains”, page 87

ing chain


3. Chain drive 97
Removing
Note:
tools:


– Turn vibration damper to “TDC” position.
NOTICE
• Notch on vibration damper and marking on cover for timing

chains (bottom) must be aligned -arrow-.
• The markings -1- on the camshaft chain sprockets must face
upwards.
Note:
The combination of ratchet wrench (21 mm) - T40263- , adapter
- T40314- and socket (24 mm) can be fitted onto the vibration
damper better than the counterhold tool - T10355- .
– Remove timing chain cover (bottom) ⇒ page 81 .
– Check “TDC” position again.
– Press retainer for oil pump chain tensioner in direction of

-arrow- and lock in place using locking pin - T40011- .
– Remove bolt -1- and detach chain tensioner -2-.
3. Chain drive 99
– Screw in assembly lever - T40243- -arrows-.

and hold in place.
– Hold chain tensioner in position with locking tool - T40267- .

– Bolt camshaft clamp - T40271/2- onto cylinder head and slide

into teeth on chain sprocket in direction of -arrow 2-; if neces‐
sary, use assembly tool - T40266- to turn inlet camshaft in
direction of -arrow 1-.

– Bolt camshaft clamp - T40271/1- onto cylinder head.

– Turn exhaust camshaft in direction of -arrow A- using assem‐
bly tool - T40266- and hold in place. Remove bolt -1- and guide
tensioning rail -2- downwards.
– Continue turning exhaust camshaft clockwise -arrow A- until
camshaft clamp - T40271/1- can be pressed into teeth -C- on
chain sprocket in direction of -arrow B-.
– Use screwdriver to release catch -arrow- and press off guide

rail -1- towards front.
– Unscrew bolts -arrows- and remove chain tensioner -1-.
– Unscrew bolts -1- and remove guide rail -2-.
3. Chain drive 101

– Remove camshaft timing chain from camshaft sprockets and

place onto camshaft journals -arrows-.
– Remove chain tensioner -1- for balance shaft timing chain.
– Remove bolts -1-. Remove tensioning rail -2- and guide rails
-3- and -4-.
– Loosen tensioning bolt -A- and remove clamping pin -B-.

– Remove three-part chain sprocket assembly; to do so, remove
oil pump chain (shown on a vehicle with alternator).
– Detach camshaft timing chain and drive chain for balance
shaft.

Installing
– Check TDC position of crankshaft; flat surface of crankshaft
-arrow- must be horizontal.
– Use a waterproof pen to mark cylinder block -1-.
– Mark tooth -1- of three-part chain sprocket adjacent to marking

-2- using waterproof pen.
– Turn idler gear/balance shaft to markings -arrow- (do not

slacken bolt -1-).
• The links with coloured markings must be positioned at the

markings on the chain sprockets.
• There is no need to note the position of any other coloured
links.
– Fit drive chain for balance shafts; links with coloured markings
-arrows- must be positioned at markings on chain sprockets.
3. Chain drive 103

– Install guide rail -1- and tighten bolts -arrows-.
– Fit camshaft timing chain so that coloured markings -arrows-

are positioned on camshaft journals.
– Fit oil pump chain onto three-part chain sprocket assembly.

– Swivel three-part chain sprocket assembly towards engine in
direction of -arrow- and secure on crankshaft. The marks
-arrows- must align.

1. Screw clamping pin - T10531/2- into crankshaft and hand-

tighten. (Illustration shows vehicle with alternator.)
2. Attach turning-over tool - T10531/3- . Screw on flange nut -
T10531/4- and hand-tighten. Move turning-over tool back
and forth slightly using open-end spanner, 32 mm; at the
same time, tighten flange nut until chain sprocket is firmly
seated on teeth of crankshaft. Now (and not before) tighten
tensioning bolt -A-.
– Position link of drive chain for balance shafts with coloured

marking -arrow- at marking on three-part chain sprocket as‐
sembly. Install tensioning rail -1- and guide rail -2-. Tighten
bolts -3-.
– Install chain tensioner -1-.
– Check setting again; links with coloured markings -arrows-

must be positioned at markings on chain sprockets.
3. Chain drive 105

– Fit camshaft timing chain onto inlet camshaft, exhaust cam‐

shaft and crankshaft. Position links with coloured markings
-arrows- at markings on chain sprockets.
– Install guide rail -2- and tighten bolts -1-.
– Install top guide rail -1-.


– Use assembly tool - T40266- to turn exhaust camshaft slightly
in direction of -arrow A- and slide camshaft clamp - T40271/1-
out of teeth on chain sprocket in direction of -arrow B-.
– Release camshaft in direction of -arrow C- until timing chain is
in contact with guide rail -1-. Hold camshaft in this position,
install tensioning rail -2- and tighten bolt -3-.
– Install chain tensioner -1- and tighten bolts -arrows-.
– Turn inlet camshaft in direction of -arrow 1- with assembly tool

- T40266- , slide camshaft clamp - T40271/2- out of teeth on
chain sprocket in direction of -arrow 2- and release camshaft.
– Remove camshaft clamp - T40271/2- .
3. Chain drive 107

– Check setting; links with coloured markings -arrows- must be

positioned at markings on chain sprockets.
– Install chain tensioner -2- and tighten bolt -1-. Remove locking
pin - T40011- ; support wire must come into contact with open‐
ing -arrow- on sump (top section).
– Fit and tighten bolts -arrows-. Tightening torque


– Check whether spring pin -1- is fitted. (Not fitted on all bearing
saddles.)

• Carefully attach bearing saddle without tilting it.

they make contact.

– Install timing valves ⇒ Item 7 (page 87) .
– Turn the engine carefully at least 2 rotations to ensure that
none of the valves make contact when the starter is operated.
Note:
Due to the ratio, the timing chain links with coloured markings are
no longer aligned after the engine has been turned.
note the following:
– Detach turning-over tool and install timing chain cover (bot‐
tom) ⇒ page 81 .
♦ Drive train
Tightening torques
♦ ⇒ “3.2 Exploded view - drive chain for balance shaft”,
page 89
3.5 Checking timing chain

3. Chain drive 109

Procedure
noise insulation .
– If fitted, unscrew bolt -arrow-; to do so, unfasten closure plate
for bumper cover at lock carrier ⇒ General body repairs, ex‐
terior; Rep. gr. 63 ; Bumper (front); Exploded view - bumper
cover .
– Press coolant pipes to the side.
– Remove sealing plug -arrow-. Sealing plug must be renewed.

NOTICE
– Turn crankshaft only in direction of normal engine rotation

-arrow- using ratchet wrench (21 mm) - T40263- , adapter -
T40314- and socket (24 mm).
– Turn vibration damper in direction of engine rotation until pis‐

ton of chain tensioner has extended as far as it will go in
direction of -arrow-.
– Count visible teeth of piston.
Note:
Visible teeth are all teeth to the right of the chain tensioner hous‐
ing -arrow-.
• The timing chain must not be renewed if six or fewer teeth are
visible.
• If six or fewer teeth are visible and there is an entry in the event
memory: Adapt chain elongation (⇒ Vehicle diagnostic tester ,
01 - Chain elongation adaption diagnosis ) and delete
event memory.
• If seven or more teeth are visible: Renew camshaft timing
chain ⇒ page 96 .
Tightening torques
3.6 Checking valve timing

3. Chain drive 111

♦ Dial gauge set, 4-part - VAS 6341-
♦ Adapter for dial gauge - T10170 A-
Procedure
noise insulation .

– If fitted, unscrew bolt -arrow-; to do so, unfasten closure plate

for bumper cover at lock carrier ⇒ General body repairs, ex‐
terior; Rep. gr. 63 ; Bumper (front); Exploded view - bumper
cover .
– Press coolant pipes to the side.
– Apply ratchet wrench (21 mm) - T40263- , adapter - T40314-

and socket (24 mm) to vibration damper to turn crankshaft in
direction of engine rotation until markings -arrows- are posi‐
tioned almost at top.
– Remove spark plug for cylinder 1 with spark plug socket and
extension - 3122B- .
– Screw dial gauge adapter - T10170/A- into spark plug thread

as far as stop.
– Insert dial gauge from dial gauge set, 4-part - VAS 6341- with
extension - T10170A/1- as far as stop and secure with locking
nut -arrow-.
– Turn crankshaft slowly in normal direction of engine rotation
until needle in dial gauge has reached maximum position.
When needle has reached maximum position (i.e. turning
point in dial gauge), piston is at »TDC«.
Note:
♦ If the crankshaft has been turned beyond the “TDC” position,
it must be turned two rotations further in normal direction of
engine rotation. Do not turn engine in opposite direction to
normal rotation.
♦ The combination of ratchet wrench (21 mm) - T40263- , adapt‐
er - T40314- and socket (24 mm) can be fitted onto the
vibration damper better than the counterhold tool - T10355-
described below.
3. Chain drive 113

With markings on cylinder head cover

• Notch on vibration damper must align with arrow marking on
timing chain cover (bottom) -arrow-.
• Markings -1- on camshaft chain sprockets must be positioned
opposite markings -2 and 3- on cylinder head.
Without markings on cylinder head cover

• Notch on vibration damper and marking on cover for timing
chains (bottom) must be aligned -arrow-.
• The markings -1- on the camshaft chain sprockets must face
upwards.
– Measure distance from edge -1- to marking -2- on exhaust

camshaft chain sprocket.
• Specification: 74 ... 77 mm

– If specification is obtained, measure distance between mark‐

ing on exhaust camshaft chain sprocket -3- and marking on
inlet camshaft chain sprocket -4-.
• Specification: 124 ... 127 mm
Note
If the timing chain is one tooth out of position, this results in a

deviation of approx. 6 mm from specification. The timing chain
must be refitted if it is not in the correct position.
Tightening torques
3. Chain drive 115

4 Cylinder head
1 - Dowel pin
tion: part number must
face cylinder head
coolant and engine oil
adaption ⇒ Vehicle di‐
agnostic tester 01 -
Engine electronics,
functions , 01 -
Chain elongation
adaption diagnosis
3 - Cylinder head
⇒ page 118
⇒ page 118
❑ Always renew cylinder
head cover as well
❑ After removal or renew‐
al, perform adaption
tester 01 - Engine
electronics, func-
tions , 01 - Chain
elongation adaption
diagnosis
4 - Bolt
❑ Slackening ⇒ page 117
❑ Tightening ⇒ page 118
5 - Bolt
❑ 9 Nm
6 - Heat shield
7 - Bolt
❑ 9 Nm
8 - Bolt
❑ 9 Nm
9 - Connection

10 - O-ring
11 - Cylinder head bolt
❑ Tightening ⇒ page 118
12 - O-ring
13 - Connection
14 - Bolt
❑ 9 Nm
16 - Bolt
❑ 10 Nm +90°
17 - Separating plate
19 - Bolt
❑ 10 Nm +90°
20 - Dowel pin
Slackening cylinder head bolts

– Slacken cylinder head bolts in the sequence -1 ... 10-.

Tightening torques and sequence for cylinder head

angle.
• Bolts - difference:
• Bolt without collar
• Bolt with collar -arrow-

tion
2. -1 … 10- Without collar: 40 Nm;
with collar: 50 Nm (difference
⇒ page 118 )
3. -1 … 10- Turn 90° further
4. -1 … 10- Turn 90° further
5. -Arrows- 10 Nm
6. -Arrows- Turn 90° further

♦ Max. permissible distortion: 0.05 mm


♦ Special wrench (Polydrive) - T10070-

♦ Bit XZN 12 - T40270-
♦ Open end spanner insert, AF 24

Removing
gr. 15 ; Cylinder head; Removing and installing cylinder head .
• All open inlet and exhaust ports must be sealed with suitable
plugs (e.g. from engine bung set - VAS 6122- ).

– If necessary, move electrical wiring harness -4- clear.

manifold.
Bracket for ancillaries - version 1:

-item 4-
Bracket for ancillaries - version 2:


– Release hose clip -1- and detach coolant hose (rear).
- G62- .

– Remove spark plugs with spark plug spanner - 3122B- .

– Use special wrench, long reach - T10070- / bit XZN 12 -
T40270- to remove cylinder head bolts in the sequence
-1 ... 10-.
• Make sure all hoses/pipes and wiring on component are dis‐
connected.
• Make sure tensioning rail and guide rail are not damaged when
lifting off cylinder head.
– Take off cylinder head.
– Place cylinder head onto soft surface (foam plastic).
– Seal off all open passages in the intake and exhaust system
with clean cloths or plugs (thoroughly cleaned) from engine
bung set - VAS 6122- .
Installing
NOTICE
Risk of damage to sealing surfaces if handled incorrectly.
– Carefully remove sealant residue from cylinder head and
cylinder block.

• Do NOT use abrasive materials (sandpaper, sanding discs,

• Sealing surface must not be raised.
• Dark discolouration does not have to be removed.
• When removing sealant residue, make sure none of the resi‐
• Ensure that nearby workspaces are kept clean and that the
• Use of non-approved abrasive materials can lead to subse‐
CAUTION

and cylinder block using a commercially available blade scra‐
per (blade width at least 40 mm).
angle.
• Renew self-locking nuts, as well as seals, gaskets and O-rings
after removing.
gasket.
• When installing an exchange cylinder head, the plastic pro‐
tectors fitted to protect the open valves should not be removed
until the cylinder head is ready to be fitted.
• When installing an exchange cylinder head, the contact sur‐
faces between roller rocker finger and cam must be oiled
before installing the cylinder head cover.
change engine oil and coolant in entire cooling system.

– Place cylinder head gasket in position.

dead centre and then turn crankshaft back slightly.
• Make sure that components are not damaged by timing chain
when rotating crankshaft.
– Fit and tighten cylinder head bolts.
Note:
after repair work.
note the following:


position.
– Install camshafts ⇒ page 132 .
ing battery .
– Install spark plugs ⇒ page 291 .
– Change engine oil ⇒ page 169 .
– Fill cooling system with fresh coolant ⇒ page 201 .
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Cylinder head;
Removing and installing cylinder head
moving or renewing cylinder head.
♦ Drive train
Tightening torques
♦ ⇒ Fig. ““Tightening torques and sequence for cylinder head”“ ,
page 118


♦ Adapter - V.A.G 1763/13- (not illustrated)

Test sequence
gr. 15 ; Cylinder head; Checking compression .
– Remove ignition coils ⇒ page 292 .
1- For FSI injectors in cylinder head
2- For MPI injectors in intake manifold (if fitted)

– Screw adapter - V.A.G 1381/13- into corresponding spark plug

hole, as shown, and connect compression tester -
V.A.G 1763- .
to use tester).
– Press down accelerator pedal completely and simultaneously
operate starter until pressure no longer increases on tester
display.
When new 11.0 … 14.0
Wear limit 7.0
Assembling
– Install ignition coils ⇒ page 292 .
– Erase any entries in engine control unit event memory result‐
ing from testing ⇒ Vehicle diagnostic tester.
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Cylinder head;
Checking compression

5 Valve gear
ment”, page 148
page 149

Part I
Part II ⇒ page 130
1 - Exhaust valve
⇒ page 161
⇒ page 160
2 - Cylinder head
head cover as well
4 - Valve spring
6 - Valve cotters
7 - Hydraulic compensation el‐
ement
❑ Lubricate contact sur‐
face
8 - Securing clip
❑ For hydraulic compen‐
sation element
stalling camshaft”,
page 132
❑ Mark installation posi‐
tion for re-installation
❑ Check roller bearings
for ease of movement
10 - Exhaust camshaft

❑ Check radial clearance with Plastigauge (roller rocker fingers removed)

❑ Radial clearance: 0.024 ... 0.066 mm
❑ Runout: max. 0.04 mm
❑ After removal or renewal, perform adaption ⇒ Vehicle diagnostic tester 01 - Engine electronics,
functions , 01 - Chain elongation adaption diagnosis
11 - Spring
12 - Ball
❑ For slider
❑ With integrated camshaft bearings
❑ Clean sealing surface; machining not permitted
❑ Remove old sealant residues
❑ Removing ⇒ “5.2 Removing and installing camshaft”, page 132
❑ Always renew cylinder head as well
14 - Bolt
❑ Tightening sequence ⇒ page 130
15 - Inlet camshaft
16 - Dowel pins
17 - Dowel pins
18 - Inlet valve
❑ Do not machine, only grinding-in is permitted
❑ Valve dimensions ⇒ page 161
❑ Checking valve guides ⇒ page 160
Loosening cylinder head cover

– Loosen cylinder head cover bolts in the sequence -1 ... 6-.
5. Valve gear 129

Tightening torques and sequence for cylinder head cover

angle.
• Take care to keep cylinder head cover straight.
tion
2. -1 … 6- 8 Nm
Different versions of valve stem oil seal

A - Valve stem oil seal with one sealing lip -A-
♦ For inlet and exhaust sides
B - Valve stem oil seal with two sealing lips -B-
♦ Only for exhaust side on some engines; for allocation refer to
⇒ Electronic parts catalogue
Part II
Part I ⇒ page 128

1 - Cylinder head
head cover as well
2 - O-ring
ly; supplied with
gine oil
3 - Actuator for camshaft ad‐
justment
♦ Actuator 1 for camshaft ad‐
justment - F366-
justment - F367-
justment - F368-
justment - F369-
justment - F370-
justment - F371-
justment - F372-
justment - F373-
⇒ page 148
❑ Bringing into installation
position ⇒ page 149
4 - Bolt
❑ 5 Nm
5 - Ball stud
❑ 9 Nm
6 - O-ring
7 - Sealing plug
8 - O-ring
10 - Bolt
11 - Oil separator
5. Valve gear 131

12 - Bolt
13 - Gasket
14 - Vacuum pump
❑ Removing and installing ⇒ Brake system; Rep. gr. 47 ; Vacuum system; Removing and installing vacuum
pump
15 - Bolt
❑ Tightening torque ⇒ Brake system; Rep. gr. 47 ; Vacuum system; Exploded view - vacuum pump
16 - Gasket
17 - O-ring
19 - Bolt
20 - Bolt
❑ 9 Nm
21 - Bracket
❑ For activated charcoal filter solenoid valve 1 - N80-



5. Valve gear 133


Removing
• Sealing surfaces at bottom of cylinder head cover and top of
cylinder head must not be machined.
• The camshaft bearings are integrated into the cylinder head
and cylinder head cover. The timing chain must be slackened
before removing the cylinder head cover.
gr. 15 ; Valve gear; Removing and installing camshaft .
– Remove oil separator ⇒ page 182 .
– Remove high-pressure pump ⇒ page 267 .
– Remove vacuum pump ⇒ Brake system; Rep. gr. 47 ; Vac‐
uum system; Removing and installing vacuum pump .
NOTICE

and socket (24 mm) to turn crankshaft -arrow- until vibration
damper is at “TDC” position.

• The markings -arrows- on the camshafts must face upwards.

– If the markings do not face upwards, turn crankshaft one turn
further.

– Use a waterproof pen to mark the position of the camshaft
sprockets -1- on the cylinder head cover -arrows-, as shown
in illustration.
All engine versions (continued)
Note:

tools:

5. Valve gear 135

– Screw in assembly lever - T40243- -arrows-.

and hold in place.
– Hold chain tensioner in position with locking tool - T40267- .


– Bolt camshaft clamp - T40271/2- onto cylinder head and slide

it into teeth of chain sprocket in direction of -arrow 2-. If nec‐
essary, rotate inlet camshaft using assembly tool - T40266-
-1-.

bly tool - T40266- and hold in place. Remove bolt -1- and guide
tensioning rail -2- downwards. Continue turning camshaft
clockwise -arrow A- until camshaft clamp - T40271/1- can be
pressed into teeth on chain sprocket -arrow B-.
– Check installation position -C- of camshaft clamp - T40271/1- .
– Use screwdriver to release catch -arrow- and press off guide

rail -1- towards front.

– Mark camshaft chain sprockets relative to camshaft clamp -
T40271/1- and camshaft clamp - T40271/2- -arrows-.
– If camshafts are renewed, markings must be transferred to
new camshafts.
5. Valve gear 137


– Press retainer for oil pump chain tensioner in direction of
-arrow- and lock in place using locking pin - T40011- .
– Unscrew bolt -1- and remove chain tensioner.
– Unscrew bolts -1- and remove guide rail -2-.

– Detach camshaft timing chain from sprockets and guide it
downwards.
– Attach turning-over tool - T10531/3- . In “TDC” position, flat

surface -1- is positioned at top (facing cylinder head).
– Screw on flange nut - T10531/4- . Turn crankshaft 90° anti-
clockwise out of “TDC” position using open-end spanner, 32
mm.
– Turn inlet camshaft in direction of -arrow 1- with assembly tool

- T40266- , slide camshaft clamp - T40271/2- out of teeth on
chain sprocket in direction of -arrow 2- and move camshaft into
rest position.

– Turn exhaust camshaft in direction of -arrow 1- with assembly

tool - T40266- , slide camshaft clamp - T40271/1- out of teeth
on chain sprocket in direction of -arrow 2- and move camshaft
into rest position.
– Remove cylinder head cover bolts in the sequence -1 ... 6-.
– Prise cylinder head cover -2- off using tool such as screwdriver
-1-, starting from chain side.
– Detach cylinder head cover.
– Detach camshafts and cover exposed parts of engine.
Installing
• Sealing surfaces must be free of oil and grease.
• Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly.
– Remove sealant residue from groove in cylinder head cover
and from sealing surfaces.
5. Valve gear 139

If crankshaft has been rotated:

– Turn crankshaft at hexagon flats -2- into “TDC” position.
• In “TDC” position, the flat surface -1- is aligned with an imag‐
inary vertical line between the camshaft chain sprockets.
– Then turn crankshaft 90° anti-clockwise again out of “TDC”
position.
– Bring pins of actuators for camshaft adjustment into installa‐
tion position ⇒ page 149 .
– Oil running surfaces of both camshafts.
CAUTION
Ball for slider may spring out - risk of eye injury.
– Fit inlet camshaft -A- in cylinder head. Rotate cams of cylinder

4 -arrows- so that they face upwards.
– Fit exhaust camshaft in cylinder head cover, as shown in il‐

lustration. Pairs of cams -A- and -B- must be pushed together.
– Rotate exhaust camshaft until markings -A- and -B- are

aligned.
Note
♦ Illustration shows version with marking -B- made at factory.

♦ If you are working on a version for which you had to make a
marking, the marking -A- must be opposite the marking on the
cylinder head that you made yourself.

– Apply sealant onto clean sealing surface -arrows- of cylinder

head cover, as shown in illustration.
NOTICE
system.
♦ Thickness of sealant bead: 1.5 ... 2.5 mm

– Hold camshaft in position and place cylinder head cover on
cylinder head with camshaft fitted.
– Press lightly on cylinder head cover with your hand and rotate
camshafts slightly until cylinder head cover comes into contact
with cylinder head such that it is free of tension.
– Renew bolts for cylinder head cover after removal.
– Tighten bolts in several stages; tightening sequence
⇒ page 130 .
• Take care to keep cylinder head cover straight.
With markings on cylinder head cover

– Turn inlet camshaft in direction of -arrow A- using assembly
tool - T40266- until markings -1- and -2- are aligned. Slide
camshaft clamp - T40271/2- into teeth of chain sprocket in di‐
rection of -arrow B-.

bly tool - T40266- until markings -1- and -2- are aligned. Slide
camshaft clamp - T40271/1- into teeth of chain sprocket in di‐
rection of -arrow B-. Marking -2- is offset slightly to the right.
5. Valve gear 141


– Turn inlet camshaft in direction of -arrow 1- until marking -3-
aligns with camshaft clamp - T40271/2- .
– Slide camshaft clamp - T40271/2- into teeth of chain sprocket
in direction of -arrow 2-.
– Turn exhaust camshaft in direction of -arrow 1- until marking

-3- aligns with camshaft clamp - T40271/1- .
– Slide camshaft clamp - T40271/1- into teeth of chain sprocket
in direction of -arrow 2-.

– Turn crankshaft at hexagon flats -2- into “TDC” position.
• In “TDC” position, the flat surface -1- is aligned with an imag‐
inary vertical line between the camshaft chain sprockets.
Installing camshaft timing chain

are positioned on camshaft journals.


shaft and crankshaft. Position links with coloured markings
-arrows- at markings on chain sprockets.
– Install guide rail -2- and tighten bolts -1-.
– Install top guide rail -1-.
5. Valve gear 143


I - Use assembly tool - T40266- to turn exhaust camshaft slightly
in direction of -arrow A- and slide camshaft clamp - T40271/1- out
of teeth on chain sprocket in direction of -arrow B-.
II - Release camshaft in direction of -arrow C- until timing chain is
in contact with guide rail -1-. Hold camshaft in this position, install
tensioning rail -2- and tighten bolt -3-. Then release camshaft.
– Use assembly tool - T40266- to turn inlet camshaft in direction

of -arrow 1- until it is possible to slide camshaft clamp -
T40271/2- out of teeth on chain sprocket in direction of
-arrow 2-. Then release camshaft.
– Remove camshaft clamps - T40271/1- and -T40271/2- .


– Check whether spring pin -1- is fitted. (Not fitted on all bearing
saddles.)

• Carefully attach bearing saddle without tilting it.

they make contact.

– Install chain tensioner -2-. Support wire must come into con‐
tact with opening -arrow- on sump (top section). Tighten bolt
-1- and remove locking pin - T40011- .
– Checking adjustment:
• Links with coloured markings must be positioned opposite
markings -arrows- on chain sprockets.
– Turn engine two rotations in direction of engine rotation.
Note:
5. Valve gear 145

– Unscrew flange nut - T10531/4- and remove turning-over tool

- T10531/3- .
– Install timing chain cover (bottom) ⇒ page 81 .
Checking valve timing - with markings on cylinder head cover

Note:
damper better than the counterhold tool - T10355- shown in the
illustration.
• Notch on vibration damper must align with arrow marking on
timing chain cover (bottom) -arrow-.
• Markings -1- on camshaft chain sprockets must be aligned
with markings -2 and 3- on cylinder head cover.

Checking valve timing - without markings on cylinder head cover

Note:
damper better than the counterhold tool - T10355- shown in the
illustration.
• The markings made on the cylinder head cover -arrows- must
align with the markings on the chain sprockets -1-.
• Notch on vibration damper must align with marking on timing
chain cover (bottom) -2-.
Note
If the markings you have made are no longer visible, check the
valve timing ⇒ page 111 .

– Install vacuum pump ⇒ Brake system; Rep. gr. 47 ; Vacuum
system; Removing and installing vacuum pump .
– Install high-pressure pump ⇒ page 267 .
– Install oil separator ⇒ page 182
NOTICE
Risk of damage to valves and piston crowns if work has been
performed on valve gear.
– After installing the camshaft, wait at least 30 minutes before
starting the engine as the hydraulic compensation elements
need time to settle.
– Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is op‐
erated.

engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Valve gear; Re‐
moving and installing camshaft
♦ Drive train
5. Valve gear 147

Tightening torques
♦ ⇒ “5.1 Exploded view - valve gear”, page 128

♦ Spacers - T40191-
♦ Safety goggles
Installing
CAUTION
Ball for slider may spring out - risk of eye injury.
– Insert spring -1- in camshaft.

– Place ball -2- on spring in camshaft.
– Push ball and spring downwards in direction of -arrow A- with
spacer - T40191/1- and hold in place.
– Push slider -3- in direction of -arrow B-.

camshaft adjustment
Removing
gr. 15 ; Valve gear ; Removing and installing actuators for cam‐
shaft adjustment.

– Unplug relevant electrical connector -2-.

– Unscrew bolt -1- and detach actuator for camshaft adjustment.
Installing
• Check O-rings for damage.
• Pin of actuator for camshaft adjustment must be brought into

installation position.
– Press down pin of actuator for camshaft adjustment -arrow- by
hand.
• Pin of actuator must not be in extended position.
– Lubricate O-rings with engine oil.
moving and installing actuators for camshaft adjustment
Tightening torques

Removing
gr. 15 ; Valve gear; Removing and installing camshaft control
valve 1 - N205- .
– Remove engine cover panel (if necessary) ⇒ page 15 .
Note:
5. Valve gear 149


1 - For exhaust camshaft control valve 1 - N318-
– Remove bolts -arrows- and detach camshaft control valves:
2 - Exhaust camshaft control valve 1 - N318-
Installing
• Renew seals and O-rings after removing.
– Use engine oil to lubricate O-rings on sealing surface for cam‐
shaft control valve.
moving and installing camshaft control valve 1 - N205- .
Tightening torques

seals


♦ Valve stem seal puller - 3364-
♦ Valve stem oil seal fitting tool - 3365- for valve stem oil seal
with one sealing lip ⇒ page 130
♦ Valve stem oil seal fitting tool - T40376/1- for valve stem oil
seal with two sealing lips ⇒ page 130
5. Valve gear 151


A-
♦ Guide plate for 2.0 ltr. and 3.0 ltr. FSI engine - VAS 5161/19C-
Procedure
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for re-installation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
Machining guide plate:

– Check whether there is a recess -arrow-.
– If necessary, machine guide plate for 2.0 ltr. and 3.0 ltr. FSI
engine - VAS 5161/19C- -arrow- so that guide plate rests on
cylinder head and guide pin -1- does not make contact.

Continued:
– Secure guide plate for 2.0 ltr. and 3.0 ltr. FSI engine - VAS
5161/19C- to cylinder head with knurled screws - VAS
5161/12- as shown.
– Screw adapter - T40012- into spark plug thread.

– Connect to compressed air supply of at least 6 bar.
– Knock loose sticking valve cotters using punch - VAS 5161/3-
and a plastic-headed hammer.
Inlet side:
– Screw snap-in device - VAS 5161/6- with engaging fork - VAS
5161/5- into centre thread on guide plate for 2.0 ltr. and 3.0 ltr.
FSI engine - VAS 5161/19C- .
Exhaust side:
5161/5- into outer thread on guide plate for 2.0 ltr. and 3.0 ltr.
Continued:
– Insert assembly cartridge - VAS 5161/8- into guide plate for
2.0 ltr. and 3.0 ltr. FSI engine - VAS 5161/19C- .
– Engage pressure fork - VAS 5161/2- on snap-in device - VAS
5161/6- .
– Press down assembly cartridge - VAS 5161/8- and at the same
time, turn knurled screw of assembly cartridge - VAS 5161/8-
– Release pressure fork - VAS 5161/2- .
– Take out assembly cartridge - VAS 5161/8- .
5. Valve gear 153

– Pull off valve stem oil seal with valve stem seal puller - 3364- .
• To avoid damaging the new valve stem oil seal -4- during in‐
stallation, fit the assembly sleeve -3- onto the valve stem -2-.
• Use either pusher - 3365- or pusher -T40376/1- , depending
on version/manufacturer of valve stem oil seal.
– Insert valve stem oil seal into valve stem oil seal fitting tool
-5- and use assembly sleeve to press it carefully onto valve
– Insert valve spring and valve spring plate.
– Set up removal and installation device for valve cotters - VAS
5161 A- as shown.
Inlet side:

Exhaust side:
Continued:
• If valve cotters have been removed from assembly cartridge,
they need to be put into insertion device - VAS 5161/18- first.
• Press assembly cartridge -VAS 5161/8- onto insertion device
from above and pick up valve cotters.
– Use pressure fork - VAS 5161/8- to press down assembly car‐
tridge - VAS 5161/2- , then turn knurled screw of assembly
cartridge back and forth while pulling upwards.
– Release pressure fork - VAS 5161/2- with knurled screw in
pulled position.
– Detach removal and installation device for valve cotters - VAS
5161A- .
Assembling

5. Valve gear 155


A-
♦ Guide plate for 2.0 ltr. and 3.0 ltr. FSI engine - VAS 5161/19C-


Procedure
and gearbox support - VAS 6095A- .
supply.
where valve stem oil seal is to be removed.
with valve heads.
Machining guide plate:

– Secure guide plate for 2.0 ltr. and 3.0 ltr. FSI engine - VAS
5161/19C- to cylinder head with knurled screws - VAS
5161/12- as shown.
– Insert drift -VAS 5161/3- into guide plate and use plastic-head‐
5. Valve gear 157

Inlet side:
5161/5- into centre thread on guide plate for 2.0 ltr. and 3.0 ltr.
Exhaust side:
5161/5- into outer thread on guide plate for 2.0 ltr. and 3.0 ltr.
Continued:
– Insert assembly cartridge - VAS 5161/8- into guide plate for
2.0 ltr. and 3.0 ltr. FSI engine - VAS 5161/19C- .
– Engage pressure fork - VAS 5161/2- on snap-in device - VAS
5161/6- .
– Press down assembly cartridge - VAS 5161/8- and at the same
time, turn knurled screw of assembly cartridge - VAS 5161/8-
– Release pressure fork - VAS 5161/2- .
– Take out assembly cartridge - VAS 5161/8- .

• Use either pusher - 3365- or pusher -T40376/1- , depending
– Set up removal and installation device for valve cotters - VAS
5161 A- as shown.
Inlet side:
Exhaust side:
Continued:
• If valve cotters have been removed from assembly cartridge,
they need to be put into insertion device - VAS 5161/18- first.
– Use pressure fork - VAS 5161/8- to press down assembly car‐
tridge - VAS 5161/2- , then turn knurled screw of assembly
cartridge back and forth while pulling upwards.
– Release pressure fork - VAS 5161/2- with knurled screw in
pulled position.
– Detach removal and installation device for valve cotters - VAS
5161- .
5. Valve gear 159



Test sequence
– Insert valve into guide. End of valve stem must be flush with
guide. Only insert inlet valve into inlet valve guide and exhaust
valve into exhaust valve guide, as the stem diameters are dif‐
ferent.

Wear limit
Inlet valve guide Exhaust valve guide
0.60 mm 0.60 mm
• If the wear limit is exceeded, repeat the measurement with
new valves. Renew cylinder head if wear limit is still exceeded.
6.2 Checking valves

faces.


Valve dimensions
in is permitted.
∅a mm 33.85 ± 0.10 28.0 ± 0.1
∅b mm 5.98 ± 0.01 5.96 ± 0.01
c mm 104.0 ± 0.2 101.9 ± 0.2
α ∠° 45 45

17 – Lubrication
cautions .

2 Sump/oil pump
page 169
er G266 ”, page 178

⇒ “2.1.1 Exploded view - sump/oil pump, version 1”, page 163
⇒ “2.1.2 Exploded view - sump/oil pump, version 2”, page 166
2.1.1 Exploded view - sump/oil pump, version

1
• If large quantities of metal shavings or particles are found in
• Oil spray jet and pressure relief valve ⇒ page 66

1 - Nut
❑ 9 Nm
sender - G266-
⇒ page 178
3 - Seal
❑ Renew
4 - Bolt
sequence
⇒ Fig. ““Metal sump
(bottom section) - tight‐
ening torque and se‐
5 - Gasket
❑ Only for sump (bottom
section), plastic version
6 - O-ring
gine oil
7 - Bolt
❑ 4 Nm +45°
8 - Suction pipe
9 - O-ring
10 - Oil pump
11 - Centring sleeve
12 - O-ring
❑ Renew
13 - Bolt
15 - Chain tensioner
16 - Drive chain for oil pump
❑ Mark direction of rotation before removing
17 - Bolt
❑ 9 Nm

18 - Cylinder block
19 - Oil strainer
22 - Bolt
⇒ Fig. ““Sump (top section) - tightening torques and sequence”“ , page 166
23 - O-ring
24 - Bolt
❑ 4 Nm +45°
25 - Oil return pipe
26 - Bolt
❑ 8 Nm +90°
27 - Baffle plate
28 - Bolt
❑ 4 Nm +45°
30 - O-ring
❑ Seal for sheet-metal version of sump (bottom section)
❑ O-ring for plastic version of sump (bottom section)
❑ Lubricate O-ring with engine oil
31 - Oil drain plug or sealing plug
❑ Oil drain plug for sheet-metal version of sump (bottom section)
❑ Oil drain plug: 30 Nm
❑ Sealing plug for plastic version of sump (bottom section)
❑ Tighten sealing plug as far as stop

Metal sump (bottom section) - tightening torque and sequence

angle.
tion
2. -1 … 19- 8 Nm
3. -1 … 19- Turn 90° further
Plastic sump (bottom section) - tightening torques and sequence

angle.
tion
2. -1 … 19- 8 Nm
3. -1 … 19- Turn 90° further
Sump (top section) - tightening torques and sequence

angle.
tion
1. -1 … 14- 8 Nm
2. -1, 2- Turn 180° further
4. -10- Turn 180° further
5. -11 … 14- Turn 90° further
2.1.2 Exploded view - sump/oil pump, version 2

• If large quantities of metal shavings or particles are found in
must be cleaned carefully, and the oil spray jets, engine oil
cooler and oil filter must be renewed in order to prevent further
damage occurring later.
• Oil spray jet and pressure relief valve ⇒ page 66

1 - Nut
❑ 9 Nm
sender - G266-
⇒ page 178
3 - Seal
4 - Bolt
⇒ page 168
⇒ page 171
6 - O-ring
gine oil
7 - Sealing plug
❑ Tighten as far as stop
8 - Gasket
9 - Bolt
❑ 4 Nm +45°
10 - Suction pipe
11 - O-ring
12 - Oil pump
❑ 2x
❑ For oil pump
14 - O-ring
15 - Bolt

18 - Bolt
❑ 9 Nm
20 - Cylinder block
21 - Bolt
❑ 4 Nm +45°
22 - Baffle plate
24 - Bolt
25 - Plug
❑ 3x
26 - Oil strainer
27 - Bolt
❑ 8 Nm +90°
28 - O-ring
Sump (bottom section) - tightening torques and sequence

angle.
tion
2. -1 … 17- 8 Nm
3. -1 … 17- Turn 90° further


angle.
Aluminium or steel bolts may be installed, depending on version.
A - aluminium bolts:
tion
1. -1 … 18- 8 Nm
2. -1 … 13- Turn 45° further
3. -14 … 18- Turn 90° further
B - steel and aluminium bolts:
– In this case, bolts 1 ... 13 are steel bolts and 14 ... 18 are alu‐
minium bolts.
tion
1. -1 … 13- 15 Nm
2. -14 … 18- 8 Nm
3. -1 … 18- Turn 90° further
2.2 Engine oil

♦ Draining and filling up engine oil, checking oil level, removing
and installing oil filter element ⇒ 4-cylinder direct injection en‐
gine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 17 ; Sump/oil pump;
Engine oil
tenance tables .

section)
⇒ “2.3.1 Removing and installing sump (bottom section) - version
1”, page 169
⇒ “2.3.2 Removing and installing sump (bottom section) - version
2”, page 171
2.3.1 Removing and installing sump (bottom

section) - version 1
gr. 17 ; Sump/oil pump; Removing and installing sump (bottom
section) .

– Unplug connector from oil level and oil temperature sender -

G266- -arrow-.

– Take off sump: if necessary loosen it by striking lightly with a
rubber hammer.
– If renewing sump (bottom section), remove oil level and oil
temperature sender - G266- ⇒ page 178 .
Installing
For vehicles with sump, sheet-metal version
Note
♦ Note expiry date of silicone sealant.

♦ The sump must be installed within 5 minutes after applying the
silicone sealant.
♦ Renew the bolts tightened with specified tightening angle.
♦ Renew seals, gaskets and self-locking nuts.
– Spray sealing surface with sealant remover and wait for it to

take effect.
– Remove sealant remaining on sump (top section) with flat
scraper.
CAUTION
– Remove sealant residue on sump (bottom section) -1- using

rotating plastic brush or similar.

– Cut off nozzle of tube at front marking (∅ of nozzle approx.

3 mm).
– Apply the bead of silicone sealant onto the clean sealing sur‐
face of the sump (bottom section), as illustrated.
♦ Thickness of sealant bead: 2 ... 3 mm
Note
♦ The sump must be installed within 5 minutes after applying the

silicone sealant.
♦ The bead of sealant must not be thicker than specified, other‐
wise excess sealant can enter the sump and obstruct the
strainer in the oil intake pipe.
♦ After fitting sump assembly, the sealant must dry for approx.
30 minutes. Then (and only then) fill the engine with engine
oil.
– Immediately fit sump (bottom section) and tighten bolts; tight‐

ening sequence ⇒ page 166 .
Vehicles with plastic version of sump (bottom section):
– Fit sump (bottom section) with new gasket and tighten bolts
⇒ page 166 .
For all vehicles
– Fill with engine oil and check oil level ⇒ page 169 .
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 17 ; Sump/oil pump;
Removing and installing sump (bottom section)
Tightening torques
♦ ⇒ Fig. ““Metal sump (bottom section) - tightening torque and
♦ ⇒ Fig. ““Plastic sump (bottom section) - tightening torques and
2.3.2 Removing and installing sump (bottom

section) - version 2
Removing
gr. 17 ; Sump/oil pump; Removing and installing sump (bottom
section) .

– Unscrew bolts -1 ... 17- and detach sump (bottom section).
Installing
Removing and installing sump (bottom section)
Tightening torques
♦ ⇒ Fig. ““Sump (bottom section) - tightening torques and se‐

Removing
– Remove sump (bottom section) ⇒ page 169 .

– Sump (bottom section, version 1): Remove bolt -arrow- and

detach baffle plate.
– Using assembly tool - T10118- , pull support wire of spring for

chain tensioner in direction of -arrow- and secure in place with
locking tool - T40265- .
– Remove bolts -arrows- and remove oil pump.

Installing
• Sump (bottom section, version 1): Renew baffle plate
⇒ Item 27 (page 165) after removal.
– Check that both centring sleeves are fitted in oil pump.
– Before installing, check passages in sump (top section) and
strainer ⇒ Item 26 (page 168) in oil pump for dirt.
– Guide oil pump sprocket into drive chain and install oil pump.

NOTICE
Risk of damage to engine if drive chain for oil pump is not ten‐
sioned correctly.
– Ensure that support wire for spring engages correctly on cast
projection on sump (top section).

chain tensioner in direction of -arrow- and remove locking tool
- T40265- .
– Check position of chain tensioner support wire.

• The support wire -2- must rest on cast projection -1- on sump
(top section), as shown -arrow-. (Shown with timing chain cov‐
er (bottom) removed.)
– Sump (bottom section, version 1): Fit and secure baffle plate
⇒ Item 27 (page 165) .
– Install sump (bottom section) ⇒ page 169 .
Tightening torques

tion)
♦ Safety goggles
Removing
• Vehicles without high-voltage system: Gearbox removed ⇒
Gearbox; Rep. gr. 34 ; Removing and installing gearbox; Re‐
moving gearbox , or ⇒ Gearbox; Rep. gr. 37 ; Removing and
installing gearbox; Removing gearbox
• Vehicles with high-voltage system: Engine removed and se‐
cured to engine and gearbox support ⇒ page 12
gr. 17 ; Sump/oil pump; Removing and installing sump (top sec‐
tion) .
– Remove oil pump ⇒ page 172 .

– Unplug electrical connector -1- for valve for oil pressure control
- N428- .

• Lever off sump (top section) at gearbox end first. Be careful
when levering off.
Sump (top section), version 1:

– Unscrew bolts -1 ... 14- and remove sump (top section).

– Use the 3 bolts to pull out plugs.
Installing
angle.
• Sump (top section, version 1): Renew baffle plate
⇒ Item 27 (page 165) after removal.

CAUTION
– Remove residual sealant on sump (top section) and timing

chain cover (bottom) -1- using rotating plastic brush or similar.
• Check whether timing chain cover is deformed. For this pur‐
pose, first fit sump (top section) without sealant and determine
gap between cover and sump (top section). If the cover is de‐
formed and cannot be straightened, renew cover after instal‐
ling sump (top section).
– Check oil passages in sump (top section) and in cylinder block
for dirt.

mm).
NOTICE
system.

– Apply sealant as shown -arrow- onto clean sealing surface of
sump (top section).


– If previously removed, install baffle plate
⇒ Item 22 (page 168) .
– Apply sealant as shown -arrows- onto clean sealing surface of
sump (top section).
Continued:
– Apply sealant between cylinder block and timing chain cover
(bottom) -arrows-.
• Sump (top section) and crankcase must be flush at gearbox
end.
• The sump (top section) must be installed within 5 minutes after
applying sealant.
– Immediately fit sump (top section) and tighten bolts.
– Fit bolts -arrows-. Tightening torques ⇒ Item 18 (page 78)

note the following:
– Install oil pump ⇒ page 172 . On sump (top section, version
1), install baffle plate ⇒ Item 27 (page 165) to do so.
– Install sealing flange (gearbox end) ⇒ page 48 .
Removing and installing sump (top section)
Tightening torques
♦ ⇒ Fig. ““Sump (top section) - tightening torques and se‐


Removing
sender - G266- -3-.
Installing
Tightening torques

3 Engine oil cooler

⇒ “3.3 Removing and installing mechanical switching valve”, page
180

catalogue
⇒ page 38
2 - Gasket
3 - O-rings
gine oil
4 - Mechanical switching valve
⇒ page 179
6 - Seal
7 - Connection
8 - Bolt
❑ 8 Nm +45°

er
Removing
– Remove bracket for ancillaries ⇒ page 38 .

– Remove bolts -4 and 5- and detach engine oil cooler -3- with
gasket -2- from bracket -1- for ancillaries.
Installing
– Install engine oil cooler -3- with new seal -2-.

– Install bracket for ancillaries ⇒ page 38 .
Tightening torques
3.3 Removing and installing mechanical

switching valve
Removing
– Remove engine oil cooler ⇒ page 179 .
– Take mechanical switching valve -1- out of bracket for ancil‐
laries -arrow-.
Installing
– Lightly lubricate O-rings of mechanical switching valve with
engine oil and install.
– Install engine oil cooler ⇒ page 179 .


2 - Gasket
3 - Hose
❑ To activated charcoal fil‐
ter solenoid valve 1 -
N80-
4 - Oil separator
⇒ page 182
5 - Seal
6 - Hose
❑ To turbocharger
catalogue
7 - Bolt
❑ Thread-forming
hand so that it is
que
❑ 4 Nm
8 - Seal
9 - Bolt
❑ Thread-forming
♦ Rest-of-world vehicles ⇒ page 182
♦ China version ⇒ page 182

Oil separator - tightening torques and sequence (rest-of-world

vehicles)
Oil separator - tightening torques and sequence (China version)


Removing
– Remove ignition coils for cylinders 3 and 4 ⇒ page 292 .
– Release fastener -arrow-, disconnect crankcase breather
hose -1- and move it clear.

– Release hose clip -1- and detach hose from activated charcoal
filter solenoid valve 1 - N80- .
– Remove bolts -arrows- and detach oil separator.
Installing
• Renew gasket and seals after removing.
Tightening torques
♦ ⇒ “4.1 Exploded view - crankcase breather system”,
page 181


page 185
page 187
”, page 188
”, page 191
N522 ”, page 192
⇒ “5.9 Checking oil pressure and oil pressure switch”,
page 195

⇒ page 38
2 - Gasket
⇒ page 169
4 - O-ring
gine oil
❑ 25 Nm
6 - Oil drain connection
7 - O-rings
ly; supplied with
8 - Bolt


pressure control
⇒ “5.2.1 Exploded view - oil pressure switches/oil pressure con‐
trol, vehicles with alternator”, page 185
trol, vehicles with starter-alternator”, page 186
5.2.1 Exploded view - oil pressure switches/oil pressure control, vehicles with al‐
ternator
1 - Bolt
❑ 4 Nm +45°
trol - N428-
agnostic tester
⇒ page 191
3 - O-ring
gine oil
4 - O-rings
gine oil
5 - Bolt
after removal
valve - N522-
⇒ page 192
7 - Seal
❑ Blue insulation
❑ 20 Nm
❑ Brown insulation
❑ 20 Nm

10 - Seal
11 - Seal
⇒ “5.5.1 Removing and installing stage 3 oil pressure switch F447 - vehicles without particulate filter”,
page 188
❑ 20 Nm
5.2.2 Exploded view - oil pressure switches/oil pressure control, vehicles with
starter-alternator
1 - Bolt
❑ 4 Nm +45°
trol - N428-
agnostic tester
⇒ page 191
3 - O-ring
gine oil
4 - O-ring
gine oil
agnostic tester
⇒ page 187
❑ 20 Nm
6 - O-ring
gine oil
❑ Blue insulation
❑ 20 Nm

8 - Bolt
❑ 9 Nm
10 - Seal
11 - Seal
⇒ “5.5.2 Removing and installing stage 3 oil pressure switch F447 - vehicles with particulate filter/cat-
back system”, page 189
❑ 20 Nm

switch - F22-
Procedure
gr. 17 ; Oil filter/oil pressure switches; Removing and installing
oil pressure switch - F22- .
escaping oil.
– Remove oil pressure switch - F22- -item 2-. (Illustration shows
vehicle with alternator.)
– Fit new oil pressure switch immediately to avoid loss of oil.
Tightening torques
♦ ⇒ “5.2 Exploded view - oil pressure switches/oil pressure con‐
trol”, page 185

Procedure
oil pressure switch for reduced oil pressure - F378- .


escaping oil.
– Unscrew oil pressure switch for reduced oil pressure - F378-
-item 1-. (Illustration shows vehicle with alternator.)
Tightening torques
trol”, page 185

sure switch - F447-
- vehicles with particulate filter/cat-back system”, page 189

sure switch - F447- - vehicles without
particulate filter
Procedure
stage 3 oil pressure switch - F447- .

– If fitted, remove bolt -1- and push bracket -2- with engine wiring

– Remove bolts -arrows- and detach toothed belt cover.
– Lay a cloth under the oil pressure switch to catch escaping
engine oil.
– Use articulated wrench, 24 mm - T40175- to unscrew stage 3
oil pressure switch - F447- -item 2-.
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 17 ; Oil filter/oil pres‐
sure switches ; Removing and installing stage 3 oil pressure
switch - F447-
Tightening torques
♦ ⇒ “5.2.1 Exploded view - oil pressure switches/oil pressure
control, vehicles with alternator”, page 185

sure switch - F447- - vehicles with par‐
ticulate filter/cat-back system
♦ Socket - T10405-

Procedure
17 ; Oil filter/oil pressure switches; Removing and installing stage
3 oil pressure switch - F447- .
– If fitted, remove bolt -1- for bracket -2- for engine wiring har‐
ness.
– Unplug electrical connector -2- for stage 3 oil pressure switch

- F447- .
– Move electrical wiring harness -3- and engine wiring harness
clear.
– Remove bolts -arrows- and detach toothed belt cover -1-.
– Lay a cloth under the oil pressure switch to catch escaping
engine oil.
engine (2.0 ltr. 4-valve TFSI); Rep. gr. 17 ; Oil filter/oil pressure
switches ; Removing and installing stage 3 oil pressure switch -
F447-
Tightening torques
control, vehicles with starter-alternator”, page 186


♦ Used oil collection and extraction unit - VAS 6622A-
Removing
noise insulation .
– If necessary, remove bolts -arrows- and press wiring duct
downwards.

– Position used oil collection and extraction unit - VAS 6622A-
below engine.
N428- (pull poly V-belt slightly downwards if necessary).
Installing
Tightening torques
trol”, page 185


⇒ “5.7.1 Removing and installing piston cooling jet control valve
N522 - vehicles with alternator”, page 192
N522 - vehicles with starter-alternator”, page 192
5.7.1 Removing and installing piston cooling

jet control valve - N522- - vehicles with
alternator
Procedure
gr. 17 ; Oil filter/oil pressure switches .
escaping oil.
– Remove bolt -3- and detach piston cooling jet control valve -
N522- -item 1-.
– Fit new piston cooling jet control valve - N522- immediately to
avoid loss of oil.
Tightening torques
control, vehicles with alternator”, page 185

jet control valve - N522- - vehicles with
starter-alternator
Procedure
gr. 17 ; Oil filter/oil pressure switches .
escaping oil.
N522- .
– Fit new piston cooling jet control valve - N522- immediately to
avoid loss of oil.
– Install intake manifold ⇒ page 240 .
Tightening torques
control, vehicles with starter-alternator”, page 186


⇒ “5.8.1 Checking engine oil pressure”, page 193
⇒ “5.8.2 Checking oil pressure for piston cavity oil jets”,
page 194
5.8.1 Checking engine oil pressure

Test requirements
• Oil level OK
run once).
♦ The oil pump is regulated and has two pressure stages. The
pressure stages are tested one after the other.
♦ During the running-in period or when the engine is in emer‐
gency running mode, the oil pump only operates in the higher
pressure stage.
♦ The oil pressure is dependent on the engine oil temperature.
The mean value should be reached at an engine oil tempera‐
ture of around 80 ℃.
Test sequence
⇒ page 187 .
– Screw oil pressure tester - V.A.G 1342- into oil filter bracket in
place of oil pressure switch.
oil pressure tester - V.A.G 1342- and plug in electrical con‐
nector.
– Start engine.

• Oil pressure at idling speed: 0.85 ... 1.6 bar

• Oil pressure at 2000 rpm: 1.2 ... 1.6 bar
• Oil pressure at 3700 rpm: 3.0 ... 4.0 bar (second pressure
stage active, valve for oil pressure control - N428- OK)
noise insulation .
- N428- . Unclip electrical wire and route downwards so that it
does not come into contact with belt drive.
Note:
When connector is unplugged, oil pump operates in the higher
pressure stage.
– Start engine and check oil pressure at specified engine
speeds.
Assembling
– Install oil pressure switch ⇒ page 187 and route electrical wir‐
ing carefully.
Tightening torques
trol”, page 185
5.8.2 Checking oil pressure for piston cavity

oil jets

♦ Test instrument adapter - VAS 5571-
Test requirements
• Oil level OK
run once).
Test sequence
– Remove stage 3 oil pressure switch - F447- ⇒ page 188 .
– Screw stage 3 oil pressure switch - F447- into oil pressure
tester - V.A.G 1342- .
– Screw in oil pressure tester - V.A.G 1342- in place of oil pres‐
sure switch.
– Connect test instrument adapter/DSO (2-pin) - VAS 5571- to
oil pressure switch.
– Plug electrical connector for stage 3 oil pressure switch - F447-
into test instrument adapter/DSO (2-pin) - VAS 5571- .
– Check oil pressure ⇒ Vehicle diagnostic tester, Stage 3 oil
pressure switch F447 .
Assembling
– Install stage 3 oil pressure switch - F447- ⇒ page 188 .
5.9 Checking oil pressure and oil pressure

switch
– Check oil pressure ⇒ page 193 .
– Check oil pressure switch ⇒ Vehicle diagnostic tester.

19 – Cooling
cautions .


All components are described in ⇒ 4-cylinder direct injection en‐
gine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Cooling system/
coolant; Connection diagram - coolant hoses .

♦ Cooling system tester adapter - V.A.G 1274B/15- for filler cap

(version 1)


(version 2)
♦ Safety goggles
Test requirements
• Ignition off
Procedure
CAUTION

Note:


nutes.
inate fault.
Note:
engine is cold.
CAUTION
– To release pressure, press pressure relief valve on cooling
system tester until reading on pressure gauge is 0.

Blue filler cap:
this level.
Black filler cap:
this level.
All filler cap types:
scribed.


V.A.G 1274/9- onto filler cap -1-.
Blue filler cap:
♦ The pressure relief valve should open at a pressure of
1.4 ... 1.6 bar.
Black filler cap:
1.6 ... 1.8 bar.
All filler cap types:
scribed.


Note

sequently to serious damage to the power unit.
♦ Because of its high boiling point, the coolant improves power
unit reliability under heavy loads, particularly in countries with
tropical climates.
++ and G12evo.
tection.
the coolant.
ses.
Draining and filling cooling system

gine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Cooling system/
coolant; Draining and filling cooling system .


page 204
page 204
page 206
”, page 211
1 - Connection
2 - O-ring
3 - Centring pin
4 - Bolt
5 - Gasket
6 - Coolant pump
⇒ page 205
❑ New coolant pump: re‐
move protective cap
7 - Bolt
⇒ page 203
8 - Toothed belt
⇒ page 206
9 - Bolt
❑ 9 Nm
11 - Bolt

❑ 10 Nm +90°
❑ Note installation position
13 - Oil seal
15 - Gasket
❑ After renewing, perform adaption ⇒ Vehicle diagnostic tester
Actuator for engine temperature regulation - N493- - tightening

sequence
Coolant pump - tightening torques and sequence

– Tighten bolts for coolant pump in the sequence -1 ... 4- to
9 Nm.

gine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pump/
thermostat assembly; Exploded view - electric coolant pump .

1 - Retaining clip
ment
❑ Push-fitted version
⇒ 4-cylinder direct in‐
jection engine, (1.8, 2.0
ltr. 4-valve TFSI); Rep.
radiator outlet coolant
G83-
3 - O-ring
4 - O-rings
er - G62-
box end)
⇒ page 211
6 - Bolt
❑ 4 Nm +45°
7 - Bolt
❑ 4.5 Nm
❑ Bolted version
❑ Different fitting locations
9 - O-rings

pump
thermostat assembly; Removing and installing electric coolant
pump .


♦ Socket T30 - T10405-
Removing
gr. 19 ; Coolant pump/thermostat assembly; Removing and in‐
stalling coolant pump .
Toothed belt cover (version 1)
- F447- -item 2-.

- F447- -item 2-.

Continued:
– Remove bolts -1 … 4- and detach coolant pump from actuator
for engine temperature regulation - N493- .
– Detach toothed belt from coolant pump.
Installing
– Fit coolant pump -1- and toothed belt.
– Check that centring elements -arrows- and gasket -3- are
seated correctly.
– Tighten coolant pump bolts ⇒ page 203 .
– After fitting new coolant pump -2-, remove protective cap -1-
from drive sprocket.
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pump/
thermostat assembly; Removing and installing coolant pump
Tightening torques

coolant pump

♦ Tool insert - T10360-
♦ Counterhold tool - T40378- or

Removing
stalling toothed belt for coolant pump .
Vibration damper - version 1:
– Counterhold crankshaft at vibration damper with ratchet
wrench (21 mm) - T40263- , adapter - T40314- and socket
(24 mm).
Vibration damper - version 2:
– Depending on version, counterhold crankshaft at vibration
damper using counterhold tool - T40378- or counterhold tool
- T40379- .


Note:
– Use torque wrench - V.A.G 1410- and insert tool - T10360- to
remove bolt on coolant pump drive sprocket -1- -arrow- (coun‐
terhold at vibration damper).
– Remove toothed belt -2-.
Installing
angle.
• Note installation position of toothed belt sprocket
⇒ Item 12 (page 203) .
thermostat assembly; Removing and installing toothed belt for
coolant pump
Tightening torques

Removing
stalling actuator for engine temperature regulation - N493- .
– Remove coolant pump ⇒ page 205 .
– Lift retaining clips -1, 3- and disconnect coolant hoses (if still
connected).

– Unplug electrical connector -arrow- for actuator for engine


– Detach actuator for engine temperature regulation - N493-
from centring pins and pull actuator off engine oil cooler.

Installing
• Renew seals/gaskets and O-rings after removal.
– Lubricate new O-rings -4- lightly with coolant, for coolant refer
to ⇒ Electronic parts catalogue .
– Check whether the two centring pins are fitted in the cylinder
block; install if necessary.
– Fit connecting piece -2- into engine oil cooler -1-.
– Push actuator for engine temperature regulation - N493- -3-
onto connecting piece and centring pins in cylinder block.
– Tighten bolts for actuator for engine temperature regulation -
N493- ⇒ page 203 .
– Connect coolant hoses with plug-in connectors ⇒ 4-cylinder
direct injection engine (2.0 ltr. 4-valve TFSI); Rep. gr. 19 ;
Radiator/radiator fans; Exploded view - radiator/radiator fans .
thermostat assembly ; Removing and installing actuator for en‐
– After renewing, perform “Adaption” for actuator for engine
temperature regulation - N493- in Guided Functions mode
of ⇒ Vehicle diagnostic tester.
Tightening torques

ature sender - G62-
Procedure
• Engine cold.
stalling coolant temperature sender - G62- .


tener -arrow- (if necessary) and briefly opening filler cap -1- on
Note:
– Unplug electrical connector -1- at coolant temperature sender

- G62- .
– Remove bolt -arrow- and detach coolant temperature sender
- G62- -3-.
– To avoid loss of coolant, insert new coolant temperature send‐
er immediately.
– Check coolant level ⇒ 4-cylinder direct injection engine (1.8,
2.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Cooling system/coolant;
Tightening torques
page 204

thermostat assembly; Removing and installing radiator outlet

Depending on model and version: All procedures are described
in ⇒ 4-cyl. direct injection engine (1.8, 2.0 ltr. 4-valve TFSI); Rep.
stalling coolant valves .

4 Coolant pipes
Coolant pipes .

Radiator/radiator fans .

cautions .

2 Turbocharger
⇒ “2.3 Removing and installing turbocharger air recirculation
valve N249 ”, page 230
”, page 231

♦ Part I ⇒ page 216
♦ Part II ⇒ page 217
♦ Part III ⇒ page 219
Part I
1 - Bolt
❑ 25 Nm
2 - Oil return line
3 - O-ring
gine oil
4 - O-ring
gine oil
5 - Turbocharger
page 220
6 - Nut
❑ Coat studs with high-
temperature paste ⇒
logue
❑ 25 Nm
7 - Gasket
8 - Bracket
9 - Coolant return line
10 - Bolt
❑ 9 Nm
11 - O-ring

13 - Bolt
❑ 9 Nm
14 - O-ring
15 - O-ring
16 - Bolt
❑ 9 Nm
17 - Connection
18 - Bolt
❑ 9 Nm
Fitting location of turbocharger air recirculation valve - N249-

– Note installation position -arrows-.
Part II
2. Turbocharger 217
1 - Support
2 - Turbocharger
page 220
3 - O-ring
gine oil
4 - Line
❑ Do not disconnect ver‐
sion with threaded con‐
nection
from turbocharger
5 - Bolt/threaded connection
bolt or threaded connec‐
tion with connected
hose is fitted
❑ Do not disconnect
threaded connection
from turbocharger
❑ Bolt, 9 Nm
page 275
7 - O-ring
8 - Oil supply line
9 - Bolt
❑ 9 Nm
10 - O-ring
11 - Bolt
❑ 9 Nm
12 - Bolt
❑ 30 Nm
❑ Coat with high-temperature paste ⇒ Electronic parts catalogue
13 - Heat shield
14 - Bolt
❑ 9 Nm

15 - Coolant supply line

16 - O-ring
17 - Bolt
❑ 9 Nm
18 - O-ring
19 - Bolt
❑ 20 Nm +90°
Part III
1 - Ball socket
- V465-
❑ Before removing charge
pressure positioner -
V465- , check it is avail‐
able in ⇒ Electronic
positioner V465 ”,
page 231
3 - Turbocharger
page 220
4 - Bolt
❑ 9 Nm
5 - Nut
❑ 8 Nm
6 - Ball socket
7 - Retaining clip
8 - Control rod
9 - Nut
❑ 8 Nm
10 - Retaining clip
2. Turbocharger 219

⇒ “2.2.1 Notes on turbocharger”, page 220
⇒ “2.2.2 Removing turbocharger - vehicles without particulate fil‐
ter”, page 220
⇒ “2.2.3 Removing turbocharger - vehicles with particulate filter
and without high-voltage system”, page 224
⇒ “2.2.4 Removing turbocharger - vehicles with high-voltage sys‐
tem”, page 227
2.2.1 Notes on turbocharger

Mechanical damage to turbocharger
If the turbocharger has suffered mechanical damage (e.g. dam‐
aged compressor wheel), it is not sufficient merely to fit a new
turbocharger. The following work must be performed in order to
avoid further damage:
♦ Check air cleaner housing, air filter element and intake hoses
♦ Check the entire charge air system (including the charge air
cooler) for foreign matter.
If foreign matter is found in the charge air system, clean all rele‐
vant ducts and hoses and renew the charge air cooler if neces‐
sary.
2.2.2 Removing turbocharger - vehicles with‐

Removing
– Observe notes ⇒ page 220 .
gr. 21 ; Turbocharger; Removing and installing turbocharger .
– Remove secondary air pump motor - V101-
⇒ “5.2 Removing and installing secondary air pump motor
V101 ”, page 287 .

– Unscrew bolt -1- and detach oil return line.

– Remove electrical connector -1- for Lambda probe 1 before

catalytic converter - GX10- -item 2- from bracket and unplug
connector.
Equipment version with bolt:

– Remove bolt -arrow- and detach crankcase breather hose
from turbocharger.
Note:
Depending on version, either a bolt or a threaded connection with
connected hose and corresponding clamp is fitted.
2. Turbocharger 221

– Unplug electrical connector -2- at charge pressure positioner
- V465- .
Equipment version with threaded connection:

-Arrows- - For cam adjustment actuators - F366...F373-

2 - For charge pressure positioner - V465-
3 - For turbocharger air recirculation valve - N249-


– Release fasteners -arrow-, disconnect crankcase breather

wards rear.
– Unscrew bolt -1- and remove coolant return line.

2. Turbocharger 223
– Pull turbocharger off studs in direction of -arrow-.

– Have a second mechanic hold turbocharger; remove bolt -1-,
disconnect coolant supply line -2- and lift out turbocharger.
2.2.3 Removing turbocharger - vehicles with

particulate filter and without high-volt‐
age system
Removing
– Observe notes ⇒ page 220 .
– Remove secondary air pump motor - V101- ⇒ page 287 .


connector.

Pfeile - For cam actuators

2. Turbocharger 225





high-voltage system
Removing
– Observe notes ⇒ “2.2.1 Notes on turbocharger”, page 220 .
– Remove secondary air pump motor - V101-
⇒ “5.2 Removing and installing secondary air pump motor
V101 ”, page 287 .
– Remove resonator
⇒ “5.5 Removing and installing resonator for secondary air
system”, page 288 .

connector.
2. Turbocharger 227

– If fitted, remove nut -2- and move earth wire -1- clear.
– Release electrical connectors and detach simultaneously from
ignition coils in direction of -arrows-.

2 - For charge pressure positioner - V465- (different installation
positions)




2. Turbocharger 229
2.2.5 Installing turbocharger

Installing
angle.
• Renew gaskets, seals, O-rings and self-locking nuts after re‐
moval.
• Lubricate studs for turbocharger with high-temperature paste
• Hose connections and charge air system hoses must be free
of oil and grease prior to fitting.
line.
• If turbocharger was renewed together with charge pressure
positioner - V465- learnt values must be adapted ⇒ Vehicle
diagnostic tester, Guided Functions , 01 - Adjust charge
pressure positioner V465 .
– Install catalytic converter ⇒ 4-cylinder direct injection engine

(1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 26 ; Emission control sys‐
tem; Removing and installing catalytic converter .
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Turbocharger;
Removing and installing turbocharger
• After installing turbocharger, allow engine to idle for approx. 1
minute and do not rev up immediately to ensure turbocharger
is supplied with oil.
Tightening torques
tem”, page 233

air recirculation valve - N249-
Removing


– Unscrew bolts -arrows- and carefully detach turbocharger air
recirculation valve - N249- .
Installing
Tightening torques

Note
Before removing charge pressure positioner - V465- , check it is
available in ⇒ Electronic parts catalogue (ETKA) .
Removing
A4, A5, Q5, A6 and A7:
– Remove air cleaner housing ⇒ 4-cylinder direct injection en‐
gine (2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Air cleaner; Removing
and installing air cleaner housing .
All vehicles:
– Loosen lock nut -2- by a quarter turn (counterhold at hexagon
flats -arrow- on control rod).
– Unscrew control rod from actuating lever -1-, taking care not
to turn lock nut.
– Remove bolts -3- and detach charge pressure positioner -
V465- .
Installing
• If renewing charge pressure positioner, ensure installation po‐
sition of lock nut is the same on new charge pressure posi‐
tioner.
2. Turbocharger 231
– Place charge pressure positioner - V465- in installation posi‐

tion and tighten bolts -3-.
– Screw control rod into actuating lever -1- until it makes contact
with lock nut -2-.
– Plug in electrical connector -4-.
– Learnt values must be adapted after renewing charge pres‐
sure positioner - V465- .
♦ Drive train
♦ 01 - Set charge pressure adjuster -V465
Tightening torques
♦ ⇒ page 219

3 Charge air system

page 233
page 234

gine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Charge air system;

charge air system
• If using used hose clips to secure the air hoses at their con‐
nections, spray rust remover onto the worm threads before
installing.
Hose clips on pressure side are fitted with retaining hooks
-arrows-.
• To disconnect air hose, hose clip must be loosened far
enough.
• Hose clips which have been loosened can be re-used.
• Hose clip -1- with retaining hooks -arrows- must not be pulled
off air hose.
• If a hose clip with retaining hooks is pulled off air hose, air hose
must be renewed.
• New air hoses are supplied with hose clip fitted.



er
Removing and installing charge air cooler .

sure sender - G31-
Removing and installing charge pressure sender - G31- .

Procedure
gr. 21 ; Charge air system; Checking charge air system for leaks .


valves -3- and -4-.
valve.
– If there is water in sight glass -6-, drain it off via drain plug.
– Open valve -3-.
NOTICE
Risk of damage to components if test pressure is set too high
– Never set test pressure higher than specified.

felt with the hand; apply commercially available leak detection
spray or use ultrasonic tester - V.A.G 1842- . (For operation of
-V.A.G 1842- , refer to ⇒ Operating instructions .)
Note:
test.
Assembling
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Charge air system;
Checking charge air system for leaks


cautions .

2 Injection system
page 237

system
gine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Injection system;
Overview of fitting locations - injection system .

– Allow engine to run for several minutes at moderate rpm.
– Check complete fuel system for leaks.
– If leaks are found although the connections have been tight‐
ened to the correct torque, the relevant component must be
renewed.
– Road-test vehicle and accelerate with full throttle at least once.
– Then inspect high-pressure section of fuel system again for
leaks.

3 Air cleaner
Air cleaner .

4 Intake manifold
241
page 243
1 - Bolt
❑ 20 Nm
2 - Support for intake manifold
3 - Nut
❑ 10 Nm
❑ 5 Nm
5 - Bolt
❑ 7 Nm
J338-
❑ Including throttle valve
drive for electric throttle
- G186- , throttle valve
drive angle sender 1 for
electric throttle - G187-
and throttle valve drive
angle sender 2 for elec‐
tric throttle - G188-
stalling throttle valve
module J338 ”,
page 241
❑ After installing, perform
agnostic tester
❑ Cleaning
⇒ “4.4 Cleaning throttle
valve module”,
page 242
7 - Seal
8 - Intake manifold
10 - Ball stud
❑ 5 Nm

11 - O-ring
12 - Bolt
❑ 1.5 Nm
❑ For some models, designation in current flow diagram may only be intake manifold pressure sender -
G71-
14 - Bolt
❑ Tighten in several stages and in diagonal sequence
❑ 9 Nm
15 - Ball stud
❑ 5 Nm
16 - Bracket
❑ For vehicles with MPI engine
17 - Bolt
❑ 5 Nm
18 - Nut/bolt
❑ 9 Nm
19 - Gasket
20 - Vacuum hose
22 - Vacuum hose
23 - Bracket
❑ For electrical connectors
24 - Bolt
❑ 5 Nm


Removing
gr. 24 ; Intake manifold; Removing and installing intake manifold .
– Unscrew bolts -1, 2- and -arrows-.
– Detach electrical connectors -1, 4- from bracket.

– Detach intake manifold and unclip electrical connector -2- from
bracket. If necessary, unplug electrical connector.
– Seal off all open passages in the intake system with clean
cloths or plugs (thoroughly cleaned) from engine bung set -
VAS 6122- .
Installing
• Renew connection for high-pressure pipe.
– Fit intake manifold onto studs (bottom left and bottom right) on
cylinder head.
ing battery .
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Intake manifold;
Removing and installing intake manifold
Tightening torques
♦ ⇒ “5.1.1 Exploded view - fuel rail with injectors, vehicles with
FSI engine”, page 245
tem”, page 233

module - J338-
Removing
gr. 24 ; Intake manifold; Removing and installing throttle valve
module - J338- .


J338- .
Installing
– Clean sealing surface for seal.
Removing and installing throttle valve module - J338-
Learnt values must be re-adapted after removing or renewing
throttle valve module.
♦ Drive train
placement
Tightening torques

♦ Safety goggles
• Take care not to scratch the throttle valve housing when clean‐
ing it.
CAUTION
Risk of injury caused by acetone. Acetone is highly flammable
and can cause irritation to the eyes and skin.



function
Only perform this test if there is a loss of engine torque (poor
flexibility or lack of pulling power).
Test condition
• Intake manifold flap valve - N316- has been checked with a
vehicle diagnostic tester.
Perform the following steps if the intake manifold flap valve -
N316- is OK.
Procedure
gr. 24 ; Intake manifold; Checking intake manifold change-over
function .
– Have a second mechanic rev up engine quickly (short burst of
throttle) and observe vacuum unit for intake manifold change-
over.

• The linkage -1- of the vacuum unit for intake manifold flap
should pick up -arrow-.
If the change-over does not operate as described:
– Check vacuum system for leaks.
– Check that vacuum lines are connected correctly.
– Check vacuum hoses for porosity.
– Move adjuster ring -1- on hand vacuum pump - VAS 6213- to

position -A- to select "vacuum".
– Connect hand vacuum pump - VAS 6213- to vacuum unit for

intake manifold flap valve - N316- .
– Operate hand vacuum pump - VAS 6213- several times.
should pick up.
– Vent vacuum.
• The linkage should return to the initial position.
• The linkage should move in both directions -arrows-.
– Renew intake manifold if linkage does not move.
Checking intake manifold change-over function

5 Injectors

⇒ “5.1.1 Exploded view - fuel rail with injectors, vehicles with FSI
engine”, page 245
⇒ “5.1.2 Exploded view - fuel rail with injectors, vehicles with MPI
engine”, page 247
5.1.1 Exploded view - fuel rail with injectors, vehicles with FSI engine
1 - Bolt
❑ Renew M8 bolt after re‐
moving
♦ M6: 9 Nm
♦ M8: 20 Nm +90°
2 - Fuel rail for FSI injectors
⇒ page 247
G247-
❑ Lubricate taper lightly
with clean engine oil; do
not lubricate thread
⇒ page 259
❑ 27 Nm
4 - Support ring
5 - O-ring
6 - Spacer ring
7 - Injector
able ⇒ page 246 ; for
allocation refer to ⇒
logue
❑ Ensure correct installa‐
tion position.
❑ Cleaning ⇒ page 257
8 - Sealing washer
9 - Combustion chamber ring seal
❑ Renewing after injector has been removed ⇒ page 248
5. Injectors 245
10 - Connection
❑ For high-pressure pipe on fuel rail
❑ Lubricate threads lightly with clean engine oil
❑ 40 Nm
11 - Bolt
❑ 5 Nm
❑ Lubricate ball lightly with clean engine oil
❑ 27 Nm
Different injectors
A - Version without ridge
♦ Removing ⇒ page 249
B - Version with ridge -arrow-
♦ Removing ⇒ page 250

5.1.2 Exploded view - fuel rail with injectors, vehicles with MPI engine
1 - Retaining clip
❑ For fuel pressure send‐
er for low pressure -
G410-
2 - O-ring
3 - Adapter
❑ Attach to fuel pressure
sender for low pressure
- G410-
❑ 27 Nm
❑ Attach to adapter
⇒ page 263
❑ 27 Nm
5 - Fuel rail for MPI injectors
6 - Bolt
❑ 9 Nm
8 - Fuel supply line
❑ To fuel rail for MPI injec‐
tors
❑ Install so that parts are
free of tension
9 - Retaining clip
10 - O-ring
11 - Injector
❑ Ensure correct installation position.
12 - O-ring

The following procedure applies to the fuel rail for FSI injectors.
Removing
gine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Injectors; Removing
Installing
– Installation is carried out in reverse order; note the following:
5. Injectors 247
• Renew support rings for injectors after removing.

• If any injectors remain lodged in the cylinder head when the
fuel rail is detached, it is only necessary to install the O-rings
and spacers from the repair set.
• If the injectors are pulled out along with the fuel rail, install all
the components of the repair set with a combustion chamber
ring seal ⇒ page 248 .
Tightening torques

gine”, page 248
gine”, page 253

• Injectors must only be installed when engine is cold.
♦ Tool set for FSI engines - T10133 C-
Removing
– Remove fuel rail ⇒ page 247 .
• Carefully pull out any injectors that remain lodged in the fuel
rail.
– Remove the injectors if they remain lodged in the cylinder
head.
– Cover open inlet ports with a clean cloth.

– Detach support ring -4- from injector -1-.
Removing injector version A ⇒ page 246

• Use a torque wrench to pull out injector.

– Set torque wrench to 5 Nm.
– Fit puller -T10133/2A- to groove on injector.
– Then fit guide puller T10133/16A .
– Pull out injector by turning bolt with torque wrench -1-.
– If injector does not come loose after limit torque of 5 Nm is
reached, remove puller and repeat procedure using stop
sleeve to loosen injector.
5. Injectors 249
Removing injector version B ⇒ page 246

– Screw puller -T10133/20- -item A- onto striker -T10133/3-
-item B-.
– Position puller behind ridge -arrow- on injector -1-.
– Pull injector out by striking it gently.
Dismantling injector
– Pull O-ring -3- and spacer ring -2- off injector -1-.
– Unclip sealing element -5-.
so, cut open combustion chamber ring seal using knife or prise
open with small screwdriver and then pull off forwards.
4 - Support ring
– Clean ring groove in area of seal -arrow-. Remove carbon de‐

posits with a brass wire brush.
• Take care not to damage groove on injector. Injector must be
renewed if groove is damaged.
Installing
• Use complete repair set when installing.
• Renew support ring after removing.
• Renew combustion chamber ring seal before re-installing in‐
jector.


T10133/4- -item A-.
with a clean cloth.


ber ring seal -1- onto assembly cone -T10133/5- as far as it
will go. (Knurled side of assembly sleeve faces towards com‐
bustion chamber ring seal.)

chamber ring seal into groove. (Smooth side of assembly
sleeve faces towards combustion chamber ring seal.)
5. Injectors 251
– Injector version B ⇒ page 246 : Place an M8 washer -item A-

on injector.
– Place assembly cone -T10133/5- with combustion chamber

ring seal on injector.
– Slide combustion chamber ring seal onto injector with assem‐
bly sleeve -T10133/6- .
– Remove assembly cone -T10133/5- and push combustion
chamber ring seal into sealing ring groove using assembly
sleeve -T10133/6- -arrow-.
Note:
– Push calibration sleeve -T10133/7- onto injector as far as stop

or up to washer -A- and simultaneously turn it slightly (approx.
180°).
opposite direction.
– Push calibration sleeve -T10133/8- onto injector as far as stop

or up to washer -A- and simultaneously turn it slightly (approx.
180°).
opposite direction.

• The combustion chamber ring seal -6- must not be lubricated.

inder head (aperture must be free of oil and grease). Ensure
that the injector is properly seated -arrow- in the cylinder head.
• Lug -1- and hole -arrow- in cylinder head must face each other.
• It should be possible to insert the injector easily. If necessary
wait until the combustion chamber ring seal has contracted
sufficiently.
– Install fuel rail ⇒ page 247 .

♦ Socket T30 - T10405-
Removing
gr. 24 ; Injectors; Removing and installing injectors .
5. Injectors 253
fold.

– Detach fuel supply line -2- from fuel rail.

– Remove bolts -arrows- from MPI fuel rail.
– Carefully lift out fuel rail with injectors.

– Release retaining clip -2- and detach injector -3- from fuel rail
-1-.

1 - Renew O-ring after removal (apply thin coating of clean engine
oil prior to installation)
2 - Injector
3 - Retaining clip
4 - Renew O-ring after removal (apply thin coating of clean engine
oil prior to installation)
Installing
– Press fuel rail with injectors by hand as far as it will go into
aperture of intake manifold (injectors must be free of oil and
grease).
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Injectors; Re‐
moving and installing injectors
Tightening torques
MPI engine”, page 247
5.4 Renewing seals on injector

♦ Tool set for FSI engines - T10133C-
♦ Washer M8
Note
♦ The following procedure is for the combustion chamber ring

seal (teflon seal)
♦ The combustion chamber ring seal must always be renewed
before the injector is re-installed.
♦ The M8 washer must be positioned on the injector before the
seal is installed. This ensures it is not possible for the calibra‐
tion sleeve to be pushed behind the seal.
• Injectors removed ⇒ page 248
5. Injectors 255
– Clean injector carefully.

– Carefully cut seal open with a knife -arrow-. When doing so,
knife blade must not come into contact with valve body.
– Remove old seal and clean ring groove where seal was loca‐
ted -arrow-. Remove any carbon deposits with a brass wire
brush.
– Fit a new seal -1- onto assembly cone - T10133/5- .

– Push seal -1- onto assembly cone as far as it will go using
assembly sleeve - T10133/6- (knurled side faces towards
seal).
– Turn assembly sleeve - T10133/6- around (knurled side no

longer faces towards seal).
– Now push seal to end of assembly cone .
– Position M8 washer -A- on injector.

– Fit assembly cone - T10133/5- with seal onto injector from the
front.
– Push seal onto injector using assembly sleeve - T10133/6- .
– Remove assembly cone - T10133/5- and push combustion

chamber ring seal into ring groove using assembly sleeve -
T10133/6- -arrow-.
– Push calibration sleeve - T10133/7- onto injector as far as

washer -A- and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve - T10133/7- off again by turning it in
opposite direction.
– Push calibration sleeve - T10133/8- onto injector as far as

washer -A- and simultaneously turn it slightly (approx. 180°).
– Pull calibration sleeve - T10133/8- off again by turning it in
opposite direction.
– Remove washer -A-.
– Renew O-ring on injector (apply thin coating of clean engine
oil prior to installation).

The following procedure applies to FSI injectors.
5. Injectors 257
Procedure
– Fill up ultrasonic unit.
• Ratio of cleaning fluid: 2,100 ml of tap water which has been
allowed to settle for a few minutes and 20 ml of cleaning fluid
- VAS 6418/2-
• The ideal fluid level is approx. 1 ... 4 mm above the base of
– Remove injectors ⇒ page 248 .

cleaning unit.
• It is important to read the safety notes in the operating instruc‐
tions before switching on the ultrasonic cleaning unit - VAS
6418- .

• The actual cleaning process commences when the tempera‐
minutes.
⇒ page 248 .


259
⇒ “6.5 Removing and installing pressure differential sender for
particulate filter G1037 ”, page 264

For some models, designation in current flow diagram may also
be intake manifold sender - GX9- or intake manifold pressure
sender - G71-
Removing
gr. 24 ; Senders and sensors; Removing and installing intake air
temperature sender - G42- / intake manifold pressure sender -
G71- .
– Release catches -arrows- and detach intake air temperature
sender - G42- / intake manifold pressure sender - G71- from
intake manifold.
Installing
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Senders and
sensors; Removing and installing intake air temperature sender -
G42- / intake manifold pressure sender - G71-
Tightening torques

sender - G247-

♦ Socket (27 mm) - T40218- or commercially available socket

(27 mm) for fuel pressure sender - G247- , version 1
♦ Socket (24 mm) - T40363- (not illustrated) for fuel pressure

sender - G247- , version 2
♦ Crow-foot wrench (24 mm), commercially available for fuel
pressure sender - G247- , version 3
♦ Safety goggles
Removing
gr. 24 ; Senders and sensors; Removing and installing fuel pres‐


-1- and unplug it.
CAUTION
– Catch escaping fuel with a cloth.

– Unscrew fuel pressure sender - G247- .
Installing
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Senders and
sensors; Removing and installing fuel pressure sender - G247-
Tightening torques


Procedure:
gr. 24 ; Senders and sensors; Checking fuel pressure sender -
G247- .
– Remove fuel pressure sender - G247- ⇒ page 259 .

– Screw in adapter - VAS 6394/2- in place of fuel pressure send‐

er - G247- and tighten adapter with same torque as specified
for -G247- .
– Unscrew plug -2- on digital pressure gauge - VAS 6394/1- and

screw in fuel pressure sender - G247- in its place (tighten to
specified torque).
– Use test instrument adapter - VAS 5570- to make electrical

connection between vehicle and fuel pressure sender -
G247- .
• The display zone shows the actual pressure value being trans‐
mitted to the engine control unit by the fuel pressure sender -
G247- .
– Switch on pressure gauge - VAS 6394/1- by pressing button

-A- once briefly.
0 bar.
-C- briefly.

– Connect pressure gauge - VAS 6394/1- to adapter - VAS

6394/2- .
– Start engine.
– Compare pressure indicated by pressure gauge - VAS 6394/1-
with actual pressure value on vehicle diagnostic tester .
CAUTION

- VAS 6394/1- .
sure sender - G247- ⇒ page 259 .
Tightening torques

The following procedure applies to MPI engines.
Removing
24 ; Senders and sensors ; Removing and installing fuel pressure
sender for low pressure - G410- .


– Pull off retaining clip -1-.
– Pull fuel pressure sender for low pressure - G410- -item 2- out
of fuel rail.
– If necessary, unscrew fuel pressure sender for low pressure

-1- from adapter -2-.
Installing
• Renew O-ring -arrow- after removal.
engine (2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Senders and sensors ;
G410-
Tightening torques

ential sender for particulate filter -
G1037-
Removing

Pressure differential sender - version 1:

– Unplug electrical connector -1- for pressure differential send‐
er .

ferential sender -item 2-.
Pressure differential sender - version 2

– Remove bolt -1- and release hose clips -2-.
– Detach pressure differential sender .
lubricant.
Installing
Tightening torques

❑ To fuel rail for FSI injec‐
tors
❑ Lightly lubricate ball of
fuel supply line with en‐
gine oil
free of tension
❑ Tightening torque for
union nut: 27 Nm
⇒ page 270
2 - Connection
❑ Must always be re‐
newed once loosened
❑ Counterhold when loos‐
ening union nut
❑ 40 Nm
❑ From fuel tank
5 - Bolt
❑ Only with protective
plate
❑ 9 Nm
7 - Quick release coupling
❑ With cut-off valve
❑ Fitted on some versions only
8 - Guard plate
9 - Bolt
❑ M6; renew after removing
❑ Without protective plate ⇒ Item 8 (page 266) : socket head bolt
❑ With protective plate ⇒ Item 8 (page 266) : centre hex stud
❑ With integrated fuel pressure regulating valve or fuel metering valve
❑ Different versions of regulating valve depending on version of high-pressure pump:

♦ Fuel pressure regulating valve - N276- or

❑ Take care not to tilt when installing
11 - O-ring
12 - Roller tappet
❑ May remain lodged in vacuum pump when high-pressure pump is removed
13 - Vacuum pump
14 - Connection/plug
❑ For fuel supply line
❑ For MPI engines
❑ Must always be renewed once loosened
Tightening torques:
♦ M10: 15 Nm
♦ M12: 20 Nm
❑ For MPI engines
❑ To fuel rail (for vehicles with MPI engine)
17 - Bolt
❑ 9 Nm
High-pressure pump - tightening torques and sequence

angle.
– To prevent flange of high-pressure pump from being deformed
during installation, tighten bolts -arrows- in stages as follows:
2. Tighten one turn alternately until
flange of high-pressure pump makes
contact with vacuum pump
3. M6 8 Nm
+90° further
M8 20 Nm

pump

♦ Safety goggles
Removing
gr. 24 ; High-pressure pump; Removing and installing high-pres‐
sure pump .
• Remove the high-pressure pump only when the engine is cold.

Vehicles with protective plate

– Unscrew bolts -arrows- and remove guard plate -1-.

CAUTION

– Vehicles with MPI engine: Release hose clip -4- and detach
fuel hose.
– Unscrew union nut -1- (counterhold at connection).
– Carefully pull out high-pressure pump. It is possible that the
roller tappet may remain lodged in the vacuum pump.
Installing
• Renew O-ring and spring-type clips after removal.
• Renew connecting piece of high-pressure pump every time it
is unscrewed.
angle.
– Check roller tappet -1- for damage and renew if necessary.

– Lightly lubricate roller tappet with oil and insert it so that lug
-arrow A- slides into guide notch -arrow B-.
NOTICE


– Have a second mechanic turn crankshaft with ratchet wrench
(21 mm) - T40263- , adapter - T40314- and socket (24 mm) in
direction of normal engine rotation -arrow- until roller tappet in
vacuum pump reaches its lowest point.
– Have a second mechanic turn crankshaft in direction of normal
engine rotation at nut for starter-alternator pulley until roller
tappet in vacuum pump reaches its lowest point.
– Insert high-pressure pump with new O-ring into vacuum pump
and tighten bolts in stages.
– Secure fuel hoses with spring-type clips.
– Tighten union nut on high-pressure pipe hand-tight, align pipe
so that it is free of stress and tighten nut to specified torque.
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; High-pressure
pump; Removing and installing high-pressure pump
Tightening torques
♦ ⇒ Fig. ““High-pressure pump - tightening torques and se‐
system

pipe
♦ Insert tool, 17 mm - V.A.G 1331/6-

♦ Socket, AF 17 mm - T10456-
♦ Socket - T40055-
Removing
gr. 24 ; High-pressure pump; Removing and installing high-pres‐
sure pump .
– Unbolt clamp -arrow-.
CAUTION
– Loosen union nut on fuel rail -arrow- using socket, AF 17 mm

- T10456- or socket - T40055- .

– Counterhold at hexagon flats -A- and loosen union nut

-arrow-. Detach high-pressure pipe.
Installing
– Lubricate balls of high-pressure pipe with engine oil and install
high-pressure pipe.
– Tighten union nuts hand-tight and align high-pressure pipe so
that it is free of stress.
– Install clamp -arrow- and tighten to 5 Nm.
– Tighten union nut on fuel rail -arrow- using socket, AF 17 mm

- T10456- or socket - T40055- .
– Counterhold at hexagon flats -A- and tighten union nut

-arrow- using insert tool, 17 mm - V.A.G 1331/6- .
– Wait at least one minute, then check tightening torque of union
nuts.
Further assembly is basically carried out in reverse order of dis‐
mantling.
Note
After completing all work steps, start engine and check fuel sys‐
tem for leaks.
Tightening torques

8 Lambda probe

⇒ “8.1.1 Exploded view - Lambda probes, vehicles without par‐
⇒ “8.1.2 Exploded view - Lambda probes, vehicles with particulate
filter/cat-back system”, page 274
8.1.1 Exploded view - Lambda probes, vehicles without particulate filter

❑ Comprises:
Z29-
❑ Installation position var‐
ies
❑ The threads on the new
Lambda probes are
coated with a special as‐
sembly paste.
❑ If re-installing old Lamb‐
da probe, coat thread
with high-temperature
paste: Refer to ⇒ Elec‐
tronic parts catalogue
for high-temperature
paste
❑ The assembly paste/
high-temperature paste
must not get into the
slots on the Lambda
probe body
page 275
❑ 60 Nm
❑ Comprises:
❑ The threads on the new Lambda probes are coated with a special assembly paste.
❑ If re-installing old Lambda probe, coat thread with high-temperature paste: Refer to ⇒ Electronic parts
catalogue for high-temperature paste
❑ The assembly paste/high-temperature paste must not get into the slots on the Lambda probe body
❑ Removing and installing ⇒ “8.2 Removing and installing Lambda probe”, page 275
❑ 60 Nm
8. Lambda probe 273

8.1.2 Exploded view - Lambda probes, vehicles with particulate filter/cat-back

system

⇒ page 264
❑ Tighten pressure line to
45 Nm
sender for particulate fil‐
ter - G1037-
⇒ page 275
❑ Comprises:
Z19-
Lambda probes are
sembly paste.
paste
slots on the Lambda
probe body
page 275
❑ 60 Nm
3 - Lambda probe 1 after catalytic converter - GX7-
❑ Comprises:
♦ Lambda probe after catalytic converter - G130-
♦ Lambda probe 1 heater after catalytic converter - Z29-
❑ Installation position varies
❑ 60 Nm
❑ Only for vehicles with particulate filter

❑ ⇒ 4-cylinder direct injection engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 26 ; Exhaust gas temperature
❑ Only for vehicles with particulate filter
❑ ⇒ 4-cylinder direct injection engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 26 ; Exhaust gas temperature
Pressure differential sender for particulate filter - G1037- - tight‐

ening torque

filter/cat-back system”, page 274

1 before catalytic converter - GX10-
Removing
gr. 24 ; Lambda probe; Removing and installing Lambda probe .
8. Lambda probe 275

Lambda probe 1 before catalytic converter - GX10- :

set - 3337- .
Installing
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Lambda probe;
Tightening torques

1 after catalytic converter - GX7-
Removing
gr. 24 ; Lambda probe; Removing and installing Lambda probe .
Note:

Lambda probe 1 after catalytic converter - GX7- (version 1):

– Unscrew Lambda probe 1 after catalytic converter - GX7-
set - 3337- .

set - 3337- .

set - 3337- .
Installing
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Lambda probe;
Tightening torques
8. Lambda probe 277


Engine control unit .

cautions .


gine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 26 ; Exhaust pipes/
silencers; Exploded view - silencers .

silencers; Separating exhaust pipes/silencers .

silencers; Removing and installing front silencer .

silencers; Removing and installing silencers .

silencers; Stress-free alignment of exhaust system .

Procedure
– Plug tailpipes (e. g. with rags or stopper) and leave plugged
until the check is complete.
– Listen for noise at connection points (cylinder head/turbo‐
charger, turbocharger/front exhaust pipe etc.) to locate any
leaks.



tem
⇒ “3.1.1 Exploded view - emission control system, vehicles with‐
particulate filter/cat-back system”, page 282
3.1.1 Exploded view - emission control system, vehicles without particulate filter
1 - Gasket
2 - Turbocharger
❑ Exploded view
⇒ page 216
❑ Comprises:
Z19-
❑ Exploded view
⇒ page 273
4 - Nut
❑ Lubricate studs for tur‐
bocharger with high-
logue .
❑ 40 Nm
❑ Comprises:
Z29-
ies
❑ Exploded view
⇒ page 273

3.1.2 Exploded view - emission control system, vehicles with particulate filter/cat-
back system

sender 4 - G648-
❑ Only for vehicles with
particulate filter
❑ ⇒ 4-cylinder direct in‐
jection engine (1.8, 2.0
sender 3 - G495-
particulate filter
❑ ⇒ 4-cylinder direct in‐
jection engine (1.8, 2.0
3 - Gasket
4 - Turbocharger
❑ Exploded view
⇒ page 216
❑ Comprises:
Z19-
❑ Exploded view
⇒ page 273
6 - Gasket
❑ Mounting components on gearbox ⇒ page 283
❑ Comprises:
9 - Nut

❑ Lubricate studs for turbocharger with high-temperature paste ⇒ Electronic parts catalogue .
❑ 40 Nm
10 - Nut
❑ 23 Nm
11 - Particulate filter/cat-back system
♦ Particulate filter - distinguishing features: with exhaust gas temperature senders and exhaust gas pressure
sensor
♦ Cat-back system - distinguishing features: without exhaust gas temperature sender and exhaust gas pres‐
sure sensor
Mounting components for particulate filter/cat-back system on

gearbox
1- Spacer sleeve
2- Spacer sleeve
4- Washer
5- Bolt, 23 Nm
6- Bolt, 23 Nm
7- Spacer sleeve
8- Buffer
9- Bracket
Mounting components for catalytic converter on gearbox

1- Spacer sleeve
3- Washer
4- Bolt, 23 Nm
5- Spacer sleeve
6- Bolt, 23 Nm
7- Buffer
8- Bracket
9- Spacer sleeve


verter
gine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 26 ; Emission control
system; Removing and installing catalytic converter .

On some models and versions, a particulate filter or cat-back
system may be fitted. All procedures are described in ⇒ 4-cylinder
Emission control system; Removing and installing particulate fil‐
ter .


Depending on model and version: All procedures and compo‐
nents are described in ⇒ 4-cylinder direct injection engine (1.8,
2.0 ltr. 4-valve TFSI); Rep. gr. 26 ; Exhaust gas temperature
control .

5 Secondary air system

⇒ “5.1 Exploded view - secondary air system”, page 286
⇒ “5.2 Removing and installing secondary air pump motor V101
”, page 287
⇒ “5.3 Removing and installing secondary air inlet valve N112 ”,
page 288
⇒ “5.4 Removing and installing sender 1 for secondary air pres‐
⇒ “5.5 Removing and installing resonator for secondary air sys‐
tem”, page 288
5.1 Exploded view - secondary air system
1 - O-ring
ly; supplied with
gine oil
2 - Sender 1 for secondary air
pressure - G609-
⇒ page 288
3 - O-ring
ly; supplied with
gine oil
4 - Resonator
5 - Nut
❑ 8 Nm
6 - O-ring
ly; supplied with
gine oil
7 - Bolt
❑ 9 Nm
8 - Bolt
❑ 9 Nm
9 - Bracket
10 - Gasket
11 - Secondary air inlet valve - N112-

12 - Bolt
❑ 9 Nm
13 - Hose
14 - Bolt
❑ 20 Nm
15 - Bolt
❑ 20 Nm
16 - Pipe
❑ For secondary air
17 - Secondary air pipe
❑ From air cleaner housing to secondary air pump motor - V101-
18 - O-ring
19 - Nut
❑ 9 Nm
20 - Bolt
❑ 9 Nm
21 - Nut
❑ 8 Nm
22 - Rubber bush
23 - Secondary air pump motor - V101-
5.2 Removing and installing secondary air

pump motor - V101-
Removing
gr. 26 ; Secondary air system; Removing and installing secon‐
dary air pump motor - V101- .
– Press release tabs on both sides and disconnect secondary
air hose -3-.
– Unscrew bolts -5- and nut -2- and detach secondary air pump
motor - V101- -item 1-.
Installing
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 26 ; Secondary air
system; Removing and installing secondary air pump motor -
V101-
Tightening torques
♦ ⇒ “5.1 Exploded view - secondary air system”, page 286
5. Secondary air system 287

5.3 Removing and installing secondary air

inlet valve - N112-
Removing
gr. 26 ; Secondary air system; Removing and installing secon‐
dary air inlet valve - N112- .
– Release hose clip -3- and detach secondary air inlet valve -
N112- .
Installing
system; Removing and installing secondary air inlet valve - N112-
Tightening torques
♦ ⇒ “5.1 Exploded view - secondary air system”, page 286
5.4 Removing and installing sender 1 for

secondary air pressure - G609-
Removing
gr. 26 ; Secondary air system; Removing and installing sender 1
for secondary air pressure - G609- .
– Release catches -arrows- and detach sender 1 for secondary
air pressure - G609- -item 2-.
Installing
system; Removing and installing sender 1 for secondary air pres‐
sure - G609-
5.5 Removing and installing resonator for

secondary air system
Removing
cylinder direct injection engine (1.8, 2.0 ltr. 4-valve TFSI - gener‐
ation III); Rep. gr. 26 ; Secondary air system; Removing and
installing secondary air pump motor - V101- .

– Unclip line -1-.

– Remove nut -3-.
– Press release tabs -arrows- together and disconnect line.
– Detach resonator -4- from bracket.
Installing
engine (2.0 ltr. 4-valve TFSI, EA 888 Gen. III); Rep. gr. 26 ; Sec‐
ondary air system; Removing and installing resonator for secon‐
dary air system
5. Secondary air system 289

cautions .

2 Ignition system
⇒ “2.2 Removing and installing ignition coils”, page 292
page 295
297
1 - Bolt
❑ Tightening torque influ‐
ences the function of the
knock sensor
❑ 8 Nm + 90°
⇒ page 295
3 - Spark plug
❑ 30 Nm
5 - Ignition coil
❑ Ignition coil 1 with output
stage - N70-
stage - N127-
stage - N291-
stage - N292-
⇒ page 292
6 - Bolt
❑ 10 Nm
7 - Nut
❑ 9 Nm
8 - Bolt
❑ 9 Nm
❑ Check O-ring for damage
10 - O-ring

11 - O-ring
13 - Bolt
❑ 9 Nm
14 - O-ring
16 - Bolt
❑ 4 Nm +45°

♦ Puller - T10530-
♦ For silicone paste, refer to ⇒ Electronic parts catalogue .

Removing
gr. 28 ; Ignition system; Removing and installing ignition coils .


catalytic converter - GX10- -item 2- from bracket.
Note:
– Remove corresponding centre hex stud -3-.
– Insert puller - T10530- into hole -1- in ignition coil.

– Turn knurled nut -2- clockwise -arrow- until puller is secured
in place.

– Carefully pull ignition coil out vertically -arrow- with puller -

T10530- .
Installing
Installation is carried out in the reverse order; note the following:
hose of ignition coil -arrow-.
Note
♦ Use only the silicone paste approved for this purpose ⇒ ET‐
KA .
♦ Using any other paste could damage the ignition coil irrepar‐
ably.
– Push spark plug connector -2- onto ignition coil -1- by hand as
far as stop.
• The arrow markings on the spark plug connector and the ig‐
nition coil must be aligned, as shown.
use tools).
engine (1.8, 2.0 ltr. 4-valve TFSI); Rep. gr. 28 ; Ignition system;
Removing and installing ignition coils
Tightening torques


- G61-
Fitting location: below intake manifold behind actuator for engine
temperature regulation - N493-
Removing
– Remove actuator for engine temperature regulation - N493-
⇒ page 209 .
– Release fastener -arrow-, detach electrical wire -1- for knock
sensor 1 - G61- from bracket -2- and move wire clear.
– Unscrew knock sensor 1 - G61- -arrow-.

Installing
– Install actuator for engine temperature regulation - N493-
⇒ page 209 .
Tightening torques

⇒ “2.4.1 Removing and installing Hall sender G40 ”, page 295
⇒ “2.4.2 Removing and installing Hall sender 3 G300 ”,
page 296
2.4.1 Removing and installing Hall sender -

G40-

♦ Bit - T10573-
Removing
– Depending on version: Detach MPI injectors with fuel rail and
move to one side ⇒ page 253 .
– Unscrew bolt -1- and remove Hall sender - G40- -item 2-.
Installing
• Check O-ring for damage.
– Install MPI injectors with fuel rail ⇒ page 253 .
moving or renewing Hall senders.
♦ Drive train
Tightening torques
2.4.2 Removing and installing Hall sender 3 -

G300-
Removing
gr. 28 ; Ignition system; Removing and installing Hall senders .

– Unplug electrical connector -3- at Hall sender 3 - G300-

-item 2-.
– Unscrew bolt -1- and detach Hall sender.
Installing
Removing and installing Hall senders
moving or renewing Hall senders.
♦ Drive train
Tightening torques

sender - G28-
Removing
gr. 28 ; Ignition system; Removing and installing engine speed
sender - G28- .


– Remove bolt -arrow- and detach engine speed sender - G28-
-item 2-.
Installing
Removing and installing engine speed sender - G28-
moving or renewing engine speed sender.
♦ Drive train
Tightening torques

Service
Workshop Manual
Audi A5 2016 ➤ , Audi A6 2019 ➤ ,
Audi A6 China 2019 ➤ ,
Audi Q5 China 2019 ➤
Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI (EA
888, Gen. III B cycle)
Engine ID
CVK DBP CWN CVLA DEM DHD DKU DKU DKY
B A A A A A B A
DLVA DLVB CVK DEM
C B
Edition 12.2019

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system

Copyright © 2019 Audi AG, Ingolstadt D4B805823A0

Audi A4 2015 ➤ , Audi A4 China 2016 ➤ , Audi A5 2016 ➤ , Audi A6 2019 ➤ ...
Servicing 4-cylinder engine, 2.0 ltr. 4-valve TFSI (EA 888, Gen. III B cycle) - Edition 12.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3.7 Nuts, bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Contents i

4.3 Renewing oil seal for balance shaft (inlet side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

1.3 Renewing oil seal for vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.2 Exploded view - drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.3 Removing and installing bearing saddle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.5 Checking chain elongation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.6 Removing and installing drive chain for balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
2.3 Removing and installing mechanical switching valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
ii Contents

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

2 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3.4 Cleaning throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
4 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
5 Gas injection valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Contents iii
6 Gas pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
7.6 Removing and installing pressure differential sender for particulate filter G1037 . . . . . . . . 242
9 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

3.2 Removing and installing parts of exhaust gas temperature control . . . . . . . . . . . . . . . . . . 267
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
1.2 Removing and installing ignition coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
iv Contents
1 Identification
(ARL006767; Edition 12.2019)

Engine number
♦ The engine number (“engine code” and “serial number”) can
be found at the front of the joint between engine and gearbox.
ers.
Engine data
♦ ⇒ Rep. gr. 00 ; Overview of engines; Overview of engines
with adjustment values .
1. Identification 1
tem”, page 2
page 3
page 3
page 4

may spray out.

fuel pump.


a road test
Or:
seat.

Risk of injury from radiator fan(s)

The radiator fans can start up automatically and trap or draw in
parts of the body.
– Do not reach into the radiator fan when unplugging the con‐
nector.

Risk to health due to chemical substances in components of ex‐

haust system
Risk to health if components of system for after-treatment of ex‐
haust gases are dismantled.
– Do NOT cut, saw or open components of system for after-
treatment of exhaust gases.

Risk of injury due to hot condensation and particles in exhaust

system
There may be hot condensation and/or particles in the exhaust
system. Risk of eye and skin injuries, damage to the respiratory
tract and poisoning.
– Wear protective gloves and safety goggles while performing
cutting work on the exhaust system.
– When performing cutting work, use an extraction system or
ensure sufficient ventilation.


6

opening.
that have been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).

Note
If the turbocharger has suffered mechanical damage

⇒ page 188

fitted.
Please note:
ranty.

and wiring
ing.
♦ After attaching, check the routing of the fuel lines and refrig‐
erant lines. They must be inserted in the retainers provided
and should not make contact with other components.


Procedure
♦ Cracks


3.7 Nuts, bolts

quence.
quence and method.
bolts.


be used.
Requirements:
speed.
able torque range.

Use:
a torque wrench.


page 9
1.1 Removing engine

gine (2.0 ltr. 4-valve TFSI); Rep. gr. 10 ; Removing and installing
engine; Removing engine .

support
Procedure
tackle - 2024A-
Note
To adjust to the centre of gravity of the assembly, the perforated

rails of the support hooks must be positioned as shown.
WARNING

– Secure support hooks and retaining pins with locking pins

-arrows-.

– Secure engine to engine and gearbox support - VAS 6095A-

using universal mounting - VAS 6095/1- .
Tightening torque
Component Nm
Bolts/nuts M6 10
M8 20
M10 45
M12 65
Assembling

gine (2.0 ltr. 4-valve TFSI); Rep. gr. 10 ; Removing and installing
engine; Installing engine .

direct injection engine (2.0 ltr. 4-valve TFSI); Rep. gr. 10 ; As‐
sembly mountings .


panel
Removing
– Carefully pull engine cover panel off ball studs one after an‐
other -arrows-. Do not jerk engine cover panel away, and do
not try to pull on one side only.
Installing
and dipstick.
– Press engine cover panel onto ball studs first on left side, then
on right side.

page 35

end)
1.1.1 Exploded view - cylinder block (pulley end), vehicles with alternator

1 - Poly V-belt
❑ Check for wear
❑ Do not kink
⇒ page 15
⇒ page 18
on pulleys.
❑ Pivot with wrench to
slacken poly V-belt
❑ Lock in position with
locking pin - T10060A- .
⇒ page 20
3 - Bolt
❑ 8 Nm +45°
4 - Bolt
ing and tightening
engine oil
150 Nm + 90°
❑ Property class 10.9: 100 Nm + 180°
❑ The property class of the bolt is visible on the bolt head
5 - O-ring
❑ Not available as replacement part; supplied together with bolt
⇒ “1.4.1 Removing and installing vibration damper - vehicles with alternator”, page 21
⇒ “1.5.1 Removing and installing bracket for ancillaries - vehicles with alternator”, page 35
8 - Gasket
9 - Bolt

10 - Bolt
11 - Alternator
12 - Dowel sleeves
14 - Bolt

1- Vibration damper
3- Alternator
Bracket for ancillaries - tightening torques and tightening se‐

quence
Note

angle.

tion
2. -1 … 5- 20 Nm

1.1.2 Exploded view - cylinder block (pulley end), vehicles with starter-alternator
1 - Poly V-belt
❑ Check for wear
❑ Do not kink
⇒ page 17
⇒ page 18
on pulleys
2 - Bolt
engine oil
❑ Different versions (de‐
pending on type of gear‐
box and property class
of bolt)
❑ Vehicles with manual
class 10.9: 240 Nm +
180°
class 8.8: 150 Nm + 90°
class 10.9: 100 Nm +
180°
bolt head
3 - O-ring
❑ Not available as replacement part; supplied together with bolt
⇒ “1.4.2 Removing and installing vibration damper - vehicles with starter-alternator”, page 27
5 - Bolt
❑ 8 Nm + 90°
7 - Gasket

8 - Bolt
10 - Bolt
11 - Tensioner
❑ For poly V-belt
⇒ “1.3.2 Removing and installing poly V-belt tensioner - vehicles with starter-alternator”, page 20
13 - Bolt
14 - Dowel sleeves
Routing of poly V-belt for starter-alternator - C29-

1- Vibration damper
2- Idler roller
Bracket for ancillaries, vehicles with starter-alternator - tightening

torques and tightening sequence
Note

angle.

tion
2. -1 … 5- 20 Nm


⇒ “1.2.1 Removing and installing poly V-belt - vehicles with alter‐
nator”, page 18
⇒ “1.2.2 Removing and installing poly V-belt - vehicles with start‐
er-alternator”, page 19
1.2.1 Removing and installing poly V-belt - ve‐

hicles with alternator
Removing
WARNING

Caution



Installing
1.2.2 Removing and installing poly V-belt - ve‐

hicles with starter-alternator
Removing
WARNING

Caution



Installing

sioner

sioner - vehicles with alternator
Removing
– Remove bolts -arrows- and take off tensioner -1- for poly V-
belt from bracket for ancillaries.
Installing
Tightening torques

sioner - vehicles with starter-alternator
Removing


– Remove tensioner -1-.
Installing
Tightening torques

er

er - vehicles with alternator

Components of assembly tool - T10531- :

♦ Support - T10531/1-
♦ Clamping pin - T10531/2-
♦ Turning-over tool - T10531/3-
♦ Flange nut - T10531/4-
Note
The securing bolt for the vibration damper -A- secures the vibra‐
tion damper -1-, timing chain sprocket -2- and crankshaft -3- to
each other. Before removing the securing bolt, the timing chain
sprocket must be secured to the crankshaft as described below.
Removing
damper .
– Remove pulley without locking tensioner in place
⇒ “1.2.1 Removing and installing poly V-belt - vehicles with
alternator”, page 18 .

Caution

slips.
-arrow-.

position.
Caution
Do not loosen bolt for vibration damper by more than a half turn
at this stage.
– Loosen bolt for vibration damper by approx. a half turn using

counterhold tool - T10355- .
“TDC” position.

and screw in knurled screws -arrows- hand-tight.


easily over clamps -B-. Turn tensioning bolt -arrow- if neces‐
sary.
Note
Do not turn the tensioning bolt from this stage onwards; otherwise
the clamping pin - T10531/2- will get stuck when it is screwed into
the crankshaft.


crankshaft.



sprocket).
-item B-.
Installing
Note
Renew bolt with O-ring after removal.

T10531/2- .



T10531/2- .
tated.

– Unscrew flange nut - T10531/4- -item A- and loosen tensioning

bolt -B-.
over tool - T10531/3- .

-1- hand-tight.

– Remove knurled screws -arrows- and detach support -

T10531/1- .
– Tighten bolt for vibration damper using counterhold tool -

T10355- .
note the following:
Note
Renew bolts for timing chain cover after removal.

Tightening torques

er - vehicles with starter-alternator


♦ Adapters - T10531/5-
♦ Clamping pin - T10531/6-
Note
The securing bolt for the vibration damper -A- secures the vibra‐
tion damper -1-, timing chain sprocket -2- and crankshaft -3- to
each other. Before removing the securing bolt, the timing chain
sprocket must be secured to the crankshaft as described below.
Removing
damper .
starter-alternator”, page 19 .
– Remove bolts -arrows- and press wiring duct downwards.

Caution

slips.
-arrow-.

position.
Caution
Do not loosen bolt for vibration damper by more than a half turn
at this stage.
– Loosen bolt for vibration damper approx. 1/2 a turn; depending

on version, use counterhold tool - T40378- or counterhold tool
- T40379- -1- to do so.
“TDC” position.

– Screw adapter -T10531/5- into cylinder block hand-tight.


easily over clamps -B-. Unscrew tensioning bolt -arrow- slight‐
ly if necessary.
Note
Do not turn the tensioning bolt from this stage onwards; otherwise
the clamping pin - T10531/6- will get stuck when it is screwed into
the crankshaft.


crankshaft.



sprocket).
-item B-.
Installing
Note
Renew bolt with O-ring after removal.

T10531/6- .



T10531/6- .
tated.

– Unscrew flange nut - T10531/4- -item A- and tensioning bolt

-B-.
over tool - T10531/3- .


-1- hand-tight.
– Remove knurled screws -1, 3- and detach support -

T10531/1- .
– Unscrew adapter - T10531/5- .
– Tighten bolt for vibration damper; depending on version, use

counterhold tool - T40378- or counterhold tool - T40379- -1-
to do so.
note the following:
Note
Renew bolts for timing chain cover after removal.

Tightening torques


cillaries

cillaries - vehicles with alternator
Removing
the side.
at bracket .

-item 4-

Note

caping oil.

Installing
Note

angle.

Note

Tightening torques

cillaries - vehicles with starter-alternator
Removing


wards.
at bracket .

Note

caping oil.

Installing
Note

angle.


– Install starter-alternator ⇒ Electrical system; Rep. gr. 27 ; Al‐
ternator; Removing and installing alternator .
Note

Tightening torques

gine (2.0 ltr. 4-valve TFSI); Rep. gr. 13 ; Cylinder block (pulley


page 41
1 - Cylinder block
2 - Dowel sleeves
end)
❑ With oil seal
⇒ page 41
❑ Before installing, re‐
move 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
4 - Bolt
5 - Drive plate
⇒ page 40
❑ A needle bearing must
be fitted in the drive
plate on vehicles with
manual gearbox; install
needle bearing if not yet
fitted ⇒ page 44
❑ There should be no nee‐
dle bearing fitted in the
drive plate on vehicles
with a dual clutch gear‐
box; remove needle
bearing if necessary
⇒ page 44
6 - Bolt
❑ 60 Nm +90°
7 - Needle bearing
❑ Do not damage/bend when assembling

Sealing flange (gearbox end) - tightening torques and sequence
Note

angle.

tion

– Engage intermediate plate on sealing flange -top arrow- and
push onto dowel sleeves -bottom arrows-.


Removing
Caution

drive plate.
– Remove bolts and take off drive plate -1-.

Installing
Note

angle.
♦ For equipment version with manual gearbox, a needle bearing
is fitted in the drive plate. Before installing, check that the nee‐
dle bearing is fitted. Removing and installing needle bearing
in drive plate (pressing in and out) ⇒ page 44 .

bolts.
Tightening torques
page 39

(gearbox end)
♦ Guide piece - T10122/6- or -T10122/6A- from fitting tool -
T10122B- or -T10122C-

♦ Assembly aid - T10122/1- from fitting tool - T10122B- or -

T10122C-

♦ Safety goggles
Removing
– Remove sealing flange.
Installing
Caution
Make sure sealant residue does not enter lubrication system.

♦ Place a clean cloth over the exposed section of the sump.
WARNING
Risk of eye injury.

– Remove sealant remaining on cylinder block -1- with flat scra‐

per or rotating plastic brush.

• Check that sealing lip of sealing flange is not bent or damaged.

• Sealing lip must face engine after installation. If the sealing lip
faces outwards after installation this will result in oil leakage.
– Check guide piece - T10122/6- -item B-; it must not have sharp
edges or be dirty.
– Fit assembly aid - T10122/1- -item A- onto guide piece
-item B-.
– Push sealing flange -C- onto guide piece -B-, starting with out‐
er edge.
– Detach assembly aid -A-.
Note

2 mm).

Note
Guide piece - T10122/6- is not shown in illustration.
Caution


• The sealing flange must be installed within 5 minutes after ap‐
plying sealant.
– Fit guide piece -A- with sealing flange -B- on crankshaft jour‐
nal.
Note:
It is not necessary to tighten bolts -arrows-.
– Push sealing flange -B- over guide piece -A- onto crankshaft
journal.
– Detach guide piece -A-.
– Secure sealing flange with bolts.
Note
After installing the sealing flange, wait about 30 minutes for the
sealant to dry. Then (and only then) fill the engine with engine oil.

note the following:
Tightening torques
page 39
Note

manual gearbox.

♦ Tube - VW 418 A-
♦ Tube - VW 421-
♦ Support - 40-103-
Procedure
– Place support - 40-103- under drive plate when pressing out
bearing.


VW 418 A- and workshop press.
gine.

3 Crankshaft
Note
Secure engine to engine and gearbox support when performing assembly work ⇒ page 9 .
1 - Cylinder block
2 - Bearing shell for cylinder
block
❑ With oil groove
shells
⇒ page 49
3 - Crankshaft
❑ After removing, place it
down so that the sender
wheel
does not become dam‐
aged
❑ If crankshaft is renewed,
new bearing shells must
be assigned to bearing
caps ⇒ page 49
ance ⇒ page 50
ance ⇒ page 51
❑ Crankshaft dimensions
⇒ page 49
4 - Bearing shell for bearing
cap
❑ Without oil groove
shells
⇒ page 49
5 - Bolt
3. Crankshaft 47

6 - Bearing caps
❑ Bearing cap 1: Pulley end
❑ Bearing caps 2, 3 and 4 are secured additionally with bolts at side
❑ Mark installation position for re-installation ⇒ page 49
7 - Bolt
❑ Sender wheel ⇒ Item 8 (page 48) must be renewed if bolts are loosened ⇒ page 52
❑ 10 Nm +90°
8 - Sender wheel
❑ For engine speed sender - G28-
❑ Can only be installed in one position
❑ Sender wheel must be renewed if bolts ⇒ Item 7 (page 48) are loosened
diagnostic tester
9 - Thrust washers
❑ For bearing No. 3
10 - Bolt
Crankshaft - tightening torques and sequence

tion
1. -1 … 10- and Screw in by hand until contact is made
-arrows A-
2. -1 … 10- 65 Nm
3. -1 … 10- Turn 90° further
4. -Arrows A- 15 Nm
5. -Arrows A- Turn 90° further

Markings on crankshaft bearing caps

– Mark position of bearing caps -1 ... 5- for re-installation.
• Lugs -arrows- on bearing caps face crankshaft bearing 3 on
inlet side.

Honing dimension Crankshaft Conrod
1) main bearing journal journal ∅ mm
∅ mm
Basic dimension 48.00 -0.032 47.80 -0.022
-0.052 -0.042
1) There is currently no provision for machining used crankshafts.

Bearing shells of the correct thickness are allocated to the cylin‐
der block and crankshaft at the factory. Coloured dots are used
to identify the thickness of the bearing shells.
Letter codes on lower sealing surface or end of cylinder block
indicate which bearing shell is to be fitted in cylinder block (top
bearing shell) at each location.
Letter codes on crankshaft indicate which bearing shell is to be
fitted in bearing cap (bottom bearing shell).
The first letter stands for bearing cap 1, the second letter for bear‐
ing cap 2, etc.
3. Crankshaft 49
Marking on bearing shell for cylinder block:

Marking on cylinder block refers to top bearing shell (bearing shell
for cylinder block).
– Note down letter and select colour coding to be fitted from the
table.
S = Black
R = Red
G = Yellow
V = Violet
W = White
Marking on bearing shell for bearing cap:

Marking on crankshaft refers to bottom bearing shell (bearing
shell for bearing cap).
– Note down letter and select colour coding to be fitted from the
table.
R = Red
G = Yellow
B = Blue
W = White
V = Violet
S = Black


Procedure
- VW387- onto cylinder block and set it against crank web.
“0”.
Axial clearance:
• New: 0.070 ... 0.231 mm.

shaft
♦ Plastigauge
Procedure
Note
♦ Use old bolts when measuring radial clearance.

♦ Renew used bearing shells.
– Remove crankshaft bearing caps and clean bearing caps and

journals.
bearing on the bearing journal or bearing shell.
ing shell
3. Crankshaft 51
– Fit crankshaft bearing caps and secure with old bolts

-1 ... 10- ⇒ page 48 without rotating crankshaft.
– Remove crankshaft bearing caps again.
Radial clearance:
• New: 0.017 ... 0.037 mm.

Removing
⇒ page 9
– Remove crankshaft and unbolt sender wheel.
Installing
– 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 wheel beneath the bolts will be
loose.
♦ Sender wheel can only be installed in one position. Holes are
off-set.
– If sender wheel was renewed, perform adaptions listed in Gui‐

ded Function “01 - Functions, engine mechanics” ⇒ Vehicle
diagnostic tester.
Tightening torques

4 Balance shaft
⇒ “4.3 Renewing oil seal for balance shaft (inlet side)”,
page 59
1 - Cylinder block
2 - Bolt
❑ 9 Nm
engine oil
sides together
⇒ page 55
4 - Pipe
❑ For balance shaft (ex‐
haust side)
⇒ page 54
5 - Bolt
❑ 9 Nm
side)
engine oil
sides together
⇒ page 58
7 - Needle bearing
❑ Needle bearing is col‐
our-coded; a needle
bearing with the same
colour must be installed
engine oil
8 - Needle bearing
❑ Needle bearing is colour-coded; a needle bearing with the same colour must be installed
9 - Pipe
10 - Oil seal
4. Balance shaft 53
Tube for balance shaft (inlet side) - installation position

• Lug -arrow A- on balance shaft must engage in notch
-arrow B- on tube.
Tube for balance shaft (exhaust side) - installation position

• Openings -right arrow- must face chain side.
– Insert tube -2- for balance shaft into cylinder block -1-.
• Installation position is correct when dimension -a- = 21 mm.


⇒ “4.2.1 Removing and installing balance shaft (inlet side)”, page
55
⇒ “4.2.2 Removing and installing balance shaft (exhaust side)”,
page 58

(inlet side)
Note
♦ The needle bearing must be renewed when removing and in‐

stalling the balance shaft.
♦ The needle bearing is colour-coded; a needle bearing with the
Removing
13 ; Balance shaft; Removing and installing balance shaft .
– Remove radiator ⇒ 4-cylinder direct injection engine (2.0 ltr.
– Remove drive chain for balance shaft ⇒ page 97 .
Caution
Risk of damage to thread.

♦ The drive sprocket bolt has a left-hand thread.

– Detach drive sprocket -1- for toothed belt for coolant pump.
– Unscrew bolt -1- and remove idler gear.
4. Balance shaft 55
– Detach bearing mounting -1-.
– Remove bolt -2- and pull out balance shaft (inlet side).
Installing
– Fit tube (pay attention to installation position ⇒ page 54 ).
– Clip on new needle bearing.
– Lubricate bearing and running surface -arrows- of balance
shaft (inlet side) with engine oil.
– Rotate balance shaft into installation position.
• The semi-circular bearing contact surface must face upwards
for installation.
– Insert balance shaft (inlet side) and tighten bolt -2-.

– Lubricate new O-ring -1- with engine oil.

– Lubricate bearing mounting with engine oil and insert it.
in cylinder block.
Caution

♦ Always renew idler gear; otherwise there will be no back‐
lash.
♦ The new idler gear has a special lubricant coating which
wears off after a short running period and thus automati‐
cally creates the specified backlash.
– Mark faces of gear teeth of idler gear with paint marker

-arrow-.
– Insert idler gear; marking on balance shaft must be positioned
between markings on faces of gear teeth.
– With gear in this position, tighten bolt -1- for idler gear: tight‐
ening sequence ⇒ page 81 .
– Check markings on idler gear/balance shaft -arrow-.
note the following:
– Install drive chain for balance shaft ⇒ page 97 .
– Renew oil seal for balance shaft (inlet side) ⇒ page 59 .
– Install radiator ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-
valve TFSI); Rep. gr. 19 ; Radiator/radiator fans; Removing
engine (2.0 ltr. 4-valve TFSI); Rep. gr. 13 ; Balance shaft; Re‐
moving and installing balance shaft
Tightening torques
4. Balance shaft 57

(exhaust side)
Note
♦ The needle bearing must be renewed when removing and in‐

stalling the balance shaft.
♦ The needle bearing is colour-coded; a needle bearing with the
Removing
13 ; Balance shaft; Removing and installing balance shaft .
– Remove radiator ⇒ 4-cylinder direct injection engine (2.0 ltr.
– Remove drive chain for balance shaft ⇒ page 97 .
– Remove bolt -1- and pull out balance shaft (exhaust side).
Installing
– Check installation position of tube for balance shaft
⇒ page 54 .
– Lubricate bearing and bearing race -arrows- of balance shaft
(exhaust side) with engine oil.
– Rotate balance shaft into installation position.
• The semi-circular bearing contact surface must face upwards
for installation.

– Insert balance shaft (exhaust side) and tighten bolt -1-.

note the following:
– Install drive chain for balance shaft ⇒ page 97 .
– Install radiator ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-
valve TFSI); Rep. gr. 19 ; Radiator/radiator fans; Removing
engine (2.0 ltr. 4-valve TFSI); Rep. gr. 13 ; Balance shaft; Re‐
moving and installing balance shaft
Tightening torques
4.3 Renewing oil seal for balance shaft (inlet

side)
♦ Thrust piece - T10353/1-
Procedure
Caution

– Unscrew bolt -2- and detach drive sprocket -1- for toothed belt
for coolant pump.
– Press screwdriver -1- firmly onto section -2- of oil seal

-arrow B-.
– Lever out oil seal -arrow A-.
4. Balance shaft 59
– Lubricate sealing surface of balance shaft -2- with gear oil.

– Fit oil seal -1- onto balance shaft.
• Marking “Inside” -arrow- must face towards engine.
Caution

– Apply thrust piece - T10353/1- to oil seal -1- and carefully

press into cylinder block as far as stop using bolt -2- (take care
not to tilt oil seal).


page 69
1 - Bolts
❑ Lubricate thread and
contact surface with en‐
gine oil
ance
❑ 45 Nm +90°
tion
conrod
-A-
Marking -B- faces to‐
wards pulley end
❑ Separating parts of new
conrod ⇒ page 69
3 - Bearing shells
⇒ page 62
shells
before installing
❑ Axial clearance
♦ New: 0.10 ... 0.35 mm
♦ Wear limit: 0.40 mm
4 - Conrod
❑ Mark cylinder and conrod bearing cap allocation

❑ Installation position: Marking -B- faces towards pulley end

❑ 27 Nm
6 - Oil spray jet
7 - Circlip
8 - Piston pin
9 - Piston
❑ Installation position: arrow on piston crown points to pulley end
❑ Mark allocation to cylinder
❑ Allocation and installation position ⇒ page 63
❑ Checking ring gap ⇒ page 68
❑ Remove and install 3-part oil scraper ring carefully by hand
❑ When installing, offset top gap of 3-part oil scraper ring by 120° to next compression ring
❑ Allocation ⇒ page 63
Bearing shell - installation position

– Position bearing shells in centre of conrod and conrod bearing
cap when fitting.


1- Compression ring with chamfer -A- (inside, top): into upper
groove. »TOP« marking or lettering faces upwards.
2- Compression ring with shoulder -B- (outer side, bottom): into
centre groove. »TOP« marking or lettering faces upwards.
3- Oil scraper ring (two or three parts, depending on version)

• »TOP« marking or lettering faces upwards.
Installing oil scraper ring - version with three parts

• Install by hand.
– 1. Insert spring -1- in groove.
– 2. Insert bottom fin -3- in groove.
– 3. Insert top fin -2- in groove.

Oil spray jets - installation position

• Side surface of oil spray jet -1- must be parallel with adjacent
crankshaft bearing -2-.

♦ Pin - VW 222A-
♦ Funnel - T40347-
Removing
• Engine secured to engine and gearbox support ⇒ page 9 .
♦ Pistons to cylinders
♦ Conrods to cylinders ⇒ Item 4 (page 61)

upwards.
Note

Installing
Note

angle.
♦ Arrow on piston crown points to pulley end.
♦ Offset top gap of 3-part oil scraper ring by 120° to next com‐
pression ring.
– Install compression rings ⇒ page 63 .

– Install oil scraper ring ⇒ page 63 .
– Lubricate running surfaces of bearing shells and cylinder walls

with engine oil.
funnel - T40347- .
Tightening torques

♦ Socket T40 - T10545-

Removing cylinders “1” to “3”:

Caution

slips.
– Using ratchet wrench (21 mm) - T40263- , adapter - T40314-

and socket (24 mm), turn crankshaft -arrow- until correspond‐
ing bolt is accessible.
Removing cylinder 4:
⇒ page 9
– Remove crankshaft.


Installing
• Installation position ⇒ page 64
Caution
Risk of damage to oil spray jets.

♦ Do not bend oil spray jets.
♦ Check that oil spray jets have adequate clearance after
re-installing pistons.
♦ Always renew bent oil spray jets.
– Install balance shaft timing chain ⇒ page 85 .

Tightening torques

Checking piston
♦ Maximum deviation from nominal dimension: 0.04 mm.
Piston ∅ mm
• 1) Dimensions not including coating (thickness 0.02 mm). The
coating will wear down in service.


♦ Cylinder gauge - VAS 6078-
Note
Do not measure the cylinder bores when the cylinder block is

mounted to the engine and gearbox support, as this may result in
incorrect measurements.
Caution
Machining (reboring, honing, grinding) cylinder bore with work‐

shop equipment is not permitted. The surface of the cylinder
bore is damaged by machining.
– Use cylinder gauge - VAS 6078- to take measurements at 3

-B-.
♦ Maximum deviation from nominal dimension: 0.08 mm.
• 1) Measure at 50 mm into cylinder bore.
Checking piston ring gap

– Insert piston 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.
mm mm
Oil scraper rings Cannot be measured


– Clamp conrod -1- in a vice below the dotted line using alumi‐
nium jaw covers.
Note
To avoid any risk of damage, the conrod should only be clamped

lightly.


bearings
♦ Plastigauge
Procedure
Radial clearance:
• New: 0.02 ... 0.06 mm.


⇒ “1.3 Renewing oil seal for vibration damper”, page 75
1 - O-ring
3 - Bolt
❑ 9 Nm
jection engine (2.0 ltr. 4-
valve TFSI); Rep. gr.
19 ; Coolant pipes; Re‐
coolant pipes
5 - Bolt
6 - Bolt
❑ 9 Nm
N205-
⇒ page 127
8 - Bolt
❑ 9 Nm
valve 1 - N318-
⇒ page 127
10 - Seals
❑ Installation position: side with small inner diameter faces outwards
❑ To renew, remove timing chain cover (top) ⇒ Item 13 (page 70)
11 - Seal
❑ Renew if damaged or leaking
12 - Filler cap
13 - Timing chain cover (top)

14 - Gasket
15 - O-rings
16 - Dowel pin
❑ 2x
❑ For timing chain cover (bottom)
17 - Bolt
❑ With oil seal
19 - Oil seal
❑ For vibration damper
20 - Sealing plug
Timing chain cover (top) - tightening torques and tightening se‐

quence
Timing chain cover (bottom) - tightening torques and tightening

sequence
Note

angle.

tion
2. -1 … 15- 8 Nm
3. -1, 2, 4, 5- and Turn 45° further
-7 … 15-
tion damper


cover
page 72

cover (top)
Removing
15 ; Timing chain cover; Removing and installing timing chain
cover .
– Remove camshaft control valves ⇒ page 127 .
the side.
– If necessary, unclip guide tube -1- for oil dipstick from timing
chain cover (top) -arrow- and pull it out of timing chain cover
(bottom).

– Unscrew bolts -1 ... 6- and remove timing chain cover (top).

Installing
Note
Renew seals and O-rings after removing.
– Lubricate seals and O-rings with engine oil.

• Installation position of seals: side with small inner diameter
faces outwards
– Install camshaft control valves ⇒ page 127 .
engine (2.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Timing chain cover;
Removing and installing timing chain cover
Tightening torques
♦ ⇒ Fig. ““Timing chain cover (top) - tightening torques and tight‐

Removing
the side.

– If necessary, unclip guide tube -1- for oil dipstick from timing
chain cover (top) -arrow-.
– Pull guide tube for oil dipstick out of timing chain cover (bot‐
tom).
– Remove tensioner for poly V-belt ⇒ page 20 .

– Prise off timing chain cover (bottom).
Installing
Note

angle.
♦ Renew timing chain cover (bottom) and seal after removal.
Caution


– Check that both dowel pins -arrows- for centring cover are fit‐
ted.

Note

3 mm).
Caution

– Apply sealant onto clean sealing surface -arrow 1- and onto

edges -arrows 2- of new cover.
Note
The cover must be installed within 5 minutes after applying seal‐

ant.
– Immediately fit cover and tighten bolts.
Note
After fitting cover, the sealant must dry for approx. 30 minutes.

– Install poly V-belt tensioner ⇒ page 20 .
Tightening torques
♦ ⇒ Fig. ““Timing chain cover (bottom) - tightening torques and
tightening sequence”“ , page 71
1.3 Renewing oil seal for vibration damper


♦ Thrust washer - T10375-
♦ Flange nut - 10531/4- from assembly tool - T10531-
♦ Extractor hook - T40274-

Removing
– Pry out oil seal -arrow- using extractor hook - T40274- .
– Fit oil seal -arrow- onto thrust piece - T10354- .

• Closed side of oil seal faces thrust piece - T10354- .
– Vehicles with alternator: Slide oil seal -arrow- with thrust piece
- T10354- onto clamping pin - T10531/2- -item 1- and position
it on timing chain cover (bottom).
– Vehicles with starter-alternator: Slide oil seal -arrow- with
thrust piece - T10354- onto clamping pin - T10531/6-
-item 1- and position it on timing chain cover (bottom).
– Also fit thrust pad - T10375- and tighten flange nut - 10531/4- .
– Drive oil seal in as far as stop using thrust piece - T10354- .
Installing

2 Chain drive
⇒ “2.2 Exploded view - drive chain for balance shaft”, page 80
⇒ “2.3 Removing and installing bearing saddle”, page 81
page 85
⇒ “2.5 Checking chain elongation”, page 96
⇒ “2.6 Removing and installing drive chain for balance shaft”,
page 97
Note
If work has been carried out on the chain drive, perform the adaptions listed in Guided Function “01 - Functions,
engine mechanics” ⇒ Vehicle diagnostic tester.
1 - Chain tensioner
❑ Exerts spring pressure
❑ Before removing, lock in
place using locking tool
- T40267-
2 - Bolt
❑ For aluminium bolts:
4 Nm + 90°
❑ For steel bolts: 9 Nm
3 - Guide pin
❑ 20 Nm
4 - Bolt
⇒ page 79
5 - Clamping sleeve
❑ Not fitted on all bearing
saddle versions
6 - Timing valve
❑ 35 Nm
7 - Timing valve
❑ 35 Nm
8 - Bearing saddle
⇒ page 81
10 - Bolt
❑ 9 Nm

11 - Guide rail
❑ For camshaft timing chain
❑ Mark direction of rotation for re-installation with a paint marker
❑ After carrying out work on chain drive, perform adaptions listed in Guided Function “01 - Functions, engine
mechanics” ⇒ Vehicle diagnostic tester
13 - Guide rail
14 - Guide pin
❑ 20 Nm
16 - Tensioning rail
Bearing saddle - tightening torques and sequence

2. -1 … 6- 9 Nm
Three-part chain sprocket assembly - installation position

• The two sections -arrows- must be aligned.
2. Chain drive 79
2.2 Exploded view - drive chain for balance shaft
1 - Three-part chain sprocket

assembly
⇒ page 79
2 - Guide pin
❑ 20 Nm
3 - Tensioning rail
❑ For drive chain for bal‐
ance shaft
4 - Drive chain for balance
shafts
⇒ page 97
5 - Guide pin
❑ 20 Nm
side)
❑ Exploded view
⇒ page 53
7 - Chain tensioner
❑ Use sealant when in‐
stalling ⇒ Electronic
parts catalogue
❑ 85 Nm
8 - Seal
9 - Cylinder block
❑ Exploded view
⇒ page 53
11 - O-ring
12 - Bearing mounting
13 - Idler gear
❑ If bolt ⇒ Item 15 (page 80) has been loosened, idler gear must be renewed
14 - Thrust washer
15 - Bolt
❑ If bolt has been loosened, idler gear ⇒ Item 13 (page 80) must be renewed
16 - Guide rail
❑ For drive chain for balance shaft
17 - Guide pin
❑ 20 Nm

18 - Guide rail
❑ For balance shaft timing chain
19 - Guide pin
❑ 12 Nm
Bearing mounting - installation position

– Lubricate new O-ring -1- with engine oil prior to installation.
in cylinder block.
– Lubricate bearing mounting with engine oil.
Idler gear - tightening torques and sequence
Note

angle.
– Tighten bolt in stages:

Stage Tightening torques/angle specification
1. 10 Nm
2. – Turn idler gear
• Idler gear must be without play; otherwise loos‐

en bolt and tighten again
3. 25 Nm
2.3 Removing and installing bearing saddle

♦ Assembly tool - T10352B-
2. Chain drive 81
Removing

Caution

♦ The timing valves have a left-hand thread.

tools:

mm).
WARNING
Risk of damage to bearing saddle.

♦ Detach bearing saddle carefully without tilting it.
2. Chain drive 83

-bottom arrows-.
Note
A second mechanic is required for the following steps.

and hold in place.
• This will press the chain tensioner back.
Note



Installing

WARNING

♦ Carefully attach bearing saddle without tilting it.
– Fit bearing saddle and screw in bolts -1 ... 6- by hand until they
make contact.
note the following:
♦ ⇒ Fig. ““Bearing saddle - tightening torques and sequence”“ ,

page 79

ing chain
2. Chain drive 85
♦ Assembly tool - T10352B-

2. Chain drive 87
Removing
Caution

♦ The timing valves have a left-hand thread.

tools:


mm).
WARNING

♦ Detach bearing saddle carefully without tilting it.
Caution

slips.
-arrow-.

• The marking -3- on each of the camshaft chain sprockets -2-

and -4- must face upwards.
• The notch -arrow- on the vibration damper -1- and the arrow
marking -5- on the timing chain cover (bottom) must be
aligned.
– Check “TDC” position again.
2. Chain drive 89
– Press support wire of tensioning spring in direction of -arrow-

and lock in place using locking pin - T40011- .
– Remove guide pin -1- and take off chain tensioner -2-.
– Detach chain for oil pump from three-part chain sprocket as‐
sembly, pull it off towards front and put it down on chain
sprocket for oil pump.

-bottom arrows-.
and hold in place.
• This will press the chain tensioner back.
Note




– Slide camshaft clamp into teeth of chain sprocket in direction
of -arrow B-.
– If necessary, turn inlet camshaft back and forth slightly
-arrows A- using assembly tool - T40266- or assembly tool -
T10567- .
Note
A second mechanic is required for the following step.
– Hold exhaust camshaft in position using assembly tool -

T40266- or assembly tool - T10567- . Remove guide pin -1-
and remove tensioning rail -2- downwards.
– Continue turning exhaust camshaft clockwise -arrow A- until
camshaft clamp - T40271/1- can be pressed into teeth
-arrow B- on chain sprocket.
– Unscrew bolts -arrows- and remove guide rail -1-.
– Remove guide pin -1- and take off guide rail -2-.
– Detach camshaft timing chain from sprockets and remove it
downwards.
Caution

♦ Do not turn the crankshaft after the camshaft timing chain
has been removed.
2. Chain drive 91
Installing
Requirements:
• Crankshaft in “TDC” position; V-shaped notch in three-part
chain sprocket assembly aligned with an imaginary vertical
line -arrows- centred between camshaft chain sprockets.
• Three-part chain sprocket assembly locked in position with
clamping pin - T10531/2- .
• Camshaft chain sprockets locked in “TDC” position with cam‐

shaft clamp - T40271/1- and -T40271/2- .
• The marks -arrows- must align.

are positioned on camshaft journals, as shown.


shaft and three-part chain sprocket assembly.
– Install guide rail -2- and tighten guide pin -1-.
– Install guide rail -1- and tighten bolts -arrows-.
2. Chain drive 93
Note
A second mechanic is required for the following step.
– Release tension on exhaust camshaft slightly by turning it in

direction of -arrow A- with assembly tool - T40266- or assem‐
bly tool - T10567- , and pull camshaft clamp - T40271/1- out
of teeth on chain sprocket -arrow B-.
– Allow exhaust camshaft to turn in direction of -arrow C- until
timing chain is in contact with guide rail -3-.
– Hold camshaft in this position, fit tensioning rail -1- and tighten
guide pin -2-.
– Release tension on inlet camshaft slightly by turning it in di‐

rection of -arrow A- with assembly tool - T40266- or assembly
tool - T10567- , pull camshaft clamp - T40271/2- out of teeth
on chain sprocket -arrow B- and bring camshaft into rest po‐
sition.



WARNING

♦ Carefully attach bearing saddle without tilting it.
– Fit bearing saddle and screw in bolts -1 ... 6- by hand until they
make contact.

– Fit drive chain for oil pump.

– Fit chain tensioner -2- and tighten guide pin -1-.
– Remove locking pin - T40011- ; support wire must come into
contact with opening -arrow- on sump (top section).
– Checking adjustment:
2. Chain drive 95
Caution

slips.
♦ Turn crankshaft only in direction of engine rotation (in
clockwise direction).
valve gear.
♦ Turn the engine carefully at least 2 rotations to ensure that
none of the valves make contact when the starter is op‐
erated.
– Fit flange nut - T10531/4- and turning-over tool - T10531/3- .

– Turn engine two rotations in direction of engine rotation.
Note
– Unscrew flange nut and remove turning-over tool.

note the following:
Learnt values for chain elongation must be re-adapted after car‐
rying out work on chain drive.
– Perform adaption ⇒ Vehicle diagnostic tester 01 - Engine
electronics, functions , 01 - Chain elongation adap-
tion diagnosis .
Tightening torques
page 80
2.5 Checking chain elongation

Procedure
noise insulation .

– Turn vibration damper in direction of engine rotation until pis‐

ton of chain tensioner has extended as far as it will go in
direction of -arrow-.
– Count visible teeth of piston.
Note:
Visible teeth are all teeth to the right of the chain tensioner hous‐
ing -arrow-.
• The timing chain must not be renewed if six or fewer teeth are
visible.
• If six or fewer teeth are visible and there is an entry in the event
memory: Adapt chain elongation (⇒ Vehicle diagnostic tester ,
01 - Chain elongation adaption diagnosis ) and delete
event memory.
• If seven or more teeth are visible: Renew camshaft timing
chain.
Tightening torques
2.6 Removing and installing drive chain for

balance shaft
♦ Sealant for chain tensioner ⇒ Electronic parts catalogue
Removing
2. Chain drive 97
Requirements:
– Remove bolts -4- and take off tensioner for camshaft timing
chain.
– Remove chain tensioner -3- for drive chain for balance shafts.
– Unscrew guide pin -1, 5- and take off tensioning rail -2- and
guide rail -6-.
– Detach drive chain for balance shaft.
Installing
Requirements:

– Start by placing drive chain for balance shafts onto balance

shafts as shown.
– Install guide rail -1- and tighten guide pins -arrows-.
– Position coloured link -arrow- of drive chain for balance shafts

as shown at marking on three-part chain sprocket assembly.
– Install tensioning rail -2- and tighten guide pin -1-.
2. Chain drive 99
– Position chain tensioner -arrow- with sealant (⇒ Electronic

parts catalogue ) and secure.
– Check adjustment again:

Tightening torques
page 80

3 Cylinder head

part number must face
cylinder head
agnostic tester 01 -
Engine electronics,
functions , 01 -
Chain elongation
adaption diagnosis
2 - Dowel pin
❑ 2x
3 - Cylinder head
⇒ page 104
⇒ page 104
❑ After renewal or remov‐
al and reinstallation,
perform adaption ⇒ Ve‐
hicle diagnostic tester
01 - Engine elec-
tronics, functions ,
01 - Chain elonga-
tion adaption diag-
nosis
4 - Bolt
5 - Heat shield
6 - Bolt
♦ Tighten initially to 5 Nm
♦ Subsequently tighten to 9 Nm
7 - O-ring

8 - Bolt
❑ 9 Nm
9 - Connection
10 - Bolt
11 - O-ring
12 - Bolt
❑ 9 Nm
13 - Connection
15 - Bolt
❑ 10 Nm +90°
16 - Separating plate
18 - Bolt
❑ 10 Nm +90°
Slackening cylinder head bolts

– Loosen and remove cylinder head bolts in sequence
-1 ... 10-.

Tightening torques and sequence for cylinder head

angle.
• Bolts - difference:
• Bolt without collar
• Bolt with collar -arrow-

tion
2. -1 … 10- Without collar: 40 Nm;
with collar: 50 Nm (difference
⇒ page 103 )
3. -1 … 10- Turn 90° further
4. -1 … 10- Turn 90° further
5. -Arrows- 8 Nm
6. -Arrows- Turn 90° further
Heat shield for vehicles with particulate filter - tightening torques

– Tighten nuts -arrows- and bolt -2- to 9 Nm.
Bracket for heat shield for vehicles with particulate filter - tighten‐
ing torques
Note:


♦ Max. permissible distortion: 0.05 mm


♦ Special wrench (Polydrive) - T10070-
♦ Bit XZN 12 - T40270-
♦ Blade scraper; blade width at least 40 mm (commercially avail‐

able)
Removing
15 ; Cylinder head; Removing and installing cylinder head .
Note
Re-install all cable ties in original positions.

battery .

– Drain coolant ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-

and filling up coolant .
Note
Place a cloth underneath to catch escaping engine oil.


– Detach electrical connectors -2, 3- from bracket and unplug.

– Unplug electrical connectors -1, 2, 3-.

manifold.
– If necessary, release and unplug electrical connector for fuel

pressure sender - G247- with assembly tool - T10118- .

-item 4-



– Release hose clip -1- and detach coolant hose (rear).
- G62- .


– Use special wrench (Polydrive) - T10070- or bit XZN 12 -
T40270- to remove cylinder head bolts in the sequence
-1 ... 10-.
Note
Make sure all hoses/pipes and wiring on component are discon‐

nected.
– Take off cylinder head.

Note
Seal off all open passages in the intake and exhaust system with
clean cloths or plugs (thoroughly cleaned) from engine bung set
- VAS 6122- .
Installing
Caution
Risk of damage to sealing surfaces.

♦ Carefully remove sealant residue from cylinder head and
cylinder block.
♦ Ensure that no long scores or scratches are made on the
surfaces.
Risk of damage to cylinder block.
♦ No oil or coolant must be allowed to remain in the blind
holes for the cylinder head bolts in the cylinder block.
Ensure that cylinder head gasket seals properly:
♦ Do not remove new cylinder head gasket from packaging
until it is ready to be fitted.
♦ Handle the cylinder head gasket very carefully to prevent
gasket.
Risk of damage to open valves.
♦ When installing an exchange cylinder head, the plastic
protectors fitted to protect the open valves should not be
removed until the cylinder head is ready to be fitted.

Note

angle.
♦ Renew self-locking nuts, as well as seals, gaskets and O-rings
after removing.
♦ When installing an exchange cylinder head, the contact sur‐
faces between the hydraulic compensation elements, roller
rocker fingers and cams must be oiled.
♦ After fitting a new cylinder head or cylinder head gasket,
Caution
Risk of engine damage due to contamination of lubrication

system with residue from abrasive materials.
♦ Do not use abrasive materials such as sandpaper, sand‐
ing discs, sanding pads, abrasive web, wire wool or similar
on sealing surfaces of cylinder block and cylinder head.
♦ When removing sealant residue, make sure none of the
residue enters the open channels of the engine.
♦ Ensure that nearby workspaces are kept clean and that
no impermissible abrasive materials are being used there.
– Remove sealant residue on cylinder block and cylinder head

using only a commercially available blade scraper (blade width
at least 40 mm).
• Sealing surface must not be raised.
• Dark discolouration does not have to be removed.

– Place cylinder head gasket in position.

dead centre and then turn crankshaft 90° anti-clockwise back
to “TDC” position.
– Insert and hand-tighten cylinder head bolts.
– Tightening sequence for cylinder head ⇒ page 103
Note

after repair work.

ing battery .
– Change coolant ⇒ 4-cylinder direct injection engine (2.0 ltr. 4-
engine (2.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Cylinder head; Re‐
moving and installing cylinder head
newing or removing and re-installing cylinder head.
tion diagnosis .
Tightening torques
gr. 26 ; Exhaust pipes/silencers; Exploded view - silencers


♦ Adapter - V.A.G 1763/13- (not illustrated)

Test sequence
– Unplug electrical connector -1- for FSI injectors.
– Unplug electrical connector -2- for MPI injectors/gas injection
valves.

– Screw adapter - V.A.G 1763/13- into corresponding spark plug

hole, as shown, and connect compression tester -
V.A.G 1763- .
to use tester).
– Press down accelerator pedal completely and simultaneously
operate starter until pressure no longer increases on tester
display.
When new 16.0 … 19.0
Wear limit 12.0
Assembling

4 Valve gear
ment”, page 126
page 127
1 - Exhaust valve
⇒ page 138
⇒ page 137
2 - Cylinder head
❑ Cylinder head and cylin‐
der head cover must be
renewed together
3 - Valve spring plate (bottom)
natural gas system
⇒ page 118
5 - Valve spring
6 - Hydraulic compensation el‐
ement
❑ Lubricate contact sur‐
face with engine oil
7 - Upper valve spring plate
8 - Valve cotters
9 - Securing clip
❑ For hydraulic compen‐
sation element
❑ Lubricate contact surfaces with engine oil
4. Valve gear 115


❑ Axial clearance when new: 0.1 +0.102 –0.05 mm
❑ After renewal or removal and reinstallation, perform adaption ⇒ Vehicle diagnostic tester 01 - Engine

❑ With integrated camshaft bearings
❑ Removing and installing ⇒ “4.2 Removing and installing camshaft”, page 118
❑ Clean but do not machine sealing surface
❑ Remove old sealant residues
❑ Cylinder head and cylinder head cover must be renewed together
13 - Bolt
14 - Ball stud
❑ 9 Nm
15 - Bracket
❑ For electrical wiring harness
16 - Bolt
❑ 9 Nm
17 - Sealing plug
18 - O-ring
19 - O-ring
❑ Not available as a replacement part, supplied together with actuator for camshaft adjustment
20 - Actuator for camshaft adjustment
♦ Actuator 1 for camshaft adjustment - F366-
21 - Bolt
❑ 4.5 Nm
22 - Spring
23 - Ball
❑ For slider


24 - Inlet camshaft
❑ Axial clearance when new: 0.1 +0.102 –0.05 mm
25 - Dowel pin
❑ 2x
26 - Inlet valve
❑ Valve dimensions ⇒ page 138
❑ Checking valve guides ⇒ page 137
Loosening cylinder head cover

– Loosen cylinder head cover bolts in the sequence -1 ... 6-.
Tightening torques and sequence for cylinder head cover
Note

angle.
♦ Take care to keep cylinder head cover straight.

tion
1. -1 … 6- Screw in by hand in several stages
until contact is made
2. -1 … 6- 8 Nm
4. Valve gear 117

Position of valve spring

• The closely spaced spring coils -arrow- face the cylinder head.
Different versions of valve stem oil seal

A - Valve stem oil seal with one sealing lip -A-
♦ For inlet and exhaust sides
B - Valve stem oil seal with two sealing lips -B-
♦ Only for exhaust side on some engines; for allocation refer to
⇒ Electronic parts catalogue

Removing
Note
♦ Do not machine the sealing surfaces between the cylinder

head cover and the cylinder head.

Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .

– If fitted, unplug electrical connector -2- for Lambda probe 1

after catalytic converter - GX7- -item 1- and move wiring clear.
Note:

2- For Lambda probe 1 before catalytic converter - GX10- (take
out of bracket)
– Unplug electrical connector -2- at actuators for camshaft ad‐

justment.
– Move vacuum hose -1- and electrical wiring clear.

4. Valve gear 119


– If necessary, release hose clip -1-, disconnect coolant hose
and move hose clear.
coal filter system.
Note:
– Lift retaining clip -3-, detach coolant hose -2-, move it clear at
cylinder head and push it to side.
– Detach vacuum hose -4-, disconnect vacuum line -1- for intake
manifold flap valve - N316- and move clear at cylinder head.
– Remove oil separator ⇒ page 152 .
– Attach turning-over tool - T10531/3- . In “TDC” position, flat

surface -1- faces upwards. Screw on flange nut - T10531/4- .
Turn crankshaft 90° anti-clockwise out of “TDC” position using
open-end spanner, 32 mm.

– Release tension on inlet camshaft slightly by turning it in di‐

rection of -arrow 1- with assembly tool - T40266- , pull cam‐
shaft clamp - T40271/2- out of teeth on chain sprocket
-arrow 2- and bring camshaft into rest position.
– Release tension on exhaust camshaft slightly by turning it in

direction of -arrow 1- with assembly tool - T40266- , pull cam‐
shaft clamp - T40271/1- out of teeth on chain sprocket
-arrow 2- and bring camshaft into rest position.
– Remove cylinder head cover bolts in the sequence -1 ... 6-.
4. Valve gear 121

– Carefully release cylinder head cover -2- from bonded joint

using a screwdriver -1- and detach it together with camshafts.
Note
Ensure that the camshafts do not fall out of the cylinder head
cover.
– Detach camshafts and cover exposed parts of engine.

– If necessary for additional work, mark roller rocker fingers and
hydraulic compensation elements for re-installation, remove
them and place them on a clean surface.
Installing
Note
♦ Crankshaft must not be at “TDC” position.

angle.
– Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly and are clipped onto their respec‐
tive hydraulic compensation elements.
If crankshaft has been rotated:

– Turn crankshaft to “TDC” position; V-shaped notch in three-
part chain sprocket assembly should be aligned with an imag‐
inary vertical line -arrows- centred between camshaft chain
sprockets.
– Then turn crankshaft 90° anti-clockwise again out of “TDC”
position.
Caution
Protect lubrication system and bearings against contamina‐

tion.
WARNING
Risk of eye injury.

– Remove sealant remaining on cylinder head with flat scraper.

– Remove sealant residue from groove in cylinder head cover
and from sealing surfaces.

Caution

♦ Pins of actuators for camshaft adjustment must be brought
– Press down pins of actuators for camshaft adjustment

-arrow- by hand.
• Pins of actuators must not be in extended position.
– Oil running surfaces of both camshafts with engine oil.
– Insert exhaust camshaft into cylinder head and rotate cams

-arrows- of cylinder 4 so that they are at top.
Caution
Risk of detaching spring-loaded ball for slider on camshaft.

♦ Do not push sliders on inlet camshaft beyond their normal
range of movement in either direction.
– Insert inlet camshaft in cylinder head cover.

• The sliders must be pushed away from the chain sprocket
-arrows-.
– With inlet camshaft fitted, push front and rear pairs of sliders
towards one another -arrows-.
4. Valve gear 123

– Turn inlet camshaft to “TDC” position.

• The marking -arrow A- must be aligned with cast projection
-arrow B- on cylinder head cover.

cylinder head cover.
♦ Thickness of sealant bead: 1.5 ... 2.5 mm
– Hold camshaft in position and place cylinder head cover on
cylinder head with camshaft fitted.
– Press lightly on cylinder head cover with your hand and rotate
camshafts back and forth slightly -arrows- until cylinder head
cover comes into contact with cylinder head such that it is free
of tension.
– Tighten bolts in several stages ⇒ page 117 .
Note
Take care to keep cylinder head cover straight.
– Turn inlet camshaft in direction of -arrow A- using assembly

tool - T40266- until markings -1- and -2- are aligned. Slide
camshaft clamp - T40271/2- into teeth of chain sprocket
-arrow B-.


bly tool - T40266- until markings -1- and -2- are aligned. Slide
camshaft clamp - T40271/1- into teeth of chain sprocket
-arrow B-.
Note
Marking -2- is offset slightly to the right.
– Turn crankshaft at hexagon flats into “TDC” position.

• The flat surface -1- must be at the top.
– Remove flange nut - T10531/4- and turning-over tool -
T10531/3- .
note the following:
Note

– Install oil separator ⇒ page 152
– Install air cleaner housing ⇒ 4-cylinder direct injection engine
(2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Air cleaner; Removing and
installing air cleaner housing .
– Connect coolant hoses with plug-in connectors ⇒ 4-cylinder
direct injection engine (2.0 ltr. 4-valve TFSI); Rep. gr. 19 ;
Radiator/radiator fans; Exploded view - radiator/radiator fans .
newing or removing and re-installing camshafts.
tion diagnosis .
Tightening torques

4. Valve gear 125

♦ Spacers - T40191-
Installing
WARNING
Ball may spring out - risk of eye injury.

– Insert spring -1- in camshaft.

– Place ball -2- on spring in camshaft.
– Push ball and spring downwards in direction of -arrow A- with
spacer - T40191/1- and hold in place.
– Push slider -3- in direction of -arrow B-.

camshaft adjustment
Removing
– Unplug relevant electrical connector -2-.
– Unscrew bolt -1- and detach actuator for camshaft adjustment.
Installing
Note
Check O-rings for damage.

Caution

♦ Pin of actuator for camshaft adjustment must be brought
– Press down pin of actuator for camshaft adjustment -arrow- by

hand.
• Pin of actuator must not be in extended position.
– Lubricate O-rings with engine oil.
Tightening torques

Removing
15 ; Valve gear; Removing and installing camshaft control valve
1 - N205- .
1 - For exhaust camshaft control valve 1 - N318-
– Remove bolts -arrows- and detach camshaft control valves:
Installing
Note
Renew seals and O-rings after removing.
– Use engine oil to lubricate O-rings on sealing surface for cam‐

shaft control valve.
engine (2.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Valve gear; Removing
and installing camshaft control valve 1 - N205- .
Tightening torques
4. Valve gear 127


seals



A- with guide plate -VAS 5161/19C-
♦ Adapters - T40012-

Removing
4. Valve gear 129

– Apply drift -VAS 5161/3A- to valve spring plate and use plastic-
headed hammer to release sticking valve cotters.

– Secure guide plate with knurled screws -VAS 5161/12- .

– Screw adapter - T40012- into spark plug thread.

– Insert assembly cartridge -VAS 5161/8A- in guide plate.
• The compressed air hose remains connected.

Installing
• Use either pusher - 3365- or pusher - T40376/1- , depending

must first be inserted in insertion device -VAS 5161/18- .
and take up valve cotters.
– Insert valve spring and valve spring plate ⇒ page 118 .
4. Valve gear 131

– Secure guide plate -VAS 5161/19C- back onto cylinder head.

– Insert assembly cartridge in guide plate.
cotters.
tion.
Assembling
– Install spark plugs ⇒ 4-cylinder direct injection engine (2.0 ltr.
4-valve TFSI); Rep. gr. 28 ; Ignition system; Exploded view -
ignition system .
Caution

valve gear.
♦ The hydraulic tappets have to settle; wait for approx. 30
minutes after installing camshafts before starting engine.



A- with guide plate -VAS 5161/19C-

Removing
4. Valve gear 133


and gearbox support - VAS 6095A- .
supply.
with valve heads.

– Secure guide plate with knurled screws -VAS 5161/12- .

– Insert drift -VAS 5161/3- into guide plate and use plastic-head‐


Installing

– Insert valve spring and valve spring plate ⇒ page 118 .
4. Valve gear 135

– Secure guide plate -VAS 5161/19C- back onto cylinder head.

– Insert assembly cartridge in guide plate.
cotters.
tion.
Assembling




Test sequence
Note
♦ If the valve has to be renewed as part of a repair, use a new

♦ Only insert inlet valve into inlet valve guide and exhaust valve

new valves.
– Renew cylinder head if wear limit is still exceeded.
Note
Valve guides cannot be renewed.
5.2 Checking valves

faces.
Note
Inlet and exhaust valves must not be machined. Only grinding-in

is permitted.

∅a mm 33.85 ± 0.10 28.0 ± 0.1
∅b mm 5.92 ± 0.02 5.92 ± 0.02
c mm 103.97 101.87
α ∠° 45 45

17 – Lubrication
1 Sump/oil pump
page 142
er G266 ”, page 148
Note
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 in order to prevent further damage occurring later. In addition, renew oil
spray jets, engine oil cooler and oil filter.

1 - Nut
❑ 9 Nm
sender - G266-
⇒ page 148
3 - Seal
4 - Bolt
⇒ page 141
⇒ page 142
6 - O-ring
gine oil
7 - Sealing plug
❑ Turn as far as stop
8 - Gasket
9 - Bolt
❑ 4 Nm +45°
10 - Suction pipe
11 - O-ring
12 - Oil pump
❑ 2x
❑ For oil pump
14 - O-ring
15 - Bolt

18 - Guide pin
❑ 9 Nm
20 - Cylinder block
21 - Bolt
❑ 4 Nm +45°
22 - Baffle plate
24 - Bolt
❑ Tightening sequence ⇒ page 142
25 - Plug
❑ 3x
26 - Oil strainer
27 - Bolt
❑ 8 Nm +90°
28 - O-ring

tion
2. -1 … 17- 8 Nm
3. -1 … 17- Turn 90° further


tion
1. -1 … 18- 8 Nm
2. -1 … 13- Turn 45° further
3. -14 … 18- Turn 90° further
1.2 Engine oil

gine (2.0 ltr. 4-valve TFSI); Rep. gr. 17 ; Sump/oil pump;
Engine oil
tenance tables .

section)
Removing
17 ; Sump/oil pump; Removing and installing sump (bottom sec‐
tion) .

– Unscrew bolts -1 ... 17- and detach sump (bottom section).
Installing
Note
Renew seal and O-ring after removal.
engine (2.0 ltr. 4-valve TFSI); Rep. gr. 17 ; Sump/oil pump; Re‐
moving and installing sump (bottom section)
Tightening torques


Removing
chain tensioner in direction of -arrow- and secure in place with
locking tool - T40265- .
– Remove bolts -arrows- and detach oil pump.

Installing
– Check that both centring sleeves are fitted in oil pump.
– Before installing, check passages in sump (top section) and
strainer ⇒ Item 26 (page 141) in oil pump for dirt.
– Guide oil pump sprocket into drive chain and install oil pump.
Caution

♦ The following step must be performed to ensure that
spring of chain tensioner returns to installation position:

chain tensioner in direction of -arrow- and remove locking tool
- T40265- .

– Check position of chain tensioner support wire.

• The support wire -2- must rest on cast projection -1- on sump
(top section), as shown -arrow-.
Note
Shown in illustration with timing chain cover (bottom) removed.

Tightening torques

tion)
♦ Safety goggles
Removing
- N428- .

– Use the 3 bolts to pull out plugs.

Caution
Risk of damage to timing chain cover.

♦ Lever off sump (top section) at gearbox end first. Be care‐
ful when levering off.
Installing
Note
After removing, renew bolts that were tightened with specified

tightening angle.
WARNING
Risk of eye injury.

– Remove residual sealant on sump (top section) and timing

chain cover (bottom) -1- using rotating plastic brush or similar.
Note
Check whether timing chain cover is deformed. For this purpose,

first fit sump (top section) without sealant and determine gap be‐
tween cover and sump (top section). If the cover is deformed and
cannot be straightened, renew cover after installing sump (top
section).

– Check oil passages in sump (top section) and in crankcase for
dirt.
Note

2 mm).

– If previously removed, install baffle plate

⇒ Item 22 (page 141) .
Caution


sump (top section).
– Apply sealant between cylinder block and timing chain cover

(bottom) -arrows-.
Note
The sump (top section) must be installed within 5 minutes after

applying sealant.
• Sump (top section) and cylinder block must be flush at gearbox

end.
– Immediately fit sump (top section) and tighten bolts.
note the following:
– Install sealing flange (gearbox end) ⇒ page 41 .
– Install oil pump ⇒ page 143 .
Tightening torques
♦ ⇒ Item 17 (page 71)


Removing
Installing
Note
Renew seal -4- after removing.
Tightening torques

2 Engine oil cooler

⇒ “2.3 Removing and installing mechanical switching valve”, page
150

catalogue
⇒ page 35
2 - Gasket
3 - O-rings
gine oil
4 - Mechanical switching valve
⇒ page 150
⇒ page 150
6 - Seal
7 - Connection
8 - Bolt
❑ 8 Nm +45°


er
Removing
– Remove bracket for ancillaries ⇒ page 35 .
– Unscrew bolts -4, 5- and detach engine oil cooler -3- with gas‐
ket -2- from bracket for ancillaries -1-.
Installing
Note
Renew gasket after removing.
– Install bracket for ancillaries ⇒ page 35 .

Tightening torques
2.3 Removing and installing mechanical

switching valve
Removing
– Remove engine oil cooler ⇒ page 150 .
– Take mechanical switching valve -1- out of bracket for ancil‐
laries -arrow-.
Installing
Note
– Lightly lubricate O-rings of mechanical switching valve with

engine oil and install.
– Install engine oil cooler ⇒ page 150 .


2 - Gasket
3 - Hose
❑ To activated charcoal fil‐
ter solenoid valve 1 -
N80-
4 - Oil separator
⇒ page 152
5 - Seal
6 - Hose
❑ To turbocharger
7 - Bolt
❑ Thread-forming
hand so that it is
que
❑ 4 Nm
8 - Seal
9 - Bolt
❑ Thread-forming
hand so that it is
que

Oil separator - tightening torques and sequence


Removing
– Remove ignition coils for cylinders 3 and 4 ⇒ page 271 .
– Remove bolts -arrows- and press engine lifting eye -1- to one
side.

– Release fastener -arrow-, disconnect crankcase breather

– Release hose clip -1- and detach hose from activated charcoal
filter solenoid valve 1 - N80- .
– Remove bolts -arrows- and detach oil separator.
Installing
Note
♦ Renew gasket and seals after removing.


Tightening torques
♦ ⇒ Fig. ““Oil separator - tightening torques and sequence”“ ,
page 152


page 155
page 157
”, page 158
”, page 161
N522 ”, page 163

catalogue
⇒ page 35
2 - Gasket
⇒ page 142
4 - O-ring
gine oil
❑ 25 Nm
6 - Oil drain connection
7 - O-rings
❑ Not available as re‐
placement part, sup‐
plied together with
8 - Bolt


pressure control
trol, version 1”, page 155
trol, version 2”, page 156
4.2.1 Exploded view - oil pressure switches/oil pressure control, version 1
1 - Bolt
❑ 4 Nm +45°
trol - N428-
agnostic tester
⇒ page 161
3 - O-ring
gine oil
4 - O-rings
gine oil
5 - Bolt
after removal
valve - N522-
⇒ page 163
7 - Seal
❑ Renew (cut seal open to
do so)
❑ If seal is not available separately, refer to ⇒ Electronic parts catalogue ; renew oil pressure switch after
removal
❑ Blue insulation
❑ 20 Nm

❑ 20 Nm
10 - Seal
❑ Renew (cut seal open to do so)
removal
11 - Seal
removal
⇒ “4.5.1 Removing and installing stage 3 oil pressure switch F447 - version 1”, page 158
❑ 20 Nm
4.2.2 Exploded view - oil pressure switches/oil pressure control, version 2
1 - Bolt
❑ 4 Nm +45°
trol - N428-
agnostic tester
⇒ page 161
3 - O-ring
gine oil
4 - Seal
do so)
❑ If seal is not available
separately, refer to ⇒
logue ; renew oil pres‐
sure switch after remov‐
al
agnostic tester
⇒ page 158
❑ 20 Nm
6 - Seal
do so)

removal
❑ Blue insulation
❑ 20 Nm
8 - Bolt
❑ 9 Nm
10 - Seal
11 - Seal
removal
⇒ “4.5.2 Removing and installing stage 3 oil pressure switch F447 - version 2”, page 159
❑ 20 Nm

switch - F22-
Procedure
Note
♦ Place a cloth underneath bracket for ancillaries to catch any

escaping oil.
♦ If re-using old oil pressure switch - F22- , check availability of
seal in ⇒ Electronic parts catalogue (ETKA). If it is not avail‐
able, renew oil pressure switch - F22- .
♦ Cut seal open to renew.
♦ Fit new oil pressure switch - F22- into hole immediately to
avoid loss of oil.
– Remove oil pressure switch - F22- -item 2-. (Illustration shows

vehicle with alternator.)
Tightening torques
trol”, page 155


Procedure
Note
♦ Place a cloth underneath bracket for ancillaries to catch any

escaping oil.
♦ If re-using old oil pressure switch for reduced oil pressure -
F378- , check availability of seal in ⇒ Electronic parts cata‐
logue (ETKA). If it is not available, renew oil pressure switch
for reduced oil pressure - F378- .
♦ Fit new oil pressure switch for reduced oil pressure - F378-
immediately into hole to avoid loss of oil.

-item 1-. (Illustration shows vehicle with alternator.)
Tightening torques
trol”, page 155

sure switch - F447-
- version 1”, page 158
- version 2”, page 159

sure switch - F447- - version 1
Procedure



Note
♦ Lay a cloth under the oil pressure switch to catch escaping

engine oil.
♦ If re-using old stage 3 oil pressure switch - F447- , check avail‐
ability of seal in ⇒ Electronic parts catalogue (ETKA). If it is
not available, renew stage 3 oil pressure switch - F447- .
♦ Fit new stage 3 oil pressure switch - F447- immediately into
hole to avoid loss of oil.

F447-
Tightening torques
control, version 1”, page 155

sure switch - F447- - version 2

Procedure


- F447- .
Note
♦ Lay a cloth under the oil pressure switch to catch escaping

engine oil.
♦ If re-using old stage 3 oil pressure switch - F447- , check avail‐
ability of seal in ⇒ Electronic parts catalogue (ETKA). If it is
not available, renew stage 3 oil pressure switch - F447- .
♦ Fit new stage 3 oil pressure switch - F447- immediately into
hole to avoid loss of oil.

F447-
Tightening torques
control, version 2”, page 156

Removing
noise insulation .


– Place used oil collection and extraction unit - VAS 6622A- un‐
derneath.
N428- (pull poly V-belt slightly downwards).
Installing
Tightening torques
trol”, page 155


N522 - version 1”, page 163
N522 - version 2”, page 163

jet control valve - N522- - version 1
Removing
Note

caping oil.
N522- -item 1-.
Note
Fit the new piston cooling jet control valve - N522- into the con‐
nection immediately to avoid loss of oil.
Installing
Note

Tightening torques
trol”, page 155

jet control valve - N522- - version 2
Removing

Note

caping oil.
N522- .
Note
Fit the new piston cooling jet control valve - N522- into the con‐
nection immediately to avoid loss of oil.
Installing
Note

Tightening torques
trol”, page 155

⇒ “4.8.1 Checking engine oil pressure”, page 164
⇒ “4.8.2 Checking oil pressure for piston cavity oil jets”,
page 166
4.8.1 Checking engine oil pressure


Test requirements
• Oil level OK
• Engine oil temperature at least 80°C (radiator fan must have
run once).
Note
♦ The oil pump is regulated and has two pressure stages. The
pressure stages are tested one after the other.
♦ During the running-in period or when the engine is in emer‐
gency running mode, the oil pump only operates in the higher
pressure stage.
♦ The oil pressure is dependent on the engine oil temperature.
The mean value should be reached at an engine oil tempera‐
ture of around 80 ℃.

Test sequence
Note

caping oil.
– Unplug electrical connector -2- (illustration shows engine with

alternator).
-item 1-.
– Screw oil pressure tester - V.A.G 1342- into oil filter bracket in
place of oil pressure switch.
oil pressure tester - V.A.G 1342- and plug in electrical con‐
nector.
– Start engine.
• Oil pressure at 3700 rpm: 3.0 ... 4.0 bar (second pressure
stage active, valve for oil pressure control - N428- OK)
Assembling
– Install oil pressure switch
oil pressure F378 ”, page 158 and route electrical wiring care‐
fully.
Tightening torques
trol”, page 155
4.8.2 Checking oil pressure for piston cavity

oil jets

Test requirements
• Oil level OK
• Engine oil temperature at least 80°C (radiator fan must have
run once).
Test sequence
– Screw oil pressure switch into oil pressure tester - V.A.G
1342- .
– Screw in oil pressure tester - V.A.G 1342- in place of oil pres‐
sure switch.
– Connect test instrument adapter/DSO (2-pin) - VAS 5571- to
oil pressure switch.
– Plug electrical connector for stage 3 oil pressure switch - F447-
into test instrument adapter/DSO (2-pin) - VAS 5571- .
– The engine should only run as long as required for the test.
– Check oil pressure ⇒ Vehicle diagnostic tester, Stage 3 oil
pressure switch F447 .
Assembling
– Install stage 3 oil pressure switch - F447-
⇒ “4.5 Removing and installing stage 3 oil pressure switch
F447 ”, page 158 .

19 – Cooling

gine (2.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Cooling system/coolant;
Connection diagram - coolant hoses .


(version 2)


(version 1)
Procedure
WARNING


expansion tank.


nutes.
inate fault.
Note

engine is cold.
Checking pressure relief valve in filler cap
Filler cap (version 1):


Blue filler cap
this level.
scribed.
Black filler cap
this level.
scribed.
Filler cap (version 2):


Blue filler cap
1.4 ... 1.6 bar.
scribed.
Black filler cap
1.6 ... 1.8 bar.
scribed.

Caution
To ensure optimal corrosion protection, only distilled water

may be mixed with coolant additives.

Note

tropical climates.
++ and G12evo.
tection.
the coolant.
ses.

– All procedures are described in ⇒ 4-cylinder direct injection
engine (2.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Cooling system/


page 175
page 175
page 177
”, page 180
1 - Connection
2 - O-ring
❑ Coat with coolant; cool‐
ant ⇒ Electronic parts
catalogue
3 - Centring pin
4 - Bolt
5 - Gasket
6 - Coolant pump
⇒ page 175
❑ New coolant pump: re‐
move protective cap
7 - Bolt
⇒ page 174
8 - Toothed belt
⇒ page 177
9 - Bolt
❑ 9 Nm
catalogue

11 - Bolt
❑ 10 Nm +90°
❑ Note installation position
13 - Oil seal
15 - Gasket
diagnostic tester
Actuator for engine temperature regulation - N493- - tightening

torques and sequence

– Tighten bolts for coolant pump in the sequence -1 ... 4- to
9 Nm.

gine (2.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pump/thermostat
assembly; Exploded view - electric coolant pump .

1 - Retaining clip
ment
❑ Push-fitted version
jection engine, (1.8, 2.0
radiator outlet coolant
G83-
3 - O-ring
4 - O-rings
er - G62-
box end)
⇒ page 180
6 - Bolt
❑ 4 Nm +45°
7 - Bolt
❑ 4.5 Nm
9 - O-rings

pump
gine (2.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pump/thermostat
assembly; Removing and installing electric coolant pump .

Removing

19 ; Coolant pump/thermostat assembly; Removing and installing

coolant pump .
- F447- -item 2-.

– Unplug electrical connector -item 2- for stage 3 oil pressure
switch - F447- .
Continued:
– Remove bolts -1 … 4- and detach coolant pump from actuator
for engine temperature regulation - N493- .
– Detach toothed belt from coolant pump.
Installing
– Fit coolant pump -1- and toothed belt.
– Check that centring elements -arrows- and gasket -3- are
seated correctly.
– Tighten coolant pump bolts ⇒ page 174 .

– After fitting new coolant pump -2-, remove protective cap -1-
from drive sprocket.
engine (2.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pump/ther‐
mostat assembly; Removing and installing coolant pump
Tightening torques

coolant pump
Removing


toothed belt for coolant pump .
– Counterhold crankshaft at vibration damper with ratchet
wrench (21 mm) - T40263- , adapter - T40314- and socket
(24 mm).
– Depending on version, counterhold crankshaft at vibration
damper using counterhold tool - T40378- or counterhold tool
- T40379- .
Caution

– Use torque wrench - V.A.G 1410- and insert tool - T10360- to

loosen bolt on coolant pump drive sprocket -1- and unscrew
three turns -arrow-.
Installing
Note

angle.
♦ Note installation position of toothed belt sprocket
⇒ Item 12 (page 174) .

mostat assembly; Removing and installing toothed belt for coolant
pump
Tightening torques

Removing
– Preparatory work may be necessary depending on model ⇒
4-cylinder direct injection engine (2.0 ltr. 4-valve TFSI); Rep.

gr. 19 ; Coolant pump/thermostat assembly; Removing and

installing actuator for engine temperature regulation - N493- .
– Remove coolant pump ⇒ page 175 .
– Unplug electrical connector -arrow- for actuator for engine


– Detach actuator for engine temperature regulation - N493-
from centring pins and pull actuator off engine oil cooler.

Installing
Note
Renew gaskets and O-rings after removal.
– Lubricate new O-rings -4- lightly with coolant ⇒ Electronic

parts catalogue .
– Check whether the two centring pins are fitted in the cylinder
block; install if necessary.
– Fit connecting piece -2- into engine oil cooler -1-.
– Push actuator for engine temperature regulation - N493-
-item 3- onto connecting piece and centring pins in cylinder
block.
– Tighten bolts for actuator for engine temperature regulation -
N493- ⇒ page 174 .
– Install coolant pump ⇒ page 175 .
– Additional work depending on model ⇒ 4-cylinder direct in‐
jection engine (2.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant
pump/thermostat assembly ; Removing and installing actuator
for engine temperature regulation - N493-
– After renewing, perform “Adaption” for actuator for engine
temperature regulation - N493- in Guided Functions mode
of ⇒ Vehicle diagnostic tester.
Tightening torques

ature sender - G62-
Procedure
• Engine cold.
sion tank.
– If not already removed during preparatory work, remove en‐
gine cover panel ⇒ page 12 .

Note

♦ Insert new coolant temperature sender - G62- immediately in‐
to connection to avoid loss of coolant.
♦ Renew O-rings after removing.
– Remove bolt -2- and detach coolant temperature sender -

G62- -item 3-.
– Check coolant level ⇒ 4-cylinder direct injection engine (2.0
ltr. 4-valve TFSI); Rep. gr. 19 ; Cooling system/coolant; Drain‐
ing and filling up coolant .
mostat assembly; Removing and installing coolant temperature
sender - G62-
Tightening torques
page 175

– All procedures are described in ⇒ 4-cylinder direct injection
engine (2.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pump/

3 Coolant pipes
direct injection engine (2.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant
pipes .

direct injection engine (2.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Radi‐
ator/radiator fans .

1 Turbocharger
”, page 196

♦ Exploded view - turbocharger, part I ⇒ page 184
♦ Exploded view - turbocharger, part II ⇒ page 185
♦ Exploded view - charge pressure positioner ⇒ page 187
Exploded view - turbocharger, part I
1 - Bolt
❑ 25 Nm
2 - Oil return line
3 - O-ring
gine oil
4 - O-ring
gine oil
5 - Turbocharger
⇒ page 188
6 - Nut
❑ Coat studs with high-
logue
❑ 25 Nm
7 - Gasket
8 - Bracket
10 - Bolt
❑ 9 Nm
11 - O-ring

13 - Bolt
❑ 9 Nm
14 - O-ring
15 - O-ring
16 - Bolt
❑ 9 Nm
17 - Connection
18 - Bolt
❑ 9 Nm
Fitting location of turbocharger air recirculation valve - N249-

– Note installation position -arrows-.
Exploded view - turbocharger, part II
1. Turbocharger 185
1 - Support
2 - Turbocharger
⇒ page 188
3 - O-ring
gine oil
4 - Line
❑ Do not disconnect ver‐
sion with threaded con‐
nection
from turbocharger
5 - Bolt/threaded connection
bolt or threaded connec‐
tion with connected
hose is fitted
❑ Do not disconnect
threaded connection
from turbocharger
❑ Bolt, 9 Nm
❑ Exploded view
⇒ page 252
7 - O-ring
gine oil
8 - Oil supply line
9 - Bolt
❑ 9 Nm
10 - O-ring
11 - Bolt
❑ 9 Nm
12 - Bolt
❑ Coat with high-temperature paste ⇒ Electronic parts catalogue
❑ 30 Nm
13 - Heat shield
14 - Bolt
❑ 9 Nm
16 - O-ring

17 - Bolt
❑ 9 Nm
18 - O-ring
19 - Bolt
❑ 20 Nm +90°
Exploded view - charge pressure positioner
1 - Lock nut
❑ 10 Nm
- V465-
❑ Before removing charge
pressure positioner -
V465- , check it is avail‐
able in ⇒ Electronic
⇒ page 196
3 - Bolt
❑ 9 Nm
1. Turbocharger 187
Caution
If the turbocharger has suffered mechanical damage (e.g.

damaged compressor wheel), it is not sufficient merely to fit a
new turbocharger. The following work must be performed in
order to avoid further damage:
♦ Check air cleaner housing, air filter element and air hoses
♦ Check the entire charge air system (including the charge
air cooler) for foreign matter.
♦ If foreign matter is found in the charge air system, clean
all relevant ducts and hoses and renew charge air cooler
if necessary.
⇒ “1.2.1 Removing turbocharger - vehicles without particulate fil‐

ter”, page 188
⇒ “1.2.2 Removing turbocharger - vehicles with particulate filter”,
page 192
⇒ “1.2.3 Installing turbocharger”, page 195
1.2.1 Removing turbocharger - vehicles with‐

Removing
Note
Observe rules for cleanliness ⇒ page 5 .

21 ; Turbocharger; Removing and installing turbocharger .
noise insulation .

Note


connector.
1. Turbocharger 189
Version with bolted connection:

– Remove bolt -arrow- and detach crankcase breather pipe from
turbocharger.

- V465- .
Version with threaded connection:





wards rear.
– Remove bolts -arrows- and detach heat shield.
1. Turbocharger 191


– Have a 2nd mechanic hold turbocharger in place.
– Unscrew bolt -1-, push heat shield slightly to one side and dis‐
connect coolant supply line -2-.
– Lift out turbocharger.

particulate filter
Removing
Note

21 ; Turbocharger; Removing and installing turbocharger .
noise insulation .



connector.
Note:
1. Turbocharger 193




– Remove bolts -arrows- and detach heat shield.


– Have a 2nd mechanic hold turbocharger in place.
– Unscrew bolt -1-, push heat shield slightly to one side and dis‐
connect coolant supply line -2-.
– Lift out turbocharger.
1.2.3 Installing turbocharger

Installing
1. Turbocharger 195
Note

angle.
♦ Renew gaskets, seals, O-rings and self-locking nuts after re‐
moval.
♦ Lubricate studs for turbocharger with high-temperature paste
♦ Fill turbocharger with engine oil at connection for oil supply
line.

Note
♦ After installing turbocharger, allow engine to idle for approx.

1 minute and do not rev up immediately to ensure turbocharger

engine (2.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Turbocharger; Re‐
moving and installing turbocharger
Tightening torques
tem”, page 198

Note
Before removing charge pressure positioner - V465- , check it is
available in ⇒ Electronic parts catalogue (ETKA) .
Removing
Note


– Loosen lock nut -2- by a quarter turn (counterhold at hexagon
flats -arrow- on control rod).
– Unscrew control rod from actuating lever -1-, taking care not
to turn lock nut.
– Remove bolts -3- and detach charge pressure positioner -
V465- .
Installing
• If renewing charge pressure positioner, ensure installation po‐
sition of lock nut is the same on new charge pressure posi‐
tioner.
– Place charge pressure positioner - V465- in installation posi‐

tion and tighten bolts -3-.
– Screw control rod into actuating lever -1- until it makes contact
with lock nut -2-.
– Plug in electrical connector -4-.
– Learnt values must be adapted after renewing charge pres‐
sure positioner - V465- .
♦ Drive train
♦ 01 - Set charge pressure adjuster -V465
Tightening torques
♦ ⇒ page 187
1. Turbocharger 197
2 Charge air system

page 198
page 199

gine (2.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Charge air system;

charge air system
Note

♦ If using used hose clips to secure the air hoses at their con‐
installing.

-arrows-.
enough.
off air hose.
must be renewed.



er
Removing and installing charge air cooler .

sure sender - G31-
Removing and installing charge pressure sender - G31- .

21 ; Charge air system; Checking charge air system for leaks .


valves -3- and -4-.
valve -2-.
water.
– Open valve -3-.
Caution


spray or use ultrasonic tester - V.A.G 1842- .
Note
♦ A small amount of air escapes through the valves and enters

the engine. Therefore it is not possible to perform a pressure
retention test.
♦ Operation of ultrasonic tester - V.A.G 1842- ⇒ Operating in‐
structions .
♦ Release pressure in test circuit by detaching coupling from
adapter before removing adapter.
Assembling
Assemble in reverse order.
engine (2.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Charge air system;
Checking charge air system for leaks


1 Injection system
gine (2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Injection system .

2 Air cleaner
direct injection engine (2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Air
cleaner .

3 Intake manifold
216
⇒ “3.4 Cleaning throttle valve module GX3 ”, page 217
page 218
1 - Bolt
❑ 20 Nm
2 - Support for intake manifold
3 - Nut
❑ 10 Nm
❑ 5 Nm
5 - Bolt
❑ 7 Nm
GX3-
❑ with
♦ Throttle valve module -
J338-
♦ Throttle valve drive for elec‐
tric throttle - G186-
♦ Throttle valve drive angle
sender 1 for electric throttle
- G187-
♦ Throttle valve drive angle
sender 2 for electric throttle
- G188-
⇒ page 216
❑ After installing, perform
agnostic tester
7 - Seal
8 - Intake manifold
10 - Ball stud
❑ 5 Nm

11 - O-ring
12 - Bolt
❑ 1.5 Nm
14 - Bolt
❑ 9 Nm
15 - Ball stud
❑ 5 Nm
16 - Bracket
17 - Bolt
❑ 5 Nm
18 - Bolt
❑ 9 Nm
19 - Gasket
20 - Vacuum hose
22 - Vacuum hose
23 - Bracket
❑ For electrical connectors
24 - Bolt
❑ 5 Nm

⇒ “3.2.3 Installing intake manifold”, page 215


♦ Socket, AF 17 mm - T10456-
♦ Safety goggles
Removing
24 ; Intake manifold; Removing and installing intake manifold .
– If there is no B+ cover on the alternator, disconnect earth wire
from battery terminal to avoid short circuits ⇒ Electrical sys‐
battery .


G31- .
Note:

with MPI engine) / gas rail temperature and pressure sensor
- GX21- (vehicles with natural gas system)
3- Central connector for injectors (MPI injection)/gas injection
valves (vehicles with natural gas system)
6- For throttle valve module - GX3-

N316- .


manifold.

the side.
WARNING


Note
Place a cloth underneath to catch escaping fuel.
– Unscrew union nut -arrow- using socket, AF 17 mm - T10456- .
– Unscrew union nut -arrow- (counterhold at connecting piece

-A-).
connect fuel hose.
side.

– Detach electrical connectors -1, 2, 4- from bracket.
– Unplug electrical connector -3- and detach intake manifold.

– Release fastener -arrow-, detach it from bracket -2- and move
electrical connector -1- for knock sensor 1 - G61- clear.
Note
Seal off all open passages in the intake system with clean cloths
or plugs (thoroughly cleaned) from engine bung set - VAS 6122- .


♦ Safety goggles
Removing
24 ; Intake manifold; Removing and installing intake manifold .
G31- .
Note:


1 - For intake manifold flap potentiometer - G336-
4 - For intake air temperature sender - G42-

N316- .
– Remove nut -arrow- on heat shield (shown with particulate fil‐

ter removed).

– Remove bolt -1- and press pressure differential sender for
particulate filter - G1037- to one side.

manifold.




the side.
WARNING

Note
– Unscrew union nut -arrow- using socket, AF 17 mm - T10456- .
– Unscrew union nut -arrow- (counterhold at connecting piece

-A-).

connect fuel hose.
side.
– Detach electrical connectors -1, 2, 4- from bracket.

– Unplug electrical connector -3- and detach intake manifold.

– Release fastener -arrow-, detach it from bracket -2- and move
electrical connector -1- for knock sensor 1 - G61- clear.
Note
Seal off all open passages in the intake system with clean cloths
or plugs (thoroughly cleaned) from engine bung set - VAS 6122- .
3.2.3 Installing intake manifold

Installing
Note
♦ Renew gaskets, connection for high-pressure pipe and spring-

type clip for fuel hose after removing.
– Push intake manifold onto studs and onto cylinder head.

ing battery .
– If intake manifold was renewed, perform adaptions listed in
Guided Function “01 - Functions, engine mechanics” ⇒ Vehi‐
cle diagnostic tester.
engine (2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Intake manifold; Re‐
moving and installing intake manifold
Tightening torques


tem”, page 198

module - GX3-
Removing
24 ; Intake manifold; Removing and installing throttle valve mod‐
ule - GX3- .
G31- .
Note:
– Loosen screw-type clip -2-, detach air pipe downwards from
throttle valve module - GX3- and tie it to side. (Shown on a
vehicle without natural gas system.)


GX3- .
Installing
– Remaining installation steps are carried out in reverse se‐
quence; note the following:
Note
♦ Renew seal after removing.

– Clean sealing surface for seal.

Learnt values must be re-adapted after removing or renewing
throttle valve module.
♦ Drive train
placement

engine (2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Intake manifold; Re‐
moving and installing throttle valve module - GX3-
Tightening torques
3.4 Cleaning throttle valve module - GX3-
Note
♦ Carbon deposits and dirt in the limit stop can lead to incorrect
adaption values.
♦ Take care not to scratch the throttle valve housing when clean‐
ing it.

♦ Brush
♦ Safety goggles

Procedure
Note

WARNING
Risk of injury Acetone is highly flammable and can cause irri‐

tation to the eyes and skin.

Note
After cleaning the throttle valve module - GX3- , perform the same
measures as those required after renewing the throttle valve
module.

function
Only perform this test if there is a loss of engine torque (poor
flexibility or lack of pulling power).
Test condition
♦ Intake manifold flap valve - N316- has been checked with a
vehicle diagnostic tester.

Perform the following steps if the intake manifold flap valve -

N316- is OK.
– Have a second mechanic rev up engine quickly (short burst of
throttle) and observe vacuum unit for intake manifold change-
over.
should pick up -arrow-.
If the change-over does not operate as described:
– Check vacuum system for leaks.
– Check proper connection of vacuum lines.
– Check vacuum hoses for porosity.

position -A- to select "vacuum".
– Connect hand vacuum pump - VAS 6213- to vacuum unit for

intake manifold flap valve - N316- .
– Operate hand vacuum pump - VAS 6213- several times.
should pick up.
– Vent vacuum.
• The linkage should return to the initial position.
• The linkage should move in both directions -arrows-.
– Renew intake manifold if linkage does not move.

4 Injectors

⇒ “4.1.1 Exploded view - fuel rail with injectors, vehicles with FSI
engine”, page 220
⇒ “4.1.2 Exploded view - fuel rail with injectors, vehicles with MPI
engine”, page 222
4.1.1 Exploded view - fuel rail with injectors, vehicles with FSI engine
1 - Injector sleeve
natural gas system
jection engine (2.0 ltr. 4-
24 ; Injectors; Removing
and installing injectors
2 - Combustion chamber ring
seal
❑ Renewing after injector
has been removed
⇒ page 223
3 - Supporting element
❑ Vehicles with natural
gas system only: If sup‐
porting element is re‐
newed, injector sleeve
must also be renewed
4 - Injector
❑ Ensure correct installa‐
tion position.
❑ Vehicles with natural
gas system only: If in‐
jector is renewed, injec‐
tor sleeve
must also be renewed
⇒ page 223
5 - Spacer ring
6 - O-ring
7 - Support ring

8 - Fuel rail for FSI injectors

❑ Lubricate taper lightly with clean engine oil; do not lubricate thread
❑ 27 Nm
11 - Bolt
❑ 9 Nm
❑ From high-pressure pump
❑ Lightly lubricate ball of fuel supply line with engine oil
❑ Install so that parts are free of tension
❑ Union nut, 27 Nm
13 - Connection
❑ Lubricate threads lightly with clean engine oil
❑ 40 Nm
14 - Bolt
❑ M6: 9 Nm
❑ Renew M8 bolt after removing
❑ M8: 20 Nm +90°
4. Injectors 221
4.1.2 Exploded view - fuel rail with injectors, vehicles with MPI engine
1 - Retaining clip
❑ For fuel pressure send‐
er for low pressure -
G410-
2 - O-ring
3 - Adapter
❑ Attach to fuel pressure
sender for low pressure
- G410-
❑ 27 Nm
❑ Attach to adapter
⇒ page 242
❑ 27 Nm
5 - Fuel rail for MPI injectors
6 - Bolt
❑ 9 Nm
8 - Fuel supply line
❑ To fuel rail for MPI injec‐
tors
free of tension
9 - Retaining clip
10 - O-ring
11 - Injector
❑ Ensure correct installation position.
12 - O-ring
Note
The following procedure applies to the fuel rail for FSI injectors.
Removing
24 ; Injectors; Removing and installing fuel rail .


– Unplug all electrical connectors at injectors and on fuel pres‐
– Detach fuel rail -1- with wiring duct -2- from injectors.
– Move wiring duct clear.
Installing
Note
♦ Renew support rings for injectors after removing.

♦ If any injectors remain lodged in the cylinder head when the
fuel rail is detached, it is only necessary to install the O-rings
and spacers from the repair set.
♦ If the injectors are pulled out along with the fuel rail, install all
the components of the repair set with a combustion chamber
ring seal ⇒ page 223 .

engine (2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Injectors; Removing
and installing fuel rail
Tightening torques

gine”, page 223
gine”, page 228
⇒ “4.3.3 Removing and installing injector sleeves - vehicles with

♦ Tool set for FSI engines - T10133 C-
4. Injectors 223
Removing
Note
♦ Injectors must only be installed when engine is cold.

♦ Observe rules for cleanliness ⇒ page 5 .
Vehicles with natural gas system

– Mark allocation of injectors to corresponding cylinder.
All vehicles
– Remove fuel rail ⇒ page 222 .
Note
Carefully pull out any injectors that remain lodged in the fuel rail.
– Remove the injectors if they remain lodged in the cylinder

head.
– Cover open inlet ports with a clean cloth.
– Detach support ring -4- from injector -1-.


Note
♦ Use a torque wrench to pull out injector.

♦ Set torque wrench to 5 Nm.
♦ Observe correct torque to avoid irreparable damage to injec‐
tor.
– Fit puller -T10133/2A- to groove on injector.

– Then fit guide puller T10133/16A .
– Pull out injector by turning bolt with torque wrench -1-.
– If injector does not come loose after limit torque of 5 Nm is
reached, remove puller and repeat procedure using stop
sleeve to loosen injector.
– Pull O-ring -3- and spacer ring -2- off injector -1-.
– Unclip supporting element -5-.
so, cut open combustion chamber ring seal using knife or prise
open with small screwdriver and then pull off forwards.
4 - Support ring
4. Injectors 225
– Clean ring groove in area of seal -arrow-. Remove carbon de‐

posits with a brass wire brush.
Note
Take care not to damage groove on injector. Injector must be re‐

newed if groove is damaged.
Installing
Note
♦ Use complete repair set when installing.

♦ Renew support ring after removing.
♦ Renew combustion chamber ring seal before re-installing in‐
jector.

T10133/4- .
with a clean cloth.


ber ring seal -1- onto assembly cone -T10133/5- as far as it
will go (knurled side of assembly sleeve faces towards com‐
bustion chamber ring seal).


chamber ring seal into groove (smooth side of assembly
sleeve faces towards combustion chamber ring seal.)
Note


opposite direction.

opposite direction.
Note
The combustion chamber ring seal -6- must not be lubricated.
Vehicles with natural gas system
Note
When re-installing injectors, make sure they are installed at cor‐

rect cylinder according to markings.
4. Injectors 227
All vehicles
inder head (aperture must be free of oil and grease). Ensure
that the injector is properly seated -arrow- in the cylinder head.
• Lug -1- and hole -arrow- in cylinder head must face each other.
Note
It should be possible to insert the injector easily. If necessary wait

until the combustion chamber ring seal has contracted sufficient‐
ly.

– Install fuel rail ⇒ page 222 .

Removing
Note

– Move electrical wiring clear at intake manifold.
fold.



– Unscrew bolts -arrows- for MPI fuel rail.
– Carefully lift out fuel rail -2- with injectors.

– Release retaining clip -2- and detach injector -3- from fuel rail
-1-.
4. Injectors 229
1 - O-ring; renew after removal
2 - Injector
3 - Retaining clip
4 - O-ring; renew after removal
Installing
Note

– Press fuel rail with injectors by hand as far as it will go into
aperture of intake manifold (injectors must be free of oil and
grease).
Tightening torques
♦ ⇒ Item 17 (page 204)
4.3.3 Removing and installing injector sleeves

gine (2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Injectors; Removing and
installing injectors .
Note
♦ The following procedure applies to FSI injectors.



Cleaning
– Fill ultrasonic unit with 2,120 ml of water which has been al‐
lowed to settle for a few minutes and cleaning fluid - VAS
6418/2- .
Mixture ratio for cleaning fluid
• 2,100 ml of tap water which has been allowed to settle for a
few minutes and 20 ml of cleaning fluid - VAS 6418/2-

cleaning unit.
Note
♦ It is important to read the safety notes in the operating instruc‐

tions before switching on the ultrasonic cleaning unit -VAS
6418- .
♦ The ideal fluid level is approx. 1 ... 4 mm above the base of

Note
♦ The temperature-controlled cleaning process is now started.

While the fluid is being heated, the ultrasound is activated at
intervals in order to circulate the cleaning solution. The ultra‐
sound is activated continuously when the preselected tem‐
perature is reached.
♦ The actual cleaning process commences when the tempera‐
minutes.

⇒ page 223 .
4. Injectors 231
5 Gas injection valves

direct injection engine (2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Gas
injection valves .

6 Gas pressure regulator

direct injection engine (2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Gas
pressure regulator .


234

Removing
– Release catches -arrows- and detach intake air temperature
sender - G42- / intake manifold pressure sender - G71- from
intake manifold.
Installing
– Installation is carried out in reverse order; note the following:
Note

Tightening torques

- G70-
gine (2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Senders and sensors;
Removing and installing air mass meter - G70- .

sender - G247-


♦ Socket, 24 mm - T40363-
♦ Safety goggles
Removing
24 ; Senders and sensors; Removing and installing fuel pressure
sender - G247- .
manifold.
– Remove bonded rubber bush -3-.

– Release electrical connector using assembly tool - T10118-

and unplug it.
WARNING

Note
Catch escaping fuel with a cloth.

24 mm - T40363- .
Installing
Tightening torques

alternator
♦ Socket, 24 mm - T40363-
♦ Safety goggles

Removing
– Release and unplug electrical connector -arrow-.
WARNING

Note
Catch escaping fuel with a cloth.
– Unscrew fuel pressure sender - G247- using socket, 24 mm -

T40363- .
Installing
Tightening torques

⇒ “7.4.1 Checking fuel pressure sender G247 - vehicles with al‐
ternator”, page 237
⇒ “7.4.2 Checking fuel pressure sender G247 - vehicles with
7.4.1 Checking fuel pressure sender - G247-

- vehicles with alternator

♦ Safety goggles

Procedure
Note

er - G247- and tighten adapter with same torque as specified
for -G247- .
– Unscrew plug -2- on digital pressure gauge - VAS 6394/1- and

screw in fuel pressure sender - G247- in its place (tighten to
specified torque).
– Use test instrument adapter - VAS 5570- to make electrical

connection between vehicle and fuel pressure sender -
G247- .
ing battery .
G247- .


-A- once briefly.
0 bar.
-C- briefly.
– Connect pressure gauge - VAS 6394/1- to adapter - VAS

6394/2- .
– Start engine.
Note
WARNING


- VAS 6394/1- .
Tightening torques
7.4.2 Checking fuel pressure sender - G247-

- vehicles with starter-alternator


♦ Test instrument adapter/DSO (2+3-pin) - VAS 5571-
♦ Safety goggles
Procedure
Note

er -G247- and tighten to 27 Nm.
– Unscrew plug on digital pressure gauge and screw in fuel
pressure sender - G247- -item 2- in its place (tighten to speci‐
fied torque).
– Connect vehicle and fuel pressure sender - G247- electrically
using test instrument adapter/DSO (+3-pin) - VAS 5571- .
G247- .


-A- once briefly.
0 bar.
-C- briefly.
– Connect and tighten pressure line of digital pressure gauge -

VAS 6394/1- -item 1- at adapter - VAS 6394/3- .
– Start engine.
Note
WARNING


- VAS 6394/1- .
Tightening torques


pressure G410 - vehicles without natural gas system”,
page 242
pressure G410 - vehicles with natural gas system”, page 242

cles without natural gas system
Removing
– Pull off retaining clip -1-.
– Pull fuel pressure sender for low pressure - G410- -item 2- out
of fuel rail.
– If necessary, unscrew fuel pressure sender for low pressure

-1- from adapter -2-.
Installing
Note
Renew O-ring -arrow- after removal.

Tightening torques

cles with natural gas system
gine (2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Senders and sensors ;
G410- .

ential sender for particulate filter -
G1037-

Removing
1:

ferential sender for particulate filter - G1037- -item 2-.


2:
– Remove bolt -1- and release hose clips -2-.
– Detach pressure differential sender for particulate filter -
G1037- .
– Spray hoses at pressure differential sender for particulate filter
- G1037- with soap solution.
Installing
Note



⇒ “8.1.1 Exploded view - high-pressure pump (version 1), vehicles
⇒ “8.1.2 Exploded view - high-pressure pump (version 2), vehicles
⇒ “8.1.3 Exploded view - high-pressure pump, vehicles with nat‐
8.1.1 Exploded view - high-pressure pump (version 1), vehicles without natural
gas system
1 - Quick release coupling

❑ With cut-off valve
or fuel pressure regulating
valve - N276-
❑ Fuel metering valve -
N290- or fuel pressure
may be fitted, depend‐
ing on version
sure pump; cannot be
renewed separately
⇒ page 248
❑ Take care not to tilt
when installing
5 - O-ring
gine oil
6 - Roller tappet
❑ May remain lodged in
vacuum pump when
high-pressure pump is
removed
7 - Vacuum pump
8 - Connection/sealing plug
❑ Sealing plug for vehicles
without MPI engine
❑ Connection for vehicles with MPI engine
❑ Connection must always be renewed once loosened
❑ M10: 15 Nm
❑ M12: 20 Nm

10 - Connection
❑ For fuel supply line at high-pressure pump
❑ Counterhold when loosening union nut
❑ 40 Nm
❑ To fuel rail (for vehicles with MPI engine)
❑ To fuel rail for FSI injectors
❑ Lightly lubricate ball of fuel supply line with engine oil
❑ Install so that parts are free of tension
13 - Bolt
❑ From fuel tank
High-pressure pump - tightening torques and sequence

– To prevent flange of high-pressure pump from being deformed
during installation, tighten bolts in stages as follows:
2. -Arrows- Tighten one turn alternately until
3. -Arrows- M6 bolt: 8 Nm + 90°; renew bolts after
removal
M8 bolt: 20 Nm

8.1.2 Exploded view - high-pressure pump (version 2), vehicles without natural
gas system
❑ To unscrew union nut,
counterhold at hexagon
flats of connecting piece
using an open-end
spanner
free of tension
❑ Lubricate thread of un‐
ion nut with clean en‐
gine oil
❑ Tighten union nut to
27 Nm
⇒ page 248
2 - Connection
❑ To unscrew union nut on
high-pressure pipe,
counterhold at hexagon
flats of connecting piece
using an open-end
spanner
❑ Must always be re‐
newed once loosened
❑ 65 Nm
❑ Depending on version of
high-pressure pump:
♦ Fuel pressure regulating
valve - N276- or
sure pump; cannot be renewed separately
❑ Take care not to tilt when installing
❑ From fuel tank
6 - Bolt
7 - O-ring
8 - Roller tappet
❑ May remain lodged in vacuum pump when high-pressure pump is removed

9 - Connection
❑ M10: 15 Nm
❑ M12: 20 Nm
❑ To fuel rail for MPI injectors
High-pressure pump (version 2) - tightening torque and sequence

To prevent flange of high-pressure pump from being deformed
during installation, fit high-pressure pump as follows:
2. -Arrows- Tighten one turn alternately until
3. -Arrows- M6 bolt: 8 Nm + 90°; renew bolts after
removal
M8 bolt: 20 Nm
8.1.3 Exploded view - high-pressure pump,

gine (2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; High-pressure pump;

pump

♦ Safety goggles
Removing
24 ; High-pressure pump; Removing and installing high-pressure
pump .
Note
♦ Remove the high-pressure pump only when the engine is cold.



WARNING

Note

– Vehicles with MPI engine: Release hose clip -4- and detach
fuel hose.
– Remove union nut -1-.
– Carefully pull out high-pressure pump. It is possible that the
roller tappet may remain lodged in the vacuum pump.
Installing
Note
♦ Renew O-ring and spring-type clips after removal.

♦ Renew connecting piece when reinstalling the same high-
pressure pump.
angle.
♦ Lubricate roller tappet and O-ring with clean engine oil for in‐
stallation.
– Check roller tappet for damage and renew if necessary.
– Fit roller tappet in vacuum pump (note position of locating el‐

ement -arrows A, B-).
Caution

ing chains slip.
♦ Turn crankshaft only in direction of engine rotation (in
clockwise direction).


– Have a second mechanic turn crankshaft with ratchet wrench
(21 mm) - T40263- , adapter - T40314- and socket (24 mm) in
direction of normal engine rotation -arrow- until roller tappet in
vacuum pump reaches its lowest point.
– Have a second mechanic turn crankshaft in direction of normal
engine rotation at nut for starter-alternator pulley until roller
tappet in vacuum pump reaches its lowest point.
– Insert high-pressure pump with O-ring into vacuum pump and
tighten bolts in stages.
– Secure fuel hoses with spring-type clips.
engine (2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; High-pressure pump;
Removing and installing high-pressure pump
Tightening torques
♦ ⇒ Fig. ““High-pressure pump - tightening torques and se‐
gr. 21 ; Charge air system; Exploded view - charge air system

9 Lambda probe

filter”, page 253
9.1.1 Exploded view - Lambda probes, vehicles without particulate filter

❑ Comprises:
Z29-
ies
Lambda probes are
sembly paste.
paste
slots on the Lambda
probe body
page 254
❑ 60 Nm
❑ Comprises:
❑ 60 Nm

9.1.2 Exploded view - Lambda probes, vehicles with particulate filter

⇒ page 242
❑ Tighten pressure line to
45 Nm
sender for particulate fil‐
ter - G1037-
⇒ page 254
❑ Comprises:
Z19-
Lambda probes are
sembly paste.
paste
slots on the Lambda
probe body
page 254
❑ 60 Nm
❑ Comprises:
❑ Installation position varies
❑ 60 Nm
❑ ⇒ Item 4 (page 267)
9. Lambda probe 253


❑ ⇒ Item 5 (page 267)
Pressure differential sender for particulate filter - G1037- (version

2) - tightening torque

Removing
Lambda probe 1 before catalytic converter - GX10- :
set - 3337- .
Note:


set - 3337- .

set - 3337- .

set - 3337- .
Installing
Note
♦ New Lambda probes are coated with an assembly paste. The

♦ In the case of a used Lambda probe grease only the thread
♦ The electrical wiring of the lambda probe must be secured at

Tightening torques
9. Lambda probe 255


direct injection engine (2.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Engine
control unit .


gine (2.0 ltr. 4-valve TFSI); Rep. gr. 26 ; Exhaust pipes/silencers;
Exploded view - silencers .

All work is described in ⇒ 4-cylinder direct injection engine (2.0
ltr. 4-valve TFSI); Rep. gr. 26 ; Exhaust pipes/silencers; Sepa‐
rating exhaust pipes/silencers .

gine (2.0 ltr. 4-valve TFSI); Rep. gr. 26 ; Exhaust pipes/silencers;
Removing and installing front silencer .

All work is described in ⇒ 4-cylinder direct injection engine (2.0
ltr. 4-valve TFSI); Rep. gr. 26 ; Exhaust pipes/silencers; Stress-
free alignment of exhaust system .

– Plug tailpipes (e. g. with rags or stopper) and leave plugged
until the check is complete.
– Listen for noise at connection points (cylinder head/turbo‐
charger, turbocharger/front exhaust pipe etc.) to locate any
leaks.



tem
⇒ “2.1.1 Exploded view - emission control system, vehicles with‐
2.1.1 Exploded view - emission control system, vehicles without particulate filter
1 - Gasket
2 - Turbocharger
❑ Exploded view
⇒ page 184
❑ Exploded view
⇒ page 252
4 - Nut
❑ Lubricate studs for tur‐
bocharger with high-
logue .
❑ 40 Nm
❑ Exploded view
⇒ page 252
and impact
⇒ page 260
⇒ page 257

2.1.2 Exploded view - emission control system, vehicles with particulate filter

sender 4 - G648-
❑ ⇒ Item 5 (page 267)
sender 3 - G495-
❑ ⇒ Item 4 (page 267)
3 - Gasket
4 - Turbocharger
❑ Exploded view
⇒ page 184
❑ Exploded view
⇒ page 252
6 - Gasket
and impact
❑ Mounting components
on gearbox
⇒ page 260
⇒ page 260
⇒ page 257
❑ Exploded view
⇒ page 252
9 - Nut
❑ 40 Nm
10 - Nut
❑ 23 Nm
11 - Particulate filter

Mounting components for particulate filter on gearbox

1- Spacer sleeve
2- Spacer sleeve
4- Washer
5- Bolt, 23 Nm
6- Bolt, 23 Nm
7- Spacer sleeve
8- Buffer
9- Bracket
Mounting components for catalytic converter on gearbox

1- Spacer sleeve
3- Washer
4- Bolt, 23 Nm
5- Spacer sleeve
6- Bolt, 23 Nm
7- Buffer
8- Bracket
9- Spacer sleeve

verter

verter - vehicles without particulate filter
Removing
Note
Re-install all cable ties in original positions.

Note

– Remove Lambda probe 1 before catalytic converter - GX10-
⇒ “9.2 Removing and installing Lambda probe”, page 254 .

– Remove electrical connector -1- for Lambda probe 1 after cat‐
alytic converter - GX7- -item 2- from bracket and unplug con‐
nector.

nector.

Continued:
– Remove nuts -1- from above and lift out catalytic converter.
Installing
Note

Tightening torques

verter - vehicles with particulate filter
Removing
– Remove particulate filter ⇒ page 263 .


nector.
– Unscrew nuts -1 and 2- and detach catalytic converter up‐

wards towards rear.
Installing
Note

Tightening torques

Removing
– Remove front silencer ⇒ 4-cylinder direct injection engine (2.0
ltr. 4-valve TFSI); Rep. gr. 26 ; Exhaust pipes/silencers; Re‐
moving and installing front silencer .



1:

– Unplug electrical connector -1- for vacuum sender - G608-

-item 2-.

2:
– Remove bolt -1- and press pressure differential sender for
particulate filter - G1037- to one side.



Installing
– Install front silencer ⇒ 4-cylinder direct injection engine (2.0
ltr. 4-valve TFSI); Rep. gr. 26 ; Exhaust pipes/silencers; Re‐
moving and installing front silencer .
Note
If the particulate filter has been renewed, the ash deposit volume
must be reset using ⇒ Vehicle diagnostic tester.

♦ 01 - Functions, engine mechanics
Tightening torques


page 267
⇒ “3.2 Removing and installing parts of exhaust gas temperature
control”, page 267

❑ ⇒ Item 1 (page 253)
❑ ⇒ Item 2 (page 253)
❑ ⇒ Item 3 (page 253)
sender 3 - G495-
⇒ page 267
❑ 45 Nm
sender 4 - G648-
⇒ page 268
❑ 45 Nm
3.2 Removing and installing parts of ex‐

haust gas temperature control
er 3 G495 ”, page 267
er 4 G648 ”, page 268


Removing
Installing
– When installing, ensure sufficient clearance.
Tightening torques
267

Removing


Installing
Tightening torques
267

1 Ignition system
⇒ “1.2 Removing and installing ignition coils”, page 271
page 273
275
1 - Bolt
❑ Tightening torque influ‐
ences the function of the
knock sensor
❑ 8 Nm +90°
⇒ page 273
3 - Spark plug
❑ 30 Nm
5 - Ignition coil
stage - N70-
stage - N127-
stage - N291-
stage - N292-
⇒ page 271
6 - Bolt
❑ 10 Nm
7 - Nut
❑ 9 Nm
8 - Bolt
❑ 9 Nm
❑ Check seal for damage.

10 - O-ring
11 - O-ring
13 - Bolt
❑ 9 Nm
14 - O-ring
16 - Bolt
❑ 4 Nm +45°

♦ Puller - T10530-
♦ For silicone paste, refer to ⇒ Electronic parts catalogue .

Removing
catalytic converter - GX10- -item 2-.
Note:
– Remove centre hex stud -3- for relevant ignition coil.
– Insert puller - T10530- into hole -1- in ignition coil.

– Turn knurled nut -2- clockwise -arrow- until puller is secured
in place.

– Carefully pull ignition coil out vertically -arrow- with puller -

T10530- .
Installing
hose of ignition coil -arrow-.
use tools).
Tightening torques

- G61-
Removing
Note
Knock sensor 1 - G61- is located below the intake manifold and

behind the actuator for engine temperature regulation - N493- .
– Remove actuator for engine temperature regulation - N493-

⇒ page 178 .


– Release fastener -arrow-, detach electrical wire -1- for knock
sensor 1 - G61- from bracket -2- and move wire clear.
– Unscrew bolt -arrow- and remove knock sensor 1 - G61- .

Installing
– Install actuator for engine temperature regulation - N493-
⇒ page 178 .
Tightening torques

⇒ “1.4.1 Removing and installing Hall sender G40 ”, page 274
⇒ “1.4.2 Removing and installing Hall sender 3 G300 ”,
page 275
1.4.1 Removing and installing Hall sender -

G40-
Removing

– Unscrew bolt -1- and remove Hall sender - G40- -item 2-.
Installing
Note

newing or removing and re-installing Hall sender.
tion diagnosis .
Tightening torques
1.4.2 Removing and installing Hall sender 3 -

G300-
Removing
– Unscrew bolt -2- and remove Hall sender 3 - G300- .
Installing
Note

newing or removing and re-installing Hall sender.
tion diagnosis .
Tightening torques

sender - G28-
Removing



Installing
newing or removing and re-installing engine speed sender.
tion diagnosis .
Tightening torques

Service
Workshop Manual
Audi A4 2015 ➤
Audi A5 2016 ➤
Audi A6 2019 ➤
Audi A7 Sportback 2018 ➤
Servicing 4-cylinder TDI engine, common rail (EA 288
EVO)
Engine ID
DEZ DEZ DFB DEZF DEZ
E B A D
Edition 11.2018

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system

Copyright © 2019 Audi AG, Ingolstadt D4B808575E7

Audi A4 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2019 ➤ , Audi A7 Sportback 20 ...
Servicing 4-cylinder TDI engine, common rail (EA 288 EVO) - Edition 11.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.6 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.8 Performing adaptions after renewing a component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Contents i


2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.3 Exploded view - coolant valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
ii Contents

2.7 Removing and installing mixing valve for charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . 126
2.9 Removing and installing coolant distribution module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.10 Removing and installing temperature sensor G18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.11 Removing and installing engine temperature sender G27 . . . . . . . . . . . . . . . . . . . . . . . . 129
2.12 Removing and installing engine temperature sender 2 G652 . . . . . . . . . . . . . . . . . . . . . . 129
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

2 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
6.4 Removing and installing exhaust gas pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . . 189
Contents iii
7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

3.3 Exploded view - delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3.9 Removing and installing pump for reducing agent V437 . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3.10 Removing and installing pressure sender for reducing agent metering system G686 . . . . 222
3.11 Removing and installing connection for SCR supply line . . . . . . . . . . . . . . . . . . . . . . . . . . 222
5.2 Removing and installing exhaust gas recirculation valve 1 GX5 . . . . . . . . . . . . . . . . . . . . 230
5.3 Removing and installing exhaust gas recirculation valve 2 GX6 . . . . . . . . . . . . . . . . . . . . 231
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
iv Contents
1 Identification
(ARL006163; Edition 11.2018)

Engine number
cated on the front of the joint between the engine and the
gearbox -arrow-.
♦ Engine codes starting with the letter “C” have four letters (pre‐
viously three letters).
♦ The first 3 characters of the engine code stand for the engine
capacity and the mechanical construction and design. They
are stamped onto the cylinder block together with the serial
number.
♦ The 4th character indicates the power output and torque of the
engine and is determined by the engine control unit.
Engine data
engines; Rep. gr. 00 ; Overview of engines .
1. Identification 1
tem”, page 2
page 3
page 3
⇒ “2.6 Safety precautions when working on the SCR system”,
page 4
page 5

may spray out.

fuel pump.


a road test
Or:
seat.

The cooling system is under pressure when the engine is hot. Risk
of scalding due to hot steam and hot coolant.


Components of the exhaust system can pose health risk

Risk to health if exhaust gas temperature sender is dismantled.
– Do not dismantle exhaust gas temperature sender.
Danger from toxic exhaust gases

Auxiliary/supplementary heater produces toxic exhaust gases.
There is a risk of poisoning and of damage to the respiratory tract.
– In enclosed spaces, only switch on the auxiliary/supplemen‐
tary heater if there is an exhaust extraction system.
– In enclosed spaces without an exhaust extraction system,
switch off the auxiliary/supplementary heater.

incorrectly.
2.6 Safety precautions when working on the SCR system

Risk of injury caused by reducing agent
Reducing agent can cause eye and skin irritation, damage to the
respiratory tract and poisoning.
Risk of damage caused by reducing agent

Reducing agent which has come into contact with trim or body
components can crystallise after some time and damage the af‐
fected surfaces.
– Ensure that no reducing agent makes contact with parts of trim
or body.
– Clean any surfaces which have come into contact with reduc‐
ing agent immediately with water and a cloth.
When removing and installing components at the SCR system,

note the following:
♦ The reducing agent tank must be empty when you are working
on the SCR system. Refer to the corresponding work descrip‐
tion to find out when the reducing agent must be drained from
the tank. Drain the reducing agent tank if necessary; proce‐
dure ⇒ page 220 .

When removing and installing the reducing agent tank, note the
following:
♦ The reducing agent tank must be empty. Drain the reducing
agent tank if necessary; procedure ⇒ page 220 .
Automatic drawing back of reducing agent
• After the ignition is switched off, the reducing agent is auto‐
matically drawn back into the reducing agent tank from the
metering line leading to the injector for reducing agent - N474- .
• Before performing work in this area, you must therefore wait
until the reducing agent has been drawn back; this can take
up to 10 minutes after the ignition has been switched off.
• It is also important to wait until the reducing agent has been
drawn back (i.e. 10 minutes after the ignition is switched off)
before disconnecting the battery ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .

tached.
9
⇒ “3.8 Performing adaptions after renewing a component”,
page 9

ply system, injection system and turbocharger:
♦ Clean connections and surrounding area thoroughly with en‐
gine cleaner or brake cleaner and dry cleaned area before
loosening.
♦ Immediately seal open lines and connections with clean plugs,
for example from engine bung set - VAS 6122- .
♦ Do not remove sealing caps from components until immedi‐
ately prior to installation. Keep components that are to be re-
used in new, sealable plastic bags.
that have not been stored in the proper packaging (e.g. in tool
boxes etc.).
♦ Do not work with compressed air when the system is open. If
possible, do not move vehicle.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
3.2 General notes

Fuel supply/injection


crash by deactivating the fuel pump.
in the fuel system ⇒ page 2 .
Glow plug system
♦ The glow plug system is activated via the automatic glow pe‐
riod control unit - J179- . The control unit is self-diagnosis
compatible.
♦ Fitting location of automatic glow period control unit - J179-
⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
♦ A fault is stored in the engine control unit - J623- if a fault oc‐
curs in the glow plug system.
♦ Checking glow plug system ⇒ Vehicle diagnostic tester
♦ For faster starting, the vehicle is equipped with electronically
controlled glow plugs and a separate glow period control unit.
♦ Each glow plug is activated and diagnosed separately.
♦ Wait for 60 seconds each time after performing final control
diagnosis of the glow period control unit. The ignition must re‐
main switched on.
♦ If you do not wait for 60 seconds (if ignition is switched off and
immediately switched on again), the glow plugs can be dam‐
aged (due to repeated pre-heating).
♦ The activation of the glow plugs is controlled according to
coolant temperature.

If components of the fuel system between the fuel tank and the
high-pressure pump are removed or renewed, the fuel system
must be bled
⇒ “1.3 Filling and bleeding fuel system”, page 153 .
Risk of irreparable damage to fuel pump
After working on the fuel system, the fuel pump may be irreparably
damaged if it is allowed to run while empty.
– Never allow fuel pump to run while it is empty.
– Fill/bleed fuel pump.

system.
♦ Before installing, check the injectors and their surroundings
visually; they must be undamaged and clean. Make sure the
injector bores in the cylinder head are clean. Wipe out if nec‐
essary using a clean cloth, taking care not to cause damage.
Do not use sharp objects of any kind.

♦ Take care not to damage the injectors when removing the old
copper seals.
♦ Check all new O-rings for damage before installing. Lubricate
O-rings with engine oil or assembly oil before installing.
♦ Press the fuel return hoses onto the injectors by hand from
above so that they engage audibly on each injector (do not
press in the release pins when doing this). Then press down
the release pin after connecting the return line. Check that the
fuel return hoses are seated securely and sealed properly by
pulling them by hand from above.
♦ Do not dismantle individual common rail components. If there
is a fault, the complete components must be renewed.
♦ When the engine is running, do not perform any repairs to the
common rail system.
♦ Do not bleed the common rail system by unfastening high-
pressure components after the engine has been started.
used.

• Check air cleaner housing, air filter element and air hoses for
dirt and foreign particles.
• Check the entire charge air system (including the charge air
• If foreign matter is found in the charge air system, clean all
relevant ducts and hoses and renew charge air cooler if nec‐
essary.

fitted.

Please note:
♦ We recommend the use of Audi Genuine Parts.
ranty.

and wiring
♦ To avoid damaging pipes, hoses and wiring, ensure sufficient
clearance from all moving or hot components in engine com‐
partment (limited space in engine compartment).

justify renewal of the radiator, charge air cooler or condenser.
3.8 Performing adaptions after renewing a

component
The learnt values must be adapted if components of the engine
or reducing agent system have been renewed or if a reducing
agent line has been opened.
After renewing engine, pistons, cylinder head or turbocharger,
“run-in function with increased oil pressure” must be activated.
ODIS path for A4/A5:
♦ Drive train
♦ 01 - Adapt learnt values for tank for reducing
agent
ODIS path for A6/A7:

♦ Systems with diagnostic capability
♦ 00AC - Control unit for reducing agent metering
system -J880
♦ 00AC - Control unit for reducing agent metering

system, functions
♦ 00AC - Adapt reduction agent tank learned values


page 11
page 13
1.1 Removing engine

All procedures are described in ⇒ 4-cylinder TDI engine, 2.0 ltr.
4-valve common rail; Rep. gr. 10 ; Removing and installing en‐
gine; Removing engine .

sembly platform

Procedure
• Engine/gearbox assembly removed and placed on scissor-
from gearbox) ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve com‐
mon rail; Rep. gr. 10 ; Removing and installing engine; Sep‐
arating engine and gearbox
CAUTION
– Transport engine only with gearbox removed and using the
method described.

VAS 6100- .
hoist, as shown.
– Detach engine support - T10533/1- from engine.



support
♦ Engine and gearbox support - VW 540-
Procedure
• Engine removed from scissor-type assembly platform -
VAS 6131 B- ⇒ page 11
– Disengage intermediate plate from sealing flange -arrow B-
and dowel sleeves -arrows A- and remove.
– Pull dowel sleeves off cylinder block.

– Secure engine to engine and gearbox support - VW 540- using

engine and gearbox support - VAS 6095A- .

gine; Installing engine .

engine, 2.0 ltr. 4-valve common rail; Rep. gr. 10 ; Assembly
mountings .


panel
Removing
– Carefully pull engine cover panel off ball studs one after an‐
other -arrows-. Do not jerk engine cover panel away, and do
not try to pull on one side only.
Installing
and dipstick.
– Press engine cover panel into ball studs first on left side, then
on right side.

page 21
page 22
23
1 - Poly V-belt
❑ Check for wear
❑ Do not kink
⇒ page 19
⇒ page 20
on pulleys.
2 - Bolt
❑ 20 Nm +180°
hole in vibration damper
must be positioned over
raised section of crank‐
shaft sprocket
⇒ page 22
⇒ page 21
5 - Bolt
Electrical system; Rep.
gr. 27 ; Alternator; Ex‐
ploded view - alternator

6 - Dowel sleeve
❑ Ensure correct seating in bracket for ancillaries
8 - Bolt
❑ 8 Nm
9 - Bracket
10 - Bolt
❑ 8 Nm
11 - Ball stud
❑ 8 Nm
12 - Bracket
13 - Bush
❑ ⇒ Fig. ““Bracket for ancillaries - tightening torque and tightening sequence”“ , page 19
14 - Bolt
❑ Different lengths ⇒ page 19
16 - Bolt
❑ Exploded view ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Exploded view -
air conditioner compressor drive unit
18 - Bracket
❑ For SCR line
19 - Nut
❑ 8 Nm
20 - Bolt
21 - Dowel sleeves
❑ Ensure correct seating in air conditioner compressor
22 - Bolt
❑ 8 Nm +90° in diagonal sequence in stages


1- Vibration damper
2- Idler roller
Bracket for ancillaries - tightening torque and tightening sequence

angle.
– Fit bolts/bush in the following sequence:
♦ Bolts -1 … 4- M10x35
♦ Bolt -5- M10x175
♦ Bolt -6- M10x115
♦ Bolt -7- M8x60
♦ Bush -8-
– Tighten bolts/bush in stages in the sequence shown:
Stage Bolts/bush Tightening torque/angle specification
2. -1 … 6- 40 Nm
5. -8- 6 Nm
7. -7- 23 Nm

1 - Bolt
❑ Contact surface be‐
tween sprocket and
crankshaft must be free
of oil
one position
❑ With crankshaft oil seal
⇒ page 23
4 - Bolt

– Tighten bolts -arrows- in stages in the sequence shown:
2. Tighten in stages and in diagonal sequence; final tor‐
que 13 Nm


Removing
NOTICE
– To slacken poly V-belt, turn tensioner clockwise -arrow- using

ratchet.
Installing
– Hold tensioner with ratchet and remove locking tool - T40098- .

poly V-belt
Removing
– Remove bolts -arrows- and take off poly V-belt tensioner -1-.
Installing
angle.
Tightening torques


er
♦ Key -T40405- (not illustrated)
Removing
cylinder TDI engine, 2.0 ltr. 4-valve common rail; Rep. gr. 13 ;
Cylinder block (pulley end); Removing and installing vibration
damper .
– To slacken bolts for vibration damper, counterhold crankshaft
using key -T40405- .
• Notch -2- aligns with “OT” (TDC) marking -1- on vibration
damper.
– Loosen bolts -arrows- for vibration damper.
– Remove bolts and take off vibration damper.
Installing
angle.
– Move vibration damper into installation position -arrow- (pay

attention to raised section of crankshaft sprocket -2-).
Additional work depending on model ⇒ 4-cylinder TDI engine, 2.0
ltr. 4-valve common rail; Rep. gr. 13 ; Cylinder block (pulley end);
Removing and installing vibration damper
Tightening torques

cillaries
Removing
– Remove starter-alternator - C29- ⇒ Electrical system; Rep.
gr. 27 ; Alternator; Removing and installing alternator .


– Unscrew bolt -7- and loosen bush -8- approx. two turns.
– Loosen bolts in the sequence -6 ... 1-.
– Remove bolts and detach bracket for ancillaries.
Installing
angle.
– Check that a dowel sleeve is fitted between bracket for ancil‐
laries and cylinder block.
– Install starter-alternator - C29- ⇒ Electrical system; Rep. gr.
27 ; Alternator; Removing and installing alternator .
Tightening torques
♦ ⇒ Fig. ““Bracket for ancillaries - tightening torque and tighten‐
ing sequence”“ , page 19

4-valve common rail; Rep. gr. 13 ; Cylinder block (pulley end);
Removing and installing engine support .

(pulley end)

Removing
– Remove toothed belt ⇒ page 53 .
– Loosen bolt -1- for crankshaft sprocket -2- using counterhold
tool - 3415- .
– Remove bolt and detach crankshaft sprocket.
– Remove bolts -arrows-, press out sealing flange -1- and re‐
move flange.
– Remove toothed belt -2- for oil pump.

Installing
– Fit toothed belt -arrow- for oil pump on crankshaft.
– Fit guide sleeve -T10053/1- onto crankshaft journal.
– Slide sealing flange over guide sleeve.
• Dowel pins should then engage in bores on cylinder block.
– Take off guide sleeve.
– Tighten sealing flange bolts ⇒ page 20 .
– Install toothed belt (adjust valve timing) ⇒ page 56 .
Tightening torques
♦ Crankshaft sprocket ⇒ Item 1 (page 45)


page 28
when assembling
2 - Dowel sleeve
❑ 2x
3 - Cylinder block
4 - Dowel pin
❑ 2x
end)
❑ With oil seal
6 - Bolt
7 - Drive plate
❑ Lock with counterhold
tool - 10-201- to slacken
off bolts
⇒ page 27
8 - Bolt
❑ 60 Nm +90°

– Engage intermediate plate on sealing flange -arrow B- and
push onto dowel sleeves -arrows A-.


– Tighten bolts -arrows- in stages in the sequence shown:
que 13 Nm

Removing
NOTICE
Risk of damage to thread if an impact driver (or similar) is used.
– When screwing in bolts, fit them manually and perform the
first few turns by hand.
– Do not use an impact driver to loosen or tighten bolts.
– Insert counterhold tool - 10-201- in hole on cylinder block,

slacken bolts for drive plate -1-.
– Remove bolts and take off drive plate.
Installing
angle.
– Pay attention to dowel pin when installing drive plate.
bolts.
Tightening torques
page 26


(gearbox end)
♦ Open end spanner insert, AF 24 - V.A.G 1332/11-
♦ Bolt, M6x35 (3x)

♦ Bolt, M7x35 (2x)
Pressing out sealing flange with sender wheel
• Gearbox removed
-2-.

– Rotate crankshaft by turning bolt for toothed belt sprocket until

crankshaft is positioned at “TDC”, as shown in illustration.
• The hole -2- in the sender wheel -3- must be aligned with the
punch mark -1- on the sealing flange.
– Remove engine speed sender - G28- ⇒ page 242 .
• The sealing flange -1- is pressed off the crankshaft -3- together



B - Nut
C - Guide pin
D - Assembly housing
F - Inner section
G - Locating pin
H - Knurled screw (3x)

T50010- :
threaded spindle.

– Press assembly housing -D- downwards -arrow- so that it rests
on nut -B-.

flat surface.
it out of position.



T50010- so that locating pin -G- is seated in hole -1- in sender
wheel -3-.

Note:
Only the two knurled screws shown in the illustration can be
screwed on.
wheel.

crankshaft flange:
-D-.


into crankshaft flange with hexagon key -3-.
– Insert guide pin -C- into crankshaft flange.
– Screw bolts M7x35 -item 1- into cylinder block to guide sealing

flange -2-.

– Press assembly housing -D- by hand in direction of -arrow-
until sealing lip support ring -2- makes contact with crankshaft
flange -1-.
– Check that guide pin -C- is fitted correctly in hole in crankshaft.
This ensures that sender wheel reaches its final installation
position.
– Use hexagon key -3- to tighten the two hexagon socket head
bolts on assembly tool - T50010- hand-tight.
assembly housing -D-.

- T50010- :
• There must be a small gap between cylinder block -2- and
sealing flange -1- after nut has been tightened to 35 Nm.



er wheel -1-.
⇒ page 33 .
⇒ page 34 .

bolts -E- hand-tight.


ing flange -1-.

again ⇒ page 33 .
ment is too small.
again ⇒ page 33 .
Assembling:
– Install intermediate plate ⇒ page 26 .
Tightening torques
♦ ⇒ “1.1 Exploded view - glow plug system”, page 238

3 Crankshaft
There is currently no provision for removing and installing the
crankshaft.

Main bearing journal Conrod journal ∅
∅ mm
mm
Basic dimension 48.000 -0.022 47.800 -0.022
-0.042 -0.042

Procedure
- VW 387- onto cylinder block (as shown in illustration) and set
it against crankshaft.
– Press crankshaft against dial gauge by hand.
Axial clearance:
• New: 0.07 ... 0.17 mm
• Wear limit: 0.37 mm
3. Crankshaft 35

⇒ “4.3 Measuring piston projection at TDC”, page 40
page 43
1 - Bolts
contact surface
❑ When measuring radial
clearance, tighten used
bolts to 30 Nm and turn
90° further
❑ 30 Nm +90°
tion
conrod
❑ Mark conrod and cylin‐
der allocation with paint
-B-
Projections -A- face to‐
wards pulley end
3 - Bearing shells
⇒ page 38
shells
❑ Note version: Upper
bearing shell (closest to
piston) is constructed
from a more wear-re‐
sistant material ⇒ Electronic parts catalogue
❑ Check that it is securely seated
4 - Conrod
❑ With industrially cracked conrod bearing cap
❑ Mark conrod bearing cap and cylinder allocation with paint -B-
❑ Axial clearance: wear limit: 0.37 mm


❑ Installation position: Markings -A- face towards pulley end
5 - Circlip
❑ 2x
6 - Piston pin
7 - Piston
❑ With combustion chamber
❑ Renew piston if cracking is visible on piston crown or piston skirt
❑ Measuring piston projection at “TDC” ⇒ page 40
❑ Measuring ring gap ⇒ page 42
❑ Measuring ring-to-groove clearance ⇒ page 42
❑ Install using piston ring pliers - VAS 211 003- ⇒ page 38
❑ Install using piston ring pliers - VAS 211 003- ⇒ page 38
❑ Offset gap by 120° to bottom compression ring

1- Compression ring with marking “TOP” on top
2- Compression ring with marking “TOP” on top and chamfer
-arrow- on inner side (bottom)
3- Two-part oil scraper ring with marking “TOP” on top

Installing piston rings

• Open up piston ring -2- using piston ring pliers - VAS 211 003-
just far enough to be able to slide it over piston -1-.
Installation position of bearing shells in conrods

cap.
Oil spray jet and pressure relief valve

1- Bolt with pressure relief valve, 24 Nm
2- Oil spray jet (for cooling of pistons)
• Installation position: align locating edge of oil spray jet with
NOTICE


♦ Pin - VW 222A-
♦ Piston ring pliers - VAS 211 003-

Removing
– Mark installation position and matching of conrod bearing caps
to cylinder and to conrods for re-installation
– Pull out pistons upwards with conrods.
Note:
Installing
angle.
– Install piston rings ⇒ page 38 .
– Install pistons using piston ring clamp.
Installation position:
• Bearing shells in conrods ⇒ page 38
– Install conrod bearing caps according to markings.
– Perform adaptions required after renewing piston using ⇒ Ve‐
hicle diagnostic tester
page 9 .
Tightening torques

4.3 Measuring piston projection at TDC

Measure piston projection at “TDC” when installing new pistons
or a short engine.
♦ Measuring bridge -VW 382/7- from measuring tool - VW 382-
♦ Measuring plate -VW 385/17- from universal measuring tool -

VW 385-

Procedure
– Secure dial gauge - VAS 6079- with measuring bridge -
VW 382/7- and measuring plate -VW 385/17- to cylinder block
– Measure projection at each piston at both locations marked
with -arrows- (seen in longitudinal direction of engine: at front
and rear of piston).
– Depending on piston projection, install corresponding cylinder
head gasket according to following table:
Piston projection above top sur‐ Identification
face of cylinder block (no. of holes)
mm
0.91 … 1.00 1
1.01 … 1.10 2

Checking piston
• Check for wear on piston skirt coating and for any carbon de‐
posits.
• Renew piston if cracking is visible on piston skirt.
Piston ∅ mm
Nominal dimension 80.92 1)
• 1)Dimensions including coating (thickness 0.02 mm). The

-B-.
– Check cylinder bore for wear, scoring and other abnormalities.
Nominal dimension 81.0
• Do not measure the cylinder bore when the cylinder block is
mounted to the engine and gearbox support , as this may result
in incorrect measurements.


of cylinder.
mm mm
1. Compression ring 0.30 … 0.40 0.55
2. Compression ring 0.20 … 0.45 0.95
Oil scraper ring 0.25 … 0.50 0.75

Piston ring Wear limit
mm
1. Compression ring 0.08
2. Compression ring 0.08
Oil scraper ring 0.08

ped lightly.



bearings
♦ Plastigauge
Procedure
– Remove conrod bearing cap. Clean bearing cap and bearing
journal.
Radial clearance:
– Renew conrod bolts.



⇒ page 47
2 - Bolt
❑ With collar
❑ Captive in toothed belt
cover
❑ 12 Nm
3 - Bolt
❑ With collar
cover
❑ 12 Nm
4 - Bolt
❑ 2.5 Nm
5 - Coolant lines
6 - Bolt
❑ With collar
cover
❑ 12 Nm
7 - Toothed belt cover (side)
8 - Bolt
❑ 2.5 Nm
9 - Bracket
❑ For SCR supply line
10 - Bracket
❑ For electrical wiring
11 - Bracket
12 - Toothed belt cover (rear)
❑ To remove, take out coolant pump ⇒ page 126
13 - Bolt
❑ With collar
❑ Captive in toothed belt cover

❑ 12 Nm
1 - Bolt
❑ Slacken and tighten with
counterhold tool - 3415-
❑ Do not additionally oil
threads and shoulder
❑ 180 Nm +135°
tween sprocket and
of oil
one position
3 - Bolt
❑ 20 Nm +90°
4 - Damper wheel
5 - Nut
❑ Make sure that stud
⇒ Item 7 (page 45) is
fitted securely
❑ 20 Nm +45°
7 - Stud
❑ 15 … 18 Nm
8 - Toothed belt
❑ Check for wear
❑ Removing ⇒ page 53
❑ Installing (adjusting valve timing) ⇒ page 56
9 - Bolt
❑ Use counterhold tool - T10051A- when loosening and tightening
❑ Do not additionally oil threads and shoulder
❑ 100 Nm
10 - Locking bolt
❑ Self-locking
❑ 9 Nm

11 - Camshaft sprocket
❑ Contact surface between sprocket, camshaft and locating arm for camshaft must be free of oil
12 - Locating arm for camshaft
13 - Idler roller
14 - Nut
15 - High-pressure pump hub
❑ Contact surface between high-pressure pump, high-pressure pump hub and high-pressure pump sprock‐
et must be free of oil
16 - High-pressure pump sprocket
17 - Bolt
❑ 20 Nm +90°
18 - Coolant pump

cover
page 46
page 47

cover (top)

Removing
– Move electrical wiring and SCR supply line -1- clear.
– Clamp off coolant hoses -4- with hose clamps, up to 25 mm -
3094- and move coolant lines clear.
– Remove bolt -2-, move coolant lines clear and push lines to‐
wards front.

– Release catches -arrows-, disengage toothed belt cover (top)
-1- and detach.
Installing
Tightening torques

cover (bottom)
Removing
– Remove toothed belt cover (top) ⇒ page 46 .
– Remove bolt -arrow- and detach toothed belt cover (side)
-1-.


– Remove toothed belt cover (bottom) -1-.
Installing
– Fit toothed belt cover -arrow- (note position of dowel pin).
– Install toothed belt cover (top) ⇒ page 46 .
Tightening torques

♦ Offset screwdriver - T10264-

♦ Crankshaft stop - T10490-
Removing
• Only turn crankshaft in direction of engine rotation.
– Rotate crankshaft by turning bolt on crankshaft sprocket until
camshaft sprocket is positioned at “TDC”.
• Locating arm -2- for camshaft must align with hole -1- behind
it in camshaft housing.

– Lock crankshaft sprocket in position with crankshaft stop -

T10490- .
• Pins of crankshaft stop - T10490- must engage in threaded
holes of crankshaft sprocket.
• Locking pin of crankshaft stop - T10490- must engage in hole
-arrow- on sealing flange.
– Slacken nut -1- for tensioning roller.

– Turn eccentric adjuster of tensioning roller with offset screw‐
driver - T10264- anti-clockwise -arrow- until tensioning roller
can be secured with locking tool - T10265- .
– Then use offset screwdriver - T10264- to turn eccentric ad‐

juster of tensioning roller clockwise -arrow- as far as stop and
tighten nut -1- by hand.
– Slacken bolt -arrow- by 90°; counterhold camshaft sprocket

-1- with counterhold tool - T10051A- when doing so.
– Take toothed belt -2- off camshaft sprocket. If necessary, push
toothed belt cover (right-side) slightly to right side.

NOTICE
Risk of damage to camshaft if handled incorrectly
– Never use camshaft clamp as a counterhold tool.
– Insert locking pin - T10492- through locating arm -2- for cam‐
shaft and into hole behind it in camshaft housing.
– If necessary, align camshaft sprocket using counterhold tool -
T10051A- .
– Remove locking bolt -1- and screw in new locking bolt loosely.
– Slacken nut -arrow- for toothed belt sprocket of high-pressure

pump approx. 90° using counterhold tool - T10051A- .
– Insert locking pin - T10492- into hub -2- and into hole -1- be‐
hind it in bracket for ancillaries.
– To do so, adjust toothed belt sprocket for high-pressure pump
using counterhold tool - T10051A- .
• Perform adjustments on toothed belt only when engine is cold.
• Renew nut for tensioning roller.
Requirements:
• Base plate -1- for tensioning roller must be engaged in cast
recess -arrow- on cylinder head, as shown.
• Tensioning roller is locked with locking tool - T10265- and se‐
cured at right stop with nut -2-.
• Crankshaft is locked in position with crankshaft stop - T10490-

-arrow-.

• Contact surface between high-pressure pump, high-pressure

pump hub and high-pressure pump sprocket must be free of
oil.
• Hub -1- of high-pressure pump locked in place with locking pin
- T10492- .
• Nut -arrow- for toothed belt sprocket for high-pressure pump
-2- screwed on loosely. It should just be possible to easily turn
the high-pressure pump sprocket, but there must be no axial
movement.
• Contact surface between camshaft, camshaft sprocket and

locating arm for camshaft must be free of oil.
• Locating arm for camshaft -1- is locked with locking pin -
T10492- .
• Bolt -arrow- for camshaft sprocket -2- screwed on loosely. It
should just be possible to turn the sprocket on the camshaft
easily without axial movement.
– Turn the camshaft sprocket and high-pressure pump sprocket

in their adjustment area clockwise as far as the stop.
– Install toothed belt in the specified sequence:
3 - Idler roller
– Check positions of camshaft sprockets. To do so, turn cam‐

shaft sprocket -3- by hand as far as stop in direction of
-arrow- and hold it in place.
• Locking bolt -1- should now be positioned in approx. the bot‐
tom half of elongated hole -2-, as shown in illustration.
• At approx. centre of area of rotation -α-, toothed belt sprocket
for high-pressure pump -4- should now be aligned with locking
pin - T10492- , as shown in illustration.
• If the installation position of the toothed belt sprockets is not
correct, adjust position of toothed belt on sprocket in question.

• Base plate for tensioning roller must remain engaged in cast

recess on cylinder head.
– Loosen nut -1- for tensioning roller and detach locking tool -
T10265- .
– Carefully turn eccentric adjuster of tensioning roller clockwise

-arrow- using offset screwdriver - T10264- until pointer -2-
aligns with centre of slot on base plate.
• Nut -1- must not turn.
– Hold tensioning roller in this position and tighten nut.
– Using counterhold tool - T10051A- , apply tension to camshaft

sprocket in anti-clockwise direction -arrow-.
– Tighten bolt -1- for camshaft sprocket and nut -2- for high-
pressure pump sprocket to 20 Nm.
– Remove locking pins -T10492- and crankshaft stop - T10490-
and check valve timing ⇒ page 59 .
Checking valve timing ⇒ page 59


Removing
– Remove toothed belt cover (bottom) ⇒ page 47 .

NOTICE

• Locating arm -2- for camshaft must align with hole -1- behind
it in camshaft housing.

T10490- .

driver - T10264- anti-clockwise -arrow- until tensioning roller
can be secured with locking tool - T10265- .
– Then use offset screwdriver - T10264- to turn eccentric ad‐

juster of tensioning roller clockwise -arrow- as far as stop and
tighten nut -1- by hand.


-1- with counterhold tool - T10051A- when doing so.
shaft and into hole -arrow- behind it in camshaft housing.
T10051A- .
– Remove locking bolt -1- and screw in new locking bolt loosely.

pump approx. 90° using counterhold tool - T10051A- .
using counterhold tool - T10051A- .
• Renew nut for tensioning roller.
Requirements:
• Base plate -1- for tensioning roller must be engaged in cast
recess -arrow- on cylinder head, as shown.
• Tensioning roller is locked with locking tool - T10265- and se‐
cured at right stop with nut -2-.


-arrow-.

oil.
- T10492- .
movement.

T10492- .

in their adjustment area clockwise as far as the stop.
3- Camshaft sprocket
4- Damper wheel
5- High-pressure pump sprocket
6- Coolant pump sprocket


• Locking bolt -1- should now be positioned in approx. bottom
half of elongated hole -2-.
Note:
Locking bolt must not come into contact with top or bottom end of
elongated hole after toothed belt has been tensioned.
– Check that locking bolt -1- is located between centre and lower
end -2- of elongated hole. If necessary, adjust position of cam‐
shaft sprocket by moving it one tooth clockwise then fit toothed
belt again.
pin - T10492- .
Note:
Toothed belt sprocket for high-pressure pump must not reach up‐
per or lower end of area of rotation -α- after toothed belt has been
tensioned.

– Loosen nut -1- for tensioning roller and detach locking tool -
T10265- .


– Using counterhold tool - T10051A- , apply tension to camshaft

sprocket in anti-clockwise direction -arrow-.
– Turn crankshaft two rotations in direction of engine rotation by
turning bolt for crankshaft sprocket until crankshaft is just be‐
fore “TDC”.
– Fit crankshaft stop - T10490- to crankshaft sprocket again.

– Then turn crankshaft in direction of engine rotation until pin on
crankshaft stop - T10490- engages in hole -arrow- in sealing
flange as crankshaft rotates.
• If crankshaft has been turned past “TDC” position, turn crank‐
shaft two further rotations until it is again positioned just before
“TDC”. Then turn further in the same direction and lock crank‐
shaft with crankshaft stop - T10490- .
• It must be possible to lock locating arm -2- for camshaft using

locking pin - T10492- .
• It is very difficult to reproduce the locking position of the high-

pressure pump hub. However, a slight deviation -arrow- does
not influence engine operation.

• Pointer -1- on tensioning roller must be centred between tabs

on base plate -2-.
Note:
The maximum permissible sideways deviation from the specified
position is 5 mm.
If requirements are met, continue with procedure after adjusting
valve timing correctly as described below ⇒ page 61 .
Re-adjust valve timing if requirements are not met ⇒ page 60 .
Re-adjusting valve timing:

– If camshaft hub cannot be locked, withdraw crankshaft stop -
T10490- until pin is clear of bore -arrow-.
– Turn crankshaft in opposite direction of engine rotation slightly
past “TDC”.
– Now turn crankshaft slowly in direction of engine rotation until
it is possible to lock camshaft hub with locking pin - T10492- .
– After locking camshaft in place, loosen bolt for camshaft
sprocket; counterhold with counterhold tool - T10051A- to do
so.
If pin of crankshaft stop - T10490- is on left side of hole:

– Tighten bolt -arrow- for camshaft sprocket -1- to 20 Nm; to do

so, remove locking pin - T10492- and counterhold camshaft
sprocket using counterhold tool - T10051A- .

If pin of crankshaft stop - T10490- is on right side of hole:

– Turn crankshaft slightly in opposite direction to engine rota‐
tion.
– Turn crankshaft in direction of engine rotation again until pin
of crankshaft stop - T10490- engages in sealing flange as
crankshaft rotates.

sprocket using counterhold tool - T10051A- .
Procedure after adjusting valve timing correctly:
– Remove locking pin - T10492- and crankshaft stop - T10490- .
fore “TDC”.
– Check valve timing once again ⇒ page 59 .
– If locating arm for camshaft can now be locked, tighten bolt

-1- for camshaft sprocket to final torque ⇒ Item 9 (page 45) ;
to do so, remove locking pin - T10492- and counterhold cam‐
shaft sprocket using counterhold tool - T10051A- .
– Tighten nut -2- for high-pressure pump sprocket to final torque
⇒ Item 3 (page 182) ; to do so, use counterhold tool -
T10051A- .
Assembling
following:
– Tighten locking bolt -arrow-.

– Install toothed belt cover ⇒ page 47 .
Tightening torques

2 Cylinder head
1 - Gasket
❑ Renew if damaged or
leaking
⇒ page 65
3 - Bolt
❑ Renew if gasket is dam‐
aged
4 - Heat shield
5 - Bolt
❑ 8 Nm
6 - Grommet
❑ In cylinder head cover
7 - Seal
❑ For injector
8 - O-ring
❑ Not supplied separately
❑ Renew hose
⇒ Item 9 (page 62) if
damaged or leaking
9 - Hose
❑ Press release tabs on
both sides to detach
10 - O-ring
❑ Renew hose ⇒ Item 9 (page 62) if damaged or leaking
11 - Sealing cap
12 - Seal
❑ For sealing cap

13 - Grommet
Cylinder head cover - tightening torque and sequence

– Tighten bolts for cylinder head cover in the sequence -1 ... 8-
to 9 Nm.
2. Cylinder head 63
1 - Cylinder block
❑ Identification of cylinder
head gasket
⇒ page 65
3 - Cylinder head
⇒ page 67
❑ To prevent damage to
glow plugs, always
place cylinder head on a
soft foam surface after
removal.
⇒ page 65
❑ Must not be machined
❑ Before installing, check
that the two dowel
sleeves for centring cyl‐
inder head are fitted on
cylinder block
4 - Washer
5 - Bolt
❑ Correct sequence when
slackening ⇒ page 82
6 - Bolt
❑ 20 Nm +45°
8 - Seal
9 - Plug
❑ 14 Nm
10 - Dowel pin
❑ For camshaft housing
11 - Dowel pin
❑ For intake manifold with charge air cooler
12 - Dowel pin


• Cylinder heads must not be reworked on TDI engines.
Identification of cylinder head gasket

1- Holes
2- Part number
♦ Select new cylinder head gasket on basis of number of holes
in old cylinder head gasket.
♦ If parts of the crankshaft drive have been renewed, select the
new cylinder head gasket by measuring the piston projection
at “TDC” ⇒ page 40 .

angle.
– Tighten bolts -1 ... 10- in stages in the sequence shown:
1. 30 Nm
2. 70 Nm

cover
Removing
– Remove high-pressure reservoir (rail) ⇒ page 179 .
2. Cylinder head 65

breather hose from cylinder head cover -arrow-.
– Slacken cylinder head cover bolts in the sequence -8 ... 1- and
remove.
Installing
• Renew gasket and bolts for cylinder head cover if damaged or
leaking.
– Install injectors ⇒ page 173 .
– Install high-pressure reservoir (rail) ⇒ page 179 .
Tightening torques
♦ ⇒ Fig. ““Cylinder head cover - tightening torque and se‐

tors
♦ Carrier - 3390-
♦ Pliers -VAS 211 007- (not illustrated)

Procedure
• Injector removed ⇒ page 173 .
– Pull off seal -1- using pliers -VAS 211 007- -arrow-.

– Use suitable thrust piece (e.g. carrier - 3390- ) and short ex‐
tension -1- to press new injector seal in from above -arrow- as
far as stop.

⇒ “2.5.1 Removing and installing cylinder head - version without
water-cooled turbocharger”, page 67
⇒ “2.5.2 Removing and installing cylinder head - version with wa‐
ter-cooled turbocharger”, page 76

version without water-cooled turbo‐
charger
2. Cylinder head 67
♦ Bit XZN 10 - T10501-
♦ Bolt, M8x20 (2x)

Removing
Cylinder head; Removing and installing cylinder head .


– Unplug electrical connector -arrow- and move electrical wire
clear.

coolant hoses.

2. Cylinder head 69

1- For turbocharger 1 control unit - J724- (fitting location varies)
2- For heater element for crankcase breather - N79-
3- For exhaust gas pressure sensor 1 - G450-
4- For exhaust gas recirculation valve 2 - GX6-
6- For fuel pressure regulating valve - N276-
7- For fuel pressure sender - G247-
Pfeile - For injectors

1- For injector for reducing agent - N474-
2- For coolant valve for cylinder head - N489-
3- For exhaust gas temperature sender 1 - G235-
5- For fuel pressure sender for low pressure - G410-
6- For charge air temperature sender after charge air cooler -
G811-
11 - For charge air temperature sender before charge air cooler
- G810-
Pfeile - For glow plugs
– Pull wiring duct off fuel rail and move electrical wiring harness
to side.
– Remove nuts -3- and detach bracket -2-.

– Remove catalytic converter ⇒ page 205 .
– Unscrew bolts -5- and move particulate filter to right side.
– Bring engine support and engine mounting into installation po‐
sition and hand-tighten bolts.
– Lower engine onto engine mounting and detach support
bracket - 10-222A- ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve
common rail; Rep. gr. 10 ; Engine mountings; Supporting en‐
gine in installation position .

– Unscrew bolts -arrows- and detach oil return line -3-.

– Remove bolt -1- and union nut -4- and detach oil supply line
-2-.
– Unscrew bolts -1, 3- and detach bracket -2- for turbocharger.
– Remove bolts -2- and press bracket -1- with auxiliary pump for
heating - V488- downwards slightly (different versions).
– Loosen bolt -4- and remove bolt -3- for bracket.

– Lift retaining clips -4- and detach coolant connection.
2. Cylinder head 71
– Unplug electrical connector -arrow- for engine temperature

sender - G27- .
– Remove camshaft housing ⇒ page 83 .
– Remove bolt -3- for dipstick guide tube.



– Remove bolt -1- for bracket for ancillaries.

– Unscrew bush -2- a few turns.

VAS 6100- .
– Attach lifting tackle - 2024A- to cylinder head and workshop
hoist, as shown.
CAUTION
Risk of injury if cylinder head drops when it is lifted
2. Cylinder head 73
NOTICE
Risk of damage to lines and hoses when lifting out cylinder head
– Check that all lines and hoses have been disconnected at
cylinder head.
– Lift off cylinder head.

• After removal, the cylinder head must not be put down on the
sealing surface with the glow plugs still installed because the
glow plugs project slightly beyond the sealing surface.
Installing
angle.
• Renew self-locking nuts, seals, gaskets and O-rings.
• Oil contact surfaces between roller rocker fingers and cams.
• Handle the cylinder head gasket very carefully to ensure it is
not damaged.
inder block.
– Carefully remove any remaining emery and abrasive material.
– Before fitting cylinder head, remove crankshaft stop - T10490-
and turn crankshaft against normal direction of rotation until
all pistons are positioned approximately equally below “TDC”.
– If not already fitted, install dowel sleeves for centring cylinder
block and cylinder head in cylinder block.
– Note cylinder head gasket identification ⇒ page 65 .

– Fit cylinder head gasket onto dowel pins -arrows- in cylinder

block.
• Installation position of cylinder head gasket: the word
“oben” (top) or the part number should face towards the cyl‐
inder head.
– Fit and tighten cylinder head bolts ⇒ page 65 .
Note:
after repair work.
note the following:
– Install camshaft housing ⇒ page 83 .
– Connect coolant hose with plug-in connector ⇒ 4-cylinder TDI
engine, 2.0 ltr. 4-valve common rail; Rep. gr. 19 ; Radiators/
radiator fan; Exploded view - radiators/radiator fan .
– Change coolant; to do so, fill coolant expansion tank and carry
out bleeding routine using ⇒ Vehicle diagnostic tester ⇒ 4-
Cooling system/coolant; Draining and filling cooling system .
ltr. 4-valve common rail; Rep. gr. 15 ; Cylinder head; Removing
and installing cylinder head
– Perform adaptions required after renewing cylinder head using
⇒ Vehicle diagnostic tester
page 9 .
Tightening torques
♦ ⇒ 4-cylinder TDI engine (2.0 ltr. 4-valve common rail); Rep.
gr. 19 ; Coolant pump/thermostat assembly; Exploded view -
electric coolant pump
♦ ⇒ Fig. ““Intake manifold with charge air cooler - tightening tor‐
♦ ⇒ “5.1 Exploded view - exhaust gas recirculation system”,
page 228
2. Cylinder head 75

version with water-cooled turbocharger

♦ Bit XZN 10 - T10501-
♦ Bolt, M8x20 (2x)

Removing
Cylinder head; Removing and installing cylinder head .
– Unplug electrical connector -arrow- and move electrical wire
clear.
2. Cylinder head 77

1- For turbocharger 1 control unit - J724-
2- For heater element for crankcase breather - N79-
3- For exhaust gas pressure sensor 1 - G450-
6- For fuel pressure regulating valve - N276-
7- For fuel pressure sender - G247-

G811-
- G810-
to side.

– Loosen bolt -1- for coolant line.

– Remove nuts -3- and detach bracket -2-.

– Unscrew bolts -5- and move particulate filter to right side.
sition and hand-tighten bolts.
– Lower engine onto engine mounting and detach support
bracket - 10-222A- ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve
common rail; Rep. gr. 10 ; Engine mountings; Supporting en‐
gine in installation position .

-2-.
– Unscrew bolts -1, 3- and detach bracket -2- for turbocharger.
2. Cylinder head 79
heating - V488- downwards slightly.

– Unplug electrical connector -arrow- for engine temperature

sender - G27- .



– Remove bolt -1- for bracket for ancillaries.

– Unscrew bush -2- a few turns.
2. Cylinder head 81

VAS 6100- .
– Attach lifting tackle - 2024A- to cylinder head and workshop
hoist, as shown.
CAUTION
Risk of injury if cylinder head drops when it is lifted
NOTICE
Risk of damage to lines and hoses when lifting out cylinder head
– Check that all lines and hoses have been disconnected at
cylinder head.
– Lift off cylinder head.

Installing
angle.
• Renew self-locking nuts, seals, gaskets and O-rings.
• Oil contact surfaces between roller rocker fingers and cams.
• Handle the cylinder head gasket very carefully to ensure it is
not damaged.
inder block.
– Carefully remove any remaining emery and abrasive material.
– Note cylinder head gasket identification ⇒ page 65 .

– Fit cylinder head gasket onto dowel pins -arrows- in cylinder

block.
inder head.
– Fit and tighten cylinder head bolts ⇒ page 65 .
Note:
after repair work.
note the following:
– Change coolant; to do so, fill coolant expansion tank and carry
out bleeding routine using ⇒ Vehicle diagnostic tester ⇒ 4-
Cooling system/coolant; Draining and filling cooling system .
ltr. 4-valve common rail; Rep. gr. 15 ; Cylinder head; Removing
and installing cylinder head
– Perform adaptions required after renewing cylinder head using
⇒ Vehicle diagnostic tester
page 9 .
Tightening torques

ing
2. Cylinder head 83
♦ Puller - T10055-

♦ Safety goggles
Removing
• Cylinder head installed.
– Detach toothed belt from camshaft
– Remove cylinder head cover
⇒ “2.3 Removing and installing cylinder head cover”,
page 65 .
– Unplug electrical connector -1- for exhaust gas pressure sen‐
sor 1 - G450- .
Note:
♦ Make sure that you do not damage vacuum hose.
♦ If damaged, vacuum hose must be renewed.
– Unlock -arrow A- and release -arrow B- fastener, and detach
vacuum hose.
– Remove bolts -3- and press bracket to one side.
– Remove bolt -4- for fuel lines.
– Unplug electrical connector -1- for Hall sender - G40- .

– Remove bolts -arrows- and press fuel lines to side.


– Remove bolt -arrow- and detach camshaft sprocket -2-.

-1-.
– Remove bolt -arrow- for toothed belt cover (rear) -1-.

quence -15 ... 1-.
2. Cylinder head 85
– Using puller - T10055- , carefully release camshaft housing

from bonded joint at projections -arrows- and detach it.
• Press toothed belt cover (rear) slightly to front in order to de‐
tach camshaft housing.
Installing
Requirements:
• Crankshaft locked in position with crankshaft stop - T10490- .
– Cover exposed parts of the engine with clean cloths.
CAUTION
– Remove remaining sealant from cylinder head and camshaft

housing -1- using rotating plastic brush or similar.
– Clean surfaces; they must be free of oil and grease.

1.5 mm).

– Apply bead of sealant -arrow- onto clean sealing surfaces of

camshaft housing, as shown.
• Width of sealant bead: 2 mm.
• Install the camshaft housing within 5 minutes after applying
the sealant.
• After installing the camshaft housing, wait about 30 minutes
for the sealant to dry.
– Carefully fit camshaft housing on cylinder head, paying atten‐
tion to dowel pins.
– Bring camshaft sprocket -2- into installation position and screw

in bolt -arrow- until it makes contact.
– Lock locating arm for camshaft -1- with locking pin - T10492- .
– Tighten camshaft housing bolts ⇒ page 91 .
note the following:
– Install cylinder head cover ⇒ page 65 .
Tightening torques
♦ ⇒ Fig. ““Camshaft housing - tightening torque and sequence”“ ,
page 91
♦ ⇒ “4.2 Exploded view - high-pressure reservoir (rail)”,
page 165

⇒ “2.7.1 Checking using diagnostic tester”, page 87
⇒ “2.7.2 Checking using compression tester”, page 88
2.7.1 Checking using diagnostic tester

Compression pressure can be checked with a vehicle diagnostic
tester or with compression tester - V.A.G 1763- .
Procedure
– Select Engine electronics in vehicle self-diagnosis.
2. Cylinder head 87
– Select Subsystems, conditions .

– Select Compression check from list.
• If the result for one of the cylinders is unusual, check the com‐
pression using the compression tester - V.A.G 1763- .
2.7.2 Checking using compression tester

♦ Compression tester - V.A.G 1763- with adapter - V.A.G
1763/8-
Procedure
– Unplug electrical connector -arrow- at fuel pressure regulating
valve - N276- .
– Remove all glow plugs ⇒ page 239 .

– Screw in adapter - V.A.G 1763/8- in place of corresponding

glow plug and connect compression tester - V.A.G 1763- .
(Using the compression tester ⇒ Operating instructions .)
– Have a second mechanic operate starter until tester shows no
further pressure increase.
When new 25.0 … 31.0
Wear limit 19.0
Assembling
– Install glow plugs ⇒ page 239 .
Tightening torques
2. Cylinder head 89
3 Valve gear

Cylinder heads with cracks between the valve seats may be used
without reducing engine life, provided the cracks are small and
not more than 0.5 mm wide.
1 - Valve
❑ Must not be machined;
only grinding-in is per‐
missible
⇒ page 101
⇒ page 100
2 - Cylinder head
❑ Valve seats may not be
machined due to the
very small tolerances
4 - Valve spring
6 - Valve cotters
ing”, page 83
❑ Lubricate contact surfa‐
ces before installing
8 - Sealing cap
❑ Renew if damaged or leaking
❑ Removing: With camshaft housing installed, pierce sealing cap in centre with an awl and pry out
❑ Installing: Drive in without sealant onto stop using suitable thrust piece, e.g. carrier - 3390-
9 - Oil seal
❑ With integrated camshafts

11 - Bolt
12 - Gasket
13 - Bolt
❑ Tightening torque ⇒ Brake system; Rep. gr. 47 ; Vacuum system; Exploded view - vacuum pump
14 - Vacuum pump
❑ Exploded view ⇒ Brake system; Rep. gr. 47 ; Vacuum system; Exploded view - vacuum pump
15 - Retaining clip
❑ For roller rocker fingers
17 - Dowel pin

angle.
Stage Procedure/tightening torque
1. Screw in by hand until bolt heads make contact with
retaining frame
2. Continue tightening 1 turn at a time in several stages
until retaining frame makes full contact with cylinder
head and a torque of 8 Nm is reached
3. 8 Nm

seal
♦ Assembly tool - T10493- with -T10493/3- , -T10493/4- and -
T10493/5-
3. Valve gear 91
♦ Hook - T40207-
Removing
– Detach toothed belt from camshaft ⇒ page 48 .
– Remove bolt -arrow- and detach camshaft sprocket -2-.
– Engage hook - T40207- at oil seal -1- -arrow- and pull out oil
seal.
– Fit guide sleeve -T10493/4- onto camshaft.

– The sealing lip of the oil seal must not be additionally oiled or
greased.
– Carefully push oil seal -1- over guide sleeve and onto cam‐
shaft.
• When pressing in oil seal, guide sleeve remains on camshaft.
– Press oil seal in onto stop using press tool -T10493/5- and bolt
-T10493/3- .

seals

A-
♦ Assembly cartridge, spacer sleeve and fitting tool from guide

plate - VAS 5161A/32- (not illustrated)
♦ Guide plate - VAS 5161A/41- (not illustrated)
♦ Valve stem seal puller -T40426- (not illustrated)
♦ Valve shaft seal fitting tool -T404196- (not illustrated)
Procedure
3. Valve gear 93
– Fit guide plate -VAS 5161 A/41- onto cylinder head and align
it with valves.
• The lettering “A” faces towards turbocharger side
• The lettering “E” faces towards intake manifold side
– Secure guide plate with bolts -arrows- by hand.
– Screw sealing pin -VAS 5161/10- into guide plate.

– Screw adapter -VAS 5161/11- hand-tight into corresponding
glow plug thread.
– Insert drift -VAS 5161/3A- into guide plate and use plastic-

– Insert assembly cartridge -VAS 5161/32-1- (slide on spacer
sleeve -VAS 5161 A/32-2- ) in guide plate.
– Take off assembly cartridge with sleeve.

– Pull off valve stem oil seal with valve stem seal puller -
T40426- .
– Insert valve stem oil seal into valve shaft seal fitting tool -
T40419- and use assembly sleeve to carefully press it onto
valve guide -1- as far as stop.

must first be inserted in fitting tool -VAS 5161 A/32-3- .
3. Valve gear 95
– Insert assembly cartridge in guide plate -VAS 5161 A/41-

again.
cotters.
tion.
Assembling

A-
♦ Assembly cartridge, spacer sleeve and fitting tool from guide

plate - VAS 5161A/32- (not illustrated)
♦ Guide plate - VAS 5161A/41- (not illustrated)

♦ Valve stem seal puller -T40426- (not illustrated)

♦ Valve shaft seal fitting tool -T404196- (not illustrated)
Procedure
• Intake manifold with charge air cooler and turbocharger must
be detached from cylinder head after it has been removed.
– Secure cylinder head in cylinder head tensioning device as
shown.
supply.
with valve heads.
– Fit guide plate -VAS 5161 A/41- onto cylinder head and align
it with valves.
• The lettering “A” faces towards turbocharger side
• The lettering “E” faces towards intake manifold side
– Secure guide plate with bolts -arrows- by hand.
3. Valve gear 97

– Insert assembly cartridge -VAS 5161/32-1- (slide on spacer
sleeve -VAS 5161 A/32-2- ) in guide plate.
– Pull off valve stem oil seal with valve stem seal puller -
T40426- .

T40419- and use assembly sleeve to carefully press it onto

must first be inserted in fitting tool -VAS 5161A/32-3- .

again.
cotters.
tion.
Assembling
3. Valve gear 99


Procedure
• End of valve stem must be flush with guide.
new valves.
4.2 Checking valves

faces.


in is permitted.
∅a mm 28.1 ± 0.1 25.0 ± 0.1
∅b mm 4.975 ± 0.007 4.965 ± 0.007
c mm 99.3 99.3
α ∠ 45° 10’ ± 10’ 45° 10’ ± 10’

17 – Lubrication
1 Sump/oil pump
page 105
er G266 ”, page 109

♦ Oil spray jet and pressure relief valve ⇒ page 38
1 - Spreader rivet
3 - Sealing plug/oil drain plug
❑ Drive in sealing plug as
far as stop
❑ Oil drain plug: 30 Nm
4 - O-ring
5 - Bolt
❑ Self-locking
❑ Clean threaded holes
for bolts using a thread
tap or similar
❑ 8 Nm +90°
6 - Oil intake pipe
7 - O-ring
8 - Bolt
sequence
⇒ Fig. ““Oil pump - tight‐
ening torque and se‐
9 - Oil pump
⇒ page 109
10 - Toothed belt
❑ To remove, remove
sealing flange (pulley

end) ⇒ page 23
11 - Cylinder block
12 - O-ring
❑ Renew if leaking
13 - Plug
❑ For dipstick guide tube
14 - Bolt
❑ 8 Nm
16 - Bolt
❑ 8 Nm
17 - O-ring
19 - Bolt
20 - Bolt
21 - Gasket
❑ Removing and installing ⇒ “1.3 Removing and installing sump (bottom section)”, page 105
23 - Bolt
⇒ Fig. ““Sump (bottom section) - tightening torque and sequence”“ , page 104
24 - Seal
25 - Nut
❑ 8 Nm

Sump (bottom section) - tightening torque and sequence

– Tighten bolts -arrows- in stages:
que 8 Nm
Oil pump - tightening torque and sequence

angle.
– Tighten bolts -1, 2, 3- in stages in the sequence shown:
2. 12 Nm
Sump (top section) - tightening torque and sequence

1. -1 … 27-, 5 Nm
-arrows-
2. -1 … 25- 13 Nm
3. -1 … 25- 13 Nm
• This procedure has been specified
in order to compensate for the set‐
tling of the components.
4. -26, 27- 40 Nm
5. -arrows- ⇒ Gearbox; Rep. gr. 34 ; Removing
and installing gearbox; Tightening tor‐
ques for gearbox
1.2 Engine oil

and installing oil filter element ⇒ 4-cylinder TDI engine (2.0 ltr.
4-valve common rail); Rep. gr. 17 ; Sump/oil pump; Engine oil
tenance tables .


section)
Removing
• Engine oil drained ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve
common rail; Rep. gr. 17 ; Sump/oil pump; Engine oil
– Detach wiring duct -1- with B+ wire from sump and press wiring
duct upwards.
sender - G266- .
– Release spreader rivets -arrows- and detach noise insulation
for sump.

– Loosen bolts -arrows- in diagonal sequence and remove.

– Remove sump.
Installing
Tightening torques
♦ ⇒ Fig. ““Sump (bottom section) - tightening torque and se‐

tion)
♦ Socket - T10058-
♦ Safety goggles
Removing
Sump/oil pump; Removing and installing sump (top section) .

– Unscrew bolt -top arrow-.

– Remove bolts -top arrows-.

– Unscrew bolts -bottom arrows- and remove engine support
(left-side).

– Loosen bolts -1 ... 27- and remove.
– Carefully release sump (top section) from bonded joint, pry
sump off dowel sleeves and detach.
Installing
• Renew gaskets, seals and O-rings after removal.

– Place clean cloths over open sections of engine to prevent

lubrication system from being contaminated by sealant resi‐
due.
CAUTION
– Remove sealant residue from sump (top section) -1- and cyl‐
inder block using rotating plastic brush or similar.

– Cut off nozzle of tube at front marking (nozzle ∅ approx. 2.5
mm).
NOTICE
– Apply bead of sealant -arrow- onto clean sealing surfaces of

sump (top section) as shown.
• The bead of sealant must project 3.5 mm above the sealing
surface.
– Carefully fit sump (top section) onto cylinder block but do not
press sealant bead on yet.
note the following:
ltr. 4-valve common rail; Rep. gr. 17 ; Sump/oil pump; Removing
and installing sump (top section)
Tightening torques
♦ ⇒ Fig. ““Sump (top section) - tightening torque and se‐
gr. 10 ; Assembly mountings; Exploded view - assembly
mountings
♦ ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve common rail; Rep. gr.
19 ; Coolant pipes; Exploded view - coolant pipes


Removing
– Remove bolts -1, 2, 3-.
– Disengage toothed belt -arrow- and remove oil pump.
• The bolt on the pump impeller must NOT be loosened.
Installing
angle.
Tightening torques
♦ ⇒ Fig. ““Oil pump - tightening torque and sequence”“ ,
page 104

Removing

sender - G266- .
– Release spreader rivets -arrows- and detach noise insulation
for sump.
Installing
• Renew seal -4- and self-locking nuts -1- after removal.
Tightening torques

2 Engine oil cooler

Engine oil cooler must not be separated from oil filter housing. If
defective, engine oil cooler must be renewed together with oil filter
housing ⇒ page 113 .


page 113
page 115
”, page 116
N522 ”, page 118
1 - Oil filter housing with engine

oil cooler
❑ Do not separate oil filter
housing and engine oil
cooler
⇒ page 113
2 - Seals
3 - O-ring
valve - N522-
⇒ page 118
5 - Bolt
❑ 9 Nm
6 - O-ring
7 - Sealing cap
❑ 25 Nm
⇒ page 104
9 - O-ring
10 - Bolt

Oil filter housing/engine oil cooler - tightening torque and se‐

quence
angle.
– Fit bolts at top left and bottom right first.
1. 20 Nm
3.2 Exploded view - oil pressure switches/oil pressure control

trol - N428-
⇒ page 116
2 - Bolt
❑ 8 Nm
3 - O-ring
agnostic tester
⇒ page 115
❑ 10 Nm + turn +45° fur‐
ther


Removing
cooling system .
– Remove engine support (left-side) ⇒ 4-cyl. TDI engine, 2.0 ltr.
– Remove bolt -2- and push coolant pipe to one side.
to one side.


– Detach electrical wiring from engine speed sender at oil filter
housing.
– Unscrew bolts -arrows- and detach oil filter housing together
with engine oil cooler.
Installing
– Install engine support (left-side) ⇒ 4-cyl. TDI engine, 2.0 ltr.
ing ⇒ Vehicle diagnostic tester ⇒ 4-cylinder TDI engine, 2.0
ltr. 4-valve common rail; Rep. gr. 19 ; Cooling system/coolant;
Tightening torques
♦ ⇒ “3.1 Exploded view - oil filter”, page 112

sender - G10-
♦ Socket, AF 24 mm - T40284-
Procedure
cylinder TDI engine, 2.0 ltr. 4-valve common rail; Rep. gr. 17 ; Oil
filter/oil pressure switches ; Removing and installing oil pressure
sender - G10- .

– Lift retaining clips -arrows- and disconnect coolant hoses.


– Unscrew oil pressure sender - G10- using socket, 24 mm -
T40284- .
– Fit new oil pressure sender immediately so that as little oil as
possible is lost.
ltr. 4-valve common rail; Rep. gr. 17 ; Oil filter/oil pressure
switches ; Removing and installing oil pressure sender - G10-
Tightening torques
trol”, page 113

Procedure
– Unscrew bolt -1- and remove valve for oil pressure control -
N428- .
– Fit new valve for oil pressure control immediately so that as
little oil as possible is lost.
– Install toothed belt cover (bottom) ⇒ page 47 .
Tightening torques
trol”, page 113


Procedure
• Oil level OK
– Remove oil pressure sender - G10- ⇒ page 115 .
– Connect oil pressure tester - V.A.G 1342- to bore for oil pres‐
sure sender.
– Screw a used oil pressure switch into threaded hole on oil
pressure tester - V.A.G 1342- to seal hole.
– Start engine and leave it running only as long as required for
the test.
• Oil pressure when starting and then at idling speed: at least
1.4 bar.
If specification is not obtained, switch off engine immediately and
check oil pump drive; renew oil pump if necessary ⇒ page 109 .
If specification is obtained, higher oil pressure must be checked
using ⇒ Vehicle diagnostic tester.
– Allow engine to warm up.
Note:
It is not possible to test all levels of the oil pressure control system
while the vehicle is stationary. The higher oil pressure must there‐
fore be checked using the ⇒ Vehicle diagnostic tester:
– Then select Basic setting .
– Select Test of pressure level change-over for oil
pump on the Basic setting page and then click on > (not >I).
– No settings are required on the parameter settings page. Now

click on > (not >I).
– Select Operating instructions and Oil pressure ac-
tual value on the measured values page and then click on
> (not >I).
– Start the basic setting routine and follow the operating instruc‐
tions.
– Do not press the pedals until requested; otherwise the routine
will be cancelled for safety reasons.
• Oil pressure must rise to at least 3.5 bar.

Assembling
– Install oil pressure sender - G10- ⇒ page 115 .

Removing
– Remove oil filter housing ⇒ page 113 .
N522- -item 2-.
Installing
– Install oil filter housing ⇒ page 113 .
Tightening torques

19 – Cooling

All components are described in ⇒ 4-cylinder TDI engine, 2.0 ltr.
4-valve common rail; Rep. gr. 19 ; Cooling system/coolant; Con‐
nection diagram - coolant hoses .


(version 2)


(version 1)
♦ Safety goggles
Note:
• To ensure that the leak test is carried out correctly, a self-test
must first be performed on the cooling system tester -
V.A.G 1274 B- .
Checking cooling system tester - V.A.G 1274 B- (self-test)
– Build up a pressure of 3.0 bar on cooling system tester.

• Cooling system tester - V.A.G 1274 B- is leaking and must not
be used.
Checking cooling system for leaks

CAUTION

expansion tank.

nutes.
Note:
engine is cold.
If the pressure drops by more than 0.2 bar:
– Examine engine and radiator to find and eliminate the leak.


Blue filler cap
this level.
scribed.
Black filler cap
this level.
scribed.

Blue filler cap
1.4 ... 1.6 bar.
scribed.
Black filler cap
1.6 ... 1.8 bar.
scribed.

4-valve common rail; Rep. gr. 19 ; Cooling system/coolant; Drain‐
ing and filling cooling system .


⇒ “2.3 Exploded view - coolant valves”, page 125
page 125
page 125
⇒ “2.7 Removing and installing mixing valve for charge air cooler”,
page 126
N489 ”, page 126
⇒ “2.9 Removing and installing coolant distribution module”, page
127
⇒ “2.10 Removing and installing temperature sensor G18 ”, page
128
⇒ “2.11 Removing and installing engine temperature sender G27
”, page 129
⇒ “2.12 Removing and installing engine temperature sender 2
G652 ”, page 129

1 - Bolt
2 - Damper wheel
3 - Coolant pump
⇒ page 126
4 - O-ring
head - N489-
⇒ page 126
6 - Bolt
❑ 6 Nm
7 - Seals
8 - Coolant distribution module
❑ On engines above
140 KW, the coolant dis‐
tribution module is
called the engine tem‐
perature regulation
module - GX33- and
contains the compo‐
nents actuator for en‐
lation - N493- and
position sender for en‐
lation - G1004-
❑
❑ On engines below 140 kW, the coolant distribution module is called the actuator for engine temperature
regulation - N493-
9 - Bolt
❑ Tighten in stages and in diagonal sequence; final torque 20 Nm
10 - Seal
11 - Bolt
❑ 20 Nm +45°

4-valve common rail; Rep. gr. 19 ; Coolant pump/thermostat as‐
sembly; Exploded view - electric coolant pump .

2.3 Exploded view - coolant valves

sembly; Exploded view - coolant valves .
1 - Spacer ring
2 - O-ring
- G27-
⇒ page 129
4 - Bolt
❑ 8 Nm
2 - G652-
⇒ page 129
6 - Bolt
❑ 8 Nm
7 - O-ring
8 - Spacer ring
9 - Bolt
❑ 8 Nm
10 - Temperature sensor -
G18-
⇒ page 128
11 - Spacer ring
12 - O-ring

pump
sembly; Removing and installing electric coolant pump .


Removing
cooling system .
– Remove bolt -4- and detach coolant valve for cylinder head -
N489- -item 3-.
– If renewing coolant pump, remove bolt -1- and detach damper
wheel -2-.
– Remove bolts -arrows- and detach coolant pump.
Installing
NOTICE
Risk of damage to coolant pump if functional check is performed
manually.
– Never pull the modulating mechanism of the coolant pump
with your hand to check its function.
• Do not hold or carry the coolant pump by the modulating

mechanism.
• Do not operate the modulating mechanism.
– Fill and bleed coolant circuit ⇒ 4-cylinder TDI engine, 2.0 ltr.
4-valve common rail; Rep. gr. 19 ; Cooling system/coolant;
Tightening torques
2.7 Removing and installing mixing valve for

charge air cooler
On engines above 140 kW, the mixing valve is called the coolant
circuit control unit - GX28- .
On engines below 140 kW, the mixing valve is called the control
unit for charge air cooler bypass - J865- .
sembly; Removing and installing mixing valve for charge air cool‐
er .

Removing
• Engine cold.


tank.
– Detach toothed belt from camshafts ⇒ page 48 .

N489- .
Installing
cooling circuit ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve com‐
mon rail; Rep. gr. 19 ; Bleeding high-temperature cooling
circuit and low-temperature cooling circuit .
Tightening torques
page 125
2.9 Removing and installing coolant distri‐

bution module
On engines above 140 KW, the coolant distribution module is
called the engine temperature regulation module - GX33- and
contains the components actuator for engine temperature regu‐
lation - N493- and position sender for engine temperature regu‐
lation - G1004- .
On engines below 140 kW, the coolant distribution module is

called the actuator for engine temperature regulation - N493- .
Removing

to one side.

– Lift retaining clips -2- and press coolant lines -3- to side.

– Lift retaining clips -2- and disconnect coolant hoses.
– Unscrew bolts -arrows- and remove coolant distribution mod‐
ule.
Installing
Tightening torques

sensor - G18-
Removing
• Engine cold.


tank.

– Unscrew bolt -2- and pull off temperature sensor - G18- .
Note:
If an O-ring or spacer ring remains lodged in coolant line, lift it out
with a piece of wire, taking care not to damage sealing surface.
Installing
cooling circuit ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve com‐
mon rail; Rep. gr. 19 ; Bleeding high-temperature cooling
circuit and low-temperature cooling circuit .
Tightening torques
page 125

ature sender - G27-

Removing
Coolant pump/thermostat assembly ; Removing and installing
engine temperature sender 2 - G652- .

– Unscrew bolt -1- and press coolant line -3- slightly to one side.
to one side.
– Remove bolts -1, 2- and detach bracket for intake manifold.


– Unscrew bolt -1- and pull off engine temperature sender 2 -
G652- .
Note:
If an O-ring or spacer ring remains lodged in cylinder block, lift it
face.
Installing
– Fill and bleed coolant circuit ⇒ 4-cylinder TDI engine, 2.0 ltr.
4-valve common rail; Rep. gr. 19 ; Cooling system/coolant;
ltr. 4-valve common rail; Rep. gr. 19 ; Coolant pump/thermostat
assembly ; Removing and installing engine temperature sender
2 - G652-
Tightening torques
page 125

3 Coolant pipes
engine, 2.0 ltr. 4-valve common rail; Rep. gr. 19 ; Coolant pipes .

engine, 2.0 ltr. 4-valve common rail; Rep. gr. 19 ; Radiators/ra‐
diator fans .

1 Turbocharger

♦ Exploded view - turbocharger, part I ⇒ page 134
♦ Exploded view - turbocharger, part II ⇒ page 135
Exploded view - turbocharger, part I
1 - Bolt
❑ 8 Nm
2 - Heat shield
3 - O-ring
4 - Bolt
❑ 8 Nm
5 - Pulsation damper
6 - Bolt
❑ Captive
❑ 5.5 Nm
8 - Intake connecting pipe
❑ With heater element for
crankcase breather -
N79-
9 - Hose
10 - O-ring
❑ Renew hose
damaged or leaking
11 - O-ring
12 - Gasket
13 - Turbocharger
❑ With turbocharger 1 control unit - J724-
❑ Performing adaptions required after renewing a component (using ⇒ Vehicle diagnostic tester)
⇒ page 9

14 - Nut
❑ Allocation, tightening torque and sequence ⇒ page 136
❑ Lubricate exhaust manifold studs with high-temperature paste
❑ If studs are renewed, too, tighten them to 14 Nm
15 - Seal
16 - Bolt
❑ 20 Nm
17 - Bracket
18 - Bolt
❑ 20 Nm
Exploded view - turbocharger, part II
1 - Oil supply line

❑ Check for obstructions
❑ Before installing turbo‐
charger, fill connection
for oil supply line with
engine oil
❑ Union nuts, 22 Nm
2 - Bolt
❑ 8 Nm
3 - O-ring
4 - Turbocharger
❑ Depending on engine:
water-cooled or not wa‐
ter-cooled
⇒ page 136
❑ Reset learnt values after
renewing turbocharger
⇒ page 9
5 - Gasket
❑ For water-cooled ver‐
sion
6 - Bolt
sion
❑ 14 Nm
7 - Coolant lines
sion
8 - Bolt
❑ For water-cooled version
❑ 20 Nm
1. Turbocharger 135
9 - Bolt
❑ 8 Nm
10 - Bolt
❑ 20 Nm
11 - Bolt
❑ 8 Nm
12 - Retaining clips
13 - Bracket
14 - Heat shield
15 - Gasket
16 - Bolt
❑ 14 Nm
18 - Bolt
❑ 8 Nm
19 - O-ring
Turbocharger - distinguishing feature of nuts, tightening torque

and tightening sequence
Engine power class Nuts Version
1 -1 … 10- -B-
2 -1 … 7-, -B-
-9, 10-
2 -8- -A-
– Tighten new nuts -1 ... 10- in stages in the sequence shown:
1. 11 Nm
2. 22 Nm
3. 22 Nm
• This procedure has been specified in order to com‐
pensate for the settling of the components.

⇒ “1.2.1 Removing and installing turbocharger (not water-
cooled)”, page 136
⇒ “1.2.2 Removing and installing turbocharger (water-cooled)”,
page 140
1.2.1 Removing and installing turbocharger

(not water-cooled)

♦ Socket - T40055-
Removing
• If the turbocharger has suffered mechanical damage
⇒ page 8
cylinder TDI engine (2.0 ltr. 4-valve common rail); Rep. gr. 21 ;
Turbocharger; Removing and installing turbocharger .
– Remove front exhaust pipe ⇒ 4-cyl. TDI engine (2.0 ltr. 4-valve
common rail); Rep. gr. 26 ; Exhaust pipes/silencers; Remov‐
ing and installing front exhaust pipe .
– Move electrical wiring clear at clip -1-.

1. Turbocharger 137
– Unscrew bolts -arrows- and detach pulsation damper -1-.

breather hose -2-.
– Unscrew bolt -3-, turn connection -1- slightly in direction of
-arrow- and detach.
page 205 .

-2-.
– Unscrew bolts -1, 3- and remove bracket -2-.

– Detach electrical connectors -1, 3- from bracket, unplug them

and move them clear.
1. Turbocharger 139
– Slacken and remove nuts in the sequence: -10 ... 1-.

– Detach turbocharger with exhaust manifold from cylinder
head.
Installing
moval.
line.
– Install front exhaust pipe ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-
valve common rail; Rep. gr. 26 ; Exhaust pipes/silencers;
Removing and installing front exhaust pipe .
– Reset learnt values after renewing turbocharger ⇒ page 9 .
Tightening torques
♦ ⇒ Fig. ““Turbocharger - distinguishing feature of nuts, tighten‐
ing torque and tightening sequence”“ , page 136
page 228
1.2.2 Removing and installing turbocharger

(water-cooled)

♦ Socket - T40055-
Removing
• If the turbocharger has suffered mechanical damage
⇒ page 8
cooling system .
– Remove exhaust gas recirculation cooler
⇒ “5.4 Removing and installing exhaust gas recirculation cool‐
er”, page 232 .

breather hose -3-.
-arrow- and detach.
page 205 .
1. Turbocharger 141

-2-.
– Unscrew bolts -1, 3- and remove bracket -2-.
– Detach electrical connectors -1, 3- from bracket, unplug them

and move them clear.
– Loosen bolt -1- for coolant line.


– Unscrew bolts -1- and remove bracket -2-.

1. Turbocharger 143
– Slacken and remove nuts in the sequence: -10 ... 1-.

– Detach turbocharger with exhaust manifold from cylinder
head.
Installing
moval.
line.
– Reset learnt values after renewing turbocharger ⇒ page 9 .
Tightening torques
♦ ⇒ Fig. ““Turbocharger - distinguishing feature of nuts, tighten‐
ing torque and tightening sequence”“ , page 136
page 228

2 Charge air system

page 146
page 147
page 147
1 - Intake manifold with charge

air cooler
❑ Intake manifold and
charge air cooler are
combined as one unit
⇒ page 158
sender after charge air cooler -
G811-
⇒ page 147
❑ 22 Nm
3 - Air hose
4 - Air pipe
5 - Seal
renew if necessary
6 - Bolt
er - G810-
stalling charge air tem‐
perature sender”,
page 147
❑ 22 Nm
8 - Bolt
❑ 8.5 Nm
9 - Air hose

Air pipe - tightening torque and sequence

– Tighten bolts in the sequence -1, 2, 3- to 8 Nm.

charge air system
installing.
-arrows-.
enough.
off air hose.
must be renewed.

Air hoses to air pipes/charge air cooler - installation position and

tightening torque
• The markings on the air hose and on the resonator must align
-arrow-.
– Tighten screw-type clip -1- to 5 Nm.

sure sender - G31-
Removing
NOTICE
Irreparable damage to charge pressure sender can be caused
if the connection breaks off.
keep hose straight.

– Release hose clip -1- and disconnect hose.
– Detach charge pressure sender - G31- .
Installing
Tightening torques

perature sender
♦ Crow-foot ring spanner, 16 mm (commercially available)

Removing
Charge air temperature sender before charge air cooler - G810-
– Unplug electrical connector -2- and remove charge air tem‐
perature sender before charge air cooler - G810- .
Charge air temperature sender after charge air cooler - G811-
– Unplug electrical connector -1- and remove charge air tem‐
perature sender after charge air cooler - G811- .
Installing
Tightening torques

♦ Adapter - V.A.G 1687/11-
♦ Adapter - V.A.G 1687/13-2-

♦ Adapter - V.A.G 1687/14-

♦ Turbocharger tester - V.A.G 1397A-
♦ Y-connector - VAS 691 005/1-
♦ Test instrument adapter - VAS 691 005/5-

Procedure
Charge air system; Checking charge air system for leaks .
expansion tank.

Connecting turbocharger tester - V.A.G 1397A- :

– Fit test adapter - VAS 691 005/5- onto coolant expansion tank.
– Fit Y-connector - VAS 691 005/1- onto test adapter - VAS 691
005/5- .
– Close valve -1- for connection »C« and open valve -2- for con‐
nection »A«.
– Attach hose from connection »A« on Y-connector to connec‐
tion »II« on turbocharger tester - V.A.G 1397A- .
– Set turbocharger tester - V.A.G 1397A- to switch position
»II« (relative pressure measurement) and switch it on. The »II«
must be visible.
– Disconnect crankcase breather pipe -arrow-.

– Seal off connecting piece with a plug -2- from engine bung set
- VAS 6122- .
– Secure plug with a hose clip -1-.
– Connect adapter - V.A.G 1687/6- with adapter - V.A.G

1687/13-2- to turbocharger.
– Connect hose -1- of charge air system tester - V.A.G 1687- to
adapter.

– Loosen clamp on exhaust pipe -arrows- and push towards

rear.
– Seal off front exhaust pipe with adapters -V.A.G 1687/11- and
-V.A.G 1687/14- .
– Seal hole in -V.A.G 1687/11- with plug-in connector -1- (com‐
mercially available).

– Connect charge air system tester - V.A.G 1687- to adapter.
– Pull pressure control valve -2- upwards, then unscrew com‐
pletely and close valves -3- and -4-.
– Open valve -3-.
NOTICE
Risk of damage to components if test pressure is set too high
– Never set test pressure higher than specified.

• A small amount of air escapes through the valves and enters
the engine and the exhaust gas recirculation cooler. Therefore
it is not possible to perform a pressure retention test.
• For operation of ultrasonic tester -V.A.G 1842- , refer to ⇒
Operating instructions .
– Check entire charge air system for leaks:
♦ By listening
♦ By feeling
♦ Using a commercially available leak detection spray
If no leak is found in the charge air system, check water-cooled
charge air cooler for leaks.

Reading off values from turbocharger tester - V.A.G 1397A- :

– Pressure must remain set to 0.5 bar.
• Observe turbocharger tester for approx. 5 minutes.
• The pressure displayed on the turbocharger tester must not
rise.
– If pressure displayed on turbocharger tester rises, this means
that compressed air is escaping into the cooling system.
– Charge air cooler has a leak, renew intake manifold with
charge air cooler.
• If there are no leaks in the charge air cooler, a vacuum may
form when the coolant cools down. A minus sign on the tur‐
bocharger tester indicates that a vacuum has formed.
Cleaning Y-connector - VAS 691 005/1- :

• After the leak test has been completed, the Y-connector - VAS
691 005/1- must be cleaned to remove any water which may
have entered.
– Insert cleaning nozzle -D- in hose from connection -A- on Y
connector .
– Fit test adapter - VAS 691 005/5- onto hose from connection
-B-.
– Fit compressed air hose on connection -C-.
– Open cut-off valves and blow through hose for approx. 15
seconds.
Assembling
ltr. 4-valve common rail; Rep. gr. 21 ; Charge air system; Check‐
ing charge air system for leaks
Tightening torques
tem”, page 146


1 Injection system
page 153

4-valve common rail; Rep. gr. 23 ; Injection system; Overview -
fuel system .

system
4-valve common rail; Rep. gr. 23 ; Injection system; Overview of
fitting locations - injection system .

must be bled.
NOTICE
Running when dry causes irreparable damage to fuel pump.
Proceed as follows to fill high-pressure pump with fuel.

• Check fuel gauge in instrument cluster; fuel gauge needle
must indicate that fuel is above reserve level.
♦ 0001 - Activate fuel pump
♦ Press Carry out check
♦ Select 120 seconds.
– The fuel pump must run for 120 seconds to ensure that the
fuel system is filled sufficiently with fuel.
– Start engine after filling fuel system.

– Run engine at moderate speed for several minutes and then

switch off.
– Erase entry in event memory.
– Then check high-pressure system again for leaks.

Procedure
– Run engine at idling speed for several minutes (do not press
accelerator) and then switch off. Fuel system will bleed itself
automatically.
renewed.

2 Air cleaner
engine, 2.0 ltr. 4-valve common rail; Rep. gr. 23 ; Air cleaner .
2. Air cleaner 155

3 Intake manifold
157
1 - Bolt
sequence
⇒ Fig. ““Intake manifold
with charge air cooler -
tightening torque and
air cooler
⇒ page 158
3 - Gasket
4 - Bracket
5 - Bolt
❑ 8 Nm
6 - Bracket
❑ For electrical connec‐
tors
7 - Bolt
❑ 8 Nm
8 - Coolant bleeder screw
9 - Bolt
❑ 8 Nm
10 - Bolt
❑ 10 Nm
12 - Seal
13 - O-rings
14 - Ball stud
❑ 8 Nm
15 - Bracket
❑ For intake manifold

16 - Coolant pipe
17 - Bolt
❑ 8 Nm
18 - Bolts
⇒ Fig. ““Intake manifold with charge air cooler - tightening torque and sequence”“ , page 157
19 - Bolt
❑ 8 Nm
21 - Bolts
⇒ Fig. ““Intake manifold with charge air cooler - tightening torque and sequence”“ , page 157
22 - Bracket
Intake manifold with charge air cooler - tightening torque and se‐
quence
angle.
Stag Bolts Tightening torque/angle specification
e
2. -1 … 10- 8 Nm
3. -1 … 10- Turn 90° further
5. -11- 20 Nm
6. -12- 20 Nm

module - J338-
Removing
Intake manifold; Removing and installing throttle valve module -
GX3- .
– Move electrical wiring clear at clip -1-.


J338- -2-.
Installing
– When fitting connection with throttle valve module - J338- , pay
attention to dowel pins.
ltr. 4-valve common rail; Rep. gr. 23 ; Intake manifold; Removing
and installing throttle valve module - GX3-
– Perform adaptions required after renewing a component (us‐
ing ⇒ Vehicle diagnostic tester) ⇒ page 9 .
Tightening torques
tem”, page 146

Intake manifold and charge air cooler are combined as one unit.

Removing
Intake manifold; Removing and installing intake manifold .
⇒ “4.9.1 Removing high-pressure pipe between high-pressure
reservoir (rail) and high-pressure pump”, page 177 .

1 - For turbocharger 1 control unit - J724- (fitting location varies)
2 - For heater element for crankcase breather - N79-
3 - For exhaust gas pressure sensor 1 - G450-
5 - For exhaust gas recirculation valve 2 - GX6-
6 - For fuel pressure regulating valve - N276-
7 - For fuel pressure sender - G247-


G811-
- G810-
to side.
heating - V488- downwards slightly. (Different versions.)

– Lift retaining clip on coolant connection (top) -4- and detach
coolant connection.



– Remove bolts -3- and press bracket to one side.
– Remove bolt -4- for fuel lines.
– Release hose clips -1 and 2- and detach fuel hoses.

– Remove bolts -arrows- and press fuel lines to side.
– Remove exhaust gas recirculation valve 1 - GX5-
⇒ “5.2 Removing and installing exhaust gas recirculation valve
1 GX5 ”, page 230 .

– Remove bolts -arrows- and detach intake manifold with charge

air cooler.
Installing
• Renew gasket and spring-type clips for fuel hoses after re‐
moving.
– Fit new gasket onto dowel pins in cylinder block.
– Fit intake manifold onto dowel pins in cylinder block and tight‐
en bolts.
note the following:
⇒ “4.9 Removing and installing high-pressure pipes”,
page 177 .
– Install exhaust gas recirculation valve 1 - GX5-
1 GX5 ”, page 230 .
– Bleed fuel system
Tightening torques
page 165

(rail)
page 167
page 169
speed”, page 172
page 179


1 - Seal
⇒ page 66
2 - Copper seal
3 - O-ring
4 - Injector
❑ Use a coloured pen to
mark allocation of injec‐
tors to corresponding
clamping piece and
high-pressure pipe, and
to corresponding cylin‐
der for re-installation;
pay attention to mark‐
ings when installing
❑ Renew copper seal after
removing
❑ To remove carbon de‐
posits from the injector
sealing surface, clean
the injector bore in the
cylinder head with
cleaning kit - VAS 6811-
(it is important to do this
to avoid leaks)
⇒ page 173
5 - O-ring
❑ To fuel tank
❑ Must not be kinked, damaged or clogged
❑ Fill and bleed fuel system after renewing ⇒ page 153
7 - Clamping piece
❑ Use a coloured pen to mark injectors and corresponding clamping piece and cylinder for re-installation;
pay attention to markings when installing
❑ The clamping pieces can be re-used when installing new injectors
❑ Each clamping piece secures two injectors
❑ Installation position: Side with lettering faces upwards
8 - Bolt
❑ Tighten initially to 2 Nm, then screw on union nuts for high-pressure pipes hand-tight and align injectors
❑ 8 Nm + 270° (3x 90° further)
❑ From high-pressure reservoir (rail) to injector
❑ Check for damage before re-installing
❑ If an injector is renewed, the corresponding high-pressure pipe must also be renewed

♦ 28 Nm if re-installing high-pressure pipe
♦ 15 Nm +60° if installing a new high-pressure pipe
10 - Grommet
4.2 Exploded view - high-pressure reservoir (rail)
1 - Fuel hose
2 - Bolt
❑ 8 Nm
3 - Retaining clamp
❑ Between high-pressure
pump and high-pres‐
sure reservoir (rail)
❑ Check for damage be‐
fore re-installing
❑ Lubricate threads of un‐
ion nuts with clean en‐
gine oil
❑ If the high-pressure
pump is renewed, the
corresponding high-
pressure pipe must also
be renewed
♦ 28 Nm if re-installing high-
pressure pipe
♦ 15 Nm +60° if installing a
new high-pressure pipe
G247-
⇒ page 186
♦ Pre-tighten to 50 Nm.
♦ Loosen by a maximum of
one turn.
♦ Tighten to 55 Nm +20°.
♦ Tighten to final torque of 130 Nm.
❑ From high-pressure reservoir (rail) to injector
❑ If an injector is renewed, the corresponding high-pressure pipe must also be renewed

7 - Damping element
❑ If the high-pressure reservoir is renewed, all corresponding high-pressure pipes must also be renewed
9 - Bolt
❑ 20 Nm
10 - O-ring
❑ Checking ⇒ “6.5 Checking fuel pressure regulating valve N276 ”, page 190
⇒ “6.6 Removing and installing fuel pressure regulating valve N276 ”, page 192
⇒ page 9
♦ Pre-tighten to 60 Nm.
♦ Loosen to 5 Nm.
♦ Tighten to 20 Nm +15°.
♦ Tighten to final torque of 130 Nm.
12 - Spring-type clips
13 - Bolt
❑ 8 Nm
14 - Fuel lines
17 - Fuel hose
18 - Bolt
❑ 18 Nm
21 - Clip


There are four different tests for checking the operation of the
injectors.
♦ ⇒ “4.4 Performing adaption of correction values for injectors”,
page 167
♦ ⇒ “4.5 Checking for injectors sticking open”, page 168
♦ ⇒ “4.6 Checking return flow rate of injectors with engine run‐
ning”, page 169
♦ ⇒ “4.7 Checking return flow rate of injectors at starter cranking
speed”, page 172
Perform the following tests first if the engine does not start at all:
speed”, page 172
♦ ⇒ “6.5 Checking fuel pressure regulating valve N276 ”,
page 190 .

ues for injectors
♦ The “Injector delivery calibration” and “Injector voltage cali‐
bration” serve to correct the injection rates for each cylinder of
a common rail system individually across the entire operating
range.
♦ The 7-digit adaption values are marked on each injector. The
values may consist of letters and/or numbers.
Injector (view from above)

1- Adaption value (checksum; details in illustration are only an
example)
2- Data matrix code
3- Part number

– Perform adaption ⇒ Vehicle diagnostic tester.

– When a new injector is installed, the adaption value for the new
injector must be stored in the engine control unit.
– Additionally, check that the “Injector delivery calibration val‐
ues” with “Injector voltage calibration values” are correctly
entered for all the other injectors. Do NOT attempt to re-enter
these values if the correct values are already stored in the en‐
gine control unit.
– When the engine control unit is renewed, the appropriate “In‐
jector delivery calibration values” with “Injector voltage cali‐
bration” values must be written into the new engine control
unit.

If one of the injectors is sticking open, this means that the injector
needle is not closing fully and fuel escapes into the cylinder.
♦ Adapter of return flow meter - VAS 6684-
Procedure
• Observe rules for cleanliness when working on the fuel supply
system ⇒ page 6 .
– Clean all connections (with commercial cleaning solution or
similar) before removing.
– Dry all components after cleaning.
Start with cylinder No. 1.

– Press retaining clip -arrow- and pull return line connection

-1- off injectors.
– Connect adapter -arrow- of return flow meter - VAS 6684- to

return line connection of injector to be tested after adapter has
been cleaned and blown out.
– Generate a vacuum of -500 mbar using the hand vacuum
pump - VAS 6213- .
• If the vacuum reading remains the same for 30 seconds, the
injector is OK.
• If the injector is faulty, the vacuum reading will fall back to 0 bar
within 2 to 3 seconds.
– Repeat test if necessary; note drop in vacuum reading on hand
vacuum pump - VAS 6213- .
– Renew faulty injectors ⇒ page 173 .
Installing fuel return lines
– Check O-ring for fuel return line connection for damage and
deformation.
If O-ring is damaged or deformed, renew O-ring.
• Lubricate all seals with engine oil or assembly oil before in‐
stalling.
– Push return line connections carefully over seals and onto in‐
jectors. The catch should engage audibly. Then press release
pin down carefully.
– Erase entry in event memory using ⇒ Vehicle diagnostic test‐
er.
Checking fuel system for leaks
automatically.
– Check the entire fuel system for leaks.
Renew the affected component if leakage occurs.
– After completing the repair, road-test the vehicle. Accelerate
with full throttle at least once. Then check the high-pressure
section of the fuel system again for leaks.

with engine running
Each injector normally has a relatively low fuel return flow rate. If
the return flow rate at one injector is relatively high compared to
the other injectors, that injector is probably defective.

Checking return flow rate of all injectors


Procedure
system ⇒ page 6 .
– Disconnect hose at non-return valve -1-.
– Seal off open return hose with clean plug -2- from engine bung
set - VAS 6122- .
– Hold end of fuel return hose (lengthen if necessary) in a meas‐
uring container to measure the total return flow rate.
– Start engine and run at idling speed for two minutes.
• Specification for 2 minutes: 0 ml to 50 ml
– If specification is attained, increase engine speed to 2000 ...
2500 rpm for approx. 2 minutes and then check return flow rate
again.
• Specification for 2 minutes: less than 250 ml
Note:
1000 ml = 1 litre
If specification is exceeded, this indicates that one or more injec‐
tors are defective. Check return flow rate of each individual injec‐
tor.
Checking return flow rate of individual injectors


Procedure
system ⇒ “3.1 Rules for cleanliness”, page 6 .
– Clean all return line connections with engine cleaner or brake
cleaner and dry.
– Clamp off fuel return hose -arrow- using hose clamp up to
25 mm - 3094- .

-1- off injectors.
– Connect adapters of return flow meter - VAS 6684- to return
line connections of all 4 injectors.
NOTICE
Risk of damage to injectors when return lines are disconnected.
– Do NOT press the accelerator during this test; the engine
must only run at idling speed.
– Start engine and run at idling speed for several minutes:

– When the engine is warm and running at idling speed, the re‐
turn flow rates at each of the 4 return lines must not differ by
more than a small amount (example -1-).
– If one injector has a significantly higher return flow rate than
the others (example -2-), it must be renewed ⇒ page 173 .
more than a small amount.
deformation.
stalling.
– Push return line connections carefully onto injectors. The
catch should engage audibly. Then press release pin down
carefully.
er.
automatically.

Only perform this test if the engine does not start at all.
♦ Return flow meter - VAS 6684- and adapter
Procedure


system ⇒ page 6 .
cleaner and dry.
-1- off injectors.
– Connect hoses of return flow meter - VAS 6684- to adapter.
– Operate starter three times (wait approx. 20 seconds each
time after operating starter to prevent it from overheating).
• Specification of return flow rate: 0 ml
– If fuel comes out of an injector, that injector must be renewed.
deformation.
stalling.
carefully.
er.
automatically.

♦ Cleaning kit - VAS 6811-

♦ Puller - T10055-
♦ Assembly sleeve - T10377-
♦ Puller - T10415-
♦ Socket - T40055-
Removing
system ⇒ page 6 .


-1- off injectors.
– Unplug electrical connector -1- for fuel pressure regulating

valve - N276- .
– Unplug electrical connectors -arrows- at injectors.
– Mark allocation of high-pressure pipe to cylinder for re-instal‐
lation.
– Unscrew union nut on corresponding high-pressure pipe
(-2 to 5-) and detach corresponding high-pressure pipe.
– Seal off open lines and connections with clean plugs.

– Detach noise insulation.

– Mark allocation of injector to cylinder for re-installation.
Note:
Each clamping piece always secures two injectors and can only
be taken out if both injectors are removed.
• Sequence for removing injectors: First remove injector for cyl‐
inder 2, then for cylinder 1/cylinder 4, and then for cylinder 3.
– Apply puller - T10055- with puller - T10415- as shown in illus‐
tration, and pull out injectors upwards with clamping piece.
Note:
To avoid damaging the sealing lip, rotate the injector while pulling
it out.
– Place removed injectors on a clean cloth.
Installing
NOTICE
Risk of damage to injector sealing surface if it is not cleaned
properly.
– To remove carbon deposits from the injector sealing surface,
clean the injector bore in the cylinder head with cleaning kit
- VAS 6811- .
Installing new injectors

When installing new injectors, the following components must be
renewed:
♦ Bolt for clamping piece
♦ O-ring for injector bore
♦ O-ring for fuel return line connection
♦ Corresponding high-pressure pipes
Installing used injectors
When re-installing used injectors, the following components must
be renewed:
♦ Copper seal
– Spray tip of injector nozzle with rust-solvent spray. Wait ap‐
prox. 5 minutes and wipe off soot particles and oil with a cloth.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.
– Clean off deposits under the copper seal using a suitable scra‐
per.
Continued (same procedure for used and new injectors):
– Fit new copper seal.

– Lubricate all O-rings with engine oil or assembly oil before in‐
stalling.
– Renew O-ring for injector bore using assembly sleeve -

T10377- .
– Install injectors.
note the following:
• Lubricate all O-rings with engine oil or assembly oil before in‐
stalling.
– Push the return line connections carefully over the new seals
and onto the injectors.
• The connection must engage audibly.
– Carefully press down release pin.
• After renewing one or more injectors, the “injector delivery cal‐
ibration values” and “injector voltage calibration values” for the
new injectors must be written into the engine control unit using
⇒ Vehicle diagnostic tester ⇒ page 9 .
Tightening torques
♦ ⇒ “4.1 Exploded view - injectors”, page 163

pipes
reservoir (rail) and high-pressure pump”, page 177
4.9.1 Removing high-pressure pipe between

high-pressure reservoir (rail) and high-
pressure pump

♦ Socket - T40055-
Removing
system ⇒ page 6 .
– Unscrew union nuts -arrows- and detach high-pressure pipe.


♦ Socket - T40055-
Installing
• Note identification marks for cylinder allocation when re-in‐
stalling high-pressure pipes.
• The high-pressure pipes can be re-used after performing the
following checks:
• Check taper seats of high-pressure pipes for deformation and
cracks.
• The bore of the pipe must not be distorted, restricted or oth‐
erwise damaged.
• Corroded pipes must not be used again.
NOTICE
High-pressure pipes must be free of tension when installed.
Risk of damage to high-pressure pipes.
– If necessary, the high-pressure reservoir can be slackened
and moved slightly so that the injector pipes are not installed
under tension.
– Never bend the high-pressure pipes or subject them to ten‐
sion.
– Use vacuum cleaner to remove dirt from taper seat at high-

pressure reservoir.
– Hand-tighten union nuts on high-pressure pipes (ensure that
pipes are not under tension).
– To tighten unions of high-pressure pipes at high-pressure res‐
ervoir and injectors, use torque wrench - V.A.G 1331- with
open end spanner insert, AF 17 - V.A.G 1331/6- or socket -
T40055- .
– Check fuel system for leaks ⇒ page 154 .
Tightening torques
page 165

reservoir (rail)

♦ Socket - T40055-
Removing
system ⇒ page 6 .
Injectors/high-pressure reservoir (rail); Removing and installing
high-pressure reservoir (rail) .
– Remove high-pressure pipe ⇒ page 177 .
1 - For turbocharger 1 control unit - J724- (fitting location varies)
2 - For heater element for crankcase breather - N79-
– Detach wiring duct -4- from high-pressure reservoir and move
to side.


– Release hose clip -2- and detach fuel return hose.
– Remove union nuts -1- for high-pressure pipes.
– Remove bolts -arrows- and detach high-pressure reservoir
-3-.
Installing
• Renew spring-type clip for fuel hose after removing.
• If the high-pressure reservoir is renewed, all corresponding
high-pressure pipes must also be renewed.
– Observe all instructions for installing high-pressure pipes
⇒ page 178 .
ltr. 4-valve common rail; Rep. gr. 23 ; Injectors/high-pressure
reservoir (rail); Removing and installing high-pressure reservoir
(rail)
Tightening torques
page 165

1 - Bolt
♦ M8x30 - 20 Nm +45°
♦ M8x65 - 20 Nm +180°
♦ M8x90 - 20 Nm +180°
sprocket
3 - Nut
T10051A- when loosen‐
ing and tightening
❑ 95 Nm
4 - Hub
❑ To remove, use puller -
T10489-
❑ Exploded view
⇒ page 17
- N290-
⇒ page 183
❑ Performing adaptions
required after renewing
a component (using
tester) ⇒ page 9
❑ Between high-pressure reservoir (rail) and high-pressure pump
❑ If the high-pressure pump is renewed, the corresponding high-pressure pipe must also be renewed

8 - Fuel hoses

pump
♦ Puller - T10489-
Removing
system ⇒ page 6 .

– Apply counterhold tool - T10051A- to high-pressure pump

sprocket.
– Detach locking pin - T10492- and slowly turn high-pressure
pump shaft to a position in which it is not under tension.
– Remove nut -arrow- and detach counterhold tool - T10051A- .
– Detach high-pressure pump sprocket.
– Engage puller - T10489- at hub of high-pressure pump by

turning it 60° clockwise -arrow-.
– Detach hub of high-pressure pump.

– Release hose clips -1- and detach fuel hoses.
– Carefully remove high-pressure pump -2-.
Installing
angle.
• Renew spring-type clips after removing.
– Apply hub to high-pressure pump shaft.
• The parallel key -1- on the high-pressure pump shaft must en‐
gage in the groove -2- in the hub.

– Place high-pressure pump sprocket on hub.

• Contact surface between hub and toothed belt sprocket must
be free of oil.
– Screw nut -arrow- onto thread of high-pressure pump shaft.
– Apply counterhold tool - T10051A- to high-pressure pump
sprocket and hand-tighten nut.
– Turn high-pressure pump sprocket with counterhold tool -
T10051A- until it can be locked in position with locking pin -
T10492- .
– To do so, insert locking pin - T10492- into fork -2- on hub and
into hole -1- behind it in bracket for ancillaries.
– Loosen nut again.
• The high-pressure pump sprocket should still just turn, but
there must be no axial movement.
⇒ page 178 .
NOTICE
Running when dry causes irreparable damage to fuel pump.

Tightening torques


186
⇒ “6.4 Removing and installing exhaust gas pressure sensor 1
G450 ”, page 189
page 190
N276 ”, page 192

- G70-
4-valve common rail; Rep. gr. 23 ; Senders and sensors; Re‐
moving and installing air mass meter - G70- .

sender - G247-
• The fuel pressure sender - G247- continuously measures the
fuel pressure in the high-pressure system. It transmits a cor‐
responding voltage signal to the engine control unit - J623- .
• Should the fuel pressure sender fail, the engine control unit
will control the fuel pressure via a mapped open-loop backup
function. Maximum engine speed in this mode is restricted.
• The fuel pressure sender - G247- has a deformable sealing lip
and no separate seal; it can therefore be used only once.

♦ Socket, 27 mm - T40218-
Removing
– Clean area all around fuel pressure sender - G247- with en‐
gine cleaner or brake cleaner and dry.
• Clean carefully; cleaning solution must not enter the electrical
connector.
• Make sure no dirt gets into opening in high-pressure reservoir
(rail).

– Move electrical wiring and fuel hoses clear, and press them to
one side.
• Do not use an open-end spanner for loosening or tightening.
27 mm - T40218- .
– Remove dirt from opening in high-pressure reservoir (rail) us‐
ing a vacuum cleaner. Do not use metal tools, etc.
– Seal off hole in high-pressure reservoir (rail) with a plug (thor‐
oughly cleaned) from engine bung set - VAS 6122- .
Installing
• Fuel pressure sender - G247- must always be renewed after
it has been removed.
• Check sealing surface at opening in high-pressure reservoir.
• Check that the deformable sealing lip and the thread on the
new fuel pressure sender are not damaged.
• The beginning of the thread and the deformable sealing lip of
the fuel pressure sender must be coated with diesel fuel.
– Screw in fuel pressure sender - G247- by hand until it makes
contact and then tighten.
After installing fuel pressure sender - G247- , leave engine run‐
ning at moderate speed for a few minutes when bleeding fuel
system and then switch off again.
• The fuel system is “self-bleeding”; do NOT open the high-
pressure connections.
– Carefully check the entire fuel system for leaks.
Renew affected component if leakage still occurs after tightening
to correct torque.
Note:
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off the engine and erase the event memory. Then
continue the road test.
– After road test, interrogate event memory again.
Tightening torques
page 165


Removing
– Release hose clips -arrows- and disconnect fuel return hoses.
Installing
Tightening torques
page 165

pressure sensor 1 - G450-
♦ Silicone-free lubricant spray (commercially available)
Removing


– Press exhaust gas pressure sensor 1 - G450- slightly to side.
– Before disconnecting, spray hoses at pressure sensor with
silicone-free lubricant.
NOTICE
breaks off.
– Carefully disconnect hoses from connections, taking care to
keep hoses straight.
Installing
• Before installing, blow out control pipes from exhaust gas
pressure sensor 1 - G450- to particulate filter towards partic‐
ulate filter with compressed air (pipes can become obstructed
or may ice up due to condensation).
• Make sure that hose is securely fitted and that there are no
leaks.
Tightening torques

- N276-


Procedure
system ⇒ page 6 .
– Lift wiring duct slightly and release hose clip -arrow-.
– Disconnect fuel return line from high-pressure reservoir and
seal off immediately with a plug (thoroughly cleaned) from en‐

– Connect test hose -2- to return line connection of high-pres‐

sure reservoir -1- and place end of hose in a measuring
container -3-.
1) Checking while engine is running
• Specification: more than 75 ml in 30 seconds
If specification is not obtained, fuel pressure regulating valve -
N276- is defective.
If condition for 1) is met, start engine and increase engine speed
to ≥ 2000 rpm.
• Fuel is still discharged in the first few seconds after the engine
is started
• Specification after a few seconds: return flow rate = 0 ml
• Drip leaks are permissible
If specification is not obtained, fuel pressure regulating valve - N
276- is defective.
3) If engine can no longer be started
Perform test with engine at cranking speed.
276- is defective.
Assembling


♦ Open end spanner insert, AF 30 - T10553-
Removing
– Remove high-pressure reservoir (rail)
page 179 .
– Before removal, clean area around thread for fuel pressure
regulating valve - N276- using e.g. commercial cleaning solu‐
tion.
• Make sure no dirt gets into opening in high-pressure reservoir.
connector.
– Dry off fuel pressure regulating valve - N276- .
Note:
The high-pressure reservoir can be clamped in a vice in order to
remove the pressure regulating valve; however, it is essential that
protective jaw covers are used. Do NOT take up the weight of the
high-pressure reservoir by the threaded connections for the high-
pressure pipes or the retaining tabs for the cylinder head.
– Mark installation position of connector of fuel pressure regu‐
lating valve - N276- relative to high-pressure reservoir.
– Unscrew fuel pressure regulating valve - N276- -item 2- from
high-pressure reservoir -1- using insert tool (30 mm) -
T10553- .
– Seal off open connection in high-pressure reservoir with a plug
(thoroughly cleaned) from engine bung set - VAS 6122- .
Installing
• Renew fuel pressure regulating valve - N276- after removing.
new regulating valve are not damaged.
• Coat beginning of thread, deformable sealing lip and O-ring of
regulating valve lightly with diesel fuel.

– Tighten fuel pressure regulating valve - N276- -item 2- using

insert tool (30 mm) - T10553- .
– Turn valve body to align connector of fuel pressure regulating
valve - N276- with high-pressure reservoir according to mark
made previously.
– If necessary, turn valve body to align regulating valve so that
connecting wire is free of tension after connector is attached.
ing ⇒ Vehicle diagnostic tester)
page 9 .
After installing fuel pressure regulating valve - N276- , leave en‐
gine running at moderate speed for a few minutes to bleed fuel
Note
♦ The fuel system is “self-bleeding”; do NOT open the high-
– Interrogate event memory.
to correct torque.
Tightening torques
page 165

7 Lambda probe
1 - Bracket
❑ For control unit 2 for
NOx sender - GX46-
2 - Bolt
❑ 5 Nm
3 - Control unit 2 for NOx send‐
er - GX46-
❑ with
♦ NOx sender 2 - G687-
♦ Control unit 2 for NOx send‐
er - J881-
⇒ page 198
NOx sender 2 - G687- :
52 Nm
4 - Nut
❑ 2.5 Nm
5 - Pressure pipe
❑ For exhaust gas pres‐
sure sensor 1 - G450-
⇒ Fig. ““Pressure pipe -
installation position”“ ,
page 196
sender 4 - G648-
7 - Bolt
❑ 8 Nm
8 - Exhaust gas pressure sensor 1 - G450-
9 - Bracket
❑ For exhaust gas pressure sensor 1 - G450-
10 - Bolt
❑ 8 Nm
❑ with
♦ NOx sender - G295-
♦ Control unit for NOx sender - J583-
7. Lambda probe 195


❑ Tightening torque for NOx sender - G295- : 52 Nm
❑ Removing and installing ⇒ Item 12 (page 223)
❑ with
❑ Observe fitting instructions ⇒ page 197
⇒ page 9
❑ 52 Nm
16 - Pressure pipe
❑ Installation position ⇒ Fig. ““Pressure pipe - installation position”“ , page 196
Pressure pipe - installation position

• Two lines visible - installed incorrectly
• One line visible - installed correctly


Lambda probe open ring spanner set - 3337-
Removing
Lambda probe; Removing and installing Lambda probe .

CAUTION

set - 3337- .
Installing
• Threads of new Lambda probes are already coated with as‐
sembly paste; the paste must not get into the slots on the probe
body.
slots on the Lambda probe body. For high-temperature paste
refer to ⇒ Electronic parts catalogue
• When installing, the Lambda probe wiring must always be re‐
attached at the same locations to prevent it from coming into
contact with the exhaust pipe.
ltr. 4-valve common rail; Rep. gr. 23 ; Lambda probe; Removing
and installing Lambda probe
Tightening torques
7. Lambda probe 197


page 198
page 198

G295-
Removing
Lambda probe; Removing and installing NOx senders .
CAUTION

da probe open ring spanner set - 3337- and move electrical
wiring clear.
Installing
and installing NOx senders
Tightening torques

G687-

Removing
Lambda probe; Removing and installing NOx senders .
CAUTION

Installing
and installing NOx senders
Tightening torques
7. Lambda probe 199


engine, 2.0 ltr. 4-valve common rail; Rep. gr. 23 ; Engine control
unit .


4-valve common rail; Rep. gr. 26 ; Exhaust pipes/silencers; Ex‐
ploded view - silencers .

pipe
4-valve common rail; Rep. gr. 26 ; Exhaust pipes/silencers; Re‐
moving and installing front exhaust pipe .

4-valve common rail; Rep. gr. 26 ; Exhaust pipes/silencers; Re‐
moving and installing silencers .

4-valve common rail; Rep. gr. 26 ; Exhaust pipes/silencers;
Stress-free alignment of exhaust system .

Procedure
– Plug tailpipes during leak test (e.g. with cloth or plug).
any leaks.


page 214
page 216

tem
♦ Exploded view - emission control system, part I ⇒ page 202
♦ Exploded view - emission control system, part II ⇒ page 204
Exploded view - emission control system, part I
1 - Compensation element
❑ Checking and aligning
⇒ page 210
2 - Bolt
3 - Bolt
4 - Stud
❑
5 - Nut
6 - Bracket
❑ For catalytic converter
⇒ page 205
8 - Bolt
9 - Screw-type clip
⇒ Fig. ““Screw-type clip
for particulate filter - in‐
stallation position”“ ,
page 204
10 - Seal

11 - Turbocharger
❑ Installation position ⇒ Fig. ““Screw-type clip for particulate filter - installation position”“ , page 204
13 - Seal
❑ Installation position ⇒ Fig. ““Seal for particulate filter - installation position”“ , page 204
14 - Bolt
❑ 40 Nm
15 - Bracket
❑ For catalytic converter and particulate filter
16 - Particulate filter
17 - Nut
18 - Bracket
❑ For particulate filter
19 - Nut
20 - Bracket
⇒ Fig. ““Screw-type clips for exhaust gas recirculation pipe - installation position”“ , page 230
22 - Seal
❑ Installation position ⇒ Fig. ““Seal for exhaust gas recirculation pipe - installation position”“ , page 230
23 - Pipe
❑ For exhaust gas recirculation
24 - Seal
❑ Installation position ⇒ Fig. ““Seal for exhaust gas recirculation pipe - installation position”“ , page 230
⇒ Fig. ““Screw-type clips for exhaust gas recirculation pipe - installation position”“ , page 230
26 - Bolt
❑ 20 Nm
27 - Bracket
28 - Bolt

Screw-type clip for particulate filter - installation position

– Screw -arrow- screw-type clip -1- onto catalytic converter -2-
as far as stop.
Seal for particulate filter - installation position

• Protrusion -1- on seal must engage in groove -arrow- on par‐
ticulate filter.
Screw-type clip for particulate filter - installation position

• Angle -α- = 45°
Exploded view - emission control system, part II

1 - Bolt
❑ 20 Nm
2 - Mounting
has been pulled off
❑ Do not bend flexible joint
more than 10°
❑ Install flexible joint so
that it is not under ten‐
sion.
❑ Take care not to dam‐
age wire mesh on flexi‐
ble joint
⇒ 4-cylinder TDI en‐
26 ; Exhaust pipes/si‐
lencers; Removing and
installing front exhaust
pipe
4 - Seal
5 - Screw-type clip
❑ 7 Nm
6 - Nut
❑ 9 Nm
8 - Bolt
9 - Clamp
❑ Installation position and tightening torque ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve common rail; Rep. gr.
26 ; Exhaust pipes/silencer; Exploded view - silencers
10 - Trap catalytic converter
11 - Gasket
12 - Nut
❑ 25 Nm

verter

Removing
Emission control system; Removing and installing catalytic con‐
verter .
– Remove underbody trim (front) ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Underbody trim; Exploded view - under‐
body trim .
– Remove air cleaner housing ⇒ 4-cylinder TDI engine (2.0 ltr.
4-valve common rail); Rep. gr. 23 ; Air cleaner; Removing and
CAUTION



– Unscrew bolts - 5- and nuts -3- and remove bracket -2-.

Note
If particulate filter is to be removed subsequently, remove union
nuts -1 and 4- and move pressure pipes clear.

wiring clear.
– Detach electrical connectors from bracket, unplug them and

move them clear:
2- For Lambda probe 1 before catalytic converter - GX10-
– Remove engine support (right-side) ⇒ 4-cyl. TDI engine, 2.0
ltr. 4-valve common rail; Rep. gr. 13 ; Cylinder block (pulley

– Release screw-type clips -arrows- and detach injector for re‐

ducing agent - N474- -item 2-.
– Place particulate filter to right side.
– Remove bolts -1, 3- and nuts -4- and detach bracket -5- and
catalytic converter.
Installing
• Renew seals, gaskets, nuts and screw-type clips after remov‐
al.
– Check and align compensation element ⇒ page 210 .

– Note installation position of screw-type clip ⇒ page 204 .
NOTICE
Catalytic converter must be installed free of tension to avoid risk
of stress fractures and engine damage.
– Adhere to sequence of steps given below.
– Move catalytic converter with screw-type clip into installation

position and loosely screw in bolts -1, 3- and nuts -4-.
• Catalytic converter is now suspended approximately in instal‐
lation position with its weight supported.
Tightening sequence - catalytic converter
Stage Threaded con‐ Step
nections
1. Screw-type Fit over sealing flange, engage screw
clip -2- and tighten to 1 Nm
2. Bolt -1- Tighten to 5 Nm and loosen immedi‐
ately by 90°
3. Nuts -4- Tighten to 5 Nm and loosen immedi‐
ately by 90°
4. Screw-type Tighten to 17 Nm
clip -2-
5. Bolt -1- Tighten to 20 Nm
6. Bolts -3- Tighten to 20 Nm
7. Nuts -4- Tighten to 20 Nm
note the following:
– Install engine support (right-side) ⇒ 4-cyl. TDI engine, 2.0 ltr.
– Install air cleaner housing ⇒ 4-cylinder TDI engine (2.0 ltr. 4-
valve common rail); Rep. gr. 23 ; Air cleaner; Removing and
ltr. 4-valve common rail; Rep. gr. 26 ; Emission control system;
Removing and installing catalytic converter
Tightening torques
page 228


♦ The particulate filter is secured to the engine in part by a com‐
pensation element. This compensation element has a left-
hand thread on the outside. When the bolt -1- is screwed in,
the friction against the retaining tabs -3- initially causes the
compensation element -2- to turn as well. Even though the bolt
is turned clockwise, the left-hand thread causes the compen‐
sation element to move towards the bolt head, which com‐
pensates for the play between the components. The compen‐
sation element must rotate freely on the left-hand thread,
otherwise the retaining tabs will not produce enough friction
on the bolt to turn the compensation element. To avoid im‐
pairing the required friction, ensure that the retaining tabs do
not come in contact with any lubricant.

♦ Socket - T40055-
♦ Calibration tool - T10512-
Removing
• Re-fit all cable ties and heat insulation sleeves in the same
locations when installing.


– Take electrical connector -arrow- for exhaust gas temperature

sender 4 - G648- out of bracket, unplug it and move wiring
clear.

-2-.
– Remove bolts -arrows- and detach bracket -1- for catalytic

converter and particulate filter.

Vehicles with water-cooled turbocharger only:

– Remove exhaust gas recirculation cooler
er”, page 232 .

breather hose -3-.
-arrow- and detach.

– Unscrew bolts -1- and remove bracket -2-.

All vehicles:
– Remove particulate filter towards front.
Installing
angle.
• Renew O-rings, seals, gaskets and screw-type clips for par‐
ticulate filter after removing.
NOTICE
Particulate filter must be installed free of tension to avoid risk of
stress fractures and engine damage.
– Adhere to sequence of steps given below.
♦ Prior to installation, ensure that the compensation element

moves easily and does not stick.
♦ Compensation element must turn easily on its threads.
♦ Lubricant must only be applied to thread; retainer tabs must
remain free of lubricant.
♦ The retainer tabs for the bolt must be bent together so that
when the bolt is screwed in, the compensation element turns
as well.
– Check to ensure freedom of movement of compensation ele‐

ment -arrow-.
– Unscrew compensation element completely in clockwise di‐
rection (left-hand thread).
– Clean thread if it does not turn easily and lubricate lightly with
rust remover if necessary.
• Do not use any kind of lubricant on the retainer tabs of the
compensation element. Reducing the build-up of friction would
compromise the function of the compensation element.
– Adjust retainer tabs to functional dimension using calibration

tool -T10512/1-2- as follows:
– Slide compensation element -1- onto pin -T10512/1- , insert
into centring sleeve -T10512/2- and bend back retainer tabs
by gently striking -arrow- ball head with heel of your hand.

– Tighten compensation element -arrow- to 3 Nm and slacken

again by 90°.
note the following:
– Move particulate filter into installation position.
– Move particulate filter and screw-type clip into installation po‐

sition -3- and loosely screw in bolt -5- and nuts -1, 2-.
• Particulate filter is now suspended approximately in installa‐
tion position with its weight supported.
Stage Threaded con‐ Step
nections
2. Screw-type Move into installation position
clip -3- ⇒ page 204 and tighten to 7 Nm
4. Bolt -4- Screw in and tighten to 20 Nm; when
doing so, check that compensation el‐
ement moves and makes contact with
particulate filter
5. Nut -2- Tighten to 20 Nm
6. Nut -1- Tighten to 20 Nm
note the following:
– Install exhaust gas recirculation cooler
er”, page 232 .
page 205 .
Perform adaptions required after renewing a component (using
⇒ Vehicle diagnostic tester)
page 9 .
Tightening torques

converter

Removing
– Remove noise insulation (front and rear) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Noise insulation; Exploded view
- noise insulation .
CAUTION

J883- -item 2-.


– Remove trap catalytic converter.
Installing
• Renew gasket and self-locking nuts after removal.
page 9 .
– Install noise insulation (front and rear) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .
Tightening torques

Removing
CAUTION
– Unscrew bolts -arrows- and remove exhaust flap control unit -

J883- .
Installing
– Fit exhaust flap control unit.
• Coupling -1- must engage in retainer of exhaust flap -2-.

– Tighten upper bolt first, then tighten lower bolt.

note the following:
ing ⇒ Vehicle diagnostic tester)
page 9 .
Tightening torques


system
⇒ “3.3 Exploded view - delivery unit”, page 219
”, page 220
⇒ “3.9 Removing and installing pump for reducing agent V437 ”,
page 222
⇒ “3.10 Removing and installing pressure sender for reducing
agent metering system G686 ”, page 222
⇒ “3.11 Removing and installing connection for SCR supply line”,
page 222

4-valve common rail; Rep. gr. 26 ; SCR (selective catalytic re‐
duction) system; Exploded view - reducing agent tank .
3.2 Exploded view - reducing agent supply line

❑ Exploded view
⇒ page 202
2 - Seal
3 - Screw-type clip
⇒ page 219
❑ 9 Nm
N474-
⇒ page 220
❑ Lugs in injector for re‐
must be inserted in cor‐
responding mountings
5 - Supply line
❑ From reducing agent
pump - V437-
❑ With heater
❑ Clip onto fuel tank
6 - O-ring
❑ Renew supply line
damaged or leaking
7 - Coolant hoses
Screw-type clip for injector for reducing agent - N474- - installation

position
– Align screw-type clip with weld seam -arrow- on catalytic con‐
verter.
3.3 Exploded view - delivery unit

duction) system; Exploded view - delivery unit .
Only fitted on Q5 and A6/A7


♦ Safety goggles
Procedure
CAUTION
The SCR system is pressurised.

duction) system; Draining reducing agent tank .

tank
duction) system; Removing and installing reducing agent tank .


Removing
when installing.
CAUTION

– Clamp off coolant hoses -2- with hose clamps, up to 25 mm -
3094- .
– Hold a cloth under separating point to catch escaping reducing

agent.
– Release pressure in SCR system ⇒ page 219 .
– Press release tab and disconnect SCR supply line -2- from
injector for reducing agent - N474- .
– Release screw-type clip -1- and detach injector for reducing
agent - N474- .
Installing
• Renew seal and screw-type clip after removing.
Installation positions:

• Screw-type clip ⇒ page 219

• Lugs in injector for reducing agent - N474- -item 2- must be
inserted -arrows- in corresponding mountings in catalytic con‐
verter -1-.
After renewing component(s) or draining reducing agent (opening
a reducing agent line), perform required adaptions using vehicle
diagnostic tester
page 9 .
Tightening torques
♦ ⇒ “3.2 Exploded view - reducing agent supply line”,
page 218

All procedures are described in ⇒ 4-cyl. TDI engine, 2.0 ltr. 4-
valve common rail; Rep. gr. 26 ; SCR (selective catalytic reduc‐
tion) system ; Removing and installing control unit for reducing
agent metering system - J880- .
3.9 Removing and installing pump for re‐

ducing agent - V437-
tion) system ; Removing and installing pump for reducing agent -
V437- .
3.10 Removing and installing pressure send‐

er for reducing agent metering system -
G686-
tion) system ; Removing and installing pressure sender for
reducing agent metering system - G686- .
3.11 Removing and installing connection for

SCR supply line
tion) system ; Removing and installing connection for SCR supply
line.


page 223
⇒ “4.2 Removing and installing parts of exhaust gas temperature
control”, page 224
1 - Bracket
❑ For control unit 2 for
NOx sender - GX46-
2 - Bolt
3 - Control unit 2 for NOx send‐
er - GX46-
ling, tightening torque
4 - Nut
5 - Pressure pipe
❑ For exhaust gas pres‐
❑ Installation position,
tightening torque
sender 4 - G648-
⇒ page 224
❑ 45 Nm
7 - Bolt
sor 1 - G450-
❑ ⇒ Item 8 (page 195)
9 - Bracket
10 - Bolt
❑ Removing and installing, tightening torque ⇒ Item 11 (page 195)
❑ 45 Nm
❑ Removing and installing, tightening torque ⇒ Item 13 (page 196)


❑ 45 Nm
❑ 45 Nm
16 - Pressure pipe
4.2 Removing and installing parts of ex‐

haust gas temperature control
⇒ “4.2.1 Removing and installing exhaust gas temperature sender
G235 / G448 / G495 ”, page 224
er 4 G648 ”, page 225

temperature sender -G235- / -G448- / -
G495-
Removing
– Exhaust gas temperature sender 3 - G495- : Remove air
cleaner housing ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve com‐
mon rail; Rep. gr. 23 ; Air cleaner; Removing and installing air
cleaner housing .

– Detach electrical connectors from bracket, unplug them and

move them clear:
CAUTION
– Unscrew exhaust gas temperature senders using flared ring

spanner tool insert (17 mm) - V.A.G 1331/10- :
1- Exhaust gas temperature sender 3 - G495-
Installing
Installation position of exhaust gas temperature sender 3 -

G495- :
• Angle -α- = max. 15°
Tightening torques
223


Removing
Exhaust gas temperature control; Removing and installing parts
of exhaust gas temperature control .
– Take electrical connector -arrow- for exhaust gas temperature
sender 4 - G648- out of bracket, unplug it and move wiring
clear.

CAUTION
– Unscrew exhaust gas temperature sender 4 - G648- -arrow-.

Installing
ltr. 4-valve common rail; Rep. gr. 26 ; Exhaust gas temperature
control; Removing and installing parts of exhaust gas temperature
control
Tightening torques
223


page 228
⇒ “5.2 Removing and installing exhaust gas recirculation valve 1
GX5 ”, page 230
⇒ “5.3 Removing and installing exhaust gas recirculation valve 2
GX6 ”, page 231
page 232
234

tion system
♦ Exhaust gas recirculation valve 1 - GX5- ⇒ page 228
♦ Exhaust gas recirculation valve 2 - GX6- ⇒ page 229
Exhaust gas recirculation valve 1 - GX5-
1 - Bolt
❑ 9 Nm
valve 1 - GX5-
❑ with
potentiometer - G212-
⇒ page 230
❑ Performing adaptions
required after renewing
a component (using
tester) ⇒ page 9
3 - Seal
4 - Gasket

Exhaust gas recirculation valve 2 - GX6-

pipe
2 - Seal
⇒ page 230
3 - Screw-type clip
⇒ page 230
❑ 6 Nm
cooler
⇒ page 232
5 - Bolt
❑ 20 Nm
6 - Bracket
lation cooler
7 - Bolt
❑ 20 Nm
8 - Bolt
❑ 9 Nm
pipe
11 - Bolt
❑ 9 Nm
12 - Gasket
❑ with
♦ Exhaust gas recirculation control motor 2 - V339-
♦ Exhaust gas recirculation potentiometer 2 - G466-
– Perform adaptions required after renewing a component (using ⇒ Vehicle diagnostic tester) ⇒ page 9 .
14 - Gasket
15 - Bolt
❑ 20 Nm
❑ 6 Nm

17 - Seal
Screw-type clips for exhaust gas recirculation pipe - installation

position
– Screw -arrows- screw-type clip -2- onto particulate filter and
onto exhaust gas recirculation pipe as far as stop -1-.
Seal for exhaust gas recirculation pipe - installation position

• Protrusion -1- on seal must engage in groove -2- on exhaust
gas recirculation pipe.

Contains exhaust gas recirculation control motor - V338-
Removing

CAUTION
– Remove bolts -arrows- and press fuel lines -1- slightly to side.
– Detach exhaust gas recirculation valve 1 - GX5- -item 3-.
Installing
• Renew connecting piece, seals and gaskets after removal.
page 9 .
Tightening torques
page 228
page 165

Contains exhaust gas recirculation control motor 2 - V339-
Removing
Emission control system; Removing and installing exhaust gas
recirculation valve 2 - GX6- .


pipe -1-.
CAUTION

valve 2 - GX6- -item 2-.
Installing
• Renew insulation mat for control motor if damaged. Addition‐
ally check control motor for thermal damage and renew if
necessary.
• Renew gasket and O-ring after removal.
ltr. 4-valve common rail; Rep. gr. 26 ; Emission control system;
Removing and installing exhaust gas recirculation valve 2 - GX6-
page 9 .
Tightening torques
page 228
tem”, page 146

circulation cooler

♦ Bit XZN 10 - T10501-
Removing
Exhaust gas recirculation; Removing and installing exhaust gas
recirculation cooler .

pipe -1-.
CAUTION


coolant hoses.
cooler -4-.
– If renewing exhaust gas recirculation cooler, remove exhaust
gas recirculation valve 2 - GX6-
2 GX6 ”, page 231 .
Installing
• Renew connecting piece, seals and gaskets after removal.
ltr. 4-valve common rail; Rep. gr. 26 ; Exhaust gas recirculation;
Removing and installing exhaust gas recirculation cooler
Tightening torques
page 228
tem”, page 146

cooler for leaks

♦ Adapter - V.A.G 1687/11-
♦ Adapter - V.A.G 1687/14-


Test condition:
• Coolant temperature must be at least 40°C.
expansion tank.


005/5- .
nection »A«.
must be visible.
Connecting tester - V.A.G 1687- :

rear.

1687/14- to trap catalytic converter.
– Connect hose of charge air system tester -V.A.G 1687- to
adapter -1-.


– Open valve -3-.

rise.
that compressed air is escaping from the exhaust end into the
cooling system. There is a leak in exhaust gas recirculation
cooler; renew exhaust gas recirculation cooler.
• If there are no leaks in the exhaust gas recirculation cooler, a
vacuum may form when the coolant cools down. A minus sign
on the turbocharger tester indicates that a vacuum has
formed.

have entered.
connector .
-B-.
seconds.


1 Glow plug system
J179 ”, page 241
242
1 - Glow plug
♦ Glow plug 3 - Q12- with cyl‐
inder 3 combustion cham‐
ber pressure sender -
G679-
❑ Glow plug versions and
tightening torques
⇒ page 239
❑ After renewing glow
plug 3 - Q12- with cylin‐
der 3 combustion cham‐
G679- , perform adap‐
tions required using
tester
⇒ “3.8 Performing adap‐
tions after renewing a
component”, page 9 .
⇒ page 239
3 - O-ring
❑ Renew Hall sender -
G40- if damaged
⇒ page 241
5 - Bolt
❑ 9 Nm
❑ With sender wheel for engine speed sender - G28-
❑ Cannot be dismantled

7 - Bolt
❑ 4.5 Nm
Glow plug versions and tightening torques

1 - Glow plug with combustion chamber pressure sender
♦ Only fitted on cylinder 3 on some versions; glow plug 3 - Q12-
with cylinder 3 combustion chamber pressure sender - G679-
♦ 12 Nm
2 - Glow plug without combustion chamber pressure sender
♦ 12 Nm

♦ Articulated wrench, 10 mm - 3220-
♦ Socket insert AF 12 for glow plugs 4-cyl.TDI CR diesel - VAS

6454- for glow plug with combustion chamber pressure sender

♦ Pliers - 3314-
Removing
NOTICE
Risk of damage to support sleeves when removing.
– Do not squeeze pliers - 3314- too firmly when removing glow
plug connectors.
– Release retaining clips at wiring harness and detach electrical

connectors from glow plugs as follows.
– Apply groove -arrow A- of pliers - 3314- to collar of support
sleeve -arrow B- as shown in illustration.
– Carefully detach glow plug connectors from glow plugs.
– Clean glow plug opening to make sure no dirt gets into cylin‐
ders; note the following:
CAUTION
♦ Use a vacuum cleaner to remove coarse dirt.

♦ Spray brake cleaner or suitable cleaning agent into glow plug
apertures, let it work in briefly, and blow out with compressed
air.
♦ Clean glow plug opening with an oily cloth.
– Loosen glow plugs using tool and unscrew by hand:

♦ Use U/J extension and socket, 10 mm - 3220- for glow plugs

without combustion chamber pressure sender.
♦ Use socket insert AF 12 for glow plugs 4-cyl.TDI CR diesel -

VAS 6454- for glow plugs with combustion chamber pressure
sender.
Installing
– Fit glow plug connectors -1- back onto glow plugs -arrow-.
• Check that glow plug connectors are securely seated.
After renewing glow plug 3 - Q12- with cylinder 3 combustion
chamber pressure sender - G679- , perform adaptions required
using ⇒ Vehicle diagnostic tester
page 9 .
Tightening torques
♦ ⇒ Fig. ““Glow plug versions and tightening torques”“ ,
page 239

4-valve common rail; Rep. gr. 28 ; Glow plug system; Removing
and installing automatic glow period control unit - J179- .

G40-

Removing
– Release hose clip (left-side) -1- and detach fuel hose (left-
side).

– Unscrew bolt -2- and pull off Hall sender - G40- -item 1-.
Installing
Tightening torques

sender - G28-

♦ Socket (4 mm) - T10370-
Removing
– Use assembly tool - T10118- to unplug electrical connector
-1-.
Installing
Tightening torques

Service
Workshop Manual
Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ ,
Audi A5 2016 ➤ , Audi A6 2019 ➤ ,
Audi Q5 2017 ➤
Servicing 4-cylinder TDI engine, common rail (EA 288
Gen. I)
Engine ID
DET DEU DEU DES CZH DEU DET
A A B A A C B
Edition 02.2019

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system

Copyright © 2019 Audi AG, Ingolstadt D4B80576B67

Audi A4 2015 ➤ , Audi A4 Avant 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2019 ➤ ...
Servicing 4-cylinder TDI engine, common rail (EA 288 Gen. I) - Edition 02.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.6 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Contents i


2 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.1 Exploded view - oil filter housing/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
ii Contents
2.7 Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.7 Removing and installing exhaust gas pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . . 193
Contents iii
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

8.3 Removing and installing NOx sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

3.2 Exploded view - control unit for SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.3 Exploded view - delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.10 Removing and installing pump for reducing agent V437 . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3.11 Removing and installing pressure sender for reducing agent metering system G686 . . . . 219
3.12 Removing and installing connection for SCR supply line . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3.13 Adapting SCR learnt values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
5.2 Removing and installing exhaust gas recirculation control motor V338 . . . . . . . . . . . . . . 230
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
iv Contents
1 Identification
(ARL006264; Edition 02.2019)

Engine number
cated on the front of the joint between the engine and the
gearbox -arrow-.
♦ Engine codes starting with the letter “C” have four letters (pre‐
viously three letters).
♦ The first 3 characters of the engine code stand for the engine
capacity and the mechanical construction and design. They
are stamped onto the cylinder block together with the serial
number.
♦ The 4th character indicates the power output and torque of the
engine and is determined by the engine control unit.
Engine data
engines; Rep. gr. 00 ; Overview of engines .
1. Identification 1
tem”, page 2
page 3
page 3
⇒ “2.6 Safety precautions when working on the SCR system”,
page 4
page 5

may spray out.

fuel pump.


a road test
Or:
seat.



Components of the exhaust system can pose health risk

Risk to health if exhaust gas temperature sender is dismantled.
– Do not dismantle exhaust gas temperature sender.
Danger from toxic exhaust gases

Auxiliary/supplementary heater produces toxic exhaust gases.
There is a risk of poisoning and of damage to the respiratory tract.
– In enclosed spaces, only switch on the auxiliary/supplemen‐
tary heater if there is an exhaust extraction system.
– In enclosed spaces without an exhaust extraction system,
switch off the auxiliary/supplementary heater.

incorrectly.
2.6 Safety precautions when working on the

SCR system
When working on the SCR system, note the following warnings:
Risk of injury caused by reducing agent
Reducing agent can cause eye and skin irritation, damage to the
respiratory tract and poisoning.
Risk of damage caused by reducing agent

Reducing agent which has come into contact with trim or body
components can crystallise after some time and damage the af‐
fected surfaces.
– Ensure that no reducing agent makes contact with parts of trim
or body.
– Clean any surfaces which have come into contact with reduc‐
ing agent immediately with water and a cloth.
When removing and installing components at the SCR system,

note the following:
♦ The reducing agent tank must be empty when you are working
on the SCR system. Refer to the corresponding work descrip‐
tion to find out when the reducing agent must be drained from

the tank. Drain the reducing agent tank if necessary; proce‐

dure ⇒ page 217 .
When removing and installing the reducing agent tank, note the
following:
♦ The reducing agent tank must be empty. Drain the reducing
agent tank if necessary; procedure ⇒ page 217 .
Automatic drawing back of reducing agent
• After the ignition is switched off, the reducing agent is auto‐
matically drawn back into the reducing agent tank from the
metering line going to the injector for reducing agent - N474- .
• Before performing work in this area, you must therefore wait
until the reducing agent has been drawn back; this can take
up to 10 minutes after the ignition has been switched off.
• It is also important to wait until the reducing agent has been
drawn back (i.e. 10 minutes after the ignition is switched off)
before disconnecting the battery ⇒ Electrical system; Rep. gr.
27 ; Battery; Disconnecting and connecting battery .

tached.
⇒ “3.4 Bolts and nuts”, page 8
9

ply system, injection system and turbocharger:
♦ Clean connections and surrounding area thoroughly with en‐
gine cleaner or brake cleaner and dry cleaned area before
loosening.
♦ Do not remove sealing caps from components until immedi‐
ately prior to installation. Keep components that are to be re-
used in new, sealable plastic bags.
that have not been stored in the proper packaging (e.g. in tool
boxes etc.).
♦ Do not work with compressed air when the system is open. If
possible, do not move vehicle.
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
3.2 General notes

Fuel supply/injection

crash by deactivating the fuel pump.
in the fuel system ⇒ page 2 .
Glow plug system
♦ The glow plug system is activated via the automatic glow pe‐
riod control unit - J179- . The control unit is self-diagnosis
compatible.
♦ Fitting location of automatic glow period control unit - J179-
⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
♦ A fault is stored in the engine control unit - J623- if a fault oc‐
curs in the glow plug system.
♦ Checking glow plug system ⇒ Vehicle diagnostic tester
♦ For faster starting, the vehicle is equipped with electronically
controlled glow plugs and a separate glow period control unit.
♦ Each glow plug is activated and diagnosed separately.
♦ Wait for 60 seconds each time after performing final control
diagnosis of the glow period control unit. The ignition must re‐
main switched on.
♦ If you do not wait for 60 seconds (if ignition is switched off and
immediately switched on again), the glow plugs can be dam‐
aged (due to repeated pre-heating).
♦ The activation of the glow plugs is controlled according to
coolant temperature.

must be bled

system.
♦ Before installing, check the injectors and their surroundings
visually; they must be undamaged and clean. Make sure the
injector bores in the cylinder head are clean. Wipe out if nec‐
essary using a clean cloth, taking care not to cause damage.
Do not use sharp objects of any kind.
♦ Take care not to damage the injectors when removing the old
copper seals.
♦ Check all new O-rings for damage before installing. Lubricate
O-rings with engine oil or assembly oil before installing.
♦ Press the fuel return hoses onto the injectors by hand from
above so that they engage audibly on each injector (do not
press in the release pins when doing this). Then press down
the release pin after connecting the return line. Check that the
fuel return hoses are seated securely and sealed properly by
pulling them by hand from above.
♦ Do not dismantle individual common rail components. If there
is a fault, the complete components must be renewed.
♦ When the engine is running, do not perform any repairs to the
common rail system.
♦ Do not bleed the common rail system by unfastening high-
pressure components after the engine has been started.
used.
3.4 Bolts and nuts

quence.
quence and method.
♦ Always renew self-locking bolts/nuts.
bolts.



⇒ page 128

fitted.
Please note:
♦ We recommend the use of Audi Genuine Parts.
ranty.

and wiring

justify renewal of the radiator, charge air cooler or condenser.

page 10
1.1 Removing engine

gine; Removing engine .

support
♦ Engine and gearbox support - VW 540-

Procedure
– Remove lifting eye of lifting tackle - 2024A- (pull out split pin
and press out pin).
– Reinsert lifting eye in 4th hole from front on lifting tackle.
– Secure pin with split pin again.
VAS 6100- with lift arm extension/workshop hoist - VAS 6101-
– Secure engine to engine and gearbox support - VW 540- using

engine and gearbox support - VAS 6095A- .

gine; Installing engine .

engine, 2.0 ltr. 4-valve common rail; Rep. gr. 10 ; Assembly
mountings .



panel
Removing
Installing
and dipstick.

page 18
page 21
22
1 - Poly V-belt
❑ Check for wear
❑ Do not kink
⇒ page 16
⇒ page 17
on pulleys.
stalling tensioner for
poly V-belt”, page 18
3 - Bolt
❑ 20 Nm +90°
4 - Bolt
❑ Use only genuine bolts
⇒ Electronic parts cata‐
logue
❑ 10 Nm +90°
hole in vibration damper
must be positioned over
raised section of crank‐
shaft sprocket

❑ Removing and installing ⇒ “1.5 Removing and installing vibration damper”, page 19
6 - Bolt
❑ 8 Nm
7 - Bracket
8 - Bolt
9 - Bolt
10 - Damper wheel
11 - Dowel sleeve
❑ Ensure correct seating in bracket for ancillaries
13 - Ball stud
15 - Alternator
16 - Bolt
17 - Bolt
18 - Dowel sleeve
❑ Bolt, 2x
❑ Ensure correct seating in air conditioner compressor
20 - Bracket
❑ For SCR line
21 - Nut
❑ 20 Nm
22 - Centre hex stud


1- Vibration damper
3- Alternator
Bracket for ancillaries - tightening torque and tightening sequence

angle.
– Fit bolts in the following sequence:
♦ Bolts -1, 2, 3, 6- M10x35
♦ Bolt -4- M10x115
♦ Bolt -5- M10x175
2. -1 … 6- 40 Nm
3. -4- and -5- Turn 180° further
4. -1, 2, 3, 6- Turn 45° further


❑ With crankshaft oil seal
⇒ page 22
2 - Bolt
tween sprocket and
of oil
one position
4 - Bolt

2. -1 … 6- Tighten in stages and in diagonal se‐
quence; final torque 13 Nm
3. -7 … 10- 13 Nm


Removing
NOTICE

Installing
– Hold tensioner with ring spanner and remove locking tool -
T40098- .

poly V-belt
Removing
– Remove bolts -arrows- and take off poly V-belt tensioner.
Installing
angle.
Tightening torques


er
♦ Torque wrench - VAS 6583A-
♦ Multi-point bit (10 mm), e.g. from plug socket set - VAS 6928-
♦ Offset ring spanner (19 mm)
Removing
noise insulation .
– Detach cap from vibration damper.

– Counterhold crankshaft on central bolt using angled ring span‐

ner -1- when loosening bolts for vibration damper.
– Loosen bolts -arrows- on vibration damper using insert tool -

T10572- and multi-point bit (10 mm) -1-.
– Remove bolts and take off vibration damper.
Installing
angle.
• Installation position: hole -arrow- in vibration damper must be

positioned over raised section of crankshaft sprocket.

– Tighten bolts -arrows- using torque wrench - VAS 6583A- and

insert tool - T10572- and using multi-point bit (10 mm) -1-.
– Fit cap on vibration damper.
– Install noise insulation (front) ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Removing and installing noise
insulation .

cillaries
Removing
– Remove bolt -arrow- and detach damper wheel.

– Loosen bolts in the sequence -6 ... 1-.

– Remove bolts and detach bracket for ancillaries.
Installing
angle.
– Check that a dowel sleeve is fitted between bracket for ancil‐
laries and cylinder block.
Tightening torques

All procedures are described in ⇒ 4-cylinder TDI engine (2.0 ltr.
4-valve common rail); Rep. gr. 13 ; Cylinder block (pulley end);

(pulley end)

♦ Safety goggles
Removing
– Loosen bolt for crankshaft sprocket using counterhold tool -
3415- .
– Remove bolt and detach crankshaft sprocket.
– Remove sump
⇒ “1.3 Removing and installing sump”, page 98 .
– Remove nut -arrow-, move cable duct -1- with B+ wire clear
– Remove bolt -3- and push coolant pipe -2- slightly to side.
NOTICE
Risk of irreparable damage to coolant pipes if they are bent
– Never bend the coolant pipes out of their original shape.
– Remove remaining bolts and carefully release sealing flange

from bonded joint.
Installing
CAUTION

– Remove sealant residue from sump -1- using rotating plastic

brush or similar.
– Clean sealing surfaces using commercially available chemical
sealant remover; they must be free of oil and grease.
• Note the use-by date of the sealant.

2 mm).
– Apply sealant bead -arrow- onto clean sealing surface of seal‐

ing flange as shown in illustration.
• The sealant bead must not be thicker than specified.
– The sealing flange must be installed within 5 minutes after ap‐
plying sealant.

– Position assembly sleeve - T10053/1- on crankshaft journal.

– Slide sealing flange over assembly sleeve - T10053/1- .
• Dowel pins should then engage in bores on cylinder block.
– Detach assembly tool - T10053/1- .
– Tighten sealing flange bolts ⇒ page 17 .
Note
It is important to tighten the bolts in the correct sequence.
– Install sump
⇒ “1.3 Removing and installing sump”, page 98 .
Tightening torques
♦ Crankshaft sprocket ⇒ Item 1 (page 45)


page 28
1 - Cylinder block
2 - Dowel pins
G28-
⇒ page 243
4 - Bolt
end)
❑ With oil seal
6 - Bolt
7 - Drive plate
❑ Lock with counterhold
tool - 3067- to slacken
off bolts
⇒ page 27
8 - Bolt
❑ 60 Nm +90°
9 - Not fitted
when assembling


– Engage intermediate plate on sealing flange -arrow B- and
push onto dowel sleeves -arrows A-.

Stag Bolts Tightening torque
e
1. -arrows- Screw in by hand until contact is made
2. -arrows- Tighten in stages and in diagonal se‐
quence; final torque 15 Nm

Removing
NOTICE
Risk of damage to thread if an impact driver (or similar) is used.
– When screwing in bolts, fit them manually and perform the
first few turns by hand.
– Do not use an impact driver to loosen or tighten bolts.

– Insert counterhold tool - 10-201- in hole on cylinder block,

slacken bolts for drive plate -1-.
– Remove bolts and take off drive plate.
Installing
angle.
bolts.
Tightening torques
page 26

(gearbox end)

♦ Bolt, M6x35 (3x)

♦ Bolt, M7x35 (2x)
Pressing out sealing flange with sender wheel
• Gearbox removed
-2-.
– Rotate crankshaft by turning bolt for toothed belt sprocket until

crankshaft is positioned at “TDC”, as shown in illustration.
• The hole -2- in the sender wheel -3- must be aligned with the
vertical rib -1- on the sealing flange.
– Remove sump ⇒ page 98 .
– Remove engine speed sender - G28- ⇒ page 243 .

• The sealing flange -1- is pressed off the crankshaft -3- together


B - Nut
C - Guide pin
D - Assembly housing
F - Inner section
G - Locating pin
H - Knurled screw (3x)

T50010- :
threaded spindle.


– Press assembly housing -D- downwards -arrow- so that it rests
on nut -B-.
• Inner part -F- of assembly device and assembly housing -D-
must be level with each other.

flat surface.
it out of position.


T50010- so that locating pin -G- is seated in hole -1- in sender
wheel -3-.


Note:
Only the two knurled screws shown in the illustration can be
screwed on.
wheel.

crankshaft flange:
-D-.

into crankshaft flange with hexagon key -3-.

ing flange -2-.


– Press assembly housing -D- by hand in direction of -arrow-
until sealing lip support ring -2- makes contact with crankshaft
flange -1-.
– Check that guide pin -C- is fitted correctly in hole in crankshaft.
This ensures that sender wheel reaches its final installation
position.
bolts on assembly tool - T50010- hand-tight.
assembly housing -D-.

- T50010- :
• There must be a small gap between cylinder block -2- and
sealing flange -1- after nut has been tightened to 35 Nm.



er wheel -1-.
⇒ page 34 .
⇒ page 34 .

bolts -E- hand-tight.

ing flange -1-.

again ⇒ page 33 .
ment is too small.
again ⇒ page 33 .
Assembling:
– Install sump ⇒ page 98 .
– Install intermediate plate ⇒ page 27 .
Tightening torques

3 Crankshaft
There is currently no provision for removing and installing the
crankshaft.

Main bearing journal Conrod journal ∅
∅ mm
mm
Basic dimension 54.00 -0.022 50.90 -0.022
-0.042 -0.042

Procedure
- VW 387- onto cylinder block (as shown in illustration) and set
it against crankshaft.
– Press crankshaft against dial gauge by hand.
Axial clearance:
• New: 0.07 ... 0.17 mm
• Wear limit: 0.37 mm
3. Crankshaft 35

⇒ “4.3 Measuring piston projection at TDC”, page 40
page 43
1 - Bolts
contact surface
❑ When measuring radial
clearance, tighten used
bolt to 30 Nm and turn
90° further
❑ 30 Nm +90°
tion
conrod
❑ Mark conrod and cylin‐
der allocation with paint
-B-
Markings -A- face to‐
wards pulley end
3 - Bearing shells
⇒ page 38
shells
❑ Note version: Upper
bearing shell (closest to
piston) is constructed
from a more wear-re‐
sistant material; refer to ⇒ Electronic parts catalogue
❑ Check that it is securely seated
4 - Conrod
❑ With industrially cracked conrod bearing cap
❑ Mark conrod bearing cap and cylinder allocation with paint -B-
❑ Axial clearance: wear limit: 0.37 mm


❑ Installation position: Markings -A- face towards pulley end
5 - Circlip
❑ 2x
6 - Piston pin
7 - Piston
❑ With combustion chamber
❑ Mark installation position and cylinder number ⇒ page 37
❑ Measuring piston projection at “TDC” ⇒ page 40
❑ Installation position: marking “TOP” or side with lettering faces towards piston crown.
❑ Installation position: marking “TOP” or side with lettering faces towards piston crown
❑ Offset gap by 120° to bottom compression ring
Installation position of pistons and allocation of piston/cylinder

– If you intend to re-install used pistons, mark the cylinder num‐
ber on the piston crown using paint.
• Arrow on piston crown points to pulley end -arrow-.

Installing piston rings

• Installation position: marking “TOP” or side with lettering faces
towards piston crown.
• Open up piston ring -2- using piston ring pliers -VAS 211 003-
just far enough to be able to slide it over piston -1-.
Installation position of bearing shells in conrods

cap.
• Distance -a- = 2.5 mm
Oil spray jet and pressure relief valve

1- Bolt with pressure relief valve, 24 Nm
2- Oil spray jet (for cooling of pistons)
• Installation position: align locating edge of oil spray jet with
NOTICE


♦ Pin - VW 222A-
♦ Piston ring pliers -VAS 211 003-

Removing
• Engine secured to engine and gearbox support ⇒ page 10 .
to cylinder and to conrods for re-installation
– Pull out pistons upwards with conrods.
Note:
Installing
angle.
– Install piston rings ⇒ page 38 .
– Install pistons using piston ring clamp.
• Pistons ⇒ page 37
• Bearing shells in conrods ⇒ page 38
– If pistons have been renewed, perform adaptions listed in
Guided Function 01 - Functions component replace-
ment ⇒ Vehicle diagnostic tester.
Tightening torques

4.3 Measuring piston projection at TDC

Measure piston projection at “TDC” when installing new pistons
or a short engine.
♦ Measuring bridge -VW 382/7- from measuring tool - VW 382-
♦ Measuring plate -VW 385/17- from universal measuring tool -

VW 385-

Procedure
– Secure dial gauge - VAS 6079- with measuring bridge -
VW 382/7- and measuring plate -VW 385/17- to cylinder block
– Measure projection at each piston at both locations marked
with -arrows- (seen in longitudinal direction of engine: at front
and rear of piston).
– Depending on piston projection, install corresponding cylinder
head gasket according to following table:
Piston projection above top sur‐ Identification
face of cylinder block (no. of holes)
mm
0.91 … 1.00 1
1.01 … 1.10 2
1.11 … 1.20 3

1- Part number
2- Ignore
3- Holes
• If the values measured for piston projection are not the same
for all pistons, use the highest value to determine the correct
gasket size.

Checking piston
• Check for wear on piston skirt coating and for any carbon de‐
posits.
• Renew piston if cracking is visible on piston skirt.
Piston ∅ mm
Nominal dimension 80.92 1)


-B-.
– Check cylinder bore for wear, scoring and other abnormalities.
Nominal dimension 81.0

of cylinder.
mm mm
Oil scraper ring 0.25 … 0.50 0.75

Piston ring Wear limit
mm
1st compression ring 0.08
2nd compression ring 0.08
Oil scraper ring 0.08

On new conrods, the rod and the bearing cap may be very firmly
attached to one another. If it is not possible to take off the conrod

– To avoid any risk of damage, the conrod should only be clam‐

ped lightly in a vice using jaw covers as shown in illustration.
• The conrod is clamped in position below the dotted line.
– Unscrew bolts -arrows- approx. 5 turns.

loose -arrow-.

bearings
♦ Plastigauge
Procedure
– Remove conrod bearing cap. Clean bearing cap and bearing
journal.
Radial clearance:
– Renew conrod bolts.



⇒ page 47
2 - Bolt
❑ With collar
cover (bottom)
❑ 12 Nm
3 - Bracket
4 - Bolt
❑ 5 Nm
5 - Bolt
❑ With collar
cover (bottom)
❑ 12 Nm
6 - Toothed belt cover (side)
7 - Bracket
⇒ page 46
9 - Bracket
10 - Bolt
❑ Clean threaded hole for
bolt using a thread tap or
similar
logue
❑ 12 Nm
11 - Toothed belt cover (rear)
❑ To remove, take out coolant pump ⇒ page 119

1 - Bolt
❑ Slacken and tighten with
counterhold tool - 3415-
❑ Tighten in three stages
as follows:
♦ 1st stage: 180 Nm
♦ 2nd stage: turn 90° further
♦ 3rd stage: turn 45° further
tween sprocket and
of oil
one position
3 - Nut
❑ Make sure that stud is
fitted securely
❑ 20 Nm
4 - Damper wheel
5 - Stud
❑ 15 Nm
6 - Nut
❑ Renew
❑ Make sure that stud is
fitted securely
❑ 20 Nm +45°
8 - Stud
❑ 15 Nm
9 - Toothed belt
❑ Check for wear
❑ Installing (adjusting valve timing) ⇒ page 57
10 - Bolt
❑ Use counterhold tool - T10172- with adapters -T10172/11- to loosen and tighten
❑ 100 Nm
11 - Locking bolt
❑ 9 Nm
❑ Contact surface between sprocket, camshaft and locating arm for camshaft must be free of oil

13 - Locating arm for camshaft

14 - Bolt
❑ 20 Nm
15 - Damper wheel
17 - High-pressure pump hub
19 - Nut
❑ Use counterhold tool - T10051- when loosening and tightening
❑ 95 Nm
20 - O-ring
21 - Coolant pump
22 - Bolt

cover
page 46
page 47

cover (top)
Removing


– Move coolant hoses -4- and SCR supply line -3- clear.
– Detach injector for reducing agent - N474- and place to left
side.
– Remove bolt -1- and push measuring tube -2- to right side.

– Release catches -arrows-, disengage toothed belt cover (top)
-1- and detach.
Installing
Tightening torques
♦ Measuring tube ⇒ Item 7 (page 65)

cover (bottom)
Removing


-1-.

– Disengage toothed belt cover (bottom) -1- and detach.
Installing
– Insert toothed belt cover (bottom) -1- into sealing flange (front)
-2- -arrow-.
– Fit toothed belt cover (note position of dowel pin -arrow-).

Tightening torques



♦ Diesel injection pump locking pin - 3359-

Note:
Diesel injection pump locking pin - 3359- or locking pin - T10492-
can be used to lock camshaft sprocket and high-pressure pump
sprocket.
Removing
• Locating arm -2- on camshaft must align with hole -1- behind
it in cylinder head.

T10490- .


driver - T10264- anti-clockwise -arrow- until toothed belt is
slackened.

-1- with counterhold tool - T10172A- and adapters -
T10172/11- when doing so.
– Take toothed belt -2- off camshaft sprocket. If necessary, push
toothed belt cover (right-side) slightly to right side.
– Lock locating arm for camshaft in place using locking pin -
T10492- , as outlined in description of continued steps.
NOTICE
shaft and into hole -arrow- behind it in cylinder head.
T10172A- with adapters -T10172/11- .
– Loosen locking bolt -1- one half turn, but do not remove it.

pump approx. 90° using counterhold tool - T10051- .
– Lock hub of high-pressure pump in place using locking pin -

using counterhold tool - T10051- .
• Renew nut and stud for tensioning roller.
Requirements:
• Base plate -arrow- for tensioning roller must be engaged in
cast recess on cylinder head, as shown.

-arrow-.

oil.
- T10492- .
movement.


T10492- .

in their elongated holes clockwise as far as the stop.
3 - Idler roller



– Using counterhold tool - T10172A- and adapters -T10172/11- ,

apply tension to camshaft sprocket in anti-clockwise direction
-arrow-.
Checking valve timing ⇒ page 59


♦ Diesel injection pump locking pin - 3359-

Note:
Diesel injection pump locking pin - 3359- or locking pin - T10492-
can be used to lock camshaft sprocket and high-pressure pump
sprocket.
Removing
NOTICE

• Locating arm -2- on camshaft must align with hole -1- behind
it in cylinder head.


T10490- .

driver - T10264- anti-clockwise -arrow- until toothed belt is
slackened.
NOTICE

-1- with counterhold tool - T10172A- and adapters -
T10172/11- when doing so.
– Lock locating arm for camshaft in place using locking pin -
shaft and into hole -arrow- behind it in cylinder head.
T10172A- with adapters -T10172/11- .
– Loosen locking bolt -1- one half turn, but do not remove it.


pump approx. 90° using counterhold tool - T10051- .
– Lock hub of high-pressure pump in place using locking pin -
using counterhold tool - T10051- .
• Renew nut and stud for tensioning roller.
Requirements:
• Base plate -arrow- for tensioning roller must be engaged in
cast recess on cylinder head, as shown.

-arrow-.


oil.
- T10492- .
movement.

T10492- .

in their elongated holes clockwise as far as the stop.
3- Camshaft sprocket
4- Damper wheel
5- High-pressure pump sprocket
6- Coolant pump sprocket


– Check that locking bolt -1- is located between centre and lower
end -2- of elongated hole. If necessary, adjust position of cam‐
shaft sprocket by moving it one tooth clockwise then fit toothed
belt again.

aligns with centre of slot on base plate -2-.
– Using counterhold tool - T10172A- and adapters -T10172/11- ,

apply tension to camshaft sprocket in anti-clockwise direction
-arrow-.
fore “TDC”.
– Fit crankshaft stop - T10490- to crankshaft sprocket again.

• If crankshaft has been turned past “TDC” position, turn crank‐
shaft two further rotations until it is again positioned just before
“TDC”. Then turn further in the same direction and lock crank‐
shaft with crankshaft stop - T10490- .

• It must be possible to lock locating arm -2- for camshaft using

locking pin - T10492- .
• It is very difficult to reproduce the locking position of the high-

pressure pump hub. However, a slight deviation -arrow- does
not influence engine operation.
• Pointer -2- on tensioner roller must be centred between tabs

-1- and -3- on base plate.
Note:
The maximum permissible sideways deviation from the specified
position is 5 mm.
If requirements are met, continue with procedure after adjusting
valve timing correctly as described below ⇒ page 61 .
Re-adjust valve timing if requirements are not met ⇒ page 60 .
Re-adjusting valve timing:

– If camshaft hub cannot be locked, withdraw crankshaft stop -
T10490- until pin is clear of bore -arrow-.
– Turn crankshaft in opposite direction of engine rotation slightly
past “TDC”.
– Now turn crankshaft slowly in direction of engine rotation until
it is possible to lock camshaft hub with locking pin - T10492- .
– After locking camshaft in place, loosen bolt for camshaft
sprocket; counterhold with counterhold tool - T10172/11- and
adapters -T10172A- to do so.

If pin of crankshaft stop - T10490- is on left side of hole:


sprocket using counterhold tool - T10172A- and adapters -
T10172/11- .
If pin of crankshaft stop - T10490- is on right side of hole:
– Turn crankshaft slightly in opposite direction to engine rota‐
tion.
– Turn crankshaft in direction of engine rotation again until pin
of crankshaft stop engages in sealing flange as crankshaft ro‐
tates.

sprocket using counterhold tool - T10172A- and adapters -
T10172/11- .
Procedure after adjusting valve timing correctly:
– Remove locking pin - T10492- and crankshaft stop - T10490- .
fore “TDC”.
– If locating arm for camshaft can now be locked, tighten bolt

-1- for camshaft sprocket to final torque ⇒ Item 10 (page 45) ;
to do so, remove locking pin - T10492- and counterhold cam‐
shaft sprocket using counterhold tool - T10172A- and adapters
-T10172/11- .
– Tighten nut -2- for high-pressure pump sprocket to final torque
⇒ Item 19 (page 46) ; to do so, use counterhold tool - T10051- .
Attaching
following:

– Tighten locking bolt -arrow-.

– Install toothed belt cover ⇒ page 47 .
Tightening torques

2 Cylinder head
1 - Cylinder block
❑ Identification of cylinder
head gasket
⇒ page 64
3 - Cylinder head
⇒ page 66
❑ To prevent damage to
glow plugs, always
place cylinder head on a
soft foam surface after
removal.
⇒ page 64
❑ Must not be machined
❑ Before installing, check
that the two dowel
sleeves for centring cyl‐
inder head are fitted on
cylinder block
4 - Dowel pin
5 - Washer
6 - Bolt
❑ Correct sequence when
slackening ⇒ page 69
7 - Bolt
❑ 20 Nm
9 - Dowel pin
2. Cylinder head 63
10 - Seal
11 - Connection
❑ For coolant hoses
12 - Bolt
❑ 10 Nm
13 - Plug
❑ 9 Nm
14 - Seal
15 - Dowel pins
❑ For intake manifold with charge air cooler
16 - Dowel sleeves

• Cylinder heads must not be reworked on TDI engines.

1- Part number
2- Ignore
3- Holes
Note:
Cylinder head gaskets of different thicknesses are fitted depend‐
ing on the amount of piston projection ⇒ page 40 . If renewing the
cylinder head gasket only, the new gasket should have the same
identification as the old one.


angle.
1. -1 … 10- 30 Nm
2. -1 … 10- 70 Nm
3. -1 … 10- Turn 90° further
4. -1 … 10- Turn 90° further
5. -1 … 10- Turn 90° further
1 - Gasket
❑ Renew if damaged or
leaking
⇒ page 72
3 - Bolt
❑ Renew if gasket is dam‐
aged
4 - O-ring
5 - Sealing plug
6 - Measuring tube
sender - G505-
7 - Bolt
❑ 8 Nm
8 - Grommet
9 - O-ring
10 - Hose
11 - Seal
❑ For injector
2. Cylinder head 65
12 - Vacuum hose
❑ Connection can break off if vacuum hose is pulled off
❑ To detach vacuum hose, insert screwdriver between hose and cover and tilt it; this will release hose from
connection
13 - Filler cap
14 - Seal
❑ For filler cap
15 - Grommet
Cylinder head cover - tightening torque and sequence

– Tighten bolts for cylinder head cover in the sequence -1 ... 7-
to 9 Nm.

♦ Bit XZN 10 - T10501-
Removing
– Remove coolant pipes (rear left and top left) ⇒ 4-cylinder TDI
engine, 2.0 ltr. 4-valve common rail; Rep. gr. 19 ; Coolant
pipes; Removing and installing coolant pipes .

– Remove throttle valve module - J338- with connection

⇒ page 153 .
– Unscrew bolt -1- and union nut -4-.
– Unscrew bolts -2 and 3- and detach oil return line.
– Remove bolt -1-; slacken bolts -2 and 3- by one turn, but do

not remove them.
– Lower engine onto engine mounting on right side and detach
support bracket - 10-222A- .

– Unscrew bolt -1- and nut -2- and push coolant pipe (rear)
slightly towards rear.
2. Cylinder head 67
– Unplug electrical connector -arrow- from exhaust gas recircu‐

lation control motor - V338- and move electrical wiring clear.


– Remove bolt -3- for bracket for intake manifold.


– Remove bolt -1- but leave cover -2- in installation position.

– Unplug electrical connector at glow plug for cylinder 1
⇒ page 240 .
– Move electrical wiring harness clear and place to one side.

– Swivel cylinder head to left and out of rear toothed belt cover
and detach tensioning roller at the same time.
– Take care not to damage oil return line for turbocharger.
– Take care to place cylinder head down without bending oil re‐
turn line. If necessary, place a block of wood below exhaust
manifold.
Installing
2. Cylinder head 69
Note
♦ Use of impermissible abrasive materials can lead to subse‐

quent damage to the turbocharger, conrod bearings or similar.
♦ Sealing surface (see photo) must not be raised.
♦ Dark discolouration (see photo) does not have to be removed.

and cylinder block using a commercially available ceramic hob
scraper.
• Sealing surfaces must NOT be damaged.
for the bolts.
• If a new cylinder head is installed, the contact surfaces be‐
tween the roller rocker fingers and the running surface of the
cam must be lubricated.
gasket.
• Turn the crankshaft carefully at least 2 rotations to ensure that
none of the valves make contact when the starter is operated.
change the engine oil and the coolant in the entire cooling
system.

– Note cylinder head gasket identification:

1- Part number
2- Ignore
3- Holes
• If the cylinder head gasket or cylinder head have been re‐
newed, select the new cylinder head gasket according to the
number of holes on the old gasket.
• If parts of the crankshaft drive have been renewed, select the
new cylinder head gasket by measuring the piston projection
at “TDC” ⇒ page 40 .
– Fit cylinder head gasket onto dowel sleeves -arrows- in cylin‐

der block.
inder head.
– Renew and tighten cylinder head bolts ⇒ page 65 .
Note:
after repair work.
2. Cylinder head 71

note the following:
– Set up support bracket - 10-222A- again on wing mounting
flanges (left and right) ⇒ 4-cyl. TDI engine (2.0 ltr. 4-valve
common rail); Rep. gr. 26 ; Emission control system; Remov‐
ing and installing emission control module .
– Attach hook - 10-222A/10- to engine lifting eye (rear right).
– Raise engine with spindle of hook until load on engine mount‐
ing (right-side) is relieved.
– Install coolant pipes ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve
common rail; Rep. gr. 19 ; Coolant pipes; Removing and in‐
stalling coolant pipes .
– Change coolant ⇒ 4-cylinder TDI engine (2.0 ltr. 4-valve com‐
mon rail); Rep. gr. 19 ; Cooling system/coolant; Draining and
– If cylinder head has been renewed, perform adaptions listed
in Guided Function 01 - Functions component re-
placement ⇒ Vehicle diagnostic tester.
Tightening torques
mountings

cover
Removing


1 - For air mass meter - G70-
7 - For position sender for charge pressure positioner - G581-
– Detach vacuum hose -2- from vacuum unit and move clear.
Note
♦ The connection for the vacuum hose -3- can break off if the
hose is pulled off.
♦ To detach the vacuum hose, insert a screwdriver between the
hose and the cover and tilt it; this will release the hose from
the connection.
– Detach vacuum hose -3- and move clear.

– Press release tabs on both sides of crankcase breather hose
-5- and disconnect hose from cylinder head cover.
– Move line -6- clear and place to one side.
– Remove exhaust gas pressure sensor 1 - G450-
⇒ page 193 .
– Version 1: Remove bolts -arrows- and push fuel lines slightly

to rear.
– Version 2: Remove bolts -arrows- and push fuel lines slightly

to rear.
2. Cylinder head 73

– Slacken cylinder head cover bolts in the sequence -7 ... 1- and
remove.
Installing
• Renew gasket and bolts for cylinder head cover if damaged or
leaking.
necessary.
– Install injectors ⇒ page 172 .
– Install exhaust gas pressure sensor 1 - G450- ⇒ page 191 .
Tightening torques
♦ ⇒ Fig. ““Cylinder head cover - tightening torque and se‐

tors
♦ Carrier - 3390-
♦ Tool set for FSI engines - T10133-

♦ Oil seal extractor - T40195-
Procedure
• Injector removed ⇒ page 172 .
– Screw oil seal extractor - T40195- into seal -1-.
– Fit striker -T10133/3- with adapter -T10133/2- on oil seal ex‐
tractor, as shown in illustration, and pull out seal upwards by
tapping gently.
– Apply carrier - 3390- and short extension -1- at top and press
new injector seal in as far as stop.

ing
♦ Bit XZN 10 - T10501- or ball head Torx T30 (commercially
available)

♦ Safety goggles
2. Cylinder head 75

Removing
• Cylinder head installed.
– Remove cylinder head cover ⇒ page 72 .
– Remove high-pressure reservoir (rail) ⇒ page 178 .
– Move electrical wiring and vacuum hoses clear.
Version 1:
– Unplug electrical connector -2- for fuel temperature sender -
G81- .
– Release hose clips -1- and detach fuel hoses from fuel lines.
– Place fuel lines to right side.
Version 2:

G81- .
– Place fuel lines to right side.


– Loosen nut -1- and bolt -3-.
Note:
To loosen bolt -3-, use bit XZN 10 - T10501- or ball head Torx
T30 (commercially available).
– Remove union nut -2-.
– Loosen bolt -4- and remove screw-type clip.

– Slacken bolts -2- and remove bolts -3, 5, 6-.
– Press emission control module slightly to right side.
2. Cylinder head 77
– Slacken camshaft housing bolts in the sequence -18 ... 1-.

– Remove bolts and carefully release and detach camshaft
housing from bonded joint.
Installing
Requirements:
• Crankshaft locked in position with crankshaft stop - T10490- .

T10492- .
• Bolt -arrow- for camshaft sprocket -2- screwed on loosely.
– Remove remaining sealant from cylinder head and camshaft

housing -1- using rotating plastic brush or similar.
CAUTION


1.5 mm).
– Apply sealant bead -arrow- onto clean sealing surfaces of

camshaft housing as shown in illustration.
• Width of sealant beads: 2 mm.
• Install the camshaft housing within 5 minutes after applying
the sealant.
• After installing the camshaft housing, wait about 30 minutes
for the sealant to dry.
– Carefully fit camshaft housing on cylinder head, paying atten‐
tion to dowel pins.
– Tighten camshaft housing bolts ⇒ page 83 .
note the following:
– Install cylinder head cover ⇒ page 72 .
Tightening torques
♦ ⇒ Fig. ““Camshaft housing - tightening torque and sequence”“ ,
page 83
♦ ⇒ Fig. ““Exhaust gas recirculation cooler - tightening torque

⇒ “2.7.1 Checking using diagnostic tester”, page 79
⇒ “2.7.2 Checking using compression tester”, page 80
2.7.1 Checking using diagnostic tester

Compression pressure can be checked with a vehicle diagnostic
tester or with compression tester - V.A.G 1763- .
Procedure
2. Cylinder head 79
– Select Subsystems, conditions .

– Select Compression check from list.
• If the result for one of the cylinders is unusual, check the com‐
pression using the compression tester - V.A.G 1763- .
2.7.2 Checking using compression tester

♦ Compression tester - V.A.G 1763- with adapter - V.A.G
1763/8-
Procedure
– Unplug electrical connector on fuel pressure regulating valve
- N276- -item 2-.
– Briefly start engine to relieve fuel pressure in high-pressure
reservoir.

– Screw in adapter - V.A.G 1763/8- in place of corresponding

glow plug and connect compression tester - V.A.G 1763- .
(Using the compression tester ⇒ Operating instructions .)
– Have a second mechanic operate starter until tester shows no
further pressure increase.
When new 25.0 … 31.0
Wear limit 19.0
Attaching
Tightening torques
2. Cylinder head 81
3 Valve gear

Cylinder heads with cracks between the valve seats may be used
without reducing engine life, provided the cracks are small and
not more than 0.5 mm wide.
1 - Valve
❑ Must not be machined;
only grinding-in is per‐
missible
⇒ page 95
⇒ page 94
2 - Cylinder head
❑ Valve seats may not be
machined due to the
very small tolerances
3 - Dowel pin
5 - Valve spring
7 - Valve cotters
ing”, page 75
❑ Lubricate contact surfa‐
ces before installing
9 - Sealing cap
❑ Renew
❑ Removing: With camshaft housing installed, pierce on one side of sealing cap with an awl and pry out
❑ Installing: Drive in without sealant until flush using suitable thrust piece, e.g. carrier - 3390-
10 - Oil seal

❑ With integrated camshafts
12 - Bolt
13 - Bolt
❑ 8 Nm
14 - Cover
15 - Seal
❑ Renew
16 - O-ring
❑ Renew
18 - Bolt
19 - Securing clip
❑ For hydraulic compensation element
21 - Dowel pin

• The camshaft housing should
make contact with the cylinder
head over the full surface.
2. -1 … 18- 10 Nm

seal
3. Valve gear 83
♦ Puller - T10443-
Procedure
All necessary preparatory work is described in ⇒ 4-cylinder TDI
engine (2.0 ltr. 4-valve common rail); Rep. gr. 15 ; Valve gear;
Removing and installing camshaft oil seal .
Note:
If the grub screw is unscrewed too far the thrust plate inside the
puller -T10443- will come loose from the thrust bolt. If this hap‐
pens, the thrust plate must be pushed back onto the thrust bolt.
– Carefully unscrew grub screw -arrow- of puller -T10443- until
slight resistance is felt.

– Apply puller - T10443- to oil seal so that it is straight.

Note:
If the engine was supported in its installation position, you will
need to raise the engine slightly with the spindles -10-222/11-
before performing this step. Take care not to damage the drive
shafts when doing so.
– Screw in a grub screw -A- to lock puller in place.
– Screw in thrust bolt -B- until oil seal is pulled out.
– Completely remove any oil residue on running and sealing
surfaces using degreasing agent.
– Clean entire outer circumference of sealing lip of new oil seal
using degreasing agent (remove wax layer).
Note:
Use silicone adhesive sealant D 176 501 A1 to seal off oil seal.
– Apply silicone adhesive sealant evenly onto sealing lip of oil
seal.
• Sealant bead must be applied evenly over entire circumfer‐
ence.
– Apply guide sleeve -T10493/1- to camshaft as shown in illus‐

tration.
– Carefully push oil seal -1- over guide sleeve and onto cam‐
shaft.
• When pressing in oil seal, guide sleeve remains on camshaft
as a stop.
– Press oil seal in onto stop using press tool -T10493/2- and bolt
-T10493/3- .
Additional work ⇒ 4-cylinder TDI engine (2.0 ltr. 4-valve common
rail); Rep. gr. 15 ; Valve gear; Removing and installing camshaft
oil seal .
3. Valve gear 85

seals

♦ Valve stem seal fitting tool - 3365-

A-
♦ Sealing pin -VAS 5161/29-1-

♦ Guide plate -VAS 5161 A/31-
♦ Sleeve -VAS 5161 A/31-1-
Procedure


Cylinders 1, 3, 4:
– Fit guide plate -VAS 5161 A/31- onto cylinder head.
• The lettering -A- faces towards turbocharger side
• The lettering -E- faces towards intake manifold side
– Secure guide plate with knurled screws -VAS 5161/12- by
hand.
• Position of knurled screws, as shown in illustration
Cylinder 2:
hand.

– Screw sealing pin -VAS 5161/29-1- into guide plate.
– Screw adapter -VAS 5161/11- hand-tight into corresponding
glow plug thread.
3. Valve gear 87

– Insert assembly cartridge -VAS 5161/8A- (slide on sleeve -
VAS 5161 A/31-1- ) in guide plate.
– Insert valve stem oil seal into valve shaft seal fitting tool - 3365-
and use assembly sleeve to carefully press it onto valve guide
-1- as far as stop.



again.
cotters.
tion.
Attaching

3. Valve gear 89
♦ Valve stem seal fitting tool - 3365-

A- with guide plate -VAS 5161 A/31- and sleeve -VAS 5161 A/
31-1- .

Procedure


• Intake manifold and exhaust manifold must be detached from
cylinder head after it has been removed.
supply.
with valve heads.
Cylinders 1, 3, 4:
hand.
Cylinder 2:
hand.

3. Valve gear 91

– Insert assembly cartridge -VAS 5161/8A- (slide on sleeve -
VAS 5161 A/31-1- ) in guide plate.
– Insert valve stem oil seal into valve shaft seal fitting tool - 3365-
and use assembly sleeve to carefully press it onto valve guide
-1- as far as stop.



again.
cotters.
tion.
Attaching
3. Valve gear 93


Procedure
• End of valve stem must be flush with guide.
new valves.
4.2 Checking valves

faces.


in is permitted.
∅a mm 28.10 26.00
∅b mm 5.975 5.965
c mm 99.30 99.10
α ∠° 45 45

17 – Lubrication
1 Sump/oil pump
⇒ “1.3 Removing and installing sump”, page 98
er G266 ”, page 101

♦ Oil spray jet and pressure relief valve ⇒ page 38
1 - Bolt
❑ Self-locking
❑ Clean threaded holes
for bolts using a thread
tap or similar
❑ 8 Nm
2 - Cover
sender - G266-
⇒ page 101
4 - Seal
5 - Oil drain plug
❑ 30 Nm
6 - Bolt
7 - Bolt
❑ 8 Nm +90°
8 - Oil intake pipe
9 - O-ring
10 - Bolt
❑ 12 Nm +180°
11 - Dowel sleeve
12 - Oil pump
❑ With vacuum pump


13 - Gasket
14 - Dowel sleeve
15 - Toothed belt
❑ Removing:
– Remove sealing flange (pulley end) ⇒ page 22 .

16 - Cylinder block
17 - O-rings
19 - Bolt
❑ 8 Nm
20 - Oil dipstick
21 - O-ring
22 - Bolt
❑ 8 Nm
24 - Bolt
❑ 8 Nm
25 - O-ring
26 - Baffle plate
27 - Sump
28 - Bolt
29 - Bolt
❑ Tightening torque ⇒ Gearbox; Rep. gr. 34 ; Removing and installing gearbox; Tightening torques for
gearbox
30 - Seal
1. Sump/oil pump 97
Sump - tightening torques and sequence

1. -1 … 10-, 5 Nm in diagonal sequence
-12 and 13-,
-15 … 20-
2. -arrows- ⇒ Gearbox; Rep. gr. 34 ; Removing
and installing gearbox; Tightening tor‐
ques for gearbox
3. -1 … 10-, Tighten in stages and in diagonal se‐
-12 and 13-, quence; final torque 13 Nm
-15 … 20-
4. -11 and 14- 40 Nm
1.2 Engine oil

and installing oil filter element ⇒ 4-cylinder TDI engine (2.0 ltr.
4-valve common rail); Rep. gr. 17 ; Sump/oil pump; Engine oil
tenance tables .
1.3 Removing and installing sump

♦ Socket - T10058-

♦ Safety goggles


Removing
All necessary preparatory work is described in ⇒ 4-cylinder TDI
engine (2.0 ltr. 4-valve common rail); Rep. gr. 17 ; Sump/oil pump;
Removing and installing sump .
– Remove nut -arrow-, move cable duct -1- with B+ wire clear
sender - G266- .
– Release fasteners -arrows- and detach noise insulation for
sump.
– Remove bolts securing sump to gearbox -arrows-.

– Slacken bolts -1 ... 20- in diagonal sequence and remove.
– Carefully release sump from bonded joint.
1. Sump/oil pump 99
Installing
– Remove sealant residue from sump -1- and cylinder block us‐
ing rotating plastic brush or similar.
CAUTION

1.5 mm).
– Apply sealant bead onto clean sealing surface of sump as il‐

lustrated.
• Thickness of sealant bead: 1.6 ... 1.9 mm
• Take particular care when applying sealant bead in area of
rear sealing flange -arrows-.
• Install sump within 5 minutes after applying the sealant.
– Insert baffle plate.
– Fit sump and tighten bolts.
• The sump must make flush contact with intermediate plate/
gearbox flange.
• When installing sump with engine removed from vehicle, en‐
sure that sump is positioned flush with cylinder block at fly‐
wheel end.
• After fitting sump, sealant must dry for approx. 30 minutes.
Additional work ⇒ 4-cylinder TDI engine (2.0 ltr. 4-valve common
rail); Rep. gr. 17 ; Sump/oil pump; Removing and installing sump
Tightening torques
♦ ⇒ Fig. ““Sump - tightening torques and sequence”“ , page 98


Removing
– Remove sump ⇒ page 98 .
– Remove bolts -arrows- and detach oil pump -1-.
• The bolt on the pump impeller must NOT be loosened.
Installing
angle.
– Insert dowel sleeves -arrows- in oil pump, if not fitted.

– Install sump ⇒ page 98 .
Tightening torques

Removing
– Remove bolts -1- and detach oil level and oil temperature
Installing
• Renew seal -4- and self-locking bolts -1- after removal.
Tightening torques

2 Engine oil cooler

Engine oil cooler must not be separated from oil filter housing. If
defective, engine oil cooler must be renewed together with oil filter
housing ⇒ page 107 .


⇒ “3.1 Exploded view - oil filter housing/oil pressure switch”, page
103
page 104
”, page 109
3.1 Exploded view - oil filter housing/oil pressure switch
1 - Gaskets
❑ Renew
2 - Oil filter housing with engine
oil cooler
❑ Do not separate oil filter
housing and engine oil
cooler
⇒ page 107
⇒ page 98
4 - Seal
do so)
5 - Sealing cap
❑ 25 Nm
sure 0.3 ... 0.6 bar
agnostic tester
⇒ page 106
❑ 20 Nm
7 - Seal
do so)
❑ If seal is not available
separately, refer to ⇒ Electronic parts catalogue ; renew oil pressure switch after removal
❑ Opening/closing pressure 2.5 ... 3.2 bar


❑ 20 Nm
9 - Seal
removal
10 - Bolt
Oil filter housing - tightening torque and sequence

angle.
– Fit bolts at top left and bottom right first.
1. -1 … 5- 20 Nm

switch - F22-
♦ Crow-foot ring spanner, 24 mm (commercially available)
Removing
– Unscrew bolt from coolant expansion tank, detach coolant ex‐
pansion tank towards front and place to one side.



– Detach air pipe towards rear and place to one side.
– Remove nut -1- and press bracket -2- with electrical wiring
– Remove bolt -3- and centre hex stud -5-, and detach support
-4- for throttle valve module - J338- .

– Use crow-foot ring spanner, 24 mm to unscrew oil pressure
switch - F22- .
Installing
necessary.
– If old oil pressure switch - F22- is to be reinstalled, renew seal
for oil pressure switch - F22- after removal.
– Cut seal open to renew.
Tightening torques
♦ ⇒ “3.1 Exploded view - oil filter housing/oil pressure switch”,
page 103
tem”, page 140


Removing




– Use articulated wrench, 24 mm - T40175- to remove oil pres‐
sure switch for reduced oil pressure - F378- .
Installing
necessary.
– Renew seal for oil pressure switch for reduced oil pressure -
F378- after removal.
– Cut seal open to renew.
Tightening torques
page 103
tem”, page 140

Removing
– Remove coolant pipes (rear left and top left) ⇒ 4-cylinder TDI
engine, 2.0 ltr. 4-valve common rail; Rep. gr. 19 ; Coolant

– Unplug electrical connector -3- at alternator -4-.
– Lift retaining clip -arrow- and detach coolant connection.
– Unplug electrical connector -arrow- on oil pressure switch -

F22- .
– Unplug electrical connector -arrow- at oil pressure switch for

reduced oil pressure - F378- .


– Unscrew bolts in the sequence -5 ... 1- and detach oil filter
housing together with engine oil cooler.
Installing
– Install coolant pipes ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve
common rail; Rep. gr. 19 ; Coolant pipes; Removing and in‐
stalling coolant pipes .
engine (2.0 ltr. 4-valve common rail); Rep. gr. 19 ; Radiator/
radiator fans; Exploded view - radiator/radiator fans .
– Fill up with coolant ⇒ 4-cylinder TDI engine (2.0 ltr. 4-valve
common rail); Rep. gr. 19 ; Cooling system/coolant; Draining
Tightening torques
page 103

Removing


– Unscrew bolt -2- and remove valve for oil pressure control -
N428- .
Installing
Tightening torques

Procedure
• Oil level OK
⇒ page 106 .
– Connect oil pressure tester - V.A.G 1342- to threaded hole for
oil pressure switch for reduced oil pressure - F378- .
– Screw a used oil pressure switch into threaded hole on oil
pressure tester - V.A.G 1342- to seal hole.
– Start engine.
• Oil pressure when starting and then at idling speed: at least
1.4 bar.
If specification is not obtained, switch off engine immediately and
check oil pump drive; renew oil pump if necessary ⇒ page 101 .
If specification is obtained, higher oil pressure must be checked
using ⇒ Vehicle diagnostic tester.
– Allow engine to warm up.
Note:
It is not possible to test all levels of the oil pressure control system
while the vehicle is stationary. The higher oil pressure must there‐
fore be checked using the ⇒ Vehicle diagnostic tester:


– Then select Basic setting .
– Select Checking oil pressure valve change-over on the
Basic setting page and then click on > (not >I).
– No settings are required on the parameter settings page. Now
click on > (not >I).
– Select Operating instructions and Oil pressure ac-
tual value on the measured values page and then click on
> (not >I).
– Start the basic setting routine and follow the operating instruc‐
tions.
– Do not press the pedals until requested; otherwise the routine
will be cancelled for safety reasons.
• Oil pressure must rise to at least 3.5 bar.

19 – Cooling

All components are described in ⇒ 4-cylinder TDI engine (2.0 ltr.
4-valve common rail); Rep. gr. 19 ; Cooling system/coolant; Con‐
nection diagram - coolant hoses .


version 1 (not illustrated)
(version 2)

♦ Safety goggles
• To ensure that the leak test is carried out correctly, a self-test
must first be performed on the cooling system tester -
V.A.G 1274 B- .
Checking cooling system tester - V.A.G 1274 B- (self-test)
– Build up a pressure of 3.0 bar on cooling system tester.

• Cooling system tester - V.A.G 1274 B- is leaking and must not
be used.
Checking cooling system for leaks
CAUTION

expansion tank.


nutes.
Note:
engine is cold.
If the pressure drops by more than 0.2 bar:
– Examine engine and radiator to find and eliminate the leak.

Blue filler cap
this level.
Black filler cap
this level.
All filler caps
scribed.


Blue filler cap
1.4 ... 1.6 bar.
Black filler cap
1.6 ... 1.8 bar.
scribed.

– Drain and fill cooling system ⇒ 4-cylinder TDI engine (2.0 ltr.
4-valve common rail); Rep. gr. 19 ; Cooling system/coolant;


page 118
page 118
⇒ “2.7 Checking thermostat”, page 119
N489 ”, page 119
”, page 120
1 - Bolt
❑ 20 Nm +45°
2 - Coolant pump
⇒ page 119
3 - O-rings
head - N489-
⇒ page 119
5 - Bolt
❑ 8 Nm
6 - Bolt
❑ 20 Nm
7 - O-ring
⇒ 4-cylinder TDI en‐
19 ; Coolant pipes; Re‐
coolant pipes
9 - O-ring

10 - O-ring
12 - Bolt
❑ 20 Nm
13 - O-ring
14 - Thermostat
❑ Can only be renewed together with coolant pipe (left-side) ⇒ Item 8 (page 116)
15 - Connection
16 - Bolt
❑ 8 Nm
17 - O-ring
18 - O-ring
19 - O-ring

4-valve common rail); Rep. gr. 19 ; Coolant pump/thermostat as‐
sembly; Exploded view - electric coolant pump .

1 - Spacer ring
2 - O-ring
er - G62-
⇒ page 120
4 - Centre hex stud
❑ 8 Nm

pump
4-valve common rail); Rep. gr. 19 ; Coolant pump/thermostat as‐


Removing
– Remove bolts -arrows- and detach coolant pump -1-.
Installing
NOTICE
Risk of damage to coolant pump if functional check is performed
manually.
– Never pull the modulating mechanism of the coolant pump
with your hand to check its function.
• Do not hold or carry the coolant pump by the connector or

modulating mechanism.
• Do not operate the modulating mechanism.
– Fill up with coolant ⇒ 4-cylinder TDI engine (2.0 ltr. 4-valve
common rail); Rep. gr. 19 ; Cooling system/coolant; Draining
Tightening torques

Thermostat can only be renewed together with coolant pipe (left-
side) ⇒ 4-cylinder TDI engine, 2.0 ltr. 4-valve common rail; Rep.
gr. 19 ; Coolant pipes; Removing and installing coolant pipes .
2.7 Checking thermostat

– Remove thermostat and heat it in a water bath.
Starts to open Fully open Opening travel
87 ± 2 °C approx. 102 °C1) at least 9 mm
• 1) Cannot be tested.

Removing
• Engine cold.


tank.

N489- -item 1-.
Installing
Tightening torques

ature sender - G62-
Removing
• Engine cold.


tank.



– Remove support mounting (right-side) ⇒ 4-cyl. TDI engine
(2.0 ltr. 4-valve common rail); Rep. gr. 10 ; Assembly mount‐
ings; Removing and installing engine mountings .

– Unscrew bolts -1, 4- and nut -2- and push coolant pipe (rear)
slightly to right side.

– Unscrew centre hex stud -2- and pull off coolant temperature
sender - G62- .
Note:
If an O-ring or spacer ring remains lodged in cylinder head, lift it
face.
Installing
necessary.
– Install support mounting ⇒ 4-cyl. TDI engine (2.0 ltr. 4-valve
common rail); Rep. gr. 10 ; Assembly mountings; Removing
and installing engine mountings .
Tightening torques
tem”, page 140

3 Coolant pipes
engine, 2.0 ltr. 4-valve common rail; Rep. gr. 19 ; Coolant pipes .

engine (2.0 ltr. 4-valve common rail); Rep. gr. 19 ; Radiator/ra‐
diator fans .

1 Turbocharger

Part I
1 - Bolt
❑ 15 Nm
2 - Heat shield
3 - Seal
4 - Air hose
6 - Bolt
❑ 8 Nm
7 - O-ring
8 - Hose
9 - Pulsation damper
10 - Bolt
❑ 8 Nm
11 - O-ring
12 - Heat shield
13 - Bolt
❑ Renew
❑ 15 Nm
14 - Bolt
⇒ “1.3 Renewing vac‐
uum unit for turbocharg‐
er”, page 132
15 - Vacuum unit for turbocharger
❑ Renewing ⇒ “1.3 Renewing vacuum unit for turbocharger”, page 132
16 - Securing clip
1. Turbocharger 125
17 - Gasket
18 - Turbocharger
❑ Adaption must be performed after renewing this component
❑ Select 01 - Engine electronics, functions and perform Guided Function 01 - Functions, en-
gine mechanics
19 - Nut
❑ Lubricate exhaust manifold studs with high-temperature paste
❑ If studs are renewed, too, tighten them to 15 Nm
Part II
Part I ⇒ page 125
1 - Gasket
2 - Seals
3 - Banjo bolt
❑ 30 Nm
4 - Oil supply line
❑ Check for obstructions
❑ Before installing turbo‐
charger, fill connection
for oil supply line with
engine oil
5 - Bolt
❑ 20 Nm
6 - Union nut
❑ 16 Nm
sender 1 - G235-
❑ Exploded view
⇒ page 221
8 - Bolt
9 - Turbocharger
❑ Adaption must be per‐
formed after renewing
this component
❑ Select 01 - Engine
electronics, func-
tions and perform Gui‐
ded Function 01 -
Functions, engine mechanics

10 - Coolant lines
11 - Bolt
❑ 8 Nm
12 - Gasket
13 - Bracket
14 - Bolt
❑ 8 Nm
15 - Bolt
16 - Bracket
❑ For emission control module
17 - O-ring
19 - Bolt
❑ 10 Nm
20 - Ribbed bolt
❑ 14 Nm
Bracket for emission control module - tightening torque and tight‐

ening sequence
– Fit bracket in correct installation position.
– Tighten bolts in stages in the sequence described:
1. -1, 2, 3- Screw in by hand until contact is made
2. -1- 20 Nm
3. -2- 40 Nm
4. -3- ⇒ 4-cylinder TDI engine (2.0 ltr. 4-
valve common rail); Rep. gr. 10 ; As‐
sembly mountings; Exploded view -
assembly mountings
1. Turbocharger 127
Turbocharger - tightening torque and sequence

– Tighten nuts in stages in the sequence given:
Stage Nuts Tightening torque
1. -arrows- Tighten to 11 Nm in diagonal se‐
quence, working from centre out‐
wards
wards
wards
• This procedure has been specified
in order to compensate for the set‐
tling of the components.

essary.
♦ Bit XZN 10 - T10501-

Removing
Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
– Unscrew bolt -1- and union nut -4-.
– Unscrew bolts -2 and 3- and detach oil return line.
– Unbolt bracket for emission control module. To do so, remove

bolts -1, 2, 3- (bracket is detached later).
1. Turbocharger 129
– Unscrew bolt -4- from coolant pipe.
– Unscrew the two bolts -bottom arrows- for the engine support
-1- by a few turns only; do not remove them.
Note:
Press coolant pipe to side to loosen bolts.
The two bolts -top arrows- have already been removed.
– Detach bracket for emission control module towards front.



– Mask suspension turret (right-side) with adhesive tape to
avoid damaging suspension turret when lifting out turbocharg‐
er.

– Detach turbocharger with exhaust manifold from cylinder head
(pay attention to oil supply line).
NOTICE
Risk of damage to oil supply line.
– Do not bend oil supply line.
1. Turbocharger 131
Note
If necessary, use hook - 10 - 222 A /10- to lift engine by approx.
25 mm.
Installing
moval.
line.
necessary.
– Connect vacuum hose ⇒ page 149 .
– If turbocharger has been renewed, perform adaptions listed in
Guided Function 01 - Functions component replace-
ment ⇒ Vehicle diagnostic tester.
Tightening torques
♦ ⇒ Fig. ““Turbocharger - tightening torque and sequence”“ ,
page 128
mountings


♦ Torque wrench - V.A.G 1783-
♦ Open-end spanner insert AF 10 - V.A.G 1783/1-
Removing
– Unclip fuel lines from air hose.
– Unplug electrical connector -3- at position sender for charge

pressure positioner - G581- .
– Detach vacuum hose -2- from vacuum unit of turbocharger,
making sure not to damage it.
– Remove circlip -4-.
– Remove bolts -1- for vacuum unit.
– Disengage control rod at adjusting lever and detach vacuum
unit.
1. Turbocharger 133
Installing
• Use new bolts and a new circlip from the repair kit.
– Attach control rod at adjusting lever, position vacuum unit and
tighten bolts -1- to 10 Nm.
• Do not insert circlip -4- at adjusting lever yet.
– Plug in electrical connector -3- at position sender for charge
Checking adjustment of vacuum unit
– Use ⇒ Vehicle diagnostic tester.
– From the list in Self-diagnosis under Measured values ,
select Turbine actuator 1 bank 1, position feedback,
raw voltage .

position -A- to select “vacuum”.
– Connect hand vacuum pump - VAS 6213- to vacuum unit

-arrow-.
NOTICE
Risk of damage to vacuum unit on account of excessive vac‐
uum.
– Vacuum must NOT exceed -800 mbar.
– Operate hand vacuum pump - VAS 6213- until a vacuum be‐

tween -650 ... -700 mbar is displayed on pressure gauge.
♦ Specification: 0.75 ± 0.05 V

If specification is obtained:
position -B- to vent vacuum in vacuum unit to ambient pres‐
sure.
– Fit circlip -4-.
– Install air hose; to do so, tighten hose clips -1, 2- and clip fuel
lines into place.
1. Turbocharger 135
– Plug in electrical connector -3- at position sender for charge

– Attach vacuum hose -2- to vacuum unit of turbocharger.
– Perform adaption ⇒ page 136 .
If specification is not obtained:

– Mark position of grommet -1- in relation to control rod -3- for
re-installation -arrows-.
– Remove vacuum unit again.
– Loosen union nut -2- on control rod and extend or retract rod
as appropriate.
• 180 degrees (half a turn) corresponds to 0.05 volts.
• If specification is too high, extend rod.
– Tighten lock nut to 7.5 Nm, noting position of grommet -1- ac‐
cording to the marking made previously.
– Install vacuum unit; engage control rod on adjusting lever to
do so.
– Tighten bolts -1- for vacuum unit to 10 Nm.

– Then check adjustment of vacuum unit again ⇒ page 134 .
Performing adaption
– Switch to Guided Functions and select 01 - Adaption
after replacing positioner .
– Perform adaption.
Check voltage value again after adaption.
– Switch to Self-diagnosis and in the list under Measured
values , select Turbine actuator 1 bank 1, position
feedback, raw voltage .

– Connect hand vacuum pump - VAS 6213- to vacuum unit

-arrow-.
NOTICE
Risk of damage to vacuum unit on account of excessive vac‐
uum.
– Vacuum must NOT exceed -800 mbar.
– Operate hand vacuum pump - VAS 6213- until a vacuum be‐

tween -650 ... -700 mbar is displayed on pressure gauge.
– A voltage of 0.75 ± 0.05 V should now be shown in the Meas-
ured values display zone.
Voltage value not OK

– Adjust voltage value again ⇒ page 136 .
Voltage value OK
necessary.
– Attach vacuum hose to vacuum unit of turbocharger.
– Fit circlip.
– Secure bolts and union nut on control rod with sealing paint.
– Erase all event memories ⇒ Vehicle diagnostic tester.
1. Turbocharger 137
2 Charge air system

page 140
page 141
page 141
2 - Bolt
3 - Bolt
4 - Bracket
air cooler
⇒ page 155
6 - Bolt
7 - Gasket
G811-
⇒ page 141
❑ 22 Nm
9 - Bracket
❑ For electrical wiring har‐
ness
pending on model
10 - Bolt
11 - Bolt
12 - Vacuum line

13 - Coolant hose
❑ A plug may be fitted depending on version
14 - Gasket
15 - Gasket
16 - Bolt
❑ 22 Nm
19 - Bracket
❑ For charge pressure sender - G31-
21 - Bolt
❑ 8 Nm
22 - Bolt
❑ 8 Nm
23 - Ball stud
24 - Bolt
25 - Connection
❑ For throttle valve module - J338-
26 - Dowel pin
27 - Seal
❑ 8 Nm
29 - Spacer sleeve
30 - Rubber buffer
31 - Air pipe
32 - Bolt
❑ 8 Nm
33 - Seal
35 - Bolt
36 - Bolt

37 - Bracket
38 - Dowel pin
39 - Gasket
40 - Bolt
41 - Bolt

charge air system
installing.


sure sender - G31-
Removing
NOTICE
Irreparable damage to charge pressure sender can be caused
if the connection breaks off.
keep hose straight.

– Detach bracket together with charge pressure sender - G31- ,
release hose clip at connection and disconnect hose.
Installing
Tightening torques

perature sender
Removing
Charge air temperature sender before charge air cooler - G810-
– Remove bolts -1- and press charge pressure sender - G31-
with bracket to side.

– Unscrew charge air temperature sender before charge air
cooler - G810- -item 1-.

Charge air temperature sender after charge air cooler - G811-

– Press coolant hose slightly to one side.
– Unscrew charge air temperature sender after charge air cooler
- G811- .
Installing
Tightening torques

Water-cooled charge air cooler is integrated in intake manifold
(combined as one part).
♦ Adapter - V.A.G 1687/11-

♦ Adapter - V.A.G 1687/15- for exhaust pipes with 60 mm and
65 mm diameter
♦ Adapter - V.A.G 1687/16- for exhaust pipe with 55 mm diam‐
eter

Procedure
005/5- .
nection »A«.
must be visible.


– Disconnect crankcase breather pipe -arrow-.

– Seal off connecting piece with a plug -1- from engine bung set
- VAS 6122- .
– Secure plug with a hose clip -2-.

1687/16- to turbocharger.
– Connect charge air system tester - V.A.G 1687- to adapter.

water.
– Open valve -3-.
NOTICE
– The pressure must not exceed 0.5 bar.


• A small amount of air escapes through the valves and enters
the engine and the exhaust gas recirculation cooler. Therefore
it is not possible to perform a pressure retention test.
• For operation of ultrasonic tester -V.A.G 1842- , refer to ⇒
Operating instructions .
– Check entire charge air system for leaks:
♦ By listening
♦ By feeling
♦ Using a commercially available leak detection spray
If no leak is found in the charge air system, check water-cooled
charge air cooler for leaks.

– Pressure must remain set to 0.5 bar.
rise.
that compressed air is escaping into the cooling system.
– Charge air cooler has a leak, renew intake manifold with
charge air cooler.
• If there are no leaks in the charge air cooler, a vacuum may
form when the coolant cools down. A minus sign on the tur‐
bocharger tester indicates that a vacuum has formed.


have entered.
connector .
-B-.
seconds.
Attaching
Tightening torques
tem”, page 140


1 Injection system
page 147

4-valve common rail); Rep. gr. 23 ; Injection system; Overview -
fuel system .

system
4-valve common rail); Rep. gr. 23 ; Injection system; Overview of
fitting locations - injection system .

must be bled.
Proceed as follows to fill high-pressure pump with fuel.

• Check fuel gauge in instrument cluster; fuel gauge needle
must indicate that fuel is above reserve level.
♦ Drive train

♦ Activate fuel pump

♦ Press Carry out check
♦ Select 120 seconds.
– The fuel pump must run for 120 seconds to ensure that the
fuel system is filled sufficiently with fuel.
– Start engine after filling fuel system.
– Run engine at moderate speed for several minutes and then
switch off.
– Erase entry in event memory.

Procedure
automatically.
renewed.

2 Vacuum system

4-valve common rail); Rep. gr. 23 ; Vacuum system; Connection
diagram - vacuum system .

Procedure
♦ Cracks
– If an entry is stored in the event memory, check all vacuum
lines leading to the corresponding component and also check
the remaining vacuum lines leading to other components.
– If it is not possible to build up a vacuum with the hand vacuum
pump - VAS 6213- or if the vacuum pressure drops again im‐
mediately, check the hand vacuum pump and connecting
hoses for leaks.

3 Air cleaner
engine (2.0 ltr. 4-valve common rail); Rep. gr. 23 ; Air cleaner .

4 Intake manifold
153
2 - Bolt
3 - Bolt
4 - Bracket
air cooler
⇒ page 155
6 - Bolt
7 - Gasket
G811-
⇒ page 141
9 - Bracket
❑ For electrical wiring har‐
ness
pending on model
10 - Bolt
❑ 8 Nm
11 - Bolt
❑ 8 Nm
12 - Vacuum line
13 - Sealing plug
14 - Gasket

15 - Gasket
16 - Bolt
❑ Removing and installing ⇒ 4-cylinder TDI engine (2.0 ltr. 4-valve common rail); Rep. gr. 21 ; Charge air
system; Removing and installing charge air temperature sender
❑ 22 Nm
19 - Bracket
❑ For charge pressure sender - G31-
21 - Bolt
22 - Bolt
23 - Ball stud
24 - Bolt
❑ 8 Nm
25 - Connection
26 - Dowel pin
27 - Seal
29 - Spacer sleeve
30 - Rubber buffer
31 - Air pipe
32 - Bolt
33 - Seal
35 - Bolt
36 - Bolt
37 - Bracket

38 - Dowel pin
39 - Gasket
40 - Bolt
❑ 8 Nm
41 - Bolt
❑ 8 Nm
Intake manifold with charge air cooler - tightening torque and se‐
quence
angle.
– Tighten bolts in stages:
e
2. -1 … 10- Tighten to 20 Nm
3. -1 … 10- Turn 90° further
Bracket for intake manifold and bracket for throttle valve module
- tightening torques and sequence
Note
When installing bracket for intake manifold/bracket for throttle
valve module, it is very important to ensure that the bracket is not
bolted on while under tension.
e
1. -1, 3, 4, 5- Screw in hand-tight as far as stop
2. -1, 3, 4, 5- Tighten to 20 Nm
3. -2- Tighten to 10 Nm

module - J338-
Removing
– Remove coolant pipes (rear left) ⇒ 4-cylinder TDI engine, 2.0
ltr. 4-valve common rail; Rep. gr. 19 ; Coolant pipes; Remov‐
ing and installing coolant pipes .


-1, 2- to one side.

– Loosen hose clip -3- and move air pipe clear towards rear.
– Remove nut -1- and press bracket -2- with electrical wiring
– Remove bolt -3- and centre hex stud -5-, and detach support
-4- for throttle valve module - J338- .


2 - For charge air temperature sender before charge air cooler -
G810-
3 - For throttle valve module - J338-
– Remove bolts -1- and detach connection with throttle valve
module - J338- .
– Remove bolts -arrows- and disconnect throttle valve module -

J338- -item 2- from connection -1-.
Installing
– When fitting connection with throttle valve module - J338- , pay
attention to dowel pins.
– Install coolant pipes (rear left) ⇒ 4-cylinder TDI engine, 2.0 ltr.
4-valve common rail; Rep. gr. 19 ; Coolant pipes; Removing
and installing coolant pipes .
Tightening torques
tem”, page 140

Intake manifold and charge air cooler are combined as one unit.

♦ Bit XZN 10 - T10501-
Removing
– Remove coolant pipe (top left) ⇒ 4-cylinder TDI engine, 2.0

– Lift retaining clips -3-, detach coolant connection and place to
side.

– Unplug electrical connectors and move clear:

1 - For injectors
2 - For glow plugs ⇒ page 240
4 - For injector for reducing agent - N474-
5 - Remove electrical connector for charge pressure control sol‐
enoid valve - N75- from bracket and place to one side.
6 - For charge air temperature sender after charge air cooler -
G811-
7 - For high-pressure pump
8 - For coolant valve for cylinder head - N489-
– Press release tabs on both sides and detach vacuum hose

-3-, taking care not to damage it.
– Remove bolt -1- at vacuum line.
– Unplug electrical connector -arrow- from exhaust gas recircu‐

lation control motor - V338- and move electrical wiring clear.
Version without water level sender:

– Release hose clips -1- and detach fuel hoses.
– Unplug electrical connector -2- on fuel temperature sender -
G81- .
– Remove bolts -arrows- and place fuel lines to one side.


G81- .
– Remove bolts -arrows- and place fuel lines to right side.


– Using bit XZN 10 - T10501- , slacken and remove bolts in the

sequence: -10 ... 1-.
Installing
necessary.
– Fit new gasket onto dowel pins in cylinder block.
– Fit intake manifold onto dowel pins in cylinder block and tight‐
en bolts.
note the following:
– Install coolant pipe (top left) ⇒ 4-cylinder TDI engine, 2.0 ltr.
– Install high-pressure pipe ⇒ page 175 .
Tightening torques

(rail)
page 164
page 167
speed”, page 170
page 178

the injectors are tightened to the specified torque
⇒ Item 8 (page 161) after installing the high-pressure pipes. If
these instructions are not observed, the engine could be dam‐
aged.

1 - Seal
⇒ page 74
2 - Copper seal
❑ Always renew copper
seal when removing and
installing
❑ Copper seal without
chamfer: has no speci‐
fied installation position
❑ Copper seal with cham‐
fer: note installation po‐
sition ⇒ page 162
3 - O-ring
4 - Injector
❑ Use a coloured pen to
mark allocation of injec‐
tors to corresponding
clamping piece and
high-pressure pipe, and
to corresponding cylin‐
der for re-installation;
pay attention to mark‐
ings when installing
❑ Renew copper seal after
removing
❑ To remove carbon de‐
posits from the injector
sealing surface, clean
the injector bore in the
cylinder head with
cleaning kit - VAS 6811-
(it is important to do this
to avoid leaks)
5 - O-ring
❑ To fuel tank
❑ Must not be kinked, damaged or clogged
❑ Fill and bleed fuel system after renewing ⇒ page 147
7 - Clamping piece
❑ Use a coloured pen to mark injectors and corresponding clamping piece and cylinder for re-installation;
pay attention to markings when installing
❑ The clamping pieces can be re-used when installing new injectors
❑ Each clamping piece secures two injectors
8 - Bolt
❑ Tighten initially to 2 Nm, then screw on union nuts for high-pressure pipes hand-tight and align injectors
❑ 8 Nm + 270° (3x 90° further)

❑ 28 Nm
10 - Grommet
Note installation position for copper seal with chamfer:
Installation position of clamping piece

• Each clamping piece secures two injectors.
• The bulge -arrow- of the clamping piece should point down‐
wards.

5.2 Exploded view - high-pressure reservoir (rail)
1 - Bolt
❑ 8 Nm
pump and high-pres‐
sure reservoir (rail)
❑ Observe all instructions
for installing high-pres‐
sure pipes ⇒ page 175
❑ 28 Nm
G247-
⇒ page 186
❑ 100 Nm
reservoir and injectors
❑ Observe all instructions
for installing high-pres‐
sure pipes ⇒ page 175
❑ 28 Nm
(rail)
⇒ page 178
6 - Bolt
❑ 20 Nm
7 - O-ring
❑ Reset learnt values after renewing ⇒ Vehicle diagnostic tester, Guided Functions , 01 - Reset learnt
values
❑ 80 Nm
12 - Fuel lines
13 - Bolt
❑ 8 Nm

❑ 2 Nm
15 - O-ring

There are four different tests for checking the operation of the
injectors.
♦ ⇒ “5.4 Performing adaption of correction values for injectors”,
page 164
♦ ⇒ “5.6 Checking return flow rate of injectors with engine run‐
ning”, page 167
speed”, page 170
Perform the following tests first if the engine does not start at all:
speed”, page 170
♦ ⇒ “7.4 Checking fuel pressure regulating valve N276 ”,
page 188 .

ues for injectors
♦ The “Injector delivery calibration” and “Injector voltage cali‐
bration” serve to correct the injection rates for each cylinder of
a common rail system individually across the entire operating
range.
♦ The 7-digit adaption values are marked on each injector. The
values may consist of letters and/or numbers.

Injector (view from above)

1- Adaption value (checksum; details in illustration are only an
example)
2- Data matrix code
3- Part number

– Perform adaption ⇒ Vehicle diagnostic tester.
– When a new injector is installed, the adaption value for the new
injector must be stored in the engine control unit.
– Additionally, check that the “Injector delivery calibration val‐
ues” with “Injector voltage calibration values” are correctly
entered for all the other injectors. Do NOT attempt to re-enter
these values if the correct values are already stored in the en‐
gine control unit.
– When the engine control unit is renewed, the appropriate “In‐
jector delivery calibration values” with “Injector voltage cali‐
bration” values must be written into the new engine control
unit.

If one of the injectors is sticking open, this means that the injector
needle is not closing fully and fuel escapes into the cylinder.

Procedure


– Clean all connections (with commercial cleaning solution or
similar) before removing.
– Dry all components after cleaning.
Start with cylinder No. 1.
– Pull release tabs upwards -arrows- and pull return line con‐
nections -1- off injectors.

– Connect adapter -arrow- of return flow meter - VAS 6684- to

return line connection of injector to be tested after adapter has
been cleaned and blown out.
– Generate a vacuum of -500 mbar using the hand vacuum
pump - VAS 6213- .
• If the vacuum reading remains the same for 30 seconds, the
injector is OK.
• If the injector is faulty, the vacuum reading will fall back to 0 bar
within 2 to 3 seconds.
– Repeat test if necessary; note drop in vacuum reading on hand
vacuum pump - VAS 6213- .
– Renew faulty injectors ⇒ page 172 .
deformation.
stalling.
– Push return line connections carefully over seals and onto in‐
jectors. The catch should engage audibly. Then press release
pin down carefully.
er.
automatically.

with engine running
Checking return flow rate of all injectors
Procedure

– Disconnect hose at non-return valve -1-.

– Seal off open return hose with clean plug -2- from engine bung
set - VAS 6122- .
– Hold end of fuel return hose (lengthen if necessary) in a meas‐
uring container to measure the total return flow rate.
– Start engine and run at idling speed for two minutes.
• Specification for 2 minutes: 0 ml to 50 ml
– If specification is attained, increase engine speed to 2000 ...
2500 rpm for approx. 2 minutes and then check return flow rate
again.
• Specification for 2 minutes: less than 250 ml
Note:
1000 ml = 1 litre
If specification is exceeded, this indicates that one or more injec‐
tors are defective. Check return flow rate of each individual injec‐
tor.
Checking return flow rate of individual injectors

♦ Return flow meter - VAS 6684-

cleaner and dry.

– Clamp off fuel return hose -arrow- with a hose clamp -3094- .
NOTICE
Risk of damage to injectors when return lines are disconnected.
– Do NOT press the accelerator during this test; the engine
must only run at idling speed.
– Start engine and run at idling speed for several minutes:

more than a small amount (example -1-).
1- Injectors OK. Return flow rate approx. identical on all injec‐
tors.
2- Injector for cylinder 3 not OK. Return flow rate greater than
three times the volume of smallest measured return flow
rate.
Note
There is a mechanical fault at the injector if the return flow rate is

greater than three times the volume of the smallest measured
return flow rate.
– If one injector has a significantly higher return flow rate than

the others (example -2-), it must be renewed ⇒ page 172 .
deformation.
stalling.
carefully.
er.
automatically.

Only perform this test if the engine does not start at all.

♦ Return flow meter - VAS 6684-
Procedure
system ⇒ page 6 .
cleaner and dry.
– Connect hoses of return flow meter - VAS 6684- to return line
connections of all four injectors.
– Operate starter three times (wait approx. 20 seconds each
time after operating starter to prevent it from overheating).
– If fuel comes out of an injector, that injector must be renewed.
deformation.
stalling.
carefully.
er.
automatically.


♦ Cleaning kit - VAS 6811-
♦ Puller - T10055-
♦ Assembly sleeve - T10377-
♦ Puller - T10415-
Removing
system ⇒ page 6 .


– Unplug electrical connectors -arrows- at injectors.

– Unscrew union nut on corresponding high-pressure pipe
(-1 to 4-) and detach corresponding high-pressure pipe.
– Seal off open lines and connections with clean plugs.

– Move electrical wiring harness clear and detach noise insula‐

tion.
Note:
Each clamping piece always secures two injectors and can only
be taken out if both injectors are removed.
– Unscrew bolt -1- and detach clamping piece.
• Sequence for removing injectors: First remove injector for cyl‐
inder 2, then for cylinder 1/cylinder 4, and then for cylinder 3.
– Apply puller - T10055- with puller - T10415- as shown in illus‐
tration, and pull out injectors upwards.
– Detach clamping piece before taking injector out.
Note:
To avoid damaging the sealing lip, rotate the injector while pulling
it out.
– Place removed injectors on a clean cloth.
Installing
NOTICE
Risk of damage to injector sealing surface if it is not cleaned
properly.
– To remove carbon deposits from the injector sealing surface,
clean the injector bore in the cylinder head with cleaning kit
- VAS 6811- .
Installing new injectors

When installing new injectors, the following components must be
renewed:
⇒ page 175 .
Installing used injectors
When re-installing used injectors, the following components must
be renewed:
♦ Copper seal
– Spray tip of injector nozzle with rust-solvent spray. Wait ap‐
prox. 5 minutes and wipe off soot particles and oil with a cloth.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.
– Clean off deposits under the copper seal using a suitable scra‐
per.
Continued (same procedure for used and new injectors):
– Fit new copper seal.

– Lubricate all O-rings with engine oil or assembly oil before in‐
stalling.
– Renew O-ring for injector bore using assembly sleeve -

T10377- .
– Install injectors.
note the following:
• Lubricate all O-rings with engine oil or assembly oil before in‐
stalling.
– Push the return line connections carefully over the new seals
and onto the injectors.
• The connection must engage audibly.
– Carefully press down release pin.
• After renewing one or more injectors, the “injector delivery cal‐
ibration values” and “injector voltage calibration values” for the
new injectors must be written into the engine control unit
⇒ page 164 .
Tightening torques

pipes
reservoir (rail) and high-pressure pump”, page 175
5.9.1 Removing high-pressure pipe between

high-pressure reservoir (rail) and high-
pressure pump

♦ Socket - T40055-
Removing
system ⇒ page 6 .
– Detach electrical connectors -2, 3, 4- from bracket and unplug
connectors.
pressure reservoir.
– Clean fuel pipe and end of pipe using cleaning solution and
dry with compressed air.

– Unscrew union nuts -arrows- and detach high-pressure pipe.


♦ Socket - T40055-
Installing
• Note identification marks for cylinder allocation when re-in‐
stalling high-pressure pipes.
• The high-pressure pipes can be re-used after performing the
following checks:
• Check taper seats of high-pressure pipes for deformation and
cracks.
• The bore of the pipe must not be distorted, restricted or oth‐
erwise damaged.
• Corroded pipes must not be used again.

NOTICE
High-pressure pipes must be free of tension when installed.
Risk of damage to high-pressure pipes.
– If necessary, the high-pressure reservoir can be slackened
and moved slightly so that the injector pipes are not installed
under tension.
– Never bend the high-pressure pipes or subject them to ten‐
sion.

pressure reservoir.
– Hand-tighten union nuts on high-pressure pipes (ensure that
pipes are not under tension).
– To tighten unions of high-pressure pipes at high-pressure res‐
ervoir and injectors, use torque wrench - V.A.G 1331- with
open end spanner insert, AF 17 - V.A.G 1331/6- or socket -
T40055- .
Tightening torques
page 163

reservoir (rail)
Removing
system ⇒ page 6 .
– Remove high-pressure pipe between high-pressure reservoir
(rail) and high-pressure pump ⇒ page 175 .
– Unplug electrical connectors and move clear:
1 - For turbocharger
2 - For injectors for cylinders 3, 4
3 - For glow plugs for cylinders 2, 3
4 - For charge air temperature sender after charge air cooler -
G811-
– Unplug electrical connector -5-, take charge pressure control
solenoid valve - N75- out of bracket and place to one side.
– Detach bracket for electrical wiring harness from high-pres‐
sure reservoir (rail) and place to one side.


– Release hose clip -3- and detach fuel return hose.
– Remove union nuts -1- for high-pressure pipes.
– Remove bolts -arrows- and detach high-pressure reservoir.
Installing
⇒ page 175 .
Tightening torques
page 163


⇒ page 21
2 - Bolt
❑ 3x
❑ Different lengths
❑ Different tightening tor‐
ques:
♦ Short bolt, 20 Nm + 45°
♦ Long bolt, 20 Nm + 180°
3 - Nut
ing and tightening
❑ 95 Nm
sprocket
5 - Hub
❑ To remove, use puller -
T10489-
- N290- (do not open)
⇒ page 181
❑ Reset learnt values after
renewing ⇒ Vehicle di‐
agnostic tester, Guided
Functions , 01 - Re-
set learnt values
❑ Between high-pressure reservoir (rail) and high-pressure pump
❑ Observe all instructions for installing high-pressure pipes ⇒ page 175
❑ 28 Nm


pump
♦ Puller - T10489-

Removing
system ⇒ page 6 .
– Remove high-pressure pipe between high-pressure reservoir
(rail) and high-pressure pump ⇒ page 175 .
– Apply counterhold tool - T10051- to high-pressure pump
sprocket.
– Detach locking pin - T10492- and slowly turn high-pressure
pump shaft to a position in which it is not under tension.
– Remove nut -arrow- and detach counterhold tool - T10051- .
– Detach high-pressure pump sprocket.
– Engage puller - T10489- at hub of high-pressure pump by

turning it clockwise.
– Detach hub of high-pressure pump.
– Disconnect fuel hoses -2-.

– Carefully take out high-pressure pump.
Installing
angle.
– Apply hub -arrow- to high-pressure pump shaft.
• The parallel key on the high-pressure pump shaft must engage
in the groove in the hub.

– Place high-pressure pump sprocket on hub.

• Contact surface between counterhold tool and toothed belt
sprocket must be free of oil.
– Screw nut -arrow- onto thread of high-pressure pump shaft.

– Apply counterhold tool - T10051- to high-pressure pump
sprocket and hand-tighten nut -arrow-.
– Turn high-pressure pump sprocket with counterhold tool -
T10051- until it can be locked in position with locking pin -
T10492- .
– To do so, insert locking pin - T10492- into fork -2- on hub and
into hole -1- behind it in bracket for ancillaries.
– Loosen nut -arrow- again.
• The high-pressure pump sprocket should still just turn, but
there must be no axial movement.
– Install high-pressure pipe ⇒ page 175 .


– Learnt values must be reset on engine control unit after re‐
newing high-pressure pump.
Select following menu options on ⇒ Vehicle diagnostic tester:


♦ Drive train
♦ 01 - Reset learnt values
Tightening torques


page 185
186
page 188
N276 ”, page 189
”, page 191
⇒ “7.7 Removing and installing exhaust gas pressure sensor 1
G450 ”, page 193

- G70-
4-valve common rail); Rep. gr. 23 ; Senders and sensors; Re‐
moving and installing air mass meter - G70- .

ture sender - G81-
Removing
Version 1:
– Release hose clips -arrows- and disconnect fuel return hoses.

Version 2:
– Unscrew fuel temperature sender - G81- -item 1-.
Installing
Tightening torques
page 163

sender - G247-
• The fuel pressure sender - G247- continuously measures the
fuel pressure in the high-pressure system. It transmits a cor‐
responding voltage signal to the engine control unit - J623- .
• Should the fuel pressure sender fail, the engine control unit
will control the fuel pressure via a mapped open-loop backup
function. Maximum engine speed in this mode is restricted.
• The fuel pressure sender - G247- does not have a seal; in‐
stead, it has a deformable sealing lip.
♦ Socket, 27 mm - T40218-
Removing

– Clean area all around fuel pressure sender - G247- with en‐
gine cleaner or brake cleaner and dry.
connector.
• Make sure no dirt gets into opening in high-pressure reservoir
(rail).
– Move electrical wiring and fuel hoses clear, and press them to
one side.
• Do not use an open-end spanner for loosening or tightening.
27 mm - T40218- .
– Seal off hole in high-pressure reservoir (rail) with a plug (thor‐
oughly cleaned) from engine bung set - VAS 6122- .
Installing
• If the deformable sealing lip and the thread of the fuel pressure
sender - G247- are not damaged, the sender can be re-used
once.
• The beginning of the thread and the deformable sealing lip of
the fuel pressure sender must be coated with diesel fuel.
– Screw in fuel pressure sender - G247- by hand until it makes
contact and then tighten.
Tightening torques
page 163
After installing fuel pressure sender - G247- , leave engine run‐
ning at moderate speed for a few minutes when bleeding fuel
• The fuel system is “self-bleeding”; do NOT open the high-
to correct torque.
Note:
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off the engine and erase the event memory. Then
continue the road test.


- N276-

Procedure
system ⇒ page 6 .
– Disconnect fuel return line from high-pressure reservoir and
seal off immediately with a plug (thoroughly cleaned) from en‐

– Connect test hose -2- to return line connection of high-pres‐

sure reservoir -1- and place end of hose in a measuring
container -3-.
• Specification: more than 75 ml in 30 seconds
If specification is not obtained, fuel pressure regulating valve -
N276- is defective.
If condition for 1) is met, start engine and increase engine speed
to ≥ 2000 rpm.
• Fuel is still discharged in the first few seconds after the engine
is started
• Specification after a few seconds: return flow rate = 0 ml
276- is defective.
3) If engine can no longer be started
Perform test with engine at cranking speed.
276- is defective.
Attaching

♦ Open-end spanner insert, 30 mm - T10553-

Removing
– Remove high-pressure reservoir (rail)
page 178 .
– Before removal, clean area around thread for fuel pressure
regulating valve - N276- using e.g. commercial cleaning solu‐
tion.
• Make sure no dirt gets into opening in high-pressure reservoir.
connector.
– Dry off fuel pressure regulating valve - N276- .
Note
The high-pressure reservoir can be clamped in a vice in order to

remove the pressure regulating valve; however, it is essential that
protective jaw covers are used. Do NOT take up the weight of the
high-pressure reservoir by the threaded connections for the high-
pressure pipes or the retaining tabs for the cylinder head.
– Mark installation position of connector of fuel pressure regu‐

lating valve - N276- relative to high-pressure reservoir.
– Unscrew fuel pressure regulating valve - N276- -item 2- from
high-pressure reservoir -1- using insert tool (30 mm) -
T10553- .
– Extract dirt from opening in high-pressure reservoir (thread
and sealing surface) using a vacuum cleaner. Do not use met‐
al tools, etc.
– Seal off open connection in high-pressure reservoir with clean
plug.
Installing
• Renew fuel pressure regulating valve - N276- after removing.
new regulating valve are not damaged.
• Coat beginning of thread, deformable sealing lip and O-ring of
regulating valve lightly with diesel fuel.

– Tighten fuel pressure regulating valve - N276- -item 2- using

insert tool (30 mm) - T10553- .
– Turn valve body to align connector of fuel pressure regulating
valve - N276- with high-pressure reservoir according to mark
made previously.
– If necessary, turn valve body to align regulating valve so that
connecting wire is free of tension after connector is attached.
– Learnt values must be reset in engine control unit after re‐
newing high-pressure pump or fuel pressure regulating valve
- N276- .
♦ Drive train
After installing fuel pressure regulating valve - N276- , leave en‐
gine running at moderate speed for a few minutes to bleed fuel
Note
♦ The fuel system is “self-bleeding”; do NOT open the high-
– Interrogate event memory.
to correct torque.
Tightening torques
page 163


The pressure differential sender - G505- detects the amount of

deposits in the particulate filter.
Removing
– Spray hose -2- with suitable release agent before disconnect‐
ing it from pressure differential sender - G505- .
NOTICE
breaks off.
keep hose straight.
– Disconnect hoses -2-.

Installing
• Before installing, blow out control pipes from pressure differ‐
ential sender - G505- to particulate filter towards particulate
filter with compressed air (pipes can become obstructed or
may ice up due to condensation).
leaks.
– Learnt values must be reset on engine control unit after re‐
newing pressure differential sender - G505- .
♦ Drive train
Tightening torques


pressure sensor 1 - G450-
Removing
– Remove bolt -1- and detach exhaust gas pressure sensor 1 -
G450- from bracket.
– Before disconnecting hoses from exhaust gas pressure send‐
er 1 - G450- , spray hoses with suitable release agent.
NOTICE
breaks off.
keep hose straight.
Installing
• Before installing, blow out control pipes from exhaust gas
pressure sensor 1 - G450- to particulate filter towards partic‐
ulate filter with compressed air (pipes can become obstructed
or may ice up due to condensation).
leaks.
– Learnt values must be adapted on engine control unit after
renewing exhaust gas pressure sensor 1 - G450- .
♦ Drive train
Tightening torques

8 Lambda probe
⇒ “8.3 Removing and installing NOx sender”, page 197

• Observe safety precautions when working on the exhaust sys‐
tem
⇒ “2.5 Safety precautions when working on the exhaust sys‐
tem”, page 3 .

sender 1 - G235-
⇒ page 222
❑ Coat with high-tempera‐
ture paste ⇒ Electronic
parts catalogue
❑ 45 Nm
sender 4 - G648-
⇒ page 226
❑ The thread of the ex‐
sender is coated; it must
not additionally be
greased with high-tem‐
perature paste
❑ 60 Nm
installing NOx sender
G295 with control unit
for NOx sender J583 ”,
page 197
❑ 55 Nm
❑ Not fitted on all country-
specific versions
stalling exhaust gas re‐
circulation temperature
sensor G98 ”, page 237
❑ 20 Nm
5 - Bolt
❑ 8 Nm
6 - Bolt
❑ 8 Nm

8 - Bolt
❑ 8 Nm
❑ After renewal, perform adaptions listed in Guided Function 01 - Functions component replace-
ment ⇒ Vehicle diagnostic tester
10 - Bracket
❑ For pressure differential sender
❑ New Lambda probes are coated with an assembly paste
❑ If you are re-using Lambda probe, coat only thread with high-temperature paste; refer to ⇒ Electronic
parts catalogue for high-temperature paste
❑ 55 Nm
❑ The thread of the exhaust gas temperature sender is coated; it must not additionally be greased with
❑ 60 Nm
⇒ “8.3.1 Removing and installing NOx sender G295 with control unit for NOx sender J583 ”, page 197
❑ 60 Nm
NOx sender 2 - G687- with control unit for NOx sender 2 - J881-
May be fitted depending on emission standard.
Tightening torque: 55 Nm
⇒ “8.3.2 Removing and installing NOx sender 2 G687 with control
unit for NOx sender 2 J881 ”, page 199

8. Lambda probe 195

♦ Socket AF 22 mm - T10491-
Removing
tem
tem”, page 3 .
– Take electrical connector -3- for Lambda probe - G39- out of
bracket, unplug and move wiring clear.

– Unscrew Lambda probe - G39- -arrow- using socket AF 22 mm

- T10491- .
Installing
• Threads of new Lambda probes are already coated with as‐
sembly paste; the paste must not get into the slots on the probe
body.
slots on the Lambda probe body. For high-temperature paste
refer to ⇒ Electronic parts catalogue
• When installing, the Lambda probe wiring must always be re‐
attached at the same locations to prevent it from coming into
contact with the exhaust pipe.
– Adaptions must be reset in engine control unit after renewing
Lambda probe - G39- .
♦ Drive train
Tightening torques
8.3 Removing and installing NOx sender

⇒ “8.3.1 Removing and installing NOx sender G295 with control
unit for NOx sender J583 ”, page 197
⇒ “8.3.2 Removing and installing NOx sender 2 G687 with control
unit for NOx sender 2 J881 ”, page 199

G295- with control unit for NOx sender -
J583-
8. Lambda probe 197


Removing
tem
tem”, page 3 .
Version 1:
Version 2:
– Remove spreader rivet -1-, detach control unit for NOx sender

wiring clear.
Installing
Tightening torques


G687- with control unit for NOx sender
2 - J881-
May be fitted depending on emission standard.
Removing
CAUTION

– Release fasteners -arrows- and move control unit for NOx
sender 2 - J881- clear.

Installing
Tightening torques
♦ ⇒ page 195
8. Lambda probe 199


engine (2.0 ltr. 4-valve common rail); Rep. gr. 23 ; Engine control
unit .


4-valve common rail); Rep. gr. 26 ; Exhaust pipes/silencers; Ex‐
ploded view - silencers .

pipe
4-valve common rail); Rep. gr. 26 ; Exhaust pipes/silencers; Re‐
moving and installing front exhaust pipe .

4-valve common rail); Rep. gr. 26 ; Exhaust pipes/silencers; Sep‐
arating exhaust pipes/silencers .

4-valve common rail); Rep. gr. 26 ; Exhaust pipes/silencers; Re‐
moving and installing silencers .

4-valve common rail); Rep. gr. 26 ; Exhaust pipes/silencers;
Stress-free alignment of exhaust system .

Procedure
tem
tem”, page 3 .
– Plug tailpipes during leak test (e.g. with cloth or plug).
any leaks.


page 205
page 214

tem
tem
tem”, page 3 .
1 - Bracket
❑ For emission control
module
2 - Bolt
3 - Hose
❑ To exhaust gas pres‐
union nut: 45 Nm
4 - Bolt
5 - Bolt
❑ Diesel particulate filter
with oxidation catalytic
converter
⇒ page 205
ded Function 01 -
Functions component
replacement ⇒ Vehicle
diagnostic tester
7 - Bolt
8 - Measuring tube
❑ To pressure differential sender - G505-
❑ Additional measuring tube to exhaust gas pressure sensor 1 - G450-
❑ Tightening torque for union nut: 45 Nm

9 - Bolt
❑ 9 Nm
10 - Bolt
11 - Bolt
Tightening torque and sequence ⇒ page 127
12 - Turbocharger
13 - Bracket
❑ For emission control module
14 - Bolt
15 - Seal
❑ Fit on emission control module
Installation position of screw-type clip for emission control module

• Angle -α- = 20° ± 10°.

verter
Removing
tem
tem”, page 3 .
– Remove underbody trim ⇒ General body repairs, exterior;
Rep. gr. 66 ; Underbody trim; Exploded view - underbody trim .


J883- -item 2-.
– Loosen bolts -arrows-, push back clamp and detach catalytic

converter.
Installing
• Renew seals and nuts after removing.
Tightening torques


trol module
♦ The emission control module is secured to the engine in part
by a compensation element. This compensation element has
a left-hand thread on the outside. When the bolt -1- is screwed
in, the friction against the retaining tabs -3- initially causes the
compensation element -2- to turn as well. Even though the bolt
is turned clockwise, the left-hand thread causes the compen‐
sation element to move towards the bolt head, which com‐
pensates for the play between the components. The compen‐
sation element must rotate freely on the left-hand thread,
otherwise the retaining tabs will not produce enough friction
on the bolt to turn the compensation element. To avoid im‐
pairing the required friction, ensure that the retaining tabs do
not come in contact with any lubricant.

♦ Socket (8 mm) - 3247-
♦ Calibration tool - T10512-
Removing
tem
tem”, page 3 .


– Move coolant hoses -4- and SCR supply line -3- clear.
– Detach injector for reducing agent - N474- and place to left
side.
– Detach electrical connectors from bracket, unplug connectors

and move electrical wiring clear:
2 - For exhaust gas temperature sender 3 - G495-
3 - For Lambda probe - G39-
4 - For exhaust gas temperature sender 2 - G448-
Version 1:

Version 2:
– Remove spreader rivet -1-, detach control unit for NOx sender

– Release hose clip -3- and detach hose.
– Remove bolt -1- and push measuring tube -2- to side.
– Remove union nut -2- and bolt -1- and move measuring tube
to one side.

using flared ring spanner tool insert (17 mm) - V.A.G 1331/10- .

– Support engine in installation position ⇒ 4-cylinder TDI engine

(2.0 ltr. 4-valve common rail); Rep. gr. 10 ; Assembly mount‐
ings; Supporting engine in installation position .
– Remove bolt -2- for engine mounting (right-side).
– Remove bolt -1- for support mounting (right-side).

– Unbolt drive shaft (right-side) from gearbox ⇒ Running gear,
axles, steering; Rep. gr. 40 ; Drive shaft; Removing and in‐
stalling drive shaft .
– Remove nut -3- and bolt -5- and push auxiliary pump for heat‐
ing - V488- clear to one side.

– Open clip -4- and place it on intake funnel of emission control

module.
– Remove bolts in the sequence: -5, 6, 2, 3- and slacken bolts
-1-.
– Use spindles -10-222A/11- to raise engine slightly (just far

enough so that emission control module can be removed).
– Lift out emission control module.
Installing
angle.
• Renew seals, self-locking nuts and screw-type clips for emis‐
sion control module after removal.
• Re-fit all cable ties and heat insulation sleeves in the same
locations when installing.
Installation requirements:
♦ Emission control module must be installed free of tension to
avoid risk of stress fractures and engine damage.
♦ Prior to installation, ensure that the compensation elements
move easily and do not stick.
♦ Compensation element must turn easily on its threads.
♦ Lubricant must only be applied to thread; retainer tabs must
remain free of lubricant.
♦ The retainer tabs for the bolt must be bent together so that
when the bolt is screwed in, the compensation element turns
as well.

– Check to ensure freedom of movement of compensation ele‐

ment -arrow-.
– Unscrew compensation element completely in clockwise di‐
rection (left-hand thread).
– Clean thread if it does not turn easily and lubricate lightly with
rust remover if necessary.
• Do not use any kind of lubricant on the retaining tabs of the
compensation element, as this will reduce the build-up of fric‐
tion and compromise the function of the compensation ele‐
ment.
– Adjust retainer tabs to functional dimension using calibration

tool -T10512/1-2- as follows:
– Slide compensation element -1- onto pin -T10512/1- , insert
into centring sleeve -T10512/2- and bend back retainer tabs
by gently striking -arrow- ball head with heel of your hand.
– Tighten compensation element -arrow- to 3 Nm and slacken

again by 90°.
• Renew seal -1- and screw-type clip -2- after removal.

– Fit seal -1- onto emission control module.
– Disengage screw on clip -2- and move clip all the way onto
intake funnel of emission control module. Do not bend clip
open.

– Guide emission control module into installation position.

– Insert bolt -arrow- to secure in place.
• Emission control module is now suspended approximately in
installation position with its weight supported.
Tightening sequence for emission control module

• Renew all securing bolts for emission control module after re‐
moval.
Stage Bolt Step
1. Screw-type Fit over sealing flange, engage screw
clip -4- and tighten to 1 Nm
2. Bolt -3- Tighten to 2 Nm and loosen immedi‐
ately by 90°
3. Screw-type Tighten to 7 Nm
clip -4-
5. Bolts -1- Tighten to 2 Nm and loosen immedi‐
ately by 90°
6. Bolts -2- Tighten to 2 Nm and loosen immedi‐
ately by 90°
– Remove bolt -arrow- previously inserted to secure in place.

– Using socket, 8 mm - 3247- , unscrew compensation element

(left-hand thread) -1- on cylinder head in direction of -arrow-
to 2 Nm until it makes contact, then turn 90° further.

Tightening sequence continued

Stage Bolt Step
11. Bolt -arrow- Insert and press until it engages
12. Bolt -arrow- Tighten to 20 Nm
13. Bolt -arrow- Turn 90° further
14. Bolt -arrow- Turn another 45° further
– Remove support mounting ⇒ 4-cyl. TDI engine (2.0 ltr. 4-valve
common rail); Rep. gr. 10 ; Assembly mountings; Supporting
engine in installation position .
following:
– Install exhaust gas temperature sender 1 - G235-
⇒ page 222 .
– Adaptions must be reset in engine control unit after renewing
emission control module.
♦ Drive train
♦ 01 - Functions, component replacement
Tightening torques
♦ Measuring tube
mountings
Removing and installing drive shaft


tem
tem”, page 3 .
Removing
– Unscrew bolts -arrows- and remove exhaust flap control unit -
J883- .
Installing
• Renew bolts and nuts after removing.
– Fit exhaust flap control unit.
• Coupling -1- must engage in retainer of exhaust flap -2-.
– Tighten upper bolt first, then tighten lower bolt.

– Remove protective cap for electrical connector and plug con‐
nector -1- in. Secure heat insulation sleeve if necessary.
Tightening torques
– Learnt values must be adapted in engine control unit after re‐
newing exhaust flap control unit - J883- .
♦ Drive train
♦ 01 - Functions, component replacement


system
”, page 217
⇒ “3.13 Adapting SCR learnt values”, page 219

4-valve common rail); Rep. gr. 26 ; SCR (selective catalytic re‐
duction) system; Exploded view - reducing agent tank .
3.2 Exploded view - control unit for SCR

system
duction) system; Exploded view - control unit for SCR system .
3.3 Exploded view - delivery unit

duction) system; Exploded view - delivery unit .
3.4 Exploded view - reducing agent supply line


⇒ page 205
2 - Screw-type clip
3 - Bolt
❑ 5 Nm
4 - Seal
N474-
⇒ page 217
❑ Lugs in injector for re‐
must be inserted in cor‐
responding mountings
❑ Adapt SCR learnt val‐
ues after filling up reduc‐
ing agent or renewing
components
⇒ “3.13 Adapting SCR
learnt values”,
page 219 .
6 - O-ring
7 - Supply line
❑ From reducing agent
pump - V437-
❑ With heater
❑ Clip onto fuel tank
❑ Disconnecting and con‐
necting plug-in connector ⇒ page 216
❑ Adapt SCR learnt values after filling up reducing agent or renewing components
⇒ “3.13 Adapting SCR learnt values”, page 219 .
8 - Coolant hoses
Disconnecting and connecting supply line - version with release

catch
Separating
• To prevent large amounts of reducing agent from escaping
when the supply line is opened, wait until the reducing agent
has been drawn back automatically ⇒ page 5 .
– To disconnect supply line, press release catches in direction
of -arrows-.
Connecting


♦ Safety goggles
Procedure
CAUTION
The SCR system is pressurised.
– Disconnect quick connector at reducing agent tank or supply

line - version with release catch ⇒ page 216 .

duction) system; Draining reducing agent tank .

tank
duction) system; Removing and installing reducing agent tank .


Removing
CAUTION

– Hold a clean cloth under separating point to catch escaping
reducing agent.
– Release pressure in SCR system ⇒ page 216 .
– Disconnect supply line -3- from injector for reducing agent -
N474- ⇒ page 216 .
– Release retaining clip -1- and detach injector for reducing
agent - N474- .
Installing
• Renew gasket and retaining clip after removing.
• Installation position: lugs in injector for reducing agent - N474-

-item 2- must be inserted -arrows- in corresponding mountings
in front exhaust pipe -1-.
– Connect supply line ⇒ page 216 .
– Adapt SCR learnt values after filling up reducing agent or re‐
newing components
⇒ “3.13 Adapting SCR learnt values”, page 219 .
Tightening torques
♦ ⇒ “3.4 Exploded view - reducing agent supply line”,
page 215

duction) system ; Removing and installing control unit for reducing
agent metering system - J880- .

3.10 Removing and installing pump for re‐

ducing agent - V437-
duction) system; Removing and installing pump for reducing
agent - V437- .
3.11 Removing and installing pressure send‐

er for reducing agent metering system -
G686-
duction) system; Removing and installing pressure sender for
reducing agent metering system - G686- .
3.12 Removing and installing connection for

SCR supply line
duction) system ; Removing and installing connection for SCR
supply line.
3.13 Adapting SCR learnt values

The learnt value in the engine control unit must be re-adapted
using the ⇒ Vehicle diagnostic tester if reducing agent has been
drained or any of the following components have been renewed:
♦ Reducing agent tank
♦ Injector for reducing agent
♦ Reducing agent line
♦ Engine control unit
♦ Control unit for reducing agent metering system - J880-
Adapting learnt values
♦ Drive train
♦ 01 - Adapt reduction agent system learned values
If control unit for reducing agent metering system - J880- was
renewed, use following function:

♦ 0001 - Reductant metering control unit, replace/

parameterise


page 221
G235 ”, page 222
G448 ”, page 223
G495 ”, page 225
G648 ”, page 226

sender 1 - G235-
⇒ page 222
❑ Coat with high-tempera‐
ture paste ⇒ Electronic
parts catalogue
❑ 45 Nm
sender 4 - G648-
⇒ page 226
❑ The thread of the ex‐
sender is coated; it must
not additionally be
greased with high-tem‐
perature paste
❑ 60 Nm
⇒ page 197
❑ 55 Nm
❑ Not fitted on all country-
specific versions
⇒ page 237
❑ 20 Nm
5 - Bolt
❑ 8 Nm
6 - Bolt
❑ 8 Nm
8 - Bolt
❑ 8 Nm


10 - Bracket
❑ For pressure differential sender
❑ New Lambda probes are coated with an assembly paste
❑ If you are re-using Lambda probe, coat only thread with high-temperature paste; refer to ⇒ Electronic
parts catalogue for high-temperature paste
❑ 55 Nm
❑ The thread of the exhaust gas temperature sender is coated; it must not additionally be greased with
❑ 60 Nm
❑ 60 Nm

Removing
tem
tem”, page 3 .
• When removing, the electrical wiring must not be cut, other‐


sender 1 - G235- from bracket, unplug connector and move

using flared ring spanner tool insert (17 mm) - V.A.G 1331/10- .
Installing
tem
tem”, page 3 .
• Coat thread with high-temperature paste ⇒ Electronic parts
catalogue .

G235- :
• Angled part of line -arrow- must point vertically downwards.
Tightening torques
221



Removing
tem
tem”, page 3 .

Installing


G448- :
• Angle -α- = 80°
Tightening torques
221

♦ Tool set - T10395 A-
♦ Supplement tool set - T10395/8-/10- with suitable tool insert

Removing
tem
tem”, page 3 .


Installing
– The threads of the exhaust gas temperature senders -G495-
and -G648- are coated. Do NOT lubricate additionally with
high-temperature paste.
Tightening torques
221


Removing
tem
tem”, page 3 .


sender 4 - G648- from bracket, unplug connector and move

Installing
– The threads of the exhaust gas temperature senders -G495-
and -G648- are coated. Do NOT lubricate additionally with
high-temperature paste.
Tightening torques
221


page 228
motor V338 ”, page 230
page 232
234
5.1 Exploded view - exhaust gas recirculation system

Exhaust gas recirculation control motor - V338-
1 - Bolt
❑ 9 Nm
G212-
⇒ page 230
❑ After renewing exhaust
gas recirculation control
motor - V338- , learnt
values must be re-adap‐
ted; see Guided Func-
tions of ⇒ Vehicle di‐
agnostic tester, 01 -
Functions component
replacement
3 - Coolant hoses
4 - Gasket
5 - Gasket
Exhaust gas recirculation control motor 2 - V339-

1 - Insulation mat
2 - Bolt
sequence ⇒ page 230 if
only exhaust gas recir‐
culation cooler was re‐
moved
3 - Nut
sequence ⇒ page 230 if
only exhaust gas recir‐
culation cooler was re‐
moved
4 - Washer
5 - Bracket
lation cooler
6 - Coolant hose
cooler
⇒ page 232
8 - Gasket
culation potentiometer 2
- G466-
⇒ page 231
❑ After renewing exhaust
gas recirculation control
motor 2 - V339- , learnt values must be re-adapted; see ⇒ Vehicle diagnostic tester, Guided Func-
tions , 01 - Functions component replacement
10 - Bolt
❑ 9 Nm
11 - Air hose
12 - Seal
13 - Coolant hose
14 - Bolt
❑ Tightening torque and sequence ⇒ page 230 if only exhaust gas recirculation cooler was removed

Exhaust gas recirculation cooler - tightening torque and sequence

Stage Bolts/nuts Tightening torque
1. -4- 20 Nm
2. -1, 2, 3- Screw in by hand until contact is made
3. -1, 2, 3- 20 Nm

circulation control motor - V338-
Removing
– Observe rules for cleanliness.
– Unscrew bolts -arrows- and detach exhaust gas recirculation
control motor - V338- -1-.
Installing
newing exhaust gas recirculation control motor - V338- .
♦ Drive train
Tightening torques
page 228


Removing
– Remove coolant pipe (rear right) ⇒ 4-cylinder TDI engine, 2.0
– Remove bolt -1- and move exhaust gas pressure sensor 1 -
G450- to side with hose -2- attached.

– Remove bolt -3- and move pressure differential sender -
G505- with bracket clear to one side.

move hose -2- clear.
– Detach pulsation damper -1-.


– Open hose clip -2- and detach intake connecting pipe -1-.

detach control motor 2 for exhaust gas recirculation - V339-
-item 1-.
Installing
• Renew insulation mat for control motor if damaged. Addition‐
ally check control motor for thermal damage and renew if
necessary.
– Install coolant pipe (rear right) ⇒ 4-cylinder TDI engine, 2.0 ltr.
newing exhaust gas recirculation control motor 2 - V339- .
♦ Drive train
Tightening torques
page 228

circulation cooler

♦ Bit XZN 10 - T10501-
Removing
– Remove exhaust gas recirculation control motor 2 - V339-
⇒ page 231 .
– Remove front exhaust pipe ⇒ page 201 .
– Country-specific version: Take electrical connector -2- out of
bracket, unplug it and move it clear.

– Remove bolt -3- and nut -2- and detach bracket.
– Unscrew bolts -4- using bit XZN 10 - T10501- .
– Detach exhaust gas recirculation cooler.
Installing
– Install exhaust gas recirculation control motor 2 - V339-
⇒ page 231 .

– Install intake connecting pipe -1- ⇒ page 125 .

– Tighten bolts securing exhaust gas recirculation cooler
⇒ page 230 .
Tightening torques
♦ ⇒ Fig. ““Exhaust gas recirculation cooler - tightening torque
page 228

cooler for leaks
♦ Adapter - V.A.G 1687/11-

♦ Adapter - V.A.G 1687/15- for exhaust pipes with 60 mm and
65 mm diameter
♦ Adapter - V.A.G 1687/16- for exhaust pipe with 55 mm diam‐
eter

Test condition:
• Coolant temperature must be at least 40°C.
005/5- .
nection »A«.
must be visible.

rear.

– On vehicles without tunnel cross-piece, exhaust pipe -1- must

be tied up with a tensioning strap -2-.
– Connect adapter - V.A.G 1687/11- with hose -A- to exhaust

pipe (engine end). Secure hose with hose clips.
Hose -A- for exhaust pipes with 55 mm diameter: Use hose -
V.A.G 1687/16- .
Hose -A- for exhaust pipes with 60 mm or 65 mm diameter:
Use hose - V.A.G 1687/15- .
– Connect charge air system tester - V.A.G 1687- to adapter -
V.A.G 1687/11- .

water.
– Open valve -3-.


rise.
that compressed air is escaping from the exhaust end into the
cooling system. There is a leak in exhaust gas recirculation
cooler; renew exhaust gas recirculation cooler.
• If there are no leaks in the exhaust gas recirculation cooler, a
vacuum may form when the coolant cools down. A minus sign
on the turbocharger tester indicates that a vacuum has
formed.

have entered.
connector .
-B-.
seconds.

♦ 14 mm socket wrench - 3150-
Removing
tem
tem”, page 3 .


to one side.

– Use socket, 14 mm - 3150- to unscrew exhaust gas recircu‐

lation temperature sensor - G98- -arrow-.
Installing
• Coat thread with high-temperature paste; for high-temperature
paste refer to ⇒ Electronic parts catalogue .
– Align exhaust gas recirculation temperature sensor - G98- with
as much clearance from surrounding components as possible.
Tightening torques
221


1 Glow plug system
J179 ”, page 243
243
1 - Glow plug
♦ Glow plug 1 - Q10- ; coun‐
try-specific version with cyl‐
G677-
G678-
♦ Glow plug 3 - Q12- with cyl‐
G679-
G680-
❑ Learnt values must be
reset in engine control
unit after renewing a
glow plug
❑ Glow plug versions and
tightening torques
⇒ page 240
⇒ page 240
3 - O-ring
❑ Renew Hall sender -
G40- if damaged
5 - Bolt
❑ 9 Nm
❑ With sender wheel for engine speed sender - G28-
❑ Cannot be dismantled


7 - Bolt
❑ 4.5 Nm
Glow plug versions and tightening torques

1 - Glow plug with combustion chamber pressure sender
♦ 12 Nm
2 - Glow plug without combustion chamber pressure sender
♦ 17 Nm

♦ Socket insert AF 12 for glow plugs 4-cyl.TDI CR diesel - VAS

6454- for glow plug with combustion chamber pressure sender

♦ Pliers - 3314-
Removing
NOTICE
Risk of damage to support sleeves when removing.
– Do not squeeze pliers - 3314- too firmly when removing glow
plug connectors.
– Release retaining clips at wiring harness and detach electrical

connectors from glow plugs as follows.
– Apply groove -arrow A- of pliers - 3314- to collar of support
sleeve -arrow B- as shown in illustration.
– Carefully detach glow plug connectors from glow plugs.
– Clean glow plug opening to make sure no dirt gets into cylin‐
ders; note the following:
CAUTION
♦ Use a vacuum cleaner to remove coarse dirt.

♦ Spray brake cleaner or suitable cleaning agent into glow plug
apertures, let it work in briefly, and blow out with compressed
air.
♦ Clean glow plug opening with an oily cloth.
– Loosen glow plugs using tool and unscrew by hand:

♦ Use U/J extension and socket, 10 mm - 3220- for glow plugs

without combustion chamber pressure sender.
♦ Use socket insert AF 12 for glow plugs 4-cyl.TDI CR diesel -

VAS 6454- for glow plugs with combustion chamber pressure
sender.
Installing
– Fit glow plug connectors -1- back onto glow plugs -arrow-.
• Check that glow plug connectors are securely seated.
newing a glow plug.
♦ Drive train
Tightening torques
♦ ⇒ Fig. ““Glow plug versions and tightening torques”“ ,
page 240


4-valve common rail); Rep. gr. 28 ; Glow plug system; Removing
and installing automatic glow period control unit - J179- .

G40-
Removing
– Unscrew bolt -1- and detach Hall sender - G40- .
Installing
Tightening torques

sender - G28-
♦ Socket (4 mm) - T10370-
Removing

– Use assembly tool - T10118- to unplug electrical connector

-1-.
Installing
Tightening torques

Service
Workshop Manual
Audi A4 2015 ➤ , Audi A5 2016 ➤ ,
Audi A8 2018 ➤ , Audi Q5 2017 ➤ ,
Audi Q5 China 2019 ➤ , Audi Q7 2016 ➤ ,
Audi Q8 2018 ➤
Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve
TFSI EA 839
Engine ID
CWG DEC CZS DLZA DKM CZS DCB DCB
D A E B A D E
Edition 02.2019

Service
Repair Group
00 - Technical data
17 - Lubrication
19 - Cooling
26 - Exhaust system

Copyright © 2019 Audi AG, Ingolstadt D4B80641D39

Audi A4 2015 ➤ , Audi A5 2016 ➤ , Audi A6 2019 ➤ , Audi A6 China 2019 ➤ ...
Servicing 6-cylinder engine, 2.9 ltr., 3.0 ltr. 4-valve TFSI EA 839 - Edition 02.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Safety precautions when working on the high-voltage system . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions when working in the vicinity of high-voltage components . . . . . . . . . . 3

2.3 Renewing crankshaft oil seal (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.7 Checking sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.8 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4 Balance shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Contents i

4.3 Renewing roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

2 Chain drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.2 Exploded view - drive chain for oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.3 Removing camshaft timing chain from camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.5 Removing and installing chain tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
5.2 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.5 Removing and installing oil baffle plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.3 Removing and installing spray nozzle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3.2 Removing and installing crankcase breather module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
ii Contents

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.8 Removing and installing engine outlet coolant temperature sender G82 . . . . . . . . . . . . . . 222
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
1 Turbochargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.4 Removing and installing temperature sender for engine cover panel G765 . . . . . . . . . . . . 258
2.3 Removing and installing air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
2.8 Removing and installing overrun air recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
3 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
4 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Contents iii

5 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
6.1 Exploded view - actuator for structure-borne sound and control unit for structure-borne
sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
6.2 Exploded view - pressure differential sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
6.3 Removing and installing actuator for structure-borne sound R214 . . . . . . . . . . . . . . . . . . 304
6.4 Removing and installing control unit for structure-borne sound J869 . . . . . . . . . . . . . . . . 304
G71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
6.8 Removing and installing pressure differential sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
8 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
iv Contents
1 Identification
(ARL006256; Edition 02.2019)

Engine number
♦ Pull off engine cover panel and heat shield to make engine
number visible.
♦ The engine number is located at the top rear of the cylinder
block.
1- Serial number
2- Engine code
ers.
Engine data
For allocation of engine code, refer to ⇒ Technical data for en‐
gines; Rep. gr. 00 ; Overview of engines .
1. Identification 1
⇒ “2.1 Safety precautions when working on the high-voltage sys‐
tem”, page 2
⇒ “2.2 Safety precautions when working in the vicinity of high-
voltage components”, page 3
tem”, page 3
page 4
page 4
page 5
page 5
2.1 Safety precautions when working on the high-voltage system

hazard. Danger of severe or fatal injuries from electric shock.
– Persons with life-sustaining or other electronic medical devi‐
ces in or on their body must not perform any work on the high-
voltage system. Such medical devices include internal anal‐
gesic pumps, implanted defibrillators, pacemakers, insulin
pumps and hearing aids.
– The high-voltage system must be de-energised by a suitably
qualified person.

It is difficult to determine whether the drive system of an electric
vehicle or hybrid vehicle is active. Moving parts can trap or draw
in parts of the body.
– Deposit the ignition key outside of the vehicle.
Risk of damage to high-voltage wiring

Incorrect handling may result in damage to the insulation of high-
voltage wires or high-voltage connectors.
– Never use high-voltage wiring or high-voltage connectors as
a support.
– Never support tools or equipment on high-voltage wires and
high-voltage connectors.
– High-voltage cables must not be excessively bent or kinked.

– Pay attention to coding when connecting high-voltage con‐

nections.
Risk of injury if auxiliary air conditioner is activated

On electric and hybrid vehicles, the auxiliary air conditioner can
switch itself on if it has been activated. The radiator fans can start
up automatically and trap or draw in parts of the body.
– Deactivate auxiliary air conditioner.
2.2 Safety precautions when working in the vicinity of high-voltage components

hazard. Danger of severe or fatal injuries from electric shock if
high-voltage components or high-voltage wiring are damaged.
– Carry out a visual check of high-voltage components and high-
voltage wiring.
– Never use cutting/forming tools or other sharp-edged imple‐
ments.
– Never perform work using welding, brazing, thermal bonding
or hot air.

may spray out.

fuel pump.

a road test
Or:
seat.

tached.




wiring.


incorrectly.

7

opening.
♦ Before removing injectors, clean surrounding area and blow
out with compressed air if necessary. Wear safety goggles to
do this.
that have been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).

♦ In the event of mechanical damage to one of the cylinder
banks, the intake and exhaust systems and combustion cham‐
bers of the opposite cylinder bank must always be examined
for foreign particles to prevent further damage occurring later.
⇒ page 242

fitted.

Please note:
ranty.

and wiring
♦ After attaching, check the routing of the fuel lines and refrig‐
erant lines. They must be inserted in the retainers provided
and should not make contact with other components.


– Allow engine to run for several minutes at moderate rpm.
renewed.


gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 10 ; Removing and
installing engine .

direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 10 ;
Assembly mountings .


panel


Removing heat shield

– Remove ball studs and bolts -arrows- and detach heat shield
-1-.
Installing
WARNING
Danger of fire and damage if the heat shield/engine cover pan‐

el is not fitted.
♦ The heat shield and the engine cover panel must always
be fitted before the bonnet is closed.
♦ If the heat shield and engine cover panel are not fitted, it
is not permissible to start the vehicle with the bonnet
closed or drive the vehicle.

and dipstick.
Tightening torques

page 30
page 38
43

end)
⇒ “1.1.1 Exploded view - cylinder block (pulley end), alternator
belt drive, vehicles with 2.9 ltr./3.0 ltr. engine”, page 12
⇒ “1.1.2 Exploded view - cylinder block (pulley end), starter-al‐
ternator belt drive, vehicles with 3.0 ltr. engine”, page 15
⇒ “1.1.3 Exploded view - cylinder block (pulley end), air condi‐
tioner compressor belt drive, vehicles with 2.9 ltr. engine without
electric compressor”, page 17
tioner compressor belt drive, vehicles with 2.9 ltr. engine with
electric compressor”, page 18
tioner compressor belt drive, vehicles with 3.0 ltr. engine”,
page 19
1.1.1 Exploded view - cylinder block (pulley end), alternator belt drive, vehicles
with 2.9 ltr./3.0 ltr. engine

1 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Belt routing
⇒ Fig. ““Belt routing for
alternator”“ , page 14
stalling poly V-belts”,
page 24
on pulleys.
2 - Bolt
❑ 25 Nm
3 - Cover
4 - Idler roller
❑ For poly V-belt
5 - Bolt
6 - Bolt
❑ 8 Nm +45°
7 - Tensioner
❑ For poly V-belt
installing poly V-belt tensioner for alternator - vehicles with 2.9 ltr./3.0 ltr. engine”, page 30
8 - Bolt
9 - Alternator
10 - Bracket
❑ For alternator
❑ Removing and installing ⇒ “1.6.1 Removing and installing bracket for alternator”, page 38
11 - Bolt
⇒ Fig. ““Bracket for alternator - tightening torques and sequence”“ , page 14
12 - Dowel sleeves
13 - Pulley
15 - Bolt

❑ 150 Nm +90°
Belt routing for alternator

1- Alternator
2- Idler roller
3- Coolant pump
4- Vibration damper
Bracket for alternator - tightening torques and sequence

angle.
tion
1. -arrows- 8 Nm in diagonal sequence
2. -arrows- Turn 90° further in diagonal sequence

1.1.2 Exploded view - cylinder block (pulley end), starter-alternator belt drive, ve‐
1 - Bolt
❑ 40 Nm
2 - Tensioner
❑ For poly V-belt
installing poly V-belt
tensioner for starter-al‐
ternator - vehicles with
2.9 ltr./3.0 ltr. engine”,
page 31
3 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Belt routing
starter-alternator”“ ,
page 16
installing poly V-belt for
starter-alternator - vehi‐
page 26
on pulleys.
4 - Pulley
5 - Bolt
Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
6 - Nut
7 - Threaded pin
9 - Bracket
❑ Removing and installing ⇒ “1.6.2 Removing and installing bracket for starter-alternator”, page 39
10 - Bolt
⇒ Fig. ““Bracket -1- for starter-alternator - tightening torque and tightening sequence”“ , page 16
11 - Dowel sleeves
12 - Bracket

13 - Bolt
❑ 25 Nm
14 - Idler roller
❑ For poly V-belt
15 - Bolt
❑ 40 Nm
16 - Cover
18 - Bolt
❑ 150 Nm +90°
Belt routing for starter-alternator

1- Starter-alternator
2- Tensioning roller (top)
3- Idler roller
4- Coolant pump
5- Vibration damper
6- Tensioning roller (bottom)
Bracket -1- for starter-alternator - tightening torque and tightening

sequence
Stage Bolts Tightening torques

1.1.3 Exploded view - cylinder block (pulley end), air conditioner compressor belt
drive, vehicles with 2.9 ltr. engine without electric compressor
1 - Bolt
Heating, air condition‐
ing; Rep. gr. 87 ; Air
conditioner compressor;
Exploded view - air con‐
ditioner compressor
drive unit
2 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Belt routing
air conditioner compres‐
sor, vehicles with 2.9 ltr.
engine”“ , page 18
sor - vehicles with 2.9 ltr.
engine”, page 28
on pulleys.
3 - Bolt
❑ 25 Nm
4 - Idler roller
❑ For poly V-belt
5 - Bolt
❑ 40 Nm
6 - Tensioner
❑ For poly V-belt
⇒ “1.4.3 Removing and installing poly V-belt tensioner for air conditioner compressor - vehicles with 2.9
7 - Bolt
9 - Bolt
⇒ Fig. ““Bracket for air conditioner compressor - tightening torques and sequence, vehicles with 2.9 ltr.

10 - Dowel sleeves
11 - Bolt
12 - Bracket
⇒ “1.6.3 Removing and installing bracket for air conditioner compressor - vehicles with 2.9 ltr. engine
without electric compressor”, page 39
Belt routing for air conditioner compressor, vehicles with 2.9 ltr.
engine
1- Vibration damper
4- Idler roller
Bracket for air conditioner compressor - tightening torques and

sequence, vehicles with 2.9 ltr. engine
tion
2. -2, 3- 22 Nm
1.1.4 Exploded view - cylinder block (pulley

end), air conditioner compressor belt
drive, vehicles with 2.9 ltr. engine with
electric compressor
gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 13 ; Cylinder block
(pulley end); Exploded view - cylinder block (pulley end) .

1.1.5 Exploded view - cylinder block (pulley end), air conditioner compressor belt
drive, vehicles with 3.0 ltr. engine
1 - Cover
2 - Bolt
❑ 25 Nm
3 - Idler roller
❑ For poly V-belt
4 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Belt routing
sor, vehicles with 3.0 ltr.
sor - vehicles with 3.0 ltr.
engine”, page 28
on pulleys.
5 - Cover
❑ For tensioner
6 - Bolt
❑ 25 Nm
7 - Tensioner
❑ For poly V-belt
⇒ “1.4.4 Removing and installing poly V-belt tensioner for air conditioner compressor - vehicles with 3.0
8 - Bolt
10 - Dowel sleeve
❑ 2x
11 - Bracket
⇒ “1.6.5 Removing and installing bracket for air conditioner compressor - vehicles with 3.0 ltr. engine”,
page 40
12 - Bolt


14 - Bolt
15 - Dowel sleeves
16 - Bolt
Belt routing for air conditioner compressor, vehicles with 3.0 ltr.
engine
1- Vibration damper
4- Idler roller
Bracket for air conditioner compressor - tightening torques and

sequence, vehicles with 3.0 ltr. engine
angle.
tion
2. -2, 3- 8 Nm

1.1.6 Exploded view - cylinder block (pulley end), vehicles with high-voltage sys‐
tem
1 - Bracket
2 - Bolt
❑ 8 Nm +90°
3 - Pulley
4 - Dowel sleeve
5 - Bracket
❑ For air conditioner com‐
pressor
installing bracket for air
- vehicles with high-volt‐
age system”, page 41
6 - Bolt
❑ 22 Nm
7 - Bolt
❑ 22 Nm
8 - Bolt
❑ Tightening torques: Ex‐
ploded view - drive unit
for electrically driven air
⇒ Heating, air condi‐
tioning; Rep. gr. 87 ; Air
conditioner compressor;
Exploded view - air con‐
ditioner compressor
drive unit
❑ Removing and installing electrically driven air conditioner compressor ⇒ Heating, air conditioning; Rep.
gr. 87 ; Air conditioner compressor; Removing and installing air conditioner compressor
10 - Bolt
11 - Poly V-belt
❑ Check for wear
❑ Do not kink
❑ Belt routing ⇒ Fig. ““Belt routing for coolant pump - vehicles with high-voltage system”“ , page 22
⇒ “1.3.7 Removing and installing poly V-belt for coolant pump - vehicles with high-voltage system”, page
29
❑ When installing, make sure it is properly seated on pulleys.
⇒ “1.5.3 Removing and installing vibration damper - vehicles with high-voltage system”, page 36

13 - Bolt
14 - Bolt
❑ 40 Nm
15 - Tensioner
❑ For poly V-belt
⇒ “1.4.5 Removing and installing tensioner for poly V-belt for coolant pump - vehicles with high-voltage
system”, page 32
Belt routing for coolant pump - vehicles with high-voltage system

2- Coolant pump
3- Vibration damper

1 - Oil seal
end)
❑ Renewing
end)”, page 42
stalling sealing flange
(pulley end)”, page 43
3 - Bolt
sequence
⇒ Fig. ““Sealing flange
(pulley end) - tightening
torques and se‐
4 - Dowel sleeve
5 - Bolt
❑ 9 Nm
7 - Seals
8 - Dowel sleeve
9 - O-ring
Sealing flange (pulley end) - tightening torques and sequence

angle.
tion
1. -1 … 17- 3 Nm
2. -1 … 17- Turn 90° further


⇒ “1.3.1 Removing and installing poly V-belt for alternator - vehi‐
⇒ “1.3.2 Removing and installing poly V-belt for alternator - vehi‐
⇒ “1.3.3 Removing and installing poly V-belt for starter-alternator
⇒ “1.3.4 Removing and installing poly V-belt for starter-alternator
compressor - vehicles with 2.9 ltr. engine”, page 28
compressor - vehicles with 3.0 ltr. engine”, page 28
⇒ “1.3.7 Removing and installing poly V-belt for coolant pump -
vehicles with high-voltage system”, page 29

alternator - vehicles with 2.9 ltr. engine
Removing
cylinder direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep.
gr. 13 ; Cylinder block (pulley end); Removing and installing poly
V-belts .
– Detach poly V-belt from air conditioner compressor ⇒ 6-cyl‐
inder direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep.
poly V-belts .

Caution


V-belt.
Installing
– Fit poly V-belt ⇒ Fig. ““Belt routing for alternator”“ , page 14 .
– Turn tensioner of poly V-belt for alternator slightly anti-clock‐
wise -arrow- using a ring spanner and pull out locking pin -
T10060A- .
– Install poly V-belt for air conditioner compressor ⇒ 6-cylinder
direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr.
V-belts .

alternator - vehicles with 3.0 ltr. engine
Removing
V-belts .

Caution


V-belt.
Installing
– Fit poly V-belt ⇒ Fig. ““Belt routing for alternator”“ , page 14 .
wise -arrow- using a ring spanner and pull out locking pin -
T10060A- .

starter-alternator - vehicles with 2.9 ltr.
engine
Removing
V-belts .
– Detach poly V-belt from air conditioner compressor ⇒ 6-cyl‐
poly V-belts .

Caution


– Lock tensioner with locking tool - T40098- and take off poly V-
belt.
Installing
– Fit poly V-belt
⇒ Fig. ““Belt routing for starter-alternator”“ , page 16 .

wise -arrow- using a ring spanner and pull out locking tool -
T40098- .
– Install poly V-belt for air conditioner compressor ⇒ 6-cylinder
V-belts .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 13 ; Cylinder block
(pulley end); Removing and installing poly V-belts .

starter-alternator - vehicles with 3.0 ltr.
engine
Removing
V-belts .

Caution


– Lock tensioner with locking tool - T40098- and take off poly V-
belt.
Installing
– Fit poly V-belt
⇒ Fig. ““Belt routing for starter-alternator”“ , page 16 .

wise -arrow- using a ring spanner and pull out locking tool -
T40098- .

air conditioner compressor - vehicles

air conditioner compressor - vehicles
Removing
⇒ “1.3.2 Removing and installing poly V-belt for alternator -
vehicles with 3.0 ltr. engine”, page 25 /
⇒ “1.3.3 Removing and installing poly V-belt for starter-alter‐
nator - vehicles with 2.9 ltr. engine”, page 26 .
– Remove cover.

– Loosen bolt -1- by 1/2 a turn.
Caution

– To slacken poly V-belt, turn tensioner clockwise -arrow A- us‐

ing special wrench Torx T55. Then remove poly V-belt.
Installing
– Fit poly V-belt
⇒ Fig. ““Belt routing for air conditioner compressor, vehicles
with 3.0 ltr. engine”“ , page 20 .
– To tension poly V-belt for air conditioner compressor, turn ten‐

sioner anti-clockwise using special wrench Torx T55
-arrow B- as far as stop (tensioner should remain under ten‐
sion).
– Tighten bolt -1-.
vehicles with 3.0 ltr. engine”, page 25 /
Tightening torques
♦ ⇒ “1.1.5 Exploded view - cylinder block (pulley end), air con‐
ditioner compressor belt drive, vehicles with 3.0 ltr. engine”,
page 19

coolant pump - vehicles with high-volt‐
age system
Removing


V-belts .
Caution

– To slacken poly V-belt, turn tensioner -3- in clockwise direction

-arrow- using ring spanner -2-.
– Lock tensioner with locking pin - T10060A- -item 1- and take
off poly V-belt.
Installing
– Fit poly V-belt

⇒ Fig. ““Belt routing for coolant pump - vehicles with high-volt‐
age system”“ , page 22 .
– Turn tensioner -3- of poly V-belt for alternator slightly clock‐
wise -arrow- using a ring spanner -2- and pull out locking pin
- T10060A- -item 1-.
– To tension poly V-belt, release tensioner by turning in anti-
clockwise direction.

poly V-belt
⇒ “1.4.1 Removing and installing poly V-belt tensioner for alter‐
nator - vehicles with 2.9 ltr./3.0 ltr. engine”, page 30
⇒ “1.4.2 Removing and installing poly V-belt tensioner for starter-
alternator - vehicles with 2.9 ltr./3.0 ltr. engine”, page 31
⇒ “1.4.3 Removing and installing poly V-belt tensioner for air con‐
ditioner compressor - vehicles with 2.9 ltr. engine”, page 31
⇒ “1.4.4 Removing and installing poly V-belt tensioner for air con‐
ditioner compressor - vehicles with 3.0 ltr. engine”, page 32
⇒ “1.4.5 Removing and installing tensioner for poly V-belt for
coolant pump - vehicles with high-voltage system”, page 32

sioner for alternator - vehicles with 2.9
ltr./3.0 ltr. engine
Removing
– Slacken poly V-belt

– Remove bolts -arrows- and detach tensioner -1-.

Installing
Tightening torques
♦ ⇒ “1.1.1 Exploded view - cylinder block (pulley end), alternator
belt drive, vehicles with 2.9 ltr./3.0 ltr. engine”, page 12

sioner for starter-alternator - vehicles
with 2.9 ltr./3.0 ltr. engine
Removing
– Remove bolt -2- and detach tensioner -1-.
Installing
Tightening torques
♦ ⇒ “1.1.2 Exploded view - cylinder block (pulley end), starter-
alternator belt drive, vehicles with 3.0 ltr. engine”, page 15

sioner for air conditioner compressor -
Removing
V-belt tensioner .
– Slacken poly V-belt ⇒ 6-cylinder direct injection engine (2.9
ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 13 ; Cylinder block (pulley

– Unscrew bolt -arrow-, push coolant hose slightly to one side

and detach tensioner -1- (illustration shows engine without
electric compressor).
Installing
– Install poly V-belt ⇒ 6-cylinder direct injection engine (2.9 ltr.,
3.0 ltr. 4-valve TFSI); Rep. gr. 13 ; Cylinder block (pulley end);
Removing and installing poly V-belts .
Tightening torques
ditioner compressor belt drive, vehicles with 2.9 ltr. engine
without electric compressor”, page 17

sioner for air conditioner compressor -
Removing
compressor - vehicles with 3.0 ltr. engine”, page 28 .
– Remove bolt -1- and detach tensioner.
Installing
Tightening torques
ditioner compressor belt drive, vehicles with 3.0 ltr. engine”,
page 19
1.4.5 Removing and installing tensioner for

poly V-belt for coolant pump - vehicles
with high-voltage system
Removing
⇒ “1.3.7 Removing and installing poly V-belt for coolant pump
- vehicles with high-voltage system”, page 29 .
– Remove bolt -1- and detach tensioner -1-.
– If bracket -2- is to be removed, unscrew bolts -3- and detach
bracket -2-.
Installing
Tightening torques


er

Preparing tool
– Secure adapter -T40330/6- to counterhold tool -T40330/1- us‐
ing bolts -arrows-.
Removing
bration damper .
vehicles with 2.9 ltr. engine”, page 24 .
⇒ “1.4.3 Removing and installing poly V-belt tensioner for air
conditioner compressor - vehicles with 2.9 ltr. engine”,
page 31 .


– Release hose clip -1-, disconnect coolant hose and push front
coolant pipe (bottom left) slightly to one side.
– Remove cover.
– Position adapter -T40330/4- with counterhold tool -T40330/1-

against vibration damper and secure with bolt -arrow- (tighten
to 23 Nm and fit spacer sleeves -T40330/7- in between).
– Unscrew bolt -arrow- and remove counterhold tool and vibra‐
tion damper.
Installing
angle.
– Position vibration damper -1- on crankshaft -2- and secure
with a new bolt (pay attention to dowel sleeve -arrow-).


– Tighten bolt -1- for vibration damper.
– Remove bolt -arrow- and detach counterhold tool.
– Install poly V-belt tensioner for air conditioner compressor
page 31 .
Tightening torques
♦ ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0 ltr. 4-valve
TFSI); Rep. gr. 19 ; Coolant pipes; Exploded view - coolant
pipes

Preparing tool
ing bolts -arrows-.
Removing
bration damper .
– Remove poly V-belt for air conditioner compressor
page 32 .

– Remove cover.

tion damper.
Installing
angle.

page 32 .
Tightening torques

er - vehicles with high-voltage system

Preparing tool
ing bolts -arrows-.
Removing
bration damper .
– Remove poly V-belt for coolant pump

tion damper.
Installing
angle.


– Fit poly V-belt for coolant pump
Tightening torques

cillaries
⇒ “1.6.1 Removing and installing bracket for alternator”,
page 38
⇒ “1.6.2 Removing and installing bracket for starter-alternator”,
page 39
pressor - vehicles with 2.9 ltr. engine without electric compressor”,
page 39
pressor - vehicles with 2.9 ltr. engine with electric compressor”,
page 40
pressor - vehicles with 3.0 ltr. engine”, page 40
pressor - vehicles with high-voltage system”, page 41
1.6.1 Removing and installing bracket for al‐

ternator
Removing
– Unscrew bolts -arrows- and detach bracket -1-.
Installing
angle.
Tightening torques
♦ ⇒ Fig. ““Bracket for alternator - tightening torques and se‐
- alternator

1.6.2 Removing and installing bracket for

starter-alternator
Removing
– Unscrew bolts -arrows- and detach bracket -1-.
Installing
angle.
Tightening torques
♦ ⇒ Fig. ““Bracket -1- for starter-alternator - tightening torque
and tightening sequence”“ , page 16
- alternator

conditioner compressor - vehicles with
2.9 ltr. engine without electric compres‐
sor
Removing
page 31 .
– Remove bolt -1- and loosen nut -2-.

– Unscrew bolts -2, 3- and remove bracket -1- for air conditioner
compressor.
Installing
page 31 .
Tightening torques
♦ ⇒ Fig. ““Bracket for air conditioner compressor - tightening
torques and sequence, vehicles with 2.9 ltr. engine”“ ,
page 18

2.9 ltr. engine with electric compressor
(pulley end); Removing and installing bracket for ancillaries .

3.0 ltr. engine
Removing
page 32 .
– All models except A8: Remove air conditioner compressor
from bracket and tie up to left side ⇒ Heating, air conditioning;
– A8: Remove air conditioner compressor ⇒ Heating, air con‐
ditioning; Rep. gr. 87 ; Air conditioner compressor; Removing
and installing air conditioner compressor .

compressor.
Installing
angle.
page 32 .
Tightening torques
♦ ⇒ Fig. ““Bracket for air conditioner compressor - tightening
torques and sequence, vehicles with 3.0 ltr. engine”“ ,
page 20
- alternator

high-voltage system
Removing
compressor.
Installing
angle.
Tightening torques
♦ Exploded view - drive unit for electrically driven air conditioner
compressor ⇒ Heating, air conditioning; Rep. gr. 87 ; Air con‐
ditioner compressor; Exploded view - air conditioner compres‐
sor drive unit

(pulley end); Removing and installing engine support .


end)
♦ Oil seal extractor - T40019-
Procedure
– Adjust inner part of oil seal extractor -T40019- so it is flush with
the outer part and lock in position with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and screw it into oil seal as far as possible (applying firm
pressure).
– 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.
– Fit guide sleeve -T40320/2- on crankshaft and slide oil seal

-1- into sealing flange (pulley end).
• Open side of oil seal faces engine.
• Leave guide sleeve -T40320/2- in position on crankshaft for
pressing in oil seal.

– Fit press tool -T40320/1- on crankshaft using bolt -1- for vi‐
bration damper.
– Press oil seal -2- in as far as stop.
note the following:

(pulley end)
♦ Safety goggles
♦ Bolt, M6x30 (2x)
Removing
gr. 13 ; Cylinder block (pulley end); Removing and installing seal‐
ing flange (pulley end) .
– Remove bracket for air conditioner compressor
page 38 .
– Remove oil pressure sender - G10-
page 205 .
page 175 .
– Unscrew bolt -arrow- and detach intake connecting pipe -1-.

– Remove bolt -2-, pull guide tube -1- for oil dipstick off sealing
flange (front) and detach guide tube.
– Unplug electrical connector -3- and detach change-over valve

from bracket -2-.
– Remove bolts -arrows- and tie up bracket to one side.

– To loosen sealing flange (front) -1-, screw in two M6x30 bolts

-arrows- as far as stop.
– Screw bolts in 1/2 turn each (one after the other) until sealing
flange (front) is released.
– Remove bolts, detach sealing flange and press out oil seal for
crankshaft.
Installing
angle.
• Renew intake connecting pipe with bolt, gaskets, seals, oil
seal for crankshaft and O-rings after removal.
– Pull dowel sleeves -arrows- off cylinder block.

– Drive dowel sleeves into corresponding holes on sealing
flange (pulley end) -1- (as shown) so that they are flush with
sealing surface.
Caution

WARNING
Risk of eye injury.

– Remove sealant residue from cylinder block and sump (top

section) -1- using rotating plastic brush or similar.

mm).

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

the cylinder block and the sump (top section) -arrows-.
– Fit seals -3-.
Caution

• The bead of sealant -2- must project 3.0 mm above the sealing
surface.
• Install sealing flange within 5 minutes of applying the sealant.
– Apply a thin coat of sealant to bottom sealing surface -1- on
sealing flange.
– Carefully position sealing flange (pulley end) by guiding it to‐
wards sealing surface on cylinder block and sump (top sec‐
tion) at an angle from above, but do not press it on yet.
– Screw in all bolts by hand and drive dowel sleeves into cylinder
block.
– Tighten sealing flange bolts (pulley end).
– Install crankshaft oil seal (pulley end)
⇒ “1.8 Renewing crankshaft oil seal (pulley end)”, page 42 .
page 175 .
– Install oil pressure sender - G10-
page 205 .
– Install bracket for air conditioner compressor
page 38 .
(pulley end); Removing and installing sealing flange (pulley end)
Tightening torques
♦ ⇒ Fig. ““Sealing flange (pulley end) - tightening torques and
♦ ⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 23


⇒ “3.7 Checking sender wheel”, page 56
⇒ “2.3 Renewing crankshaft oil seal (gearbox end)”, page 48

• When carrying out repairs, secure engine to engine and gear‐
box support ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0
ltr. 4-valve TFSI); Rep. gr. 10 ; Removing and installing en‐
gine; Securing engine to engine and gearbox support .
1 - Bolt
❑ 60 Nm +90°
2 - Drive plate
❑ With bearing flange
❑ Check running surface
on bearing flange and
holes for torque convert‐
er for cracks and scoring
stalling drive plate”,
page 47
3 - Sender wheel
er - G28-
stalling sender wheel”,
page 56
❑ Checking
⇒ “3.7 Checking sender
wheel”, page 56
4 - Oil seal
end)
❑ Renewing
shaft oil seal (gearbox
end)”, page 48
5 - Dowel pin
6 - Crankshaft
❑ Exploded view


Removing
Caution

drive plate.
– Remove bolts and take off drive plate -1- and sender wheel.
Installing
• If the drive plate has been removed or renewed, check that the
sender wheel is operating correctly before installation
⇒ “3.7 Checking sender wheel”, page 56 .
angle.
bolts.
Tightening torques
page 47
2.3 Renewing crankshaft oil seal (gearbox

end)

♦ Fitting tool - T10122B-
♦ Extractor tool - T20143/2-
Procedure
– Remove sender wheel
⇒ “3.6 Removing and installing sender wheel”, page 56 .
– Pry out oil seal using extractor tool -T20143/2- .

– Fit assembly aid -T10122/1- onto guide piece - T10122/6- and
slide oil seal -A- onto guide piece (closed side first).
– Detach assembly aid -T10122/1- .

– Fit guide piece - T10122/6- onto crankshaft.

– Use bolts -arrows- to secure guide piece to crankshaft through
securing points -A-.
Caution
Risk of leaks if installed incorrectly.

♦ Slide oil seal onto crankshaft by hand to prevent sealing
lip on oil seal from folding over.
– Slide oil seal over guide piece - T10122/6- onto crankshaft by

hand.
– Press in oil seal evenly all round using thrust piece -

T10122/5- .
– Remove guide piece - T10122/6- .
– Check that oil seal and its sealing lip are correctly seated. If
sealing lip is partially folded over, repeat procedure with a new
oil seal.
– Install sender wheel

3 Crankshaft
⇒ “3.7 Checking sender wheel”, page 56
⇒ “3.8 Removing and installing crankshaft”, page 57

• When carrying out repairs, secure engine to engine and gear‐
box support ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0
ltr. 4-valve TFSI); Rep. gr. 10 ; Removing and installing en‐
gine; Securing engine to engine and gearbox support .
1 - Cylinder block
2 - Bracket
❑ For vacuum reservoir
3 - Plug
❑ For “TDC” bore
❑ Different versions; allo‐
cation and tightening
torques ⇒ page 53
4 - O-ring
❑ For plug version A
⇒ page 53
5 - Bolt
sequence
⇒ Fig. ““Bearing caps -
tightening torques and
6 - Bearing shell
❑ For cylinder block (with
oil groove)
shells
❑ Install new bearing
shells for the bearing
caps with the correct
coloured markings
⇒ “3.3 Allocation of main
bearing shells”,
page 54
7 - Dowel sleeve
8 - Crankshaft
❑ Measuring axial clearance ⇒ “3.4 Measuring axial clearance of crankshaft”, page 54
3. Crankshaft 51
❑ Measuring radial clearance ⇒ “3.5 Measuring radial clearance of crankshaft”, page 55

❑ Crankshaft dimensions ⇒ “3.2 Crankshaft dimensions”, page 54
❑ Removing and installing ⇒ “3.8 Removing and installing crankshaft”, page 57
❑ Renew dowel sleeve ⇒ Item 7 (page 51) and dowel pin ⇒ Item 14 (page 52) when installing a new
crankshaft
❑ Note installation position in relation to balance shaft
9 - Bearing shell
❑ For bearing cap (without oil groove)
❑ Renew used bearing shells
❑ Install new bearing shells for the bearing caps with the correct coloured markings
10 - Dowel sleeve
❑ 2x per bearing cap
11 - Bearing caps
❑ Allocation ⇒ Fig. ““Allocation of bearing cap”“ , page 53
❑ Bearing shell retaining lugs (cylinder block/bearing cap) must be on the same side
12 - Bolt
⇒ Fig. ““Bearing caps - tightening torques and sequence”“ , page 53
13 - Thrust washers
❑ Only fitted on 3rd crankshaft bearing
❑ Installation position: oil grooves face outwards
❑ Make sure it engages in retaining frame
14 - Dowel pin
15 - Thrust washers
❑ Only fitted on 3rd crankshaft bearing
❑ Installation position: oil grooves face outwards
16 - Bolt
⇒ Fig. ““Bearing caps - tightening torques and sequence”“ , page 53

Plug for “TDC” drilling - allocation and tightening torques

– Clean threaded hole in cylinder block.
Plug version A:
– Renew O-ring after removal.
– Clean plug, fit with new O-ring and tighten to 25 Nm.
Plug version B:
– Renew plug after removal.
– Tighten plug to 40 Nm.
Allocation of bearing cap

– Allocate bearing caps -1 ... 4- as shown.
Bearing caps - tightening torques and sequence

angle.
2. -1 … 8- 30 Nm
3. -1 … 8- 50 Nm
5. -arrows- 20 Nm
6. -arrows- Turn 90° further
3. Crankshaft 53

Crankshaft main bearing Crankshaft main bearing Crankshaft conrod journal
journal ∅ journal ∅ ∅
2.9 ltr. engine 3.0 ltr. engine All engines
mm mm mm
Basic dimension 67.000 – 0.022 65.000 – 0.022 56.000 – 0.022
– 0.042 – 0.042 – 0.042

Allocation of crankshaft bearing shells for cylinder block
♦ Bearing shells of the correct thickness are matched to the
bearings in the cylinder block at the factory. Coloured dots on
the side of the bearing shells are used to identify the bearing
shell thickness.
♦ The allocation of the bearing shells to the cylinder block is in‐
dicated by letters on the right of the cylinder block, as shown.
Letter on cylinder block Colour coding of bearing
R = Red
S = Black
G = Yellow
U = Green
B = Blue
Allocation of crankshaft bearing shells for bearing caps

♦ Bearing shells of the correct thickness are assigned to the
bearing caps at the factory. Coloured dots on the side of the
bearing shells are used to identify the bearing shell thickness.
♦ The allocation of the bearing shells to the bearing caps is in‐
dicated by letters on the rear crankshaft flange, as shown in
the illustration.
♦ The row of letters begins with crankshaft bearing “1” (pulley
end) and ends with crankshaft bearing “4” (gearbox end).
Letter on crankshaft flange Colour coding of bearing
R = Red
S = Black
G = Yellow
U = Green
B = Blue


Procedure
– Bolt dial gauge - VAS 6079- with dial gauge bracket - VW 387-
to cylinder block.
– Apply dial gauge to crank web.
“0”.
• Axial clearance: 0.013 ... 0.251 mm

shaft
♦ Plastigauge
Procedure
– Remove bearing cap and clean bearing journal.
ing shell.
– Fit bearing caps and tighten through specified angle
⇒ Fig. ““Bearing caps - tightening torques and sequence”“ ,
page 53 without rotating crankshaft.
– Remove bearing cap again.
3. Crankshaft 55

Radial clearance:
• New: 0.021 ... 0.036 mm.

Removing
Caution
Risk of magnetic fields causing irreparable damage to sender

wheel.
♦ The sender wheel must be kept away from magnets (e.g.
base of torch, loudspeaker).
♦ If the drive plate/flywheel or the sender wheel itself has
been removed or renewed, check that the sender wheel
is operating correctly before installation
⇒ “3.7 Checking sender wheel”, page 56 .
– Detach sender wheel -arrow-.

Installing
– If sender wheel has been renewed, perform corresponding
adaptions listed in Guided Function “01 - Functions, engine
mechanics” / “0001 - Work steps after component replace‐
ment” ⇒ Vehicle diagnostic tester.
3.7 Checking sender wheel
Caution
Risk of magnetic fields causing irreparable damage to sender

wheel.
♦ The sender wheel must be kept away from magnets (e.g.
base of torch, loudspeaker).
♦ If the drive plate/flywheel or the sender wheel itself has
been removed or renewed, check that the sender wheel
is operating correctly before installation.

♦ Sensor gauge - T10473-
Procedure
• Sender wheel removed
– Check entire circumference of sender wheel using sensor
gauge - T10473- , as shown in illustration.
Inspection image of sender wheel

A - Sender wheel OK
B - Sender wheel defective
3.8 Removing and installing crankshaft

3. Crankshaft 57
♦ Puller - T10055-
♦ Screwdriver Torx T25 - T10248- (not illustrated)

♦ Puller -T40332-
♦ Adjustment pin -T40362- (not illustrated)

Preparing extractor -T40332-

– Secure tensioning bolts -1- to crosspiece of puller -T40332-
using bolts -arrows-, as shown.
– Unscrew threaded pins -2- for assembling tool later.
Removing
• Engine secured to engine and gearbox support ⇒ 6-cylinder
10 ; Removing and installing engine; Securing engine to en‐
gine and gearbox support .
– Remove piston
⇒ “5.2 Removing and installing pistons”, page 72 .
– Remove sealing flange (pulley end)
⇒ “1.9 Removing and installing sealing flange (pulley end)”,
page 43 .
– If not yet removed, remove timing chain cover (bottom)
page 84 .
– Press tensioning rail in direction of -arrow- and lock in place

using locking pin - T40011- .
– Unscrew bolts -2- and detach guide rail -1-.
– Remove oil pump together with chain sprocket
– Lock backlash compensation assembly at gear by inserting

adjustment pin -T40362- into sprocket as far as stop and turn‐
ing it 180° clockwise -arrow-.
3. Crankshaft 59
– Remove bolts -arrows- and -1 … 8-.
– Remove plug (front left) -arrow-.
– Apply and secure extractor -T40332- (prepared previously) at

grooves -arrows- on corresponding bearing cap; to do so,
screw in threaded pins -1- on left and right as far as stop using
screwdriver Torx T25 - T10248- .
– Secure puller - T10055- to extractor -T40332- and pull off
bearing cap.
– Pull off remaining bearing caps and remove crankshaft.

Installing
angle.
• Backlash compensation assembly locked at balance shaft
gear with adjustment pin -T40362-
– Ensure correct version:
♦ Bearing caps ⇒ Fig. ““Allocation of bearing cap”“ , page 53
♦ Bearing shells
– Oil running surface of bearing shells with engine oil.
– Move crankshaft into installation position and press it on; pay

attention to markings:
• Marking -A- for crankshaft -1- must be between the two mark‐
ings -B- on balance shaft gear -2-.
Tightening torques
♦ ⇒ Fig. ““Bearing caps - tightening torques and sequence”“ ,
page 53
3. Crankshaft 61
4 Balance shaft
1 - Bolt
❑ 40 Nm +45°
2 - Gear
❑ With sprockets for cam‐
shaft timing chains
3 - Bolt
❑ 9 Nm
4 - Balance shaft
stalling balance shaft”,
page 62
5 - Roller bearing
❑ Renewing
⇒ “4.3 Renewing roller
bearing”, page 66
6 - Balance weight
❑ Can only be fitted on
balance shaft in one po‐
sition.
7 - Bolt
❑ 40 Nm +90°
8 - Roller bearing
❑ Renewing
⇒ “4.3 Renewing roller
bearing”, page 66
9 - Thrust washer
10 - Gasket
11 - Bearing plate


♦ Key - T40049-
♦ Camshaft clamp - T40264- (not illustrated)

Removing
– Remove timing chains
page 113 .
– Secure key - T40049- to crankshaft using bolts -1, 2-.
– Remove sealing flange (pulley end)
page 43 .
Caution

♦ Do NOT turn crankshaft.
– Unscrew bolts -arrows- and remove guide rail -1-.
4. Balance shaft 63
– Unscrew guide pins -arrows- and remove guide rail -1-.
– Remove bolt -arrow- on pulley end, using key - T40049- to

counterhold crankshaft (balance weight -1- is removed later).
– Lock backlash compensation assembly at gear by inserting

adjustment pin -T40362- into sprocket as far as stop and turn‐
ing it 180° clockwise -arrow-.
– Remove bolt -arrow- (counterhold crankshaft with key -

T40049- ).
– Remove gear -1-.

– Remove bolts -arrows- and detach bearing plate -1- for bal‐
ance shaft.
– Remove balance shaft -2- from cylinder block towards gear‐
box end and, at the same time, detach balance weight on
pulley end.
Installing
angle.
• Backlash compensation assembly locked at gear with adjust‐
ment pin -T40362- .
• A new gear is supplied with an assembly aid which is inserted
in place of the adjustment pin -T40362- .
– Move balance shaft -1- into installation position.

– Fit balance weight -2- onto balance shaft at pulley end.
• Machined surface -arrow- of balance weight must be posi‐
tioned over machined surface of balance shaft.
– Move gear -1- into installation position; marking -2- must align
with dual toothing of balance shaft -arrow-.
4. Balance shaft 65
– Fully slide gear onto balance shaft, noting marking:

• Marking -A- for crankshaft -1- must be between the two mark‐
ings -B- on balance shaft gear -2-.
– Counterhold crankshaft with key - T40049- and tighten bolt for
gear and balance weight.
– Install sealing flange (pulley end)
page 43 .
– Adjust crankshaft so that notch -1- on vibration damper aligns

with cast projection -2- on sealing flange (pulley end).
– Screw camshaft clamp - T40264/3- through bore in vibration
damper into sealing flange (pulley end) by hand until it makes
contact. If necessary, turn crankshaft back and forth slightly.
– Install camshaft timing chains
page 113 .
Tightening torques
4.3 Renewing roller bearing

♦ Special tool -T40395-
Pulling out
– Remove crankshaft
⇒ “3.1 Exploded view - crankshaft”, page 51 .
– Remove balance shaft
⇒ “4.2 Removing and installing balance shaft”, page 62 .

– Position special tool correctly on roller bearing:

• The chamfer -arrow- faces towards the roller bearing.
– Align adapter -T40395/3- .

• The side without the chamfer -arrows- faces downwards.
– Pull roller bearings (front -1- and rear -2-) out inwards using
spindle -T40395/1- and adapters -T40395/2- / -T40395/3- ; to
do so, turn nut -T40395/4- .
– Detach special tool and remove roller bearing.
Installing
– Position adapter correctly on roller bearing:
• Chamfer -arrow- must face roller bearing; chamfer determines
installation depth.
4. Balance shaft 67
– Align adapter -T40395/3- .

• The side without the chamfer -arrows- faces downwards.
– Pull roller bearings (front -1- and rear -2-) in as far as stop
using spindle -T40395/1- and adapters -T40395/2- / -
T40395/3- ; to do so, turn nut -T40395/4- .
• The sides of the roller bearings with identification lettering face
outwards.
– Install balance shaft
⇒ “4.2 Removing and installing balance shaft”, page 62 .
– Install crankshaft
⇒ “3.1 Exploded view - crankshaft”, page 51 .


page 78
1 - Bolts
ance
❑ Lubricate thread and
contact surface with oil
❑ 50 Nm +90°
⇒ Fig. ““Marking con‐
rods”“ , page 72
❑ Installation position of
conrod pairs
sition of conrods”“ ,
page 72
3 - Bearing shells
❑ Ensure that retaining
lugs are securely seat‐
ed.
shells
4 - Conrod
❑ Only renew as a com‐
plete set
rod bearing cap alloca‐
tion in colour
⇒ Fig. ““Marking con‐
rods”“ , page 72
❑ Installation position of
conrod pairs
sition of conrods”“ , page 72
❑ Axial clearance for each conrod pair (when new): 0.30 … 0.54 mm
❑ Measuring radial clearance ⇒ “5.5 Checking radial clearance of conrod bearings”, page 78
5 - Circlip
6 - Piston pin

7 - Piston
❑ Mark installation position and cylinder number ⇒ Fig. ““Installation position of pistons”“ , page 72
❑ Install with piston installation sleeve -T40369-
❑ Checking pistons and cylinder bores ⇒ “5.4 Checking pistons and cylinder bores”, page 77
8 - Circlip
9 - Compression ring
❑ Allocation and installation position ⇒ Fig. ““Allocation of piston rings”“ , page 71
❑ Offset gaps by 120° to ⇒ Item 10 (page 70)
10 - Compression ring
❑ Allocation and installation position ⇒ Fig. ““Allocation of piston rings”“ , page 71
❑ Remove and install 3-part oil scraper ring carefully by hand
❑ Installation position ⇒ Fig. ““Installing oil scraper ring”“ , page 71
12 - Oil spray jet
❑ With spray nozzle valve
❑ Do not bend
❑ Removing and installing ⇒ “5.3 Removing and installing oil spray jets”, page 76
13 - Banjo bolt
❑ 10 Nm +45°


1- Compression ring with chamfer -arrow A- (inner side, top)
2- Compression ring with shoulder -arrow B- (outer side, bot‐
tom)

Installing oil scraper ring

• Offset top gap of 3-part oil scraper ring by 120° to next com‐
pression ring.

Installation position of pistons
Caution
Do not damage the coating of the piston crown.

♦ If you intend to re-install used pistons, mark the cylinder
number on the piston crown using paint. Do not mark pis‐
ton crown by means of centre punch, notch or the like.
Pfeil - points to pulley end
x - Cylinder bank identification: L = left, R = right
Marking conrods
– Use a coloured pen to mark matching conrods and conrod
bearing caps with cylinder numbers -arrow- for re-installation.
Installation position of conrods

• The cast lugs on the ground surfaces -arrows- of the conrod
pairs must face each other.


♦ Pin - VW 222A-
♦ Wrench, 21 mm - T40263-
♦ Piston installation sleeve -T40369- (not illustrated)

♦ Piston ring pliers -VAS 211 003- (not illustrated)
Removing
– Remove corresponding cylinder head
– Remove oil baffle plate
⇒ “1.5 Removing and installing oil baffle plate”, page 185 .
• Conrod bearing caps to cylinders and to conrods
⇒ Fig. ““Marking conrods”“ , page 72
• Pistons to cylinders
⇒ Fig. ““Installation position of pistons”“ , page 72
• Conrods to cylinders ⇒ Item 4 (page 69)

– If necessary, unscrew camshaft clamp -T40264/3- and turn

crankshaft as appropriate.
Caution

ing chains slip.
– Turn crankshaft using wrench, 21 mm - T40263- and adapter

- T40314- -arrow-, paying attention to camshaft timing chain
or guiding camshaft timing chain.
– Unscrew relevant bolts -arrows- and detach conrod bearing

cap.
Caution

• Never bend oil spray jets.
– Detach piston, paying attention to oil spray jets.

Note:
Installing
angle.
Installation positions:
• Piston rings ⇒ Fig. ““Allocation of piston rings”“ , page 71
• Pistons ⇒ Fig. ““Installation position of pistons”“ , page 72
• Conrods ⇒ Fig. ““Installation position of conrods”“ , page 72
– Install compression rings
⇒ Fig. ““Installing compression rings”“ , page 71 .
– Install oil scraper ring
⇒ Fig. ““Installing oil scraper ring”“ , page 71 .

– Oil running surfaces of bearing shells and cylinder wall.

piston installation sleeve -T40369- .
Caution

• Never bend oil spray jets.
– Check that oil spray jets have adequate clearance after instal‐
ling pistons.
• If pistons are only removed on one cylinder bank, “TDC” po‐

sition of crankshafts must be checked with camshaft housing
fitted.
Caution

♦ Camshafts must be at “TDC” position, as described below.
– Unscrew bolt -3- and detach cover -2-.

• Exhaust camshaft -1- has an asymmetrically positioned pair
of grooves -arrows-. In TDC position, the asymmetrically posi‐
tioned pair of grooves must be above the imaginary horizontal
centre line, as shown. (Shown on exhaust camshaft, cylinder
bank 2)
• Notch -1- on vibration damper must align with cast projection

-2- on sealing flange (pulley end).
– Screw locking pin - T40069- into hole and tighten to 20 Nm. If

necessary, turn crankshaft back and forth slightly. The locking
pin will engage in the crank web hole.
– Install oil baffle plate
– Install cylinder head
⇒ “3.3.6 Installing cylinder head - vehicles with 3.0 ltr. engine”,
page 137 .
Tightening torques


Removing
– Remove oil baffle plate
Caution

slips.
– Use wrench, 21 mm - T40263- and adapter - T40314- to turn

crankshaft -arrow- until corresponding oil spray jet is accessi‐
ble.

to cylinder and to conrods for re-installation ⇒ page 72 .
– Unscrew relevant bolts -arrows- and detach conrod bearing
cap.
– Unscrew banjo bolt -2- and remove oil spray jet -1-.
– Repeat procedure for each oil spray jet if necessary.
Installing
• Renew banjo bolts after removal.
angle.
• Do not bend oil spray jets.
• Check clearance of oil spray jets.
– Install oil baffle plate
Tightening torques


Checking piston
Piston ∅ mm
2.9 ltr. 3.0l
Nominal dimension 84.471) 84.451)

-B-.
Nominal dimension 84.510 + 0.005 1)
• 1) Measure at 50 mm into cylinder bore.

of cylinder.
2.9 ltr. engine
mm mm
Oil scraper ring (3 parts) Cannot be measured
3.0 ltr. engine
mm mm


2.9 ltr. engine
mm mm
3.0 ltr. engine
mm mm

bearings
♦ Plastigauge
Procedure
– Fit conrod bearing caps and tighten through specified angle
Radial clearance:
• New: 0.027 ... 0.072 mm.


1 - Bolt
sequence
⇒ Fig. ““Timing chain
cover (bottom) - tighten‐
ing torques and tighten‐
ing sequence”“ ,
page 81
2 - Oil seal
end)
❑ Renewing
shaft oil seal (gearbox
end)”, page 48
3 - Dowel sleeve
❑ 2x
installing timing chain
cover (bottom)”,
page 84
5 - Cylinder head gasket, bank
2 (left-side)
6 - Centre hex stud
sequence
⇒ Fig. ““Timing chain
cover for cylinder bank 2
(left-side) - tightening
torques and se‐
7 - Bolt
⇒ Fig. ““Timing chain cover for cylinder bank 2 (left-side) - tightening torques and sequence”“ ,
page 80
8 - Timing chain cover (top) for cylinder bank 2 (left-side)
❑ Removing and installing ⇒ “1.2.1 Removing and installing timing chain covers (top)”, page 81
9 - Dowel sleeve
❑ 2x
10 - Bolt
❑ 9 Nm

11 - Heat shield
❑ Cylinder bank 2 (left-side): exhaust camshaft control valve 2 - N319-
13 - Seal
14 - Dowel sleeve
❑ 2x
15 - Timing chain cover (top) for cylinder bank 1 (right-side)
❑ Removing and installing ⇒ “1.2.1 Removing and installing timing chain covers (top)”, page 81
16 - Bolt
⇒ Fig. ““Timing chain cover for cylinder bank 1 (right-side) - tightening torques and sequence”“ ,
page 80
17 - Seal
❑ Cylinder bank 2 (left-side): camshaft control valve 2 - N208-
19 - Bolt
❑ 9 Nm
20 - Cylinder head gasket, bank 1 (right-side)
21 - Dowel sleeve
❑ 2x
Timing chain cover for cylinder bank 1 (right-side) - tightening

torques and sequence
Timing chain cover for cylinder bank 2 (left-side) - tightening tor‐

ques and sequence

Timing chain cover (bottom) - tightening torques and tightening

sequence
angle.
1. -arrows- 3 Nm
2. -1 … 6- 3 Nm
3. -arrows- 8 Nm

cover
⇒ “1.2.1 Removing and installing timing chain covers (top)”, page
81
page 84

covers (top)
♦ Safety goggles
Removing
installing.
– Remove high-pressure pipe (rear)
page 315 .
– If fitted, remove coolant circulation pump - V50- ⇒ 6-cylinder
19 ; Coolant pump/thermostat assembly; Removing and in‐
stalling electric coolant pump .
– Unplug electrical connector -2- for camshaft control valve 1 -
N205- and move electrical wiring clear.


– If fitted, unclip bracket -arrow- from timing chain cover and
press it to side with vacuum hose still attached.
– Open heat insulation sleeve and unplug electrical connector

-arrow- on oil pressure switch - F22- . (Shown on vehicle with
3.0 ltr. engine.)

– Unplug electrical connector -1- at oil temperature sender -

G8- . (Shown on vehicle with 3.0 ltr. engine.)
– Move wiring harness clear at timing chain cover.

– Carefully release and detach timing chain cover from bonded
joints.
Caution

♦ Block off the opening in the valve timing housing with a
clean cloth to prevent small items from dropping into the
engine when the timing chain cover (top) is removed.
Installing
angle.
– Remove old sealant from sealing surfaces.
Caution

WARNING
Risk of eye injury.

– Remove remaining sealant on timing chain cover -1- and cyl‐

inder head using rotating plastic brush or similar.


mm).
Caution

• Width of sealant bead: 3.0 mm.
– Apply sealant bead -arrow- onto clean sealing surface of tim‐

ing chain cover for cylinder bank 1 (right-side).
– Apply sealant bead -arrow- onto clean sealing surface of tim‐

ing chain cover for cylinder bank 2 (left-side).
• Install timing chain cover within 5 minutes of applying sealant.
– Slide timing chain cover carefully onto dowel sleeves on cyl‐
inder head but do not press sealant bead on yet.
– First, screw all bolts for timing chain cover in by hand and then
tighten.
note the following:
– Install high-pressure pipe (rear)
page 315 .
Tightening torques
♦ ⇒ Fig. ““Timing chain cover for cylinder bank 1 (right-side) -
tightening torques and sequence”“ , page 80
♦ ⇒ Fig. ““Timing chain cover for cylinder bank 2 (left-side) -
tightening torques and sequence”“ , page 80

cover (bottom)

♦ Bolt, M6x20 (3x)

♦ Safety goggles
Removing
– Remove timing chain covers (top)
⇒ “1.2.1 Removing and installing timing chain covers (top)”,
page 81 .
– Unplug electrical connector -2- for engine speed sender -
G28- .

– Remove bolts -arrows- and -1 … 6-.
– To loosen cover (bottom) -1- for timing chains, tighten 3 bolts

M6x20 -arrows- as far as stop.
– Tighten bolts one after the other by 1/2 each until timing chain
cover (bottom) is loosened.
– Remove bolts again, detach timing chain cover (bottom) and
press out crankshaft oil seal (gearbox end).
Installing
angle.
– Pull dowel sleeve at top right out of cylinder block.
– Bevel the dowel sleeve with a file, as shown.
• Dimension -x- = 6.5 mm
• Dimension -y- = 8 mm
– Fit dowel sleeve on cylinder block in such a way that the bev‐
elled side points upwards. Bevelling the dowel sleeve makes
it easier to fit the timing chain cover (bottom) with the cylinder
head installed.
Caution


WARNING
Risk of eye injury.

– Remove remaining sealant on timing chain cover (bottom)

-1-, cylinder block and cylinder head using rotating plastic
brush or similar.
– The old sealing compound must not be removed from the

groove -arrow- in the cylinder head gaskets. With the cylinder
head installed, the groove is only half visible.
Caution
Avoid damage to cylinder head gasket.

♦ Only bend the ends of the cylinder head gaskets slightly
and do not kink.
• The cylinder head gasket must be renewed if it is bent or

kinked.
– Carefully bend the cylinder head gasket -1- down very slightly
-arrows- on both sides, just far enough to be able to clean the
upper sealing surface between the gasket and the cylinder
head.
– Clean cylinder head gaskets (top and bottom); they must be
free of oil and grease.

mm).

– Apply a small amount of sealant to sealing surfaces of cylinder

head gasket -1- (top and bottom) on both sides. To do so, bend
cylinder head gasket down again very slightly -arrows-.
– Use a flat object (e.g. a feeler gauge) to apply sealant to the
area between cylinder head and gasket.
Caution

– Apply sealant beads -1, 2, 3- onto the clean sealing surfaces

of the timing chain cover (bottom).
• Width of sealant beads: 3.0 mm.
• Install timing chain cover within 5 minutes of applying sealant.
• Take care not to damage the cylinder head gaskets when fit‐
ting the timing chain cover (bottom).
– Fit timing chain cover (bottom), guiding it towards sealing sur‐
face on cylinder block and cylinder head at an angle from
below, but do not press sealant bead on yet.
note the following:
– Install crankshaft oil seal (gearbox end)
⇒ “2.3 Renewing crankshaft oil seal (gearbox end)”,
page 48 .
– Install timing chain covers (top)
⇒ “1.2 Removing and installing timing chain cover”, page 81 .
Tightening torques
♦ ⇒ Fig. ““Timing chain cover (bottom) - tightening torques and
tightening sequence”“ , page 81

2 Chain drive
⇒ “2.2 Exploded view - drive chain for oil pump”, page 92
⇒ “2.3 Removing camshaft timing chain from camshafts”,
page 93
page 113
⇒ “2.5 Removing and installing chain tensioner”, page 114

Camshaft timing chain for cylinder bank 1 (right-side)
1 - Guide pin
❑ 5 Nm +45°
2 - Guide rail
3 - Gear
❑ With sprockets for cam‐
shaft timing chains
shafts
⇒ “2.3 Removing cam‐
shaft timing chain from
camshafts”, page 93
tensioning rail
stalling camshaft timing
chain”, page 113
5 - Tensioning rail
camshaft timing chain
6 - Pivot pin
❑ 23 Nm
7 - Bolt
❑ 9 Nm
8 - Chain tensioner
stalling chain tension‐
er”, page 114
9 - Seal
10 - Timing valve
❑ For camshaft adjuster
2. Chain drive 89
11 - O-ring
12 - Camshaft adjuster
❑ Allocation ⇒ Electronic parts catalogue
❑ After removing, renew friction washer (diamond-coated washer) ⇒ Item 13 (page 90)
❑ Removing and installing ⇒ “2.3 Removing camshaft timing chain from camshafts”, page 93
13 - Friction washer (diamond-coated washer)
❑ To ensure secure fit between camshaft adjuster and end of camshaft
❑ Bring new friction washer (diamond-coated washer) into installation position carefully without bending it
16 - O-ring
17 - Timing valve
18 - Slide
19 - Guide pin
❑ 5 Nm +45°
20 - Guide pin
❑ 5 Nm +45°
Camshaft timing chain for cylinder bank 2 (left-side)

1 - Pivot pin
❑ 23 Nm
2 - Tensioning rail
❑ Mark direction of rota‐
with a paint marker
shafts
⇒ “2.3 Removing cam‐
shaft timing chain from
camshafts”, page 93
stalling camshaft timing
chain”, page 113
4 - Chain tensioner
stalling chain tension‐
er”, page 114
5 - Bolt
❑ 9 Nm
6 - Gasket
7 - Slide
8 - Timing valve
9 - O-ring
2. Chain drive 91
14 - O-ring
15 - Timing valve
16 - Guide rail
17 - Bolt
❑ 9 Nm
18 - Gear
❑ With sprockets for camshaft timing chains
2.2 Exploded view - drive chain for oil pump
1 - Guide rail
2 - Bolt
❑ 9 Nm
3 - Bolt
❑ 9 Nm
4 - Drive chain
❑ For oil pump
5 - Guide pin
❑ 5 Nm +45°
6 - Guide pin
❑ 5 Nm +45°
7 - Crankshaft
❑ With drive chain sprock‐
et for oil pump
8 - Tensioning rail
9 - Oil pump
stalling oil pump”,
page 187
10 - Chain sprocket
❑ For oil pump
11 - Bolt

2.3 Removing camshaft timing chain from

camshafts
⇒ “2.3.1 Removing camshaft timing chain from camshafts - cyl‐
inder bank 1 (right-side)”, page 93
⇒ “2.3.2 Removing camshaft timing chain from camshafts - cyl‐
inder bank 2 (left-side)”, page 102

camshafts - cylinder bank 1 (right-side)
In the following procedure the camshaft timing chain remains on
the engine.
2. Chain drive 93
♦ Locking pin - T40069- (with engine removed)
♦ Wrench, 21 mm - T40263-
♦ Camshaft clamp - T40264/3-

♦ Socket E24 - T90000- (not illustrated)
♦ Counterhold tool - T90001- (not illustrated)
♦ Socket -VAS 261 001- (not illustrated)

Preparing camshaft clamp - T40331-

• Lettering “A” on camshaft clamp - T40331/1- faces forwards.
• Camshaft clamps - T40331/4- and -T40331/5- and washers
on bolts -T40331/9- must be positioned using dowel pins
-arrows-.
– Tighten bolts hand tight.
Removing
For the preparatory work required before removing camshaft tim‐
ing chain from camshafts (with engine installed), refer to ⇒ 6-
gr. 15 ; Chain drive; Removing camshaft timing chain from cam‐
shafts .
Caution

♦ The crankshaft and camshafts must only be turned with
the chain drive mechanism fully installed.
– Remove timing chain cover (top) for cylinder bank 1 (right-

side)
page 81 .
– Remove air pipe (top) ⇒ 6-cylinder direct injection engine (2.9
ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Charge air system;
Removing and installing air pipe .
Caution

slips.

crankshaft -arrow- until vibration damper is at “TDC” position.
(Shown on vehicle with 3.0 ltr. engine.)
2. Chain drive 95
• The marking -1-/-2- on the camshaft adjusters must be oppo‐

site the corresponding projections -arrows- on the camshaft
housing. Turn crankshaft one turn if necessary.
– Unscrew bolts -arrows- and remove sealing plugs -1, 2-.
– Tighten adapter -T40331/2- on camshaft housing to 9 Nm.

• It should be possible to insert the camshaft clamp -T40331/1-

easily.
– Insert camshaft clamp -T40331/1- prepared previously into
camshafts as far as stop. Turn crankshaft slightly if necessary.
• Camshaft clamp -T40331/4- engages in flat surface -1- on inlet
camshaft, as shown.
• Camshaft clamp -T40331/5- engages in asymmetrically posi‐
tioned groove (top) -2- on exhaust camshaft, as shown.
Note:
Counterhold tool - T90001- can only be fitted in one position;
notch -1- and marking -2- on camshaft adjuster must align.
Caution

♦ Do NOT use camshaft clamps -T40331- to counterhold
when loosening timing valves for camshaft adjusters.
– Fit socket -VAS 261 001- with counterhold tool - T90001- to

counterhold on corresponding camshaft adjuster and loosen
timing valve -1- with socket E24 - T90000- .
– Mark position of camshaft adjusters in relation to camshafts
with paint for re-installation.

Procedure if engine has NOT been removed during preparatory
work:
contact. If necessary, turn crankshaft backwards and forwards
slightly to fully centralise locking pin.
2. Chain drive 97
Procedure if engine has been removed during preparatory work:

– If still fitted, unscrew plug.
necessary, turn crankshaft back and forth slightly.
Continued:
– Press piston of chain tensioner -2- back as far as stop
-arrow- using a screwdriver -1-. Then lock chain tensioner by
inserting locking pin - T03006- .
Note:
The piston is oil-damped and can therefore only be pressed back
slowly by applying constant pressure.
– Unscrew timing valves -1, 2- and detach both camshaft ad‐

justers.
Installing
• Crankshaft locked in “TDC” position with camshaft clamp -
T40264/3- / locking pin - T40069- .
• Camshaft clamp -T40331/1- screwed on to camshaft housing
(9 Nm)
• Renew friction washers (diamond-coated washers)
⇒ Item 13 (page 90) and ⇒ Item 15 (page 90) after removal.
Caution
Risk of damage to engine if camshaft adjusters are loosened.

♦ When installing, it is very important to ensure that the re‐
quired friction washer (diamond-coated washer) is fitted.
This is necessary to ensure a secure fit between the cam‐
shaft adjuster and the stub on the camshaft.
♦ Bring new friction washer (diamond-coated washer) into
installation position carefully without bending it.
♦ The camshaft adjusters MUST be installed as described
in the following work steps:
• The markings -1, 2- on the camshaft adjusters must be oppo‐

housing.

– With camshaft timing chain fitted, bring camshaft adjusters in‐

to installation position described previously (note marks ap‐
plied when removing).
– Oil timing valves -1, 2- on thread and bolt head contact surface
and screw in without tightening.
• It should still be possible to turn both camshaft adjusters on
the camshaft.

– Have a second mechanic use torque wrench - VAS 6583- with
socket -VAS 261 001- and counterhold tool - T90001- to apply
30 Nm of torque at exhaust camshaft adjuster in anti-clockwise
direction -arrow- and maintain this torque.
– Tighten timing valves as follows using socket E24 - T90000- ,
while keeping camshaft adjuster under tension:
♦ Timing valve -2- on inlet camshaft: 30 Nm
♦ Timing valve -1- on exhaust camshaft: 30 Nm
Checking valve timing
– Remove camshaft clamp -T40331/1- .
– Remove camshaft clamp - T40264/3- / locking pin - T40069- .
Caution


crankshaft two turns -arrow- until vibration damper is back at
“TDC” position.
2. Chain drive 99
• The markings -1, 2- on the camshaft adjusters must be oppo‐

housing.

work:

Continued:
30 Nm of torque at exhaust camshaft adjuster in anti-clockwise


easily.
camshaft as far as stop.
camshaft, as shown.
If it is NOT possible to insert the camshaft clamp -T40331/1- :

camshafts as far as stop, as described previously. To do so,
turn crankshaft slightly.
– Loosen timing valves -1, 2- half a turn using socket E24 -
T90000- .

work:

Continued:
– Repeat adjustment ⇒ page 99 .
2. Chain drive 101

If it is possible to insert the camshaft clamp -T40331/1- :

– Apply counterhold tool - T90001- and counterhold tool -
T90002- to exhaust camshaft adjuster.
– Support counterhold tool at timing valve -2- for inlet camshaft.
If necessary, turn crankshaft clockwise slightly (only clock‐
wise).
– Turn timing valve -1- 35° further using socket E24 - T90000- .

T90002- to inlet camshaft adjuster.
– Support counterhold tool at timing valve -1- for exhaust cam‐
shaft. If necessary, turn crankshaft clockwise slightly (only
clockwise).
– Remove counterhold tool - T90001- and counterhold tool -
T90002- .
– Install air pipe (top) ⇒ 6-cylinder direct injection engine (2.9
– Install timing chain cover (top) for cylinder bank 1
page 81 .
Additional work ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0
ltr. 4-valve TFSI); Rep. gr. 15 ; Chain drive; Removing camshaft
timing chain from camshafts
– If changes have been made to timing chain drive and/or com‐
ponents have been renewed, perform corresponding adap‐
tions listed in Guided Function “0001 - Functions, engine
mechanics” ⇒ Vehicle diagnostic tester.
Tightening torques

camshafts - cylinder bank 2 (left-side)
In the following procedure the camshaft timing chain remains on
the engine.

♦ Locking pin - T40069- (with engine removed)
2. Chain drive 103

♦ Wrench, 21 mm - T40263-
♦ Camshaft clamp - T40264/3-

♦ Socket E24 - T90000- (not illustrated)
♦ Socket -VAS 261 001- (not illustrated)

Preparing camshaft clamp - T40331-

• Lettering “B” on camshaft clamp - T40331/1- faces forwards.
• Camshaft clamps - T40331/5- and -T40331/6- and washers
on bolts -T40331/9- must be positioned using dowel pins
-arrows-.
– Tighten bolts hand tight.
Removing
For the preparatory work required before removing camshaft tim‐
ing chain from camshafts (with engine installed), refer to ⇒ 6-
gr. 15 ; Chain drive; Removing camshaft timing chain from cam‐
shafts .
Caution

– Remove timing chain cover (top) for cylinder bank 2 (right-

side)
page 81 .
– Remove air pipe (top) ⇒ 6-cylinder direct injection engine (2.9
Caution

slips.

crankshaft -arrow- until vibration damper is at “TDC” position.
2. Chain drive 105

• The marking -1, 2- on the camshaft adjusters must be opposite

the corresponding projections -arrows- on the camshaft hous‐
ing. Turn crankshaft one turn if necessary.
– Unscrew bolts -arrows- and remove sealing plugs -2-.

– Press guide tube for oil dipstick -1- slightly to one side.
– Tighten adapter -T40331/2- on camshaft housing to 9 Nm.


easily.
camshafts as far as stop. Turn crankshaft slightly if necessary.
camshaft, as shown.
Note:
Counterhold tool - T90001- can only be fitted in one position;
notch -1- and marking -2- on camshaft adjuster must align.
Caution

♦ Do NOT use camshaft clamps -T40331- to counterhold
when loosening timing valves for camshaft adjusters or
camshaft chain sprocket.
– Fit counterhold tool - T90001- with socket -VAS 261 001- to

counterhold on corresponding camshaft adjuster and loosen
timing valve -1- with socket E24 - T90000- .
– Mark position of camshaft adjusters in relation to camshafts
with paint for re-installation.
2. Chain drive 107


work:

– If still fitted, unscrew plug.
Continued:
– Press guide rail -2- back -arrow- and lock piston of chain ten‐
sioner -1- using locking pin - T03006- .
Note:
– Unscrew timing valves -1, 2- and detach both camshaft ad‐

justers.
Installing
T40264/3- / locking pin - T40069- .
• Camshaft clamp -T40331/1- screwed on to camshaft housing
(9 Nm)
• Renew friction washers (diamond-coated washers)
⇒ Item 11 (page 91) and ⇒ Item 12 (page 91) after removal.

Caution
Risk of damage to engine if camshaft adjusters are loosened.

♦ When installing, it is very important to ensure that the re‐
quired friction washer (diamond-coated washer) is fitted.
This is necessary to ensure a secure fit between the cam‐
shaft adjuster and the stub on the camshaft.
♦ Bring new friction washer (diamond-coated washer) into
installation position carefully without bending it.
♦ The camshaft adjusters MUST be installed as described
in the following work steps:

ing.
– With camshaft timing chain fitted, bring camshaft adjusters in‐

to installation position described previously (note marks ap‐
plied when removing).
– Oil timing valves -1, 2- on thread and bolt head contact surface
and screw in without tightening.
• It should still be possible to turn both camshaft adjusters on
the camshaft.

30 Nm of torque at inlet camshaft adjuster in anti-clockwise
– Tighten timing valves as follows using socket E24 - T90000- ,
while keeping camshaft adjuster under tension:
♦ Timing valve -2- on exhaust camshaft: 30 Nm
♦ Timing valve -1- on inlet camshaft: 30 Nm
Checking valve timing
Caution

2. Chain drive 109


crankshaft two turns -arrow- until vibration damper is back at
“TDC” position.

ing.

work:


Continued:
30 Nm of torque at inlet camshaft adjuster in anti-clockwise

easily.
camshaft as far as stop.
camshaft, as shown.
If it is NOT possible to insert the camshaft clamp -T40331/1- :
camshafts as far as stop, as described previously. To do so,
turn crankshaft slightly.
– Loosen timing valves -1, 2- half a turn using socket E24 -

T90000- .

work:
2. Chain drive 111


Continued:
– Repeat adjustment ⇒ page 109 .
If it is possible to insert the camshaft clamp -T40331/1- :

T90002- to inlet camshaft adjuster.
– Support counterhold tool at timing valve -2- for exhaust cam‐
shaft. Turn crankshaft slightly if necessary.

T90002- to exhaust camshaft adjuster.
– Support counterhold tool at timing valve -1- for inlet camshaft.
Turn crankshaft slightly if necessary.
– Install timing chain cover (top) for cylinder bank 2
page 81 .
Additional work ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0
ltr. 4-valve TFSI); Rep. gr. 15 ; Chain drive; Removing camshaft
timing chain from camshafts
Tightening torques
♦ ⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 23


ing chain
Removing
– Remove timing chain cover (bottom)
page 84 .
Camshaft timing chain for cylinder bank 2 (left-side):
Caution
If a used timing chain rotates in the opposite direction when it

is refitted, this can cause breakage.
♦ Paint an arrow on timing chain (left-side) to mark running
direction and allocation for re-installation.
– Remove camshaft timing chain from camshafts for cylinder

bank 2 (left-side)
⇒ “2.3 Removing camshaft timing chain from camshafts”, page
93 .
– Unscrew guide pins -arrow- and detach guide rail -1- down‐
wards.
– Lift off timing chain -2-.
2. Chain drive 113

Camshaft timing chain for cylinder bank 1 (right-side):

• Camshaft timing chain for cylinder bank 2 (left-side) removed.
– Remove camshaft timing chain from camshafts for cylinder
bank 1 (right-side)
93 .
– Unscrew bolts -arrows- and detach chain tensioner -4-.
– Unscrew mounting pin -2- and remove camshaft timing chain
-3- with tensioning rail -1-.
• Camshaft timing chain must not be separated from tensioning
rail.
Installing
note the following:
– Fit timing chains on camshafts
93 .
– Install timing chain cover (bottom)
page 84 .
Tightening torques
2.5 Removing and installing chain tensioner


♦ Wrench, 21 mm - T40263-
Removing
– Remove relevant timing chain cover (top)
page 81 .
Caution

slips.

crankshaft -arrow- until vibration damper is at “BDC” position.
2. Chain drive 115

Chain tensioner for cylinder bank 1 (right-side):

• The markings -1- on the camshaft adjusters must be opposite
– Press piston of chain tensioner -3- back as far as stop

-arrow- using a screwdriver -1-. Then lock chain tensioner by
inserting locking pin - T03006- .
Note:
– Remove bolts -2 and 4- and take off chain tensioner.
Caution

Chain tensioner for cylinder bank 2 (left-side):

• The markings -1- on the camshaft adjusters must be opposite

– Press guide rail -3- back -arrow- and lock piston of chain ten‐
sioner -1- using locking pin - T03006- .
Note:
– Remove bolts -2 and 4- and take off chain tensioner.
Caution

Installing
– Install timing chain cover (top)
page 81 .
Tightening torques
2. Chain drive 117

3 Cylinder head
❑ For coolant
2 - Cylinder head
2 (left-side)
page 124
⇒ Fig. ““Checking cylin‐
der head for distortion”“ ,
page 121
❑ Machining limit
⇒ Fig. ““Cylinder head
machining limit”“ ,
page 121
3 - Bolt
❑ Loosening sequence:
♦ Cylinder bank 1 (right-side)
⇒ page 126
♦ Cylinder bank 2 (left-side)
⇒ page 136
sequence:
⇒ Fig. ““Cylinder head,
bank 1 (right-side) - tighten‐
ing torques and se‐
⇒ Fig. ““Cylinder head, bank 2 (left-side) - tightening torques and sequence”“ , page 120
5 - Bolt
❑ 22 Nm
6 - Ball stud
❑ 5 Nm +45°

7 - Bolt
❑ 22 Nm
9 - Bolt
♦ Cylinder bank 1 (right-side) ⇒ page 126
♦ Cylinder bank 2 (left-side) ⇒ page 136
❑ Tightening torques and sequence:
⇒ Fig. ““Cylinder head, bank 1 (right-side) - tightening torques and sequence”“ , page 119
❑ Renewing ⇒ “3.3 Removing and installing cylinder head”, page 124
❑ Installation position: part number must face cylinder head
❑ If renewed, change coolant and engine oil
11 - Bolt
♦ Cylinder bank 1 (right-side) ⇒ page 126
♦ Cylinder bank 2 (left-side) ⇒ page 136
⇒ Fig. ““Cylinder head, bank 1 (right-side) - tightening torques and sequence”“ , page 119
Cylinder head, bank 1 (right-side) - tightening torques and se‐

quence
angle.
2. -1 … 8- 30 Nm
3. -1 … 8- 50 Nm
6. -9- 10 Nm
7. -arrows- 8 Nm

Cylinder head, bank 2 (left-side) - tightening torques and se‐

quence
angle.
2. -1 … 8- 30 Nm
3. -1 … 8- 50 Nm
6. -9- 10 Nm
7. -arrows- 8 Nm
Installing coolant bleeder line, cylinder bank 1 (right-side)

Installing coolant bleeder line, cylinder bank 2 (left-side)

– Tighten bolt -arrow- for coolant bleeder line -3- to 9 Nm.


Cylinder head machining limit

Machining of the cylinder head (surface grinding) is only permis‐
sible down to the minimum dimension -a-.
• Minimum dimension -a- = 138.0 ± 0.1 mm

1 - Bolt
❑ 9 Nm
2 - Bearing caps
page 154
tion
3 - Dowel sleeves
page 154
ance
⇒ “4.2 Measuring axial
clearance of camshaft”,
page 153
ance
⇒ “4.3 Measuring radial
clearance of camshaft”,
page 154
5 - Retention valve
❑ For oil separator
6 - O-ring
7 - Gasket
8 - Bolt
❑ 9 Nm
9 - Sealing plug
10 - O-ring
❑ Shown for cylinder bank 2 (left-side)
12 - Bolt
⇒ Fig. ““Camshaft housing, cylinder bank 1 (right-side) - tightening torques and sequence”“ , page 124
⇒ Fig. ““Camshaft housing, cylinder bank 2 (left-side) - tightening torques and sequence”“ , page 124
13 - Plug
❑ 5 Nm +90°

14 - Seal
15 - Restrictor
❑ Cylinder bank I: 20 Nm
❑ Cylinder bank II: 15 Nm
16 - O-ring
17 - Plug
❑ 25 Nm
18 - Bolt
❑ 3 Nm +90°
19 - Cam actuator
❑ Removing and installing ⇒ “4.5 Removing and installing cam actuators”, page 156
20 - O-ring
❑ Supplied with ⇒ Item 19 (page 123) ; not available separately
21 - Plug
❑ 5 Nm +90°
22 - Seal
23 - Rectangular section seals
24 - Sleeve bearing
25 - Rectangular section seals
26 - Axial bearing
27 - Inlet camshaft
❑ Measuring axial clearance ⇒ “4.2 Measuring axial clearance of camshaft”, page 153
❑ Measuring radial clearance ⇒ “4.3 Measuring radial clearance of camshaft”, page 154

Camshaft housing, cylinder bank 1 (right-side) - tightening tor‐

ques and sequence
angle.
2. -1 … 20- 8 Nm
3. -1 … 20- Turn 90° further
Camshaft housing, cylinder bank 2 (left-side) - tightening torques

and sequence
angle.
2. -1 … 19- 8 Nm
3. -1 … 19- Turn 90° further

⇒ “3.3.1 Removing cylinder head, bank 1 (right-side) - vehicles
⇒ “3.3.2 Removing cylinder head, bank 2 (left-side) - vehicles with
page 129
⇒ “3.3.4 Removing cylinder head, bank 1 (right-side) - vehicles
⇒ “3.3.5 Removing cylinder head, bank 2 (left-side) - vehicles with
page 137
3.3.1 Removing cylinder head, bank 1 (right-

side) - vehicles with 2.9 ltr. engine

Procedure
– Remove camshaft housing for cylinder bank 1 (right-side)
bank 1 (right-side)”, page 141 .
– Remove turbocharger (right-side)
⇒ “1.2.1 Removing turbocharger, cylinder bank 1 (right-side) -
– Remove coolant pipe (front) ⇒ 6-cylinder direct injection en‐
gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pipes;
Removing and installing coolant pipes .
– Remove intake manifold (right-side)
sition and screw in bolts until they make contact.
– Remove support bracket ⇒ 6-cylinder direct injection engine
(2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 10 ; Assembly mount‐
– Remove bolt -1- and detach breather line -2- from cylinder
head.


– Detach Lambda probe.
– Remove bolts -2- and detach chain tensioner -1-.

– Remove guide pin -5-.
– If cylinder head is being removed with engine installed: Press
guide rail -4- upwards and secure it to camshaft timing chain
-3- using cable tie, as shown.

– Remove bolts and carefully take off cylinder head.
3.3.2 Removing cylinder head, bank 2 (left-


Procedure
– Remove camshaft housing (left-side)
bank 2 (left-side)”, page 145 .
– Remove turbocharger (left-side)
⇒ “1.2.2 Removing turbocharger, cylinder bank 2 (left-side) -
Audi A6/A7 without electric compressor:
– Bring engine mounting into installation position and screw in
bolts until they make contact.
Audi A6/A7 with electric compressor:
– Bring subframe into installation position and tighten bolts to
115 Nm.
– Lower engine onto engine mounting.
– Remove coolant pipes ⇒ 6-cylinder direct injection engine (2.9
ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pipes; Re‐
moving and installing coolant pipes .
♦ Coolant pipe (front)
♦ Coolant pipe (front left)

– Pull guide tube -2- for oil dipstick off sealing flange (pulley end)
and detach guide tube.
– Remove bolt -arrow- and detach breather line -3- from cylinder
head.
– Disconnect vacuum hose -1-, taking care not to damage it.
– Take electrical connector -1- for Lambda probe 2 after catalytic

converter - G131- out of bracket, unplug and move wiring
clear.
– Detach catalytic converter (left-side).

– Remove bolt -5- for guide rail.
tensioning rail -2- upwards -arrow- and secure it to camshaft
timing chain -1- using cable tie, as shown.


3.3.3 Installing cylinder head - vehicles with

2.9 ltr. engine
able)
Procedure
Note

inder block.
Caution


• Carefully remove sealant residue from cylinder head and cyl‐
inder block.
• Ensure that no long scores or scratches are made on the sur‐
faces.
gasket.
angle.


after removing.
• The gaskets for the left and right cylinder heads have different
shapes and cannot be interchanged.
necessary.
– Check if non-return valve for coolant -arrow- is fitted in cylinder
head (shown on cylinder bank 2).
– Check that dowel sleeves -arrows- are fitted in cylinder block

(shown on cylinder block, bank 2).

2.0 mm).
Caution

♦ The sealant beads must not be thicker than specified.


– Apply beads of sealant -1, 2- onto clean sealing surfaces of
cylinder block and timing chain cover (bottom) as shown.


– Fit cylinder head gasket onto dowel sleeves in cylinder block.
inder head.
– Screw in cylinder head bolts by hand until they make contact.
– Tighten cylinder head bolts.
Note:
after repair work.
note the following:
– Install coolant pipes ⇒ 6-cylinder direct injection engine (2.9
page 141 .
– Change engine oil ⇒ “1.2 Engine oil”, page 175 .
Tightening torques
♦ ⇒ Fig. ““Cylinder head, bank 1 (right-side) - tightening torques
♦ ⇒ Fig. ““Cylinder head, bank 2 (left-side) - tightening torques
♦ ⇒ Fig. ““Installing coolant bleeder line, cylinder bank 1 (right-
side)”“ , page 120
♦ ⇒ Fig. ““Installing coolant bleeder line, cylinder bank 2 (left-
3.3.4 Removing cylinder head, bank 1 (right-


Procedure
– Remove camshaft housing for cylinder bank 1 (right-side)
bank 1 (right-side)”, page 141 .
– Remove intake manifold (right-side)
– If fitted, remove coolant pipe (right-side) ⇒ 6-cylinder direct
injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ;

– Remove bolt -1- and detach breather line -2- from cylinder
head.

– Remove guide pin -5-.
guide rail -4- upwards and secure it to camshaft timing chain
-3- using cable tie, as shown.

3.3.5 Removing cylinder head, bank 2 (left-


Procedure
– Remove camshaft housing (left-side)
bank 2 (left-side)”, page 145 .
Audi A6/A7:
– Bring engine mounting into installation position and screw in
bolts until they make contact.
– Lower engine onto engine mounting.

– Pull guide tube -2- for oil dipstick off sealing flange (pulley end)
and detach guide tube.
– Remove bolt -arrow- and detach breather line -3- from cylinder
head.
– Disconnect vacuum hose -1-, taking care not to damage it.

- G62- .
– Unscrew bolt -5- and move coolant line -6- clear to one side.
– Release screw-type clip -1- and remove nuts -3-.
– Unscrew threaded pins -arrows- and detach flexible joint -2-.

– Remove bolt -5- for guide rail.
tensioning rail -2- upwards -arrow- and secure it to camshaft
timing chain -1- using cable tie, as shown.


3.3.6 Installing cylinder head - vehicles with

3.0 ltr. engine
able)
Procedure
Note

inder block.
Caution


• Carefully remove sealant residue from cylinder head and cyl‐
inder block.
• Ensure that no long scores or scratches are made on the sur‐
faces.
gasket.
angle.


after removing.
• The gaskets for the left and right cylinder heads have different
shapes and cannot be interchanged.
• 3.0 ltr. engine: Renew flexible joint after removing
⇒ Item 19 (page 237) .
necessary.
– Check if non-return valve for coolant -arrow- is fitted in cylinder
head (shown on cylinder bank 2).
– Check that dowel sleeves -arrows- are fitted in cylinder block

(shown on cylinder block, bank 2).


2.0 mm).
Caution

♦ The sealant beads must not be thicker than specified.


– Fit cylinder head gasket onto dowel sleeves in cylinder block.
inder head.
– Screw in cylinder head bolts by hand until they make contact.
– Tighten cylinder head bolts.
Note:
after repair work.
note the following:
page 141 .
– Cylinder head, bank 1 (right-side): Install turbocharger

– Cylinder head, bank 2 (left-side): Fit flexible joint -2- with

screw-type clip -1-. Fit and tighten studs -arrows-.
– Tighten nuts -3-.
– Press flexible joint in direction of -arrow- by hand while tight‐

ening screw-type clip.
• Pressure must be applied at right angle -arrow- to flexible joint.
– When tightening, ensure that flange contour of flexible joint

-1- is positioned flush with contour on turbine housing of tur‐
bocharger.
Note
It is possible to check the correct installation -arrow- of the flexible

joint -1- by examining the screw-type clip from above.
– Change engine oil ⇒ “1.2 Engine oil”, page 175 .

Tightening torques
♦ ⇒ Fig. ““Cylinder head, bank 1 (right-side) - tightening torques
♦ ⇒ Fig. ““Cylinder head, bank 2 (left-side) - tightening torques
♦ ⇒ Fig. ““Installing coolant bleeder line, cylinder bank 1 (right-
♦ ⇒ Fig. ““Installing coolant bleeder line, cylinder bank 2 (left-


ing
bank 1 (right-side)”, page 141
bank 2 (left-side)”, page 145

ing - cylinder bank 1 (right-side)
♦ Impact extractor attachment -T10133/3- from tool set for FSI
engines - T10133 C-
♦ Locating pins - T40116-

♦ Safety goggles
♦ Bolt, M8x25 (2x)
Removing
gr. 15 ; Cylinder head; Removing and installing camshaft hous‐
ing .
– Remove high-pressure pump
⇒ “7.2 Removing and installing high-pressure pump”,
page 313 .
– Remove timing chain from camshafts
93 .

2.9 ltr. engine:

3- For tank breather pressure sensor 1 - G950-
4- For temperature sender for engine cover panel - G765-
5- For overrun air recirculation valve for bank 1 - N625-
6- For switch valve for mechanical coolant pump - N649-
8- For charge pressure control solenoid valve - N75-
– Detach wiring harness and move clear to the side.
bracket and press to side.
3.0 ltr. engine:

3- For tank breather pressure sensor 1 - G950-
4- For temperature sender for engine cover panel - G765-
5- For overrun air recirculation valve for bank 1 - N625-
6- For switch valve for mechanical coolant pump - N649-
8- For charge pressure control solenoid valve - N75-
– Detach wiring harness and move clear to the side.
bracket and press to side.

– Remove nuts -arrows- and detach bracket -1- for solenoid
valves.

– Detach noise insulation (bottom section).

quence -20 ... 1-.
– To loosen camshaft housing -1-, screw in two M8x25 bolts

– Screw bolts in 1/2 turn each (one after the other) until camshaft
housing is released.
– Remove bolts and detach camshaft housing.
Installing
angle.
• Hydraulic compensation elements and roller rocker fingers in‐
stalled.
If only one of the camshaft housings was removed, “TDC” position
of crankshafts must be checked with camshaft housing fitted.
Caution

– Unscrew bolt -3- and remove sealing plug -2-.

centre line, as shown. Turn crankshaft one turn if necessary.
(Shown on exhaust camshaft, cylinder bank 2)
T40264/3- / locking pin - T40069- .
• Camshaft clamp -T40331/1- screwed into camshaft housing
(right-side)
Caution


WARNING
Risk of eye injury.

– Remove remaining sealant from camshaft housing -1- and

cylinder head using rotating plastic brush or similar.

mm).
– Fit gasket -4-.
Caution
Make sure excess sealant does not contaminate camshaft

bearings.
– Apply sealant beads -1, 2, 3- to the clean sealing surfaces of

the camshaft housing.
• Install camshaft housing within 5 minutes after applying the
sealant.
– Place camshaft housing -1- on cylinder head but do not press

sealant beads on yet.
– Insert locating pins - T40116- in camshaft housing and cylinder
head.
– Screw in all bolts for camshaft housing by hand initially and
then tighten.

– Use impact extractor attachment -T10133/3- to pull out locat‐

ing pins - T40116- .
note the following:
– Insert noise insulation (bottom section).
– Install injectors
– Fit camshaft timing chain (adjust valve timing)
93 .
– Install high-pressure pump
⇒ “7.2 Removing and installing high-pressure pump”,
page 313 .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Cylinder head;
Removing and installing camshaft housing
Tightening torques
♦ ⇒ Fig. ““Camshaft housing, cylinder bank 1 (right-side) - tight‐
ening torques and sequence”“ , page 124

ing - cylinder bank 2 (left-side)
♦ Impact extractor attachment -T10133/3- from tool set for FSI
engines - T10133 C-
♦ Adjusting pin - T40060- (with engine installed)

♦ Locating pins - T40116-

♦ Safety goggles
♦ Bolt, M8x25 (2x)
Removing
– Remove timing chain from camshafts
93 .
– Remove crankcase breather module
⇒ “3.2 Removing and installing crankcase breather module”,
page 195 .
– Detach noise insulation (bottom section).
quence -19 ... 1-.

– To loosen camshaft housing -1-, screw in two M8x25 bolts

– Screw bolts in 1/2 turn each (one after the other) until camshaft
housing is released.
– Remove bolts and detach camshaft housing.
Installing
angle.
• Hydraulic compensation elements and roller rocker fingers in‐
stalled.
If only one of the camshaft housings was removed, “TDC” position
of crankshafts must be checked with camshaft housing fitted.
Caution

– Unscrew bolt -3- and remove sealing plug -2-.

centre line, as shown. Turn crankshaft one turn if necessary.
T40264/3- / locking pin - T40069- .
• Camshaft clamp -T40331/1- screwed into camshaft housing
(left-side)
Caution

WARNING
Risk of eye injury.

– Remove remaining sealant from camshaft housing -1- and

cylinder head using rotating plastic brush or similar.


mm).
– Check whether retention valve -5- is fitted.

– Fit gasket -4-.
Caution
Make sure excess sealant does not contaminate camshaft

bearings.
– Apply sealant beads -1, 2, 3- to the clean sealing surfaces of

the camshaft housing.
• Install camshaft housing within 5 minutes after applying the
sealant.

– Insert locating pins - T40116- in camshaft housing and cylinder
head.

work:
gr. 15 ; Cylinder head; Removing and installing camshaft hous‐
ing .
– Insert locating pin - T40116- at front of camshaft housing and
cylinder head.
– Insert adjusting pin - T40060- at rear of camshaft housing and
cylinder head.

Continued:
– Screw in all bolts for camshaft housing by hand initially and
then tighten.
– Use impact extractor attachment -T10133/3- to pull out locat‐
ing pin - T40116- .
– If necessary, pull adjusting pin - T40060- out with pliers.
note the following:
– Insert noise insulation (bottom section).
– Install injectors
– Fit camshaft timing chain (adjust valve timing)
93 .
– Install crankcase breather module
⇒ “3.2 Removing and installing crankcase breather module”,
page 195 .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Cylinder head;
Removing and installing camshaft housing
Tightening torques
♦ ⇒ Fig. ““Camshaft housing, cylinder bank 2 (left-side) - tight‐
ening torques and sequence”“ , page 124

♦ Spark plug socket, 3/8" - VAS 6919-

Procedure
– Remove fuse for fuel pump control unit - J538- ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
– Unscrew spark plugs using spark plug socket, 3/8" - VAS
6919- .

With adapter - V.A.G 1763/12- :

– Screw compression tester - V.A.G 1763- into corresponding
spark plug hole, as shown.
With adapter - V.A.G 1763/12A- :

– Screw compression tester - V.A.G 1763- into corresponding
spark plug hole, as shown.
Continued:
to use tester).
– Have a 2nd mechanic press down the accelerator pedal com‐
pletely and at the same time operate the starter until the
pressure on the tester display no longer increases.

2.9 ltr. engine 3.0 ltr. engine
When new 12.0 … 17.0 14.0 … 18.5
Wear limit 10.0 12.0
Maximum difference between cylinders 3.0 3.0

– Install spark plugs
⇒ “1.1 Exploded view - ignition system”, page 340 .
– Insert fuse for fuel pump control unit - J538- ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.

4 Valve gear
page 157
1 - Exhaust valve
sions”, page 170
guides”, page 169
❑ Different versions; allo‐
cation ⇒ page 153
❑ Renewing
stalling valve stem oil
seals”, page 158
3 - Valve spring
♦ Inlet valve
⇒ Fig. ““Installation position
of valve spring for inlet
valve”“ , page 152
♦ Exhaust valve
⇒ Fig. ““Installation position
of exhaust valve spring”“ ,
page 152
5 - Valve cotters
with a coloured pen
❑ Oil running surfaces before fitting
❑ Clip onto hydraulic compensation element ⇒ Item 8 (page 152) using securing clip
7 - Securing clip
4. Valve gear 151

❑ Check for firm attachment

❑ Clipped onto roller rocker finger ⇒ Item 6 (page 151)
❑ Mark installation position for re-installation with a coloured pen
❑ Oil running surfaces before fitting
9 - Cylinder head
❑ Checking valve guides ⇒ “5.1 Checking valve guides”, page 169
10 - Inlet valve
❑ Valve dimensions ⇒ “5.3 Valve dimensions”, page 170
❑ Checking valve guides ⇒ “5.1 Checking valve guides”, page 169
Installation position of valve spring for inlet valve

• Closely spaced spring coils -arrow- face towards cylinder
head.
Installation position of exhaust valve spring

• Coloured markings -arrows- face upwards.

Allocation of valve stem oil seals

A - Exhaust side, painted red
B - Inlet side, painted green

4. Valve gear 153

Procedure
• Camshaft housing removed
page 141 .
et - VW 387- to camshaft housing.
– Press camshaft against dial gauge by hand.
– Press camshaft away from dial gauge and read off value:
Axial clearance
• Inlet camshaft: 0.014 ... 0.064 mm
• Exhaust camshaft: 0.048 ... 0.155 mm

♦ Plastigauge
Procedure
– Remove camshafts
⇒ “4.4 Removing and installing camshaft”, page 154 .
– Mark allocation of roller rocker fingers for re-installation.
– Carefully remove roller rocker fingers and place them on a
clean surface.
– Clean bearings and bearing journals.
bearing on the bearing journal or bearing shell to be measured.
ing.
– Re-insert camshafts, fit camshaft housing and tighten to speci‐
fied torque without rotating camshafts
⇒ Fig. ““Camshaft housing, cylinder bank 1 (right-side) - tight‐
ening torques and sequence”“ , page 124 .
– Remove camshaft housing and camshafts again.
Radial clearance:
• 0.024…0.066 mm

The procedure is described for the cylinder bank 1 (right-side).

Removing
– Remove relevant camshaft housing
page 141 .
– Remove camshaft clamp -T40331/1- -arrows-.
– Unscrew bolts -arrows- and detach bearing caps -1 … 4-.

– Detach camshafts -5, 6-.
Installing
To prevent installation at the wrong locations, bearing caps are
marked in relation to camshaft housing as shown.
Note
The camshaft must be renewed if the slider for cam travel adjust‐
ment has been pushed out of the camshaft splines.
4. Valve gear 155

– Bring axial bearing -2- and camshafts into installation position

on camshaft housing.
• The ends of the rectangular section seals -5- must point up or
down, never to the side.
• Sleeve bearing -1- must be fitted on camshaft housing
– Bring all bearing caps -4- into installation position and secure
with bolts, noting allocation.
• Both dowel sleeves -3- must engage in holes in each bearing
cap.
• Spring pins must engage in holes in camshaft housing.
– Align camshafts and insert camshaft clamp -T40331/1- as far

as stop.
• Lettering on camshaft clamp faces forwards (“A” for cylinder
bank 1).
– Tighten bolts -arrows- hand-tight.
camshaft.
tioned groove (top) -2- on exhaust camshaft.
page 141 .

Removing cylinder bank 1 (right-side)
gr. 15 ; Valve gear; Removing and installing cam actuators .
1- For inlet cam actuator -F448- , -F452- , -F456-
2- For ignition coils -N70- , -N127- , -N291-
– Remove bolts -arrows- and move earth wiring clear.

Removing cylinder bank 2 (left-side)

gr. 15 ; Valve gear; Removing and installing cam actuators .
1- For inlet cam actuator -F460- , -F464- , -F468-
2- For ignition coils -N292- , -N323- , -N324- (lift wiring duct
slightly if necessary)
– Remove bolts -arrows- and move earth wiring clear.

– Press top section of noise insulation upwards.
– Remove bolts -arrows- and detach cam actuator -1-.
Installing
• Check O-rings for damage ⇒ page 265 .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Valve gear;
Tightening torques
♦ Earth wires ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations

This procedure applies to camshaft control valves -N205- , -
N208- , -N318- and -N319- .
Removing
gr. 15 ; Valve gear; Removing and installing camshaft control
valve 1 - N205- .
4. Valve gear 157


– Unscrew bolts -arrows- and remove camshaft control valve
-1-.
Installing
page 10 .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 15 ; Valve gear;
Tightening torques

seals

♦ Valve stem seal puller - 3364- for inlet side
♦ Valve stem oil seal fitting tool - 3365- for inlet side, or (de‐
pending on version/manufacturer of valve stem oil seal)
♦ Valve shaft seal fitting tool - T40376/1- (not illustrated)


A- with guide plate - VAS 5161A/38-
♦ Spark plug socket, 3/8" - VAS 6919- (not illustrated)

♦ Valve stem pliers - VAS 6770- for exhaust side
♦ Wrench, 21 mm - T40263-
4. Valve gear 159

♦ Valve shaft seal fitting tool -T40376/2- for exhaust side (not
illustrated)
Preparing tool
– Secure M8 hexagon socket head bolts with large bolt head
diameter -arrows- (from tool kit) to underside of guide plate -
VAS 5161A/38- , as shown.
• Guide plate is centred to cylinder head using hexagon socket
head bolts.
Procedure
– Remove relevant camshaft housing
page 141 .
– Unscrew spark plugs using spark plug socket, 3/8" - VAS
6919- .
Caution
Avoid damage to timing chain.

♦ Camshaft timing chains must be guided when crankshaft
is turned.

crankshaft -arrow- until piston of corresponding cylinder is at
“bottom dead centre” position.

– Align guide plate - VAS 5161A/38- on cylinder head, noting

markings:
A - Exhaust side
E - Inlet side
– Tighten bolts -arrows- for guide plate to 9 Nm.
– Screw sealing pin -VAS 5161/10- hand-tight into guide plate -

VAS 5161A/38- .
– Screw adapter - T40012/1- with seal hand-tight into the cor‐
responding spark plug thread.
available connection piece -arrow- and apply constant air
pressure.
– Screw snap-in device -VAS 5161/6- with engaging fork into

guide plate using M8 stud -VAS 5161/5- .
– At the same time, turn knurled screw -arrow- of assembly car‐
tridge clockwise until tips engage in valve cotters.
• Knurled screw should slide into assembly cartridge as far as
stop.
Caution
Risk of damage to valves if handled incorrectly.

♦ To prevent valve from falling into cylinder, do not unbolt
guide plate and sealing pin.
♦ The pressure in the cylinder must be held at at least 6 bar.
– Mark installation position of springs for exhaust valve with

paint for re-installation.
4. Valve gear 161

– Detach valve stem oil seal.

Inlet side:
– Use valve stem seal puller - 3364- to do so.
Exhaust side:
– Use valve stem pliers - VAS 6770- to do so. If difficult to re‐
move, heat with hot air blower - V.A.G 1416- .
Continued:
If the valve stem seal puller - 3364- cannot be used on some of
the valve stem oil seals due to the confined space, proceed as
follows:
– Knock out pin -arrow- of puller using a drift and remove impact
extractor attachment.
– Secure bottom section of puller -3364- with punch or roll-pin

drift -1-.
– Apply puller at valve stem oil seal.
– Apply assembly lever to puller and pull out valve stem oil seal
-arrow-.
Inlet side:
– Insert valve stem oil seal into valve shaft seal fitting tool -5-
and use assembly sleeve to press it carefully onto valve guide
-1- as far as stop.

Exhaust side:
T40376/2- and use assembly sleeve to carefully press it onto
Continued:
– Insert valve spring and valve spring plate:
• Installation position of inlet valve
⇒ Fig. ““Installation position of valve spring for inlet valve”“ ,
page 152
• Installation position of exhaust valve
⇒ Fig. ““Installation position of exhaust valve spring”“ ,
page 152
– Insert assembly cartridge -VAS 5161/8A- in guide plate - VAS

5161A/38- again.
– Press down pressure fork -VAS 5161/2- and pull knurled
screw -arrow- upwards while turning screw in both directions
- this will insert the valve cotters.
tion.
Attaching
– Install camshafts
⇒ “4.4 Removing and installing camshaft”, page 154 .
– Install spark plugs
⇒ “1.1 Exploded view - ignition system”, page 340 .

4. Valve gear 163

♦ Valve stem seal puller - 3364- for inlet side
♦ Valve stem oil seal fitting tool - 3365- for inlet side, or (de‐
pending on version/manufacturer of valve stem oil seal)
♦ Valve shaft seal fitting tool - T40376/1- (not illustrated)

A- with guide plate - VAS 5161A/38-

♦ Valve stem pliers - VAS 6770- for exhaust side
♦ Valve shaft seal fitting tool -T40376/2- for exhaust side (not
illustrated)
Preparing tool
– Secure M8 hexagon socket head bolts with large bolt head
diameter -arrows- (from tool kit) to underside of guide plate -
VAS 5161A/38- , as shown.
• Guide plate is centred to cylinder head using hexagon socket
head bolts.
Procedure

– Secure cylinder head in cylinder head tensioning device.
supply.
with valve heads.
4. Valve gear 165

– Align guide plate - VAS 5161A/38- on cylinder head, noting

markings:
A - Exhaust side
B - Inlet side
– Tighten bolts -arrows- for guide plate to 9 Nm.
– Screw snap-in device -VAS 5161/6- with engaging fork into

guide plate using M8 stud -VAS 5161/5- .
– At the same time, turn knurled screw -arrow- of assembly car‐
tridge clockwise until tips engage in valve cotters.
• Knurled screw should slide into assembly cartridge as far as
stop.
– Mark installation position of springs for exhaust valve with
paint for re-installation.
– Detach valve stem oil seal:

Inlet side:
– Use valve stem seal puller - 3364- to do so.
Exhaust side:
– Use valve stem pliers - VAS 6770- to do so. If difficult to re‐
move, heat with hot air blower - V.A.G 1416- .

Inlet side:
– Insert valve stem oil seal into valve shaft seal fitting tool -5-
and use assembly sleeve to press it carefully onto valve guide
-1- as far as stop.
Exhaust side:
T40376/2- and use assembly sleeve to carefully press it onto
Continued:
– Insert valve spring and valve spring plate:
• Installation position of inlet valve
⇒ Fig. ““Installation position of valve spring for inlet valve”“ ,
page 152
• Installation position of exhaust valve
⇒ Fig. ““Installation position of exhaust valve spring”“ ,
page 152
4. Valve gear 167

– Insert assembly cartridge -VAS 5161/8A- in guide plate - VAS

5161A/38- again.
– Press down pressure fork -VAS 5161/2- and pull knurled
screw -arrow- upwards while turning screw in both directions
- this will insert the valve cotters.
tion.
Attaching
page 141 .



Procedure
into exhaust valve guide.
– Secure dial gauge - VAS 6079- to cylinder head with universal
dial gauge bracket - VW 387- as shown in illustration.
new valves.
5.2 Checking valves

faces.


in is permitted.
2.9 ltr. 3.0l 2.9 ltr. 3.0l
∅a mm 32.0 ± 0.1 28.0 ± 0.1
∅b mm 5.92 ± 0.02 5.92 ± 0.02
c mm 102.43 103.184
α ∠ 44°50’ ± 10’ 45 44° 45
50’ ± 10’

17 – Lubrication
1 Sump/oil pump
page 175
⇒ “1.5 Removing and installing oil baffle plate”, page 185
er G266 ”, page 189

must be cleaned thoroughly to ensure that this does not result
in damage. In addition, renew oil spray jets, engine oil cooler
and oil filter element.
♦ Oil spray jet for piston cooling
⇒ “5.1 Exploded view - pistons and conrods”, page 69 .

1 - Bolt
sequence
⇒ Fig. ““Sump (bottom
section) - tightening tor‐
ques and sequence”“ ,
page 173
stalling sump (bottom
section)”, page 175
❑ For oil pump
❑ Supplied with
4 - Bolt
❑ Supplied with
⇒ Item 3 (page 172) ; not
available separately
❑ 8 Nm +90°
5 - Chain sprocket
❑ For oil pump
6 - Bolt
❑ 20 Nm +90°
7 - Bolt
sequence
⇒ Fig. ““Sump (top section) - tightening torques and sequence with bottom cover for camshaft timing
chains fitted”“ , page 174 or
⇒ Fig. ““Sump (top section) - tightening torques and sequence with camshaft timing chain cover (bottom)
removed”“ , page 174
9 - Dowel sleeve
10 - Bolt
⇒ Fig. ““Oil baffle plate - tightening torques and sequence”“ , page 174
11 - Oil baffle plate
❑ Removing and installing ⇒ “1.5 Removing and installing oil baffle plate”, page 185
12 - Dowel sleeve
13 - Dowel sleeve
14 - Bolt


⇒ Fig. ““Timing chain cover (bottom) - tightening torques and tightening sequence”“ , page 81 and
⇒ Fig. ““Oil baffle plate - tightening torques and sequence”“ , page 174
15 - Dowel sleeve
16 - Gasket
17 - Dowel sleeve
18 - Bolt
❑ 8 Nm +90°
19 - Oil pump
❑ Removing and installing ⇒ “1.6 Removing and installing oil pump”, page 187
20 - O-ring
21 - Seal
22 - Oil drain plug
❑ Lubricate thread
❑ 30 Nm
⇒ “1.7 Removing and installing oil level and oil temperature sender G266 ”, page 189
24 - Bolt
❑ 3 Nm +90°
25 - Seal

angle.
2. -1 … 17- 3 Nm
3. -1 … 17- Turn 90° further

Oil baffle plate - tightening torques and sequence

angle.
1. -arrows- Screw in by hand until contact is made
2. -1, 2- 3 Nm
5. -arrows- Turn 90° further in diagonal sequence
Sump (top section) - tightening torques and sequence with bottom

cover for camshaft timing chains fitted
angle.
2. -20, 21- 3 Nm
3. -1 … 19- 3 Nm
4. -20, 21- Turn 90° further
5. -1 … 19- Turn 90° further
Sump (top section) - tightening torques and sequence with cam‐

shaft timing chain cover (bottom) removed
angle.
2. -1 … 19- 3 Nm
3. -1 … 19- Turn 90° further

1.2 Engine oil

gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 17 ; Sump/oil
pump; Engine oil
tenance tables .

section)

♦ Safety goggles
Removing
• Engine oil drained ⇒ “1.2 Engine oil”, page 175 .
– If fitted, remove bolt -1- and press bracket -2- with electrical
wiring harness to one side.

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

ature sender - G266- .
Caution
Take care to keep components clean.

♦ There will still be some oil in the sump (bottom section).

– Carefully release sump (bottom section) from bonded joint and
detach.
Installing
angle.
Caution

tion.
WARNING
Risk of eye injury.

– Remove remaining sealant on bottom section -1- and top sec‐

tion of sump with a rotating plastic brush or similar.

mm).

Caution

– Apply sealant bead -arrow- onto clean sealing surface of sump

(bottom section) as shown in illustration.
• Install sump (bottom section) within 5 minutes of applying
sealant.
– Carefully fit bottom section of sump onto top section but do not
press sealant bead on yet.
note the following:
– Fill with engine oil and check oil level
⇒ “1.2 Engine oil”, page 175 .
Tightening torques

tion)
⇒ “1.4.1 Removing and installing sump (top section) with timing
chain cover (bottom) installed”, page 177
⇒ “1.4.2 Removing and installing sump (top section) with timing
chain cover (bottom) removed”, page 181
1.4.1 Removing and installing sump (top sec‐

tion) with timing chain cover (bottom)
installed
Complete procedure if timing chain cover (bottom) has NOT been
removed during preparatory work


♦ Safety goggles
♦ Bolt, M6x30 (4x)
Removing
tion) .
– If not yet removed, remove steering rack ⇒ Running gear,
axles, steering; Rep. gr. 48 ; Steering rack; Removing and
installing steering rack .
page 175 .
– 2.9 ltr. engine: Remove bracket for air conditioner compressor
compressor - vehicles with 2.9 ltr. engine without electric com‐
pressor”, page 39 .
– 3.0 ltr. engine: Detach poly V-belt for air conditioner compres‐
sor from pulley
– Vehicles with brace for subframe: Remove bolts -arrows- and
detach brace -1-.


– To loosen sump (top section) -1-, screw in four M6x40 bolts

– Screw bolts 1/2 turn each in diagonal sequence until sump (top
section) is released.
– Remove bolts and detach sump (top section).
Installing
• Renew intake connecting pipe with bolt and O-ring after re‐
moval.
Caution

tion.
WARNING
Risk of eye injury.

– Remove sealant residue from sump (top section) and cylinder

block -1- using rotating plastic brush or similar.


mm).
– Detach dowel sleeves -1, 2-.

– Apply sealant at joints between cylinder block and timing chain
cover (bottom) -arrow-.

Caution


sump (top section).
chanic. To do so, guide it towards sealing surface on cylinder
block and timing chain cover (bottom) at an angle from below,
but do not press sealant bead on yet.
note the following:
– 2.9 ltr. engine: Install bracket for air conditioner compressor
– 3.0 ltr. engine: Install poly V-belt for air conditioner compressor
page 175 .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 17 ; Sump/oil pump;
Removing and installing sump (top section) .
Tightening torques
♦ ⇒ Fig. ““Sump (top section) - tightening torques and sequence
with bottom cover for camshaft timing chains fitted”“ ,
page 174
1.4.2 Removing and installing sump (top sec‐

tion) with timing chain cover (bottom)
removed
Simplified procedure if timing chain cover (bottom) has been re‐
moved during preparatory work


♦ Safety goggles
♦ Bolt, M6x30 (4x)
Removing
tion) .
– If not yet removed, remove steering rack ⇒ Running gear,
axles, steering; Rep. gr. 48 ; Steering rack; Removing and
installing steering rack .
page 175 .
– 2.9 ltr. engine: Remove bracket for air conditioner compressor
– Vehicles with brace for subframe: Remove bolts -arrows- and
detach brace -1-.


– To loosen sump (top section) -1-, screw in four M6x40 bolts

– Screw bolts 1/2 turn each in diagonal sequence until sump (top
section) is released.
– Remove bolts and detach sump (top section).
Installing
• Renew intake connecting pipe with bolt and O-ring after re‐
moval.
Caution

tion.

WARNING
Risk of eye injury.

– Remove sealant residue from sump (top section) and cylinder

block -1- using rotating plastic brush or similar.

mm).

Caution


sump (top section).
chanic but do not press sealant bead on yet.
note the following:
– Install timing chain cover (bottom)
page 84 .
– 2.9 ltr. engine: Install bracket for air conditioner compressor
page 175 .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 17 ; Sump/oil pump;
Removing and installing sump (top section) .
Tightening torques
♦ ⇒ Fig. ““Sump (top section) - tightening torques and sequence
with camshaft timing chain cover (bottom) removed”“ ,
page 174
1.5 Removing and installing oil baffle plate

♦ Safety goggles
Removing
– With timing chain cover (bottom) fitted, remove sump (top sec‐
tion)

⇒ “1.4.1 Removing and installing sump (top section) with tim‐

ing chain cover (bottom) installed”, page 177 .
– Remove bolts -arrows- and -1, 2-.
– Lever oil baffle plate downwards out of bonded joint on timing
chain cover (bottom) and detach oil baffle plate.
Installing
Caution

tion.
WARNING
Risk of eye injury.

– Remove sealant residue from oil baffle plate and cylinder block
-1- using rotating plastic brush or similar.

Caution

♦ The sealant must not be applied thicker than specified.
– Thinly coat sealing surfaces -arrows- on oil baffle plate and

timing chain cover (bottom) -2- with sealant.
• Install oil baffle plate within 5 minutes of applying sealant.
– Carefully fit oil baffle plate. To do so, guide it towards sealing
surface on cylinder block and timing chain cover (bottom) at
an angle and from below.
note the following:
Tightening torques
♦ ⇒ Fig. ““Oil baffle plate - tightening torques and sequence”“ ,
page 174

Removing

– Fit counterhold tool - T10172- with adapter -T10172/2- and

remove bolt -arrow-.
– Pull chain sprocket -1- off oil pump and leave it in position.
– Remove bolts -arrows- and detach oil pump -1-.

Installing
angle.
– Check that centring sleeves -arrows- are fitted in oil pump.

– Fit gasket -1-.
⇒ “1.4.1 Removing and installing sump (top section) with tim‐
ing chain cover (bottom) installed”, page 177 .
Tightening torques


Removing
– Remove bolts -1- and detach oil level and oil temperature
Installing
– Fill with engine oil and check oil level
⇒ “1.2 Engine oil”, page 175 .
Tightening torques

2 Engine oil cooler

⇒ “2.3 Removing and installing spray nozzle valve”, page 192
1 - O-ring
2 - O-ring
3 - Spray nozzle valve
stalling spray nozzle
valve”, page 192
4 - Seal
5 - Plug
❑ 10 Nm +45°
6 - Seals
7 - O-rings
8 - Hose
❑ Cannot be removed
without being damaged
irreparably
stalling engine oil cool‐
er”, page 190
❑ If renewed, refill system
with fresh coolant
10 - Bolt
❑ 9 Nm
11 - Seals

er

♦ Safety goggles
Removing
gr. 17 ; Engine oil cooler; Removing and installing engine oil
cooler .
– Release engine oil cooler -2- from bonded joint and detach
with crankcase breather hose -1-.
Installing
Caution

tion.
♦ Cover exposed parts of engine and engine oil cooler.
WARNING
Risk of eye injury.

– Remove sealant residue on engine oil cooler -1- and cylinder

block using rotating plastic brush or similar.

mm).

Caution

– Fit seals -2, 3-.

– Apply bead of sealant -1- onto clean sealing surface of cylinder
block.
• Install engine oil cooler within 5 minutes of applying the seal‐
ant.
– Fit engine oil cooler and tighten bolts.
note the following:
– Check oil level ⇒ “1.2 Engine oil”, page 175 .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 17 ; Engine oil
cooler; Removing and installing engine oil cooler
Tightening torques
2.3 Removing and installing spray nozzle

valve
♦ Hook - T40207-
Removing
– Remove engine oil cooler
⇒ “2.2 Removing and installing engine oil cooler”, page 190 .
– Remove screw plug -arrow-.

– Pull out spray nozzle valve -1- using hook - T40207- .

Installing
– Install engine oil cooler
⇒ “2.2 Removing and installing engine oil cooler”, page 190 .
Tightening torques

⇒ “3.2 Removing and installing crankcase breather module”, page
195
2 - Hose/sealing plug
3 - O-ring
❑ For specific equipment
version
4 - Gasket
5 - Crankcase breather module
stalling crankcase
breather module”,
page 195
6 - Grommet
7 - Seal
8 - Filler cap
9 - Bolt
sequence
⇒ Fig. ““Crankcase
breather module - tight‐
ening torques and se‐
10 - O-ring
11 - Hose
❑ Crankcase breather hose cannot be detached from air pipe without being irreparably damaged
⇒ “2.1 Exploded view - charge air system”, page 259 .

Crankcase breather module - tightening torques and sequence

– Tighten bolts to 9 Nm in the sequence shown.
3.2 Removing and installing crankcase

breather module
Removing
installing.
– Remove engine cover panel and heat shield
page 10 .
– If fitted, open heat shield sleeve.
breather connection -arrow-.
– Unscrew bolts -1 … 6- and remove crankcase breather mod‐
ule.
Installing
• Renew seal/gasket and O-ring after removal.
– Install heat shield and engine cover panel
page 10 .
Tightening torques
♦ ⇒ Fig. ““Crankcase breather module - tightening torques and


page 198
page 201
203
page 205
”, page 207
1 - Temperature regulator for

engine oil
stalling oil filter hous‐
ing”, page 199
2 - Gasket
3 - Bracket
❑ For air pipe (top)
❑ Not fitted on all models
4 - Bolt
sequence
⇒ Fig. ““Oil filter housing
- tightening torques and
stalling oil filter hous‐
ing”, page 199
6 - O-ring
8 - O-ring
9 - Bolt
❑ 9 Nm
10 - Oil supply line
❑ Removing and installing ⇒ “1.2 Engine oil”, page 175

12 - O-ring
❑ Part of oil filter element
13 - Sealing cap
❑ 25 Nm
14 - Bolt
⇒ Fig. ““Oil filter housing - tightening torques and sequence”“ , page 197
15 - Bracket
16 - Cylinder block
Oil filter housing - tightening torques and sequence

angle.
2. -1 … 6- 5 Nm
3. -1 … 6- 8 Nm

4.2 Exploded view - oil pressure switches/oil pressure control

Shown on vehicle with 3.0 ltr. engine.

stalling oil pressure
sender G10 ”,
page 205
❑ 20 Nm
2 - Seal
sure 0.3 … 0.6 bar
(monitoring of switcha‐
ble piston oil spray jets)
agnostic tester
stalling oil pressure
switch F22 ”, page 201
❑ 20 Nm
4 - Seal
5 - Bolt
❑ 9 Nm
6 - Oil temperature sender -
G8-
stalling oil temperature
7 - O-rings
8 - Bolt
❑ 9 Nm
⇒ “4.8 Removing and installing valve for oil pressure control N428 ”, page 207
10 - O-ring



Removing
– Remove turbocharger (left-side)
– Remove bolt -arrow- and disconnect oil supply line -1-.

– Unscrew bolts -1 … 6- using socket Torx T30 - T10405- , de‐

tach oil filter housing.
– Detach temperature regulator for engine oil.
Installing
• Renew O-ring and gasket after removal.
angle.
– Install oil filter element ⇒ “1.2 Engine oil”, page 175 .
– Install turbocharger (left-side)
Tightening torques

Removing
oil filter housing .

– Unscrew bolts -1 … 6- using socket Torx T30 - T10405- , de‐

tach oil filter housing.
– Detach temperature regulator for engine oil.
Installing
• Renew O-ring and gasket after removal.
angle.
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 17 ; Oil filter/oil
pressure switches; Removing and installing oil filter housing
Tightening torques

switch - F22-
⇒ “4.4.1 Removing and installing oil pressure switch F22 - vehi‐
⇒ “4.4.2 Removing and installing oil pressure switch F22 - vehi‐

switch - F22- - vehicles with 2.9 ltr. en‐
gine
Procedure
installing.
– Remove catalytic converter (left-side) ⇒ 6-cylinder direct in‐
jection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 26 ;
Emission control system; Removing and installing catalytic
converter , move it to one side and secure it with Lambda
probe connected (to do so, move electrical wiring clear).


– Use articulated wrench, 24 mm - T40175- to unscrew oil pres‐
sure switch - F22- .
– Install catalytic converter (left-side) ⇒ 6-cylinder direct injec‐
tion engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 26 ;
converter .
Tightening torques
trol”, page 198

switch - F22- - vehicles with 3.0 ltr. en‐
gine
Procedure
installing.
Audi Q8
gine (3.0 ltr. 4-valve TFSI EA 839); Rep. gr. 24 ; Air cleaner;
Removing and installing air cleaner housing .
All models except Audi Q8
page 10 .


– Use articulated wrench, 24 mm - T40175- to unscrew oil pres‐
sure switch - F22- .
page 10 .
Tightening torques
trol”, page 198
♦ ⇒ 6-cylinder direct injection engine (3.0 ltr. 4-valve TFSI EA
839); Rep. gr. 24 ; Air cleaner; Exploded view - air cleaner
housing

sender - G8-
⇒ “4.5.1 Removing and installing oil temperature sender G8 - ve‐
⇒ “4.5.2 Removing and installing oil temperature sender G8 - ve‐
4.5.1 Removing and installing oil temperature

gine
Removing
– Remove catalytic converter (left-side) ⇒ 6-cylinder direct in‐
converter , move it to one side and secure it with Lambda
probe connected (to do so, move electrical wiring clear).


– Unscrew bolt -2- and pull off oil temperature sender - G8- .
Note:
If O-rings remain lodged in cylinder block, lift them out with a piece
of wire.
– Fit new oil temperature sender immediately so that as little oil
as possible is lost.
– Install catalytic converter (left-side) ⇒ 6-cylinder direct injec‐
tion engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 26 ;
converter .
Tightening torques
trol”, page 198
4.5.2 Removing and installing oil temperature

gine
Removing
Audi Q8
gine (3.0 ltr. 4-valve TFSI EA 839); Rep. gr. 24 ; Air cleaner;
Removing and installing air cleaner housing .
All models except Audi Q8
page 10 .


– Unscrew bolt -2- and pull off oil temperature sender - G8- .
Note:
If O-rings remain lodged in cylinder block, lift them out with a piece
of wire.
– Fit new oil temperature sender immediately so that as little oil
as possible is lost.
page 10 .
Tightening torques
trol”, page 198
♦ ⇒ 6-cylinder direct injection engine (3.0 ltr. 4-valve TFSI EA
839); Rep. gr. 24 ; Air cleaner; Exploded view - air cleaner
housing

sender - G10-

gine
♦ Socket, 24 mm - T40363- (not illustrated)
Procedure
gr. 17 ; Oil filter/oil pressure switches ; Removing and installing
oil pressure sender - G10- .
– If not removing oil pressure sender - G10- to measure oil pres‐
sure, remove coolant pipe (front left) ⇒ 6-cylinder direct in‐
– If removing oil pressure sender - G10- to measure oil pressure,
remove radiator with radiator cowl ⇒ 6-cylinder direct injection
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Radiators/
radiator fans; Removing and installing radiator .


T40363- .
– Fit new oil pressure sender immediately so that as little oil as
possible is lost.
– If removed previously, install radiator ⇒ 6-cylinder direct in‐
Radiators/radiator fans; Removing and installing radiator .
– If removed previously, install coolant pipe (front left) ⇒ 6-cyl‐
gr. 19 ; Coolant pipes; Removing and installing coolant pipes .
- G10-
Tightening torques
trol”, page 198

gine
♦ Socket, 24 mm - T40363- (not illustrated)
Procedure
gr. 17 ; Oil filter/oil pressure switches ; Removing and installing
oil pressure sender - G10- .
T40363- .
possible is lost.
- G10-
Tightening torques
trol”, page 198


Procedure
• Oil level OK
• Engine oil temperature approx. 80 °C
– Remove oil pressure sender - G10-
page 205 .
– Connect oil pressure tester - V.A.G 1342- to opening for oil
pressure sender and tie up test hose so it is clear of vibration
damper.
– Screw oil pressure sender - G10- into oil pressure tester.
– Start engine and leave it running only as long as required for
the test.
– Start engine.
• Minimum oil pressure at idling speed: 0.9 bar.
Attaching
– Install oil pressure sender - G10-
page 205 .


2.9 ltr. engine
Removing
valve for oil pressure control - N428- .
– If not removed already, remove noise insulation (front) ⇒

– If not yet removed, remove front left wheel spoiler ⇒ General

moving and installing wheel housing liner (front) .
– Unplug electrical connector -2- and move electrical wiring har‐
ness clear.
– Detach valve for oil pressure control - N428- from cylinder
block.
Installing
control - N428-
Tightening torques
trol”, page 198

3.0 ltr. engine
Removing
valve for oil pressure control - N428- .
– Unplug electrical connector -2- and move electrical wiring har‐
ness clear.
– Detach valve for oil pressure control - N428- from cylinder
block.
Installing
control - N428-
Tightening torques
trol”, page 198

19 – Cooling

gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Cooling system/
coolant; Connection diagram - coolant hoses .


version 1

♦ Cooling system tester adapter - V.A.G 1274/9- for filler cap,

version 2
Procedure
leaks .
WARNING


expansion tank.


nutes.
inate fault.
Note:
engine is cold.
WARNING

• To release pressure, press pressure relief valve on cool‐
ing system tester until reading on pressure gauge is 0.

Blue filler cap:
this level.
scribed.
Black filler cap:
this level.
scribed.


Blue filler cap:
1.4 ... 1.6 bar.
scribed.
Black filler cap:
1.6 ... 1.8 bar.
scribed.
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Cooling sys‐
tem/coolant; Checking cooling system for leaks


Note

tropical climates.
++ and G12evo.
tection.
the coolant.
ses.

gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Cooling system/


page 216
page 217
”, page 220
⇒ “2.8 Removing and installing engine outlet coolant temperature



installing coolant
valves”, page 227
2 - Bolt
❑ 9 Nm
stalling map-controlled
engine cooling system
thermostat F265 ”, page
217
4 - Bolt
❑ 10 Nm +90°
5 - Pulley
6 - Coolant pump
stalling coolant pump”,
page 217
7 - Bolt
sequence
⇒ Fig. ““Coolant pump -
8 - Gasket
9 - Seal
❑ Renew after removing map-controlled engine cooling system thermostat -F265-
10 - O-ring
11 - O-ring
12 - Seal
13 - Bolt
❑ 9 Nm


1. -1, 2- 9 Nm
2. -1 … 7- 9 Nm

gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pump/
thermostat assembly; Exploded view - electric coolant pump .

1 - O-rings
❑ Renew
stalling engine outlet
coolant temperature
sender G82 ”,
page 222
3 - Bolt
❑ 9 Nm
4 - O-rings
❑ Renew
G694-
❑ Black insulation
installing temperature
sender for engine tem‐
perature regulation
G694 ”, page 225
6 - Bolt
❑ 9 Nm
7 - Bolt
❑ 9 Nm
er - G62-
stalling coolant temper‐
ature sender G62 ”, page 220

9 - O-rings
❑ Renew
10 - O-rings
❑ Renew
❑ Different installation position depending on model
❑ Removing and installing ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ;
Coolant pump/thermostat assembly; Removing and installing radiator outlet coolant temperature sender
- G83-
12 - Bolt
❑ Thread-forming
❑ 4.5 Nm

pump
thermostat assembly; Removing and installing electric coolant
pump .

Removing
it.
– Remove bolts -1 ... 7- and detach coolant pump.
Installing
angle.
necessary.
Tightening torques
♦ ⇒ Fig. ““Coolant pump - tightening torques and sequence”“ ,
page 216

F265-

♦ -VW 771/37- from multi-purpose tool - VW 771- with:
♦ Adapter -T10055/3-
♦ Striker -T10133/3- from tool set for FSI engines - T10133C-
♦ Press tool -T40357- (not illustrated)

♦ Threaded pin M10x20
Preparing tool
– Attach striker -T10133/3- to -VW 771/37- . Use adapter -
T10055/3- and threaded pin -1- to do so.

Removing
– Preparatory work may be necessary depending on model ⇒
6-cylinder direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI);
Rep. gr. 19 ; Coolant pump/thermostat assembly; Removing
and installing map-controlled engine cooling system thermo‐
stat - F265- .
– Remove coolant pipe (front left) ⇒ 6-cylinder direct injection
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant
– Detach coolant valve for cylinder block - N545- -item 4- from
bracket and press it to side.
– Unplug electrical connector -2- and move electrical wiring
clear at map-controlled engine cooling system thermostat -
F265- .
– Remove bolts -arrows- and detach -F265- .
– Pull seal -arrow- off using tool prepared previously.
Installing
• Renew seal and O-ring after removing.
– Slide seal -arrow- on using press tool -T40357- and drive it in
as far as stop.
• Open side of oil seal faces engine.
– Install coolant pipe (front left) ⇒ 6-cylinder direct injection en‐
– Additional work depending on model ⇒ 6-cylinder direct in‐
Coolant pump/thermostat assembly; Removing and installing
map-controlled engine cooling system thermostat - F265-
Tightening torques


ature sender - G62-

ature sender - G62- - vehicles with 2.9
ltr. engine
Procedure
• Engine cold.
sion tank.
page 10 .


G62- .
Note:
piece of wire.
page 10 .
– Fill up coolant ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pump/
ture sender - G62-
Tightening torques
page 216

ature sender - G62- - vehicles with 3.0
ltr. engine
Procedure
• Engine cold.
sion tank.
– Depending on model, remove engine cover panel
page 10 .


G62- .
Note:
piece of wire.
– Depending on model, install engine cover panel
page 10 .
ture sender - G62-
Tightening torques
page 216
2.8 Removing and installing engine outlet

⇒ “2.8.1 Removing and installing engine outlet coolant tempera‐
ture sender G82 - vehicles with 2.9 ltr. engine”, page 222
⇒ “2.8.2 Removing and installing engine outlet coolant tempera‐
ture sender G82 - vehicles with 3.0 ltr. engine”, page 223
2.8.1 Removing and installing engine outlet

coolant temperature sender - G82- - ve‐

able)
♦ Flat-nose pliers, angled (45°) and long version (commercially
available)

Procedure
– Drain coolant ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0
page 10 .
– Remove bolts -1, 2-, detach coolant pipes from turbochargers
and press to one side.

– Move crankcase breather hose -2- clear and press bracket
-1- to one side.

– Detach engine outlet coolant temperature sender - G82- and
unplug electrical connector -2- using flat-nose pliers.
– Fit coolant temperature sender using flat-nose pliers.
– Install large coolant pipe (rear right) ⇒ 6-cylinder direct injec‐
tion engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant
page 10 .
Tightening torques
page 216
2.8.2 Removing and installing engine outlet

coolant temperature sender - G82- - ve‐
Procedure

gr. 19 ; Coolant pump/thermostat assembly ; Removing and in‐

stalling engine outlet coolant temperature sender - G82- .
• Engine cold.
sion tank.
page 10 .

– Unscrew bolt -2- and pull off engine outlet coolant temperature
sender - G82- .
Note:
piece of wire.
page 10 .
thermostat assembly; Removing and installing engine outlet cool‐
ant temperature sender - G82-
Tightening torques
page 216



tion - G694-
⇒ “2.10.1 Removing and installing temperature sender for engine
temperature regulation G694 - vehicles with 2.9 ltr. engine”, page
225
⇒ “2.10.2 Removing and installing temperature sender for engine
temperature regulation G694 - vehicles with 3.0 ltr. engine”, page
226
2.10.1 Removing and installing temperature

tion - G694- - vehicles with 2.9 ltr. engine

able)
♦ Flat-nose pliers, angled (45°) and long version (commercially
available)
Procedure
– Drain coolant ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0
page 10 .
– Remove bolts -1, 2-, detach coolant pipes from turbochargers
and press to one side.


– Detach temperature sender for engine temperature regulation
- G694- and unplug electrical connector -1- using flat-nose pli‐
ers.
– Fit coolant temperature sender using flat-nose pliers.
– Install large coolant pipe (rear right) ⇒ 6-cylinder direct injec‐
tion engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant
page 10 .
Tightening torques
2.10.2 Removing and installing temperature

tion - G694- - vehicles with 3.0 ltr. engine
Procedure
stalling temperature sender for engine temperature regulation -
G694- .
• Engine cold.
sion tank.


– Install oil filter housing
⇒ “4.3 Removing and installing oil filter housing”, page 199 .
thermostat assembly; Removing and installing temperature send‐
er for engine temperature regulation - G694-
Tightening torques

⇒ “2.11.1 Removing and installing coolant shut-off valve - vehicles
⇒ “2.11.2 Removing and installing coolant shut-off valve - vehicles
2.11.1 Removing and installing coolant shut-off

valve - vehicles with 2.9 ltr. engine
Removing
– Remove air pipe (bottom) ⇒ 6-cylinder direct injection engine
(2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Charge air system;
– If necessary, remove coolant pipe (front) ⇒ 6-cylinder direct
injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ;

– Unscrew bolts -arrows- and detach coolant shut-off valve -2-.

Installing
• Renew O-ring and seal after removal.
necessary.
– Install coolant pipe (front) ⇒ 6-cylinder direct injection engine
(2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pipes;
– Install air pipe (bottom) ⇒ 6-cylinder direct injection engine
(2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Charge air system;
Tightening torques
2.11.2 Removing and installing coolant shut-off

valve - vehicles with 3.0 ltr. engine
Removing
stalling coolant valves .
– Unscrew bolts -arrows- and detach coolant shut-off valve -2-.
Installing
• Renew O-ring and seal after removal.
necessary.
– Install coolant pipe (front) ⇒ 6-cylinder direct injection engine
(2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant pipes;
thermostat assembly; Removing and installing coolant valves
Tightening torques

3 Coolant pipes
Coolant pipes .

Radiators/radiator fans .

1 Turbochargers

⇒ “1.1.1 Exploded view - turbocharger, vehicles with 2.9 ltr. en‐
gine”, page 231
⇒ “1.1.2 Exploded view - turbocharger, vehicles with 3.0 ltr. en‐
gine”, page 234
1.1.1 Exploded view - turbocharger, vehicles with 2.9 ltr. engine

Part I
1 - Bolt
❑ 9 Nm
valve
♦ Overrun air recirculation
♦ Overrun air recirculation
installing overrun air re‐
circulation valve - vehi‐
page 277
3 - O-ring
4 - O-ring
5 - Connection
❑ For activated charcoal
filter system
6 - Bolt
❑ 9 Nm
7 - Coolant pipe (rear right)
❑ Exploded view ⇒ 6-cyl‐
inder direct injection en‐
gine (2.9 ltr., 3.0 ltr. 4-
19 ; Coolant pipes; Ex‐
ploded view - coolant
pipes
8 - Bolt
❑ Tightening torque ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant
pipes; Exploded view - coolant pipes
9 - O-ring
❑ Fitting instructions ⇒ 6-cylinder direct injection engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 19 ; Coolant
pipes; Exploded view - coolant pipes
11 - Bolt
❑ 9 Nm
12 - O-ring
13 - Turbocharger
❑ Removing and installing ⇒ “1.2 Removing and installing turbocharger”, page 238
14 - Bolt
❑ 9 Nm
16 - Bolt
❑ 9 Nm
17 - O-ring
18 - O-ring
19 - O-ring
❑ Green
20 - Venturi nozzle
❑ Press in until it engages
21 - O-ring
❑ Red
22 - Seal
23 - Plug
❑ 25 Nm
Part II
Part I ⇒ page 231

1 - Oil return line

2 - Clip
3 - Bottom air pipe
❑ Exploded view
⇒ “2.1.1 Exploded view
- charge air system (en‐
gine end), vehicles with
2.9 ltr. engine”,
page 259
4 - Bolt
5 - Gaskets
6 - Air pipe
7 - Bolt
❑ 9 Nm
8 - Vacuum unit
❑ Different versions. Re‐
pair kit ⇒ Electronic
parts catalogue
er”, page 246
9 - Nut
❑ 8 Nm
10 - Threaded piece
11 - Retaining clip
12 - Ball socket
13 - Nut
❑ 8 Nm
14 - Nut
❑ 9 Nm
15 - Turbocharger
❑ Removing and installing ⇒ “1.2 Removing and installing turbocharger”, page 238
16 - Nut
♦ 2nd stage: 30 Nm
♦ 3rd stage: After finishing work, tighten nuts to 30 Nm
17 - Nut
❑ 30 Nm
18 - Tensioner
19 - Gasket
20 - Stud
❑ Renew
❑ 15 Nm
1.1.2 Exploded view - turbocharger, vehicles with 3.0 ltr. engine

Part I
Part III ⇒ page 237
1 - Connecting pipe
❑ For activated charcoal
filter system
2 - O-ring
3 - Turbocharger
page 238
4 - O-ring
6 - Bolt
❑ 9 Nm
7 - O-ring
installing overrun air re‐
circulation valve - vehi‐
page 278
9 - Bolt
❑ 9 Nm
10 - Bolt
11 - Bolt
❑ 9 Nm
13 - O-ring


14 - O-ring
15 - Bolt
❑ 9 Nm
17 - Bolt
❑ 9 Nm
18 - O-ring
19 - O-ring
20 - Bolt
❑ 9 Nm
21 - Venturi nozzle
❑ Press in until it engages
22 - Plug
❑ 25 Nm
23 - Seal
24 - O-ring
❑ Red
25 - O-ring
❑ Green
Part II
Part I ⇒ page 234
Part III ⇒ page 237
1 - Nut
❑ If loosened, renew stud
❑ 30 Nm
2 - Tensioner
3 - Gasket
4 - Stud
❑ Renew if nut
has been loosened
❑ 15 Nm
5 - Tensioner
6 - Nut
❑ If loosened, renew stud
❑ 30 Nm
7 - Oil return line
8 - Clip
9 - Air pipe
10 - Bolt
11 - Seal
12 - Air pipe
13 - Bolt
14 - Seal
15 - Nut
16 - Turbocharger
⇒ “1.2.4 Removing and installing turbocharger - vehicles with 3.0 ltr. engine”, page 242
❑ 20 Nm
18 - Gasket

19 - Flexible joint (decoupling element)

❑ If a new turbocharger is fitted, also renew flexible joint
20 - Nut
21 - Gasket
22 - Stud
❑ Renew if nut ⇒ Item 20 (page 237) has been loosened
❑ 15 Nm
Part III
Part I ⇒ page 234
1 - Bolt
❑ 9 Nm
2 - Bracket
❑ For vacuum unit
3 - Turbocharger
installing turbocharger -
vehicles with 3.0 ltr. en‐
gine”, page 242
4 - Nut
❑ 9 Nm
5 - Retaining clip
6 - Ball socket
7 - Nut
❑ 8 Nm
8 - Threaded piece
9 - Nut
❑ 8 Nm
10 - Vacuum unit
❑ Repair kit ⇒ Electronic
parts catalogue
er”, page 246
Temperature sender for engine cover panel - G765- - tightening

torque

⇒ “1.2.1 Removing turbocharger, cylinder bank 1 (right-side) -
⇒ “1.2.2 Removing turbocharger, cylinder bank 2 (left-side) - ve‐
⇒ “1.2.3 Installing turbocharger - vehicles with 2.9 ltr. engine”,
page 241
⇒ “1.2.4 Removing and installing turbocharger - vehicles with 3.0
1.2.1 Removing turbocharger, cylinder bank 1

(right-side) - vehicles with 2.9 ltr. engine
⇒ page 242
Removing
gr. 21 ; Turbochargers; Removing and installing turbochargers .

– Unscrew bolts -arrows-, disconnect hose -1- for activated

charcoal filter system from turbochargers and move it to one
side.
– Loosen screw-type clip -1- and press catalytic converter slight‐

ly towards rear.
– Unplug electrical connector -2- for Lambda probe - G39- and

move wiring clear.
– Unscrew bolts -left arrows- and detach air pipe slightly.
– Unscrew bolts -arrows- and disconnect oil line and coolant

line.
– Unplug electrical connector -4- for overrun air recirculation
valve for bank 1 - N625- .
– Remove nuts -2- and detach turbocharger -3-.
Installing
page 241
1.2.2 Removing turbocharger, cylinder bank 2

(left-side) - vehicles with 2.9 ltr. engine
⇒ page 242
Removing
– Unscrew bolts -arrows-, disconnect hose -1- for activated
charcoal filter system from turbochargers and move it to one
side.


ly towards rear.
– Unplug electrical connector -2- for Lambda probe 2 - G108-

and move wiring clear.
– Unscrew bolts -arrows- and detach air pipe slightly.
– Unscrew bolts -arrows- and disconnect oil line and coolant

line.
– Remove nuts -2- and detach turbocharger -1-.
Installing
page 241
1.2.3 Installing turbocharger - vehicles with

2.9 ltr. engine
Installing
• Renew screw-type clip and oil return line after removing.

moval.
• Renew studs.
line.
necessary.
– Install catalytic converter ⇒ 6-cylinder direct injection engine
(2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 26 ; Emission control
system; Removing and installing catalytic converter .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Turbochargers;
Removing and installing turbochargers
– Tighten nuts ⇒ Item 16 (page 233) and
⇒ Item 17 (page 233) . This step is necessary to compensate
for the settling of the turbocharger connection.
Tightening torques
♦ ⇒ “1.1.1 Exploded view - turbocharger, vehicles with 2.9 ltr.
engine”, page 231

essary.
Removing

– Unplug electrical connector -2- for Lambda probe - G39- , re‐

move from bracket and move electrical wire clear.
– Unscrew bolts -arrows- and detach coolant lines -2, 4- and oil
supply line -3-.
– If fitted, disconnect hose -5- for activated charcoal filter system
by pressing release tabs on both sides.

– Remove studs -arrows-.

ly towards rear.
– Unscrew nuts -arrows- and studs and lift out turbocharger
-1-.
– Detach retaining clip -arrow- and remove oil return line -1-.
Installing
• Renew screw-type clip and oil return line after removing.
• If fitting a new turbocharger, renew flexible joint and screw-
type clip.
moval.
• Renew studs.
line.
necessary.
If turbocharger was renewed:

– Fit new flexible joint -1- on turbocharger -3- using a new screw-
type clip -2-, as shown in illustration.
– Tighten screw-type clip -2- far enough for flexible joint to still
be able to move at turbocharger flange.

– Move oil return line -1- into installation position and secure it
with retaining clip -arrow-.
– Move turbocharger into installation position while guiding oil
return line to cylinder block.
– Tighten studs and nuts -arrows-.

– Fit and tighten studs -arrows-.

– Tighten nuts -3-.
If turbocharger was renewed:

– Press flexible joint in direction of -arrow- by hand while tight‐
ening screw-type clip.
• Pressure must be applied at right angle -arrow- to flexible joint.
– When tightening, ensure that flange contour of flexible joint

-1- is positioned flush with contour on turbine housing of tur‐
bocharger.
Note
It is possible to check the correct installation -arrow- of the flexible

joint -1- by examining the screw-type clip from above.
quence.
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Turbochargers;
Removing and installing turbochargers
– Tighten nuts ⇒ Item 15 (page 236) and
⇒ Item 20 (page 237) . This step is necessary to compensate
for the settling of the turbocharger connection.
page 10 .
Tightening torques
engine”, page 234
tem”, page 269

⇒ “1.3.1 Renewing vacuum unit for turbocharger, cylinder bank 1
(right-side) - vehicles with 2.9 ltr. engine”, page 246
⇒ “1.3.2 Renewing vacuum unit for turbocharger, cylinder bank 2
(left-side) - vehicles with 2.9 ltr. engine”, page 250
⇒ “1.3.3 Renewing vacuum unit for turbocharger - vehicles with
1.3.1 Renewing vacuum unit for turbocharger,

cylinder bank 1 (right-side) - vehicles
A repair kit is available to renew the vacuum unit ⇒ Electronic
parts catalogue (ETKA) .

♦ Pressure sensor - V.A.G 1397B- (not illustrated)

♦ Pressure control valve - VAS 6342-
♦ Small mole grips, long version (commercially available)
Removing
page 10 .
– Detach vacuum hose -4- from vacuum unit, making sure not
to damage it.
tion valve - N249- , move electrical wiring harness clear and
press it to one side.
– Remove retaining clip -1- and detach control rod from actuat‐
ing lever of turbocharger.
– Remove nuts -arrows- and detach vacuum unit -2-.
– If vacuum unit cannot be removed as described, remove over‐
run air recirculation valve for bank 1 - N625-
⇒ “2.8.1 Removing and installing overrun air recirculation
valve - vehicles with 2.9 ltr. engine”, page 277 .
Installing
– Install vacuum unit -2- with adjustable control rod on turbo‐
charger.
– To do so, tighten nuts -arrows- and press ball socket -1- onto
ball stud of operating lever.
– Adjust control rod on threaded collar so that operating lever

-1- makes contact at stop -2-.
– From this position, turn threaded collar -2- 1.5 turns anti-clock‐
wise.
• This will increase the length of the control rod.
– Tighten lock nuts -1, 3-.

– Clamp small vice-grip pliers -1- on ball socket shaft -2-. The
vice-grip pliers serve as a stop for the dial gauge.
– Secure universal dial gauge bracket - VW 387- to engine lifting

eye -2-.
– Align dial gauge, 0-30 mm - VAS 6341/1- in universal dial
gauge bracket - VW 387- so that measurement button is as
parallel as possible with control rod of vacuum unit. To do so,
have measurement button make contact with vice-grip pliers
-1-.
– With 20 mm preload, set dial gauge to “0”.
– Set up measuring equipment and testers as shown and con‐

nect to pressure sensor - V.A.G 1397B- and to vacuum unit
for turbocharger.
– Close lever -1- on pressure control valve - VAS 6342- .

– Switch on pressure sensor - V.A.G 1397B- .
– Generate a vacuum of -300 mbar using hand vacuum pump -
VAS 6213- .
– Open testing valve and slowly reduce vacuum pressure:
• The operating rod should start to move at a pressure of -200
mbar at the latest.
• At 230 … 170 mbar, travel of 7 … 9 mm should be shown on
dial gauge.
dial gauge.
– If necessary, loosen lock nuts -1, 3- and adjust threaded collar

-2-.
– Repeat test.
– Tighten lock nuts.
• The ball socket must be parallel to the operating lever.

necessary.
– Remove measuring equipment and connect vacuum hose to
vacuum unit.
page 10 .
1.3.2 Renewing vacuum unit for turbocharger,

cylinder bank 2 (left-side) - vehicles with
2.9 ltr. engine

♦ Small mole grips, long version (commercially available)

Removing
page 10 .
to damage it.
ing lever of turbocharger.
– Remove nuts -arrows- and detach vacuum unit -2-.
Installing
– Install vacuum unit -2- with adjustable control rod on turbo‐
charger.
– To do so, tighten nuts -arrows- and press ball socket -1- onto
ball stud of operating lever.

wise.


eye -2-.
-1-.

for turbocharger.

VAS 6213- .
mbar at the latest.
dial gauge.
dial gauge.

-2-.
– Repeat test.

necessary.
vacuum unit.
page 10 .
1.3.3 Renewing vacuum unit for turbocharger


♦ Small vice-grip pliers (commercially available)

Removing
page 10 .
to damage it.
ing lever -4- of turbocharger.
– Remove nuts -2, 5- and detach vacuum unit.
Installing
– Install vacuum unit with adjustable control rod on turbocharg‐
er.
– To do so, tighten nuts -1, 2- and press ball socket -3- onto ball
stud of operating lever.

wise.


eye -2-.
-1-.

for turbocharger.

VAS 6213- .
mbar at the latest.
dial gauge.
dial gauge.

-2-.
– Repeat test.

necessary.
vacuum unit.
page 10 .

sender for engine cover panel - G765-
cylinder direct injection engine (3.0 ltr. 4-valve TFSI EA 839); Rep.
gr. 21 ; Turbochargers; Exploded view - turbochargers , Remov‐
ing and installing temperature sender for engine cover panel -
G765- .
Removing
page 10 .
cover panel - G765- .
Installing
engine (3.0 ltr. 4-valve TFSI EA 839); Rep. gr. 21 ; Turbocharg‐
ers; Exploded view - turbochargers , Temperature sender for
engine cover panel - G765- .
page 10 .
Tightening torques
♦ ⇒ Fig. ““ Temperature sender for engine cover panel -G765- -

2 Charge air system

page 269
⇒ “2.3 Removing and installing air pipe”, page 270
page 276
page 276
⇒ “2.8 Removing and installing overrun air recirculation valve”,
page 277

⇒ “2.1.1 Exploded view - charge air system (engine end), vehicles
with 3.0 ltr. engine (version 1)”, page 263
with 3.0 ltr. engine (version 2)”, page 266
⇒ “2.1.4 Exploded view - charge air system (body end)”,
page 269
2.1.1 Exploded view - charge air system (engine end), vehicles with 2.9 ltr. engine

1 - O-ring
sender - G42- / intake manifold
stalling intake air tem‐
perature sender G42 /
intake manifold pres‐
sure sender G71 ”, page
304
3 - Bolt
❑ 5 Nm
4 - Air pipe (top)
jection engine (2.9 ltr.,
3.0 ltr. 4-valve TFSI);
Rep. gr. 21 ; Charge air
system; Removing and
installing air pipe
5 - Bolt/nut
❑ Tightening torque:
♦ Bolt, 9 Nm
♦ Nut, 20 Nm
6 - Bracket
❑ For air pipe (bottom)
7 - Bolt
❑ 9 Nm
8 - Washer
9 - Grommet
10 - Air hose
11 - Air hose
12 - Bottom air pipe
Charge air system; Removing and installing air pipe
13 - Bolt
❑ 9 Nm
14 - O-ring
❑ 2.9 ltr. engine with electric compressor only
15 - Charge pressure sender 2 - G447-
Charge air system ; Removing and installing charge pressure sender 2 - G447-
16 - Bolt
❑ 9 Nm

17 - Seal
❑ Removing and installing ⇒ “2.7 Removing and installing charge air temperature sender”, page 276
❑ 22 Nm
19 - Gasket
20 - Intake manifold
⇒ “2.4.1 Removing and installing intake manifold - vehicles with 2.9 ltr. engine”, page 271
21 - Bolt
❑ 9 Nm
22 - Gasket
23 - Turbocharger
❑ Cylinder bank 1 (right-side)
❑ Exploded view ⇒ “1.1.1 Exploded view - turbocharger, vehicles with 2.9 ltr. engine”, page 231
24 - Turbocharger
25 - Intake manifold with crankcase breather hose
❑ Depending on the version of the replacement intake manifold supplied, the retaining tab for the retaining
clip on the electrical wiring harness may be located in a different position on the new intake manifold. In
this case, the retaining clip on the electrical wiring harness must be repositioned
❑ Removing and installing ⇒ “2.4 Removing and installing intake manifold”, page 271
❑ Crankcase breather hose is connected to intake manifold and cannot be separated; observe notes:
♦ Crankcase breather hose on intake manifold - rest-of-world vehicles ⇒ page 262
♦ Crankcase breather hose on intake manifold - USA vehicles ⇒ page 263
26 - Gasket
27 - Bolt
❑ 9 Nm
28 - Gasket
❑ Removing and installing ⇒ “2.7 Removing and installing charge air temperature sender”, page 276
❑ 22 Nm
30 - Seal
31 - Bolt
❑ 9 Nm

33 - Spacer sleeve
Intake manifold; Removing and installing throttle valve module - J338-
35 - Seal
36 - Connection
37 - Bolt
❑ Thread-forming
⇒ Fig. ““ Throttle valve module -J338- - tightening torques and sequence”“ , page 266
39 - Seal
40 - Bolt
❑ Thread-forming
❑ Tightening torques and sequence ⇒ Fig. ““Top air pipe - tightening torques and sequence”“ , page 266
41 - Seal
42 - Bolt
Crankcase breather hose on intake manifold - rest-of-world vehi‐

cles
Crankcase breather hose -2- cannot be detached from intake
manifold -1- without being irreparably damaged.
• Renew crankcase breather hose.
• When installing, ensure plug-in connector engages audibly
and that it is not seated at an angle on connection for intake
manifold -1-.

Crankcase breather hose on intake manifold - USA vehicles
Caution
Risk of violating emission legislation applying to USA vehicles.

♦ Do not disconnect crankcase breather hose -2-.
On USA vehicles, the crankcase breather hose -2- must not be

separated from the intake manifold -1-.
• The crankcase breather hose -2- supplied via the ⇒ Electronic
parts catalogue (ETKA) is only available together with the in‐
take manifold -1-.
(version 1)
1 - Bolt
sequence
⇒ Fig. ““Top air pipe -
2 - Air pipe (top)
jection engine (2.9 ltr.,
3.0 ltr. 4-valve TFSI);
Rep. gr. 21 ; Charge air
system; Removing and
installing air pipe
3 - Bolt
❑ Thread-forming
hand so that it is
que
sequence
4 - Bolt
❑ 5 Nm
5 - Bolt
❑ For model variant
❑ 8 Nm
6 - Connection
❑ Model variant
7 - Seal
❑ For model variant
8 - Air pipe

9 - Bolt
❑ 9 Nm
10 - Seal
❑ Removing and installing ⇒ “2.4 Removing and installing intake manifold”, page 271
12 - Bolt
❑ 9 Nm
13 - Seal
14 - Turbocharger
⇒ “6.5 Removing and installing intake air temperature sender G42 / intake manifold pressure sender G71
”, page 304
16 - O-ring
18 - Seal
19 - Connection
20 - Bolt
❑ Thread-forming
♦ 1st stage: 5 Nm
♦ 2nd stage: 6 Nm
21 - Seal
23 - Seal
24 - Bolt
❑ Thread-forming


cles
manifold -1-.
Caution


take manifold -1-.
Checking O-rings for damage

– Check O-rings for damage and renew if necessary.
1- O-ring (black)
2- O-ring (blue)
3- Crankcase breather hose
5- Hose for activated charcoal filter system
6- O-ring (black)
7- O-ring (orange)
9- Vacuum hose

Top air pipe - tightening torques and sequence

Stage Bolts Procedure/tightening torques
1. Bring air pipe into installation position
2a. -1 … 7- • Air pipe to used intake manifolds:
Fit and screw in by hand so that bolts
make contact and are screwed into old
thread
2b. -1 … 3- • Air pipe to new intake manifolds:
Fit and screw in by hand until contact is
made
3. -2 … 7- 6 Nm
4. -1- 9 Nm
Throttle valve module - J338- - tightening torques and sequence

1. Move throttle valve module - J338- with
connection into installation position
2. -arrows- Fit and screw in by hand in diagonal se‐
quence so that bolts make contact and are
screwed into old thread
(version 2)

1 - Air pipe
2 - Bolt
❑ Thread-forming
hand so that it is
que
sequence
3 - Bolt
❑ Thread-forming
hand so that it is
que
sequence
4 - O-ring
G31-
sender G31 ”,
page 276
6 - Bolt
❑ 5 Nm
7 - Bolt
❑ Thread-forming
8 - Air pipe (top)
9 - Bolt
11 - Bolt
❑ 9 Nm
12 - Seal


⇒ “2.4.3 Removing and installing intake manifold - Audi A8 with 3.0 ltr. engine”, page 275
14 - Bolt
❑ 9 Nm
15 - Seal
16 - Turbocharger
⇒ “6.5 Removing and installing intake air temperature sender G42 / intake manifold pressure sender G71
”, page 304
18 - Bolt
❑ 5 Nm
19 - O-ring
21 - Seal
22 - Bolt
❑ Thread-forming
23 - Seal
25 - Seal

cles
manifold -1-.

Caution


take manifold -1-.
Top air pipe - tightening torques and sequence

1. Bring air pipe into installation position
2 -1- Fit and screw in by hand until contact is
made
3 -2 … 7- Fit and screw in by hand so that bolts
thread
4. -1- 9 Nm
5. -2 … 7- 5 Nm
Throttle valve module - J338- - tightening torques and sequence

1. Move throttle valve module - J338- with air
pipe into installation position
2. -1 … 5- Fit and screw in by hand so that bolts
thread
3. -2 … 5- 5 Nm
4. -1- 5 Nm
2.1.4 Exploded view - charge air system (body

end)
gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Charge air
system; Exploded view - charge air system .

charge air system
installing.


-arrows-.
enough.
off air hose.
must be renewed.
Tightening torques for:

1- Hose clip with width -a- = 12 mm: 5 Nm
Air hoses to air pipes/charge air cooler - installation position and

tightening torque
• Markings on air hose must be aligned opposite edge of hous‐
ing and notch on air pipe/charge air cooler -arrows-.
– Tighten hose clips to 5 Nm.
2.3 Removing and installing air pipe

system; Removing and installing air pipe .


⇒ “2.4.2 Removing and installing intake manifold - Audi A4/A5/
A6/A7/Q5 with 3.0 ltr. engine”, page 273
⇒ “2.4.3 Removing and installing intake manifold - Audi A8 with

Note
Crankcase breather hose is connected to intake manifold and

cannot be separated; observe notes ⇒ Item 25 (page 261) .

Removing
– Observe repair instructions ⇒ “3 Repair instructions”, page 6 .
page 10 .
Audi A4/A5, Q5:
– Release hose clip -right arrow- and detach air hose -1-.

Audi A6/A7:
– Remove bolts -arrows-. Detach air duct -1-.
– Release hose clip -right arrow- and detach air hose -1-.
All vehicles:
ness clear:

breather hose -2-.
– Move intake manifold -1- clear.


breather hose -arrows-.
– Detach intake manifold.
Installing
• Check O-rings for damage
⇒ Fig. ““Checking O-rings for damage”“ , page 265 .
page 10 .
Tightening torques
♦ ⇒ “2.1.1 Exploded view - charge air system (engine end), ve‐
tem”, page 269

- Audi A4/A5/A6/A7/Q5 with 3.0 ltr. en‐
gine
Note


Removing
page 10 .

Audi A4/A5:
Audi A6/A7:
– Unscrew bolts -arrows- and remove air duct.
Audi Q5:
All vehicles:
– Detach intake manifold and remove crankcase breather hose
-1-. To do so, press release tabs on both sides.


breather hose -arrow-.
Installing
Tightening torques
hicles with 3.0 ltr. engine (version 1)”, page 263
tem”, page 269

- Audi A8 with 3.0 ltr. engine
Note


Removing
page 10 .


breather hose -4-.
– Remove bolts -arrows- and move intake manifold -2- clear.

breather hose -arrow-.
Installing
Tightening torques
hicles with 3.0 ltr. engine (version 2)”, page 266
tem”, page 269

er
system; Removing and installing charge air cooler .

sure sender - G31-
system; Removing and installing charge pressure sender - G31- .

perature sender
Procedure applies for vehicles with 2.9 ltr. engine only.
Removing
page 10 .

– Unplug corresponding electrical connector:

– Unscrew charge air temperature sender.
Installing
page 10 .
Tightening torques
2.8 Removing and installing overrun air re‐

circulation valve

engine
Removing
gr. 21 ; Charge air system; Removing and installing overrun air
circulation valve .
– Remove oil filter element ⇒ page 175 and cover opening with
a clean cloth.
ness clear:


breather hose -2-.

– Remove bolts -arrows- and detach overrun air recirculation
valve for bank 1 - N625- -item 2-.

Installing
– Install oil filter element ⇒ page 175 .
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Charge air
system; Removing and installing overrun air circulation valve
Tightening torques
engine”, page 231

engine
Removing
page 10 .


Installing
page 10 .
Tightening torques
engine”, page 234

♦ Ultrasonic tester - V.A.G 1842- (not illustrated)
♦ Leak detection spray (commercially available)
Procedure
gr. 21 ; Charge air system; Checking charge air system for leaks .


valves -3, 4-.
valve.
water.
– Open valve -3-.
Caution


spray or use ultrasonic tester - V.A.G 1842- (refer to ⇒ oper‐
ating manual ).
Note:
test.
Attaching
engine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 21 ; Charge air
system; Checking charge air system for leaks


1 Injection system
gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Injection system .

2 Vacuum system

⇒ “2.1.1 Connection diagram - vacuum system, vehicles with
2.9 ltr. engine without electric compressor”, page 282
⇒ “2.1.2 Connection diagram - vacuum system, vehicles with
2.9 ltr. engine with electric compressor”, page 283
⇒ “2.1.3 Connection diagram - vacuum system, vehicles with 3.0
2.1.1 Connection diagram - vacuum system,

vehicles with 2.9 ltr. engine without elec‐
tric compressor
Caution
Risk of engine malfunctions

♦ When routing vacuum lines, make sure they are not
kinked, twisted or crushed.


block - N545-
2 - Coolant pump
4 - Vacuum unit
❑ For turbocharger, cylin‐
der bank 1 (right-side)
5 - Vacuum unit
❑ For turbocharger, cylin‐
der bank 2 (left-side)
7 - Vacuum pump
8 - To brake servo
9 - Vacuum connecting piece
10 - Vacuum reservoir
11 - To air pipe

vehicles with 2.9 ltr. engine with electric
compressor
gine (2.9 ltr., 3.0 ltr. 4-valve TFSI); Rep. gr. 24 ; Vacuum system;
Connection diagram - vacuum system .

Caution
Risk of engine malfunctions

♦ When routing vacuum lines, make sure they are not
kinked, twisted or crushed.


block - N545-
2 - Coolant pump
5 - Vacuum unit
6 - Vacuum reservoir
7 - To brake servo
8 - Vacuum connecting piece
9 - To air pipe
10 - Vacuum pump

Procedure
♦ Cracks


– If it is not possible to build up a vacuum with the hand vacuum
pump - VAS 6213- or if the vacuum pressure drops again im‐
mediately, check the hand vacuum pump and connecting
hoses for leaks.

3 Air cleaner
Air cleaner .

4 Intake manifold
290
1 - Air pipe (top)

❑ Exploded view
page 259
2 - Seal
❑ When renewing lever
out with screwdriver
❑ Press in by hand
3 - Gasket
4 - Bolt
sequence:
⇒ Fig. ““Intake manifold,
cylinder bank 1 (right-side)
- tightening torques and se‐
⇒ Fig. ““Intake manifold,
cylinder bank 2 (left-side) -
tightening torques and se‐
5 - Intake manifold
2 (left-side)
stalling intake manifold”,
page 288
6 - Bolt

Intake manifold, cylinder bank 1 (right-side) - tightening torques

and sequence
angle.
tion
1. -1 … 10- 2 Nm
2. -1 … 10- 8 Nm
3. -1 … 10- Turn 45° further
Intake manifold, cylinder bank 2 (left-side) - tightening torques

and sequence
angle.
tion
1. -1 … 10- 2 Nm
2. -1 … 10- 8 Nm
3. -1 … 10- Turn 45° further

Removing
gr. 24 ; Intake manifold; Removing and installing intake manifold .


– Unscrew bolts -arrows- and remove connection -2-.
– Remove bolts -arrows- for air pipe.
– Take electrical connectors -arrows- out of bracket and move

clear to side.
– Loosen and remove bolts in the sequence: -10 ... 1- and de‐
tach intake manifold.

– Remove bolts -arrows- for air pipe.

– Vehicles with 2.9 ltr. engine: Detach electrical connectors

-1, 2- from bracket and place to one side.
– Loosen and remove bolts in the sequence: -10 ... 1- and de‐
tach intake manifold.
Caution
Risk of ir

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2019 Audi AG, Ingolstadt D4B806E4CA8

3.38 Roof insert - sliding/tilting sunroof: cleaning and lubricating . . . . . . . . . . . . . . . . . . . . . . . . 50

3.89 Vehicle cover: checking position and correcting if necessary . . . . . . . . . . . . . . . . . . . . . . 119

1.1 --- Change history ---

1.2 Engine number

The engine number consists of the engine code letters (3 or 4

4-cyl. petrol engine 1.4 TFSI ⇒ page 2

1.2.1 4-cyl. petrol engine 1.4 TFSI

1.2.2 4-cyl. petrol engine 2.0 TFSI

1.2.3 6-cyl. petrol engine 2.9 TFSI

1.2.4 6-cyl. petrol engine 3.0 TFSI

1.2.5 4-cyl. diesel engine 2.0 TDI

1.2.6 6-cyl. diesel engine 3.0 TDI

1.3 Vehicle identification number

The vehicle identification number consists of the following:

1.4 Vehicle data sticker

The vehicle data sticker contains the following vehicle data:

2.1 Vehicle: raising

– Rear: Position support plates of lifting platform under lifting

♦ The location of the lifting points is indicated by markings stam‐

2.2 Engine cover panel: removing and in‐

2.2.1 4-cyl. petrol engine 1.4 TFSI

2.2.2 4-cyl. petrol engine 2.0 TFSI

2.2.3 6-cyl. petrol engine 2.9 TFSI

Removing engine cover panel (version 2)

Removing heat shield

– To avoid damage, do not strike the engine cover panel with

2.2.4 6-cyl. petrol engine 3.0 TFSI

Remove the engine cover panel according to the instructions in

2.2.5 4-cyl. diesel engine 2.0 TDI

2.2.6 6-cyl. diesel engine 3.0 TDI

2.3 Noise insulation: removing and installing

2.3.1 Noise insulation (front)

Procedure for removing:

♦ Ensure that you feel the quick-release fasteners engage when

2.3.2 Noise insulation (rear)

Ensure that you feel the quick-release fasteners engage when

2.4 Window regulators: activating automatic

– Release switch and pull on it again for at least one second.

2.5 Vehicle diagnostic tester: connecting

♦ Remote diagnosis head - VAS 5054A-

ERA-GLONASS: checking emergency call function ⇒ page 17

Poly V-belt for ancillaries: renewing ⇒ page 122

3.1 Diesel particulate filter: reading out ash

– Continue to follow instructions on screen.

– Select control unit “01 — Engine electronics” and carry out

3.2 ERA-GLONASS: checking emergency

– Check if LED -2- is lit in green.

♦ If the LED lights up in red or if it is not possible to activate the

3.3 Emergency call function: checking sta‐

♦ It may take up to 15 minutes for the emergency call system to

3.4 Event memory: reading out

– Select Diagnosis mode and begin diagnosis.

3.5 Service interval display: resetting serv‐

The test program Predelivery inspection total may also be

– Switch to “Special functions” tab.

3.6 Diagnostic work: performing

– Start program by selecting Carry out check .

3.7 Transport mode: deactivating

The test program Predelivery inspection total may also be

– Switch to “Special functions” tab and select following program: