Service Workshop Manual Audi A6 1998 > 6-cylinder engine (2.4 ltr. and 2.8 Itr. 5-valve), mechanics Ersinei0 | ACK | AGA| AGE | AHA | AJG | ALF | ALG ALW AMX | APC | APR | APS | APZ ATQ | ATX | BDV Edition 08.2019 Service Department. Technical InformationGe Service List of Workshop Manual Repair Groups Repair Group 00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, va've gear 17 - Lubrication 19 - Cooling 26 - Exnaust system Technical information should always be available to the foremen and mechanics, because their careful and ccnstant adherence to the instructions is essential to ensure vehicle road-worthness and safety. in addition, the normal basic safety precautions for working on motor vehicles must 2s a matter of course, be observed All rights reserved. Ne reroduction withcut prior agreement from publisher. Copyright © 2019 Audi AG, Ingolstadt 40056007120Audi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 Contents 00 - Technical data 1 1 Technical data 1 4.4 Engine numoer 1 1.4 Engine data 1 2 Safety precautions 4 2.1 Working on the fuel system 4 2.2 Procedure before opening high pressure section of injection system. . 4 . 5 5 5 6 2.3. Working on the cooling system 24 Using testers and measuring instruments during 2 road test 2.5 — Working on the exhaust system . 3 General repair instructions 3.1 Rules for cleanliness when working on fuel supply system, injection system and turbocharger 6 32 Checking fuel system for leaks 6 3.3. Foreign parlices in engine 6 3.4 Contact corrosion 6 3.5 Routing and attachment of pipes, hoses end wiring 7 36 Nuts, bolts 7 3.7 Identification plates 7 3.9 Use of impact wrenches 7 3.8 Checking vacuum system . 8 3.10. Installing radiators, condensers and charge air coolers. 8 10 - Removing and installing engine ............ - 10 1 Removing and installing engine 10 1.1 Removing engine 10 1 2mm Seouringenginetto assembly stand 28 13 (ineteling engine 28 444 “Vacuum congections 34 13-Crankshaft group ........... 20. 33 Juco Servicing work on pulley end 36 1.1. Exploded view - poly V-belt drive viene : : 36 4.2" "Removing and installing poly V-belt. ee ! cess 87 1.3) "Removing and installing’ pulleyiibretion dampers 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 4.1 Different versions of conrods and conrod bolts 69 4.2 Exploded view - sawn conrods 69 4.3 Exploded view- industrially cracked conrods ....... veces on 4.4 Piston and cylinder dimensions. . ceceeees . 74 4.5 Checking radial clearance of conrod bearings . seeee 4 15 - Cylinder head, valve gear .......... Fee eee eee nena . 7 1 Removing and installing cylinder head 78 1.1 Exploded - cylinder head 78 1.2. Removing and installing cylinder head cover (left-side) 79 4.3. Removing and installing cylinder head cover (right-side) 80 1.4 Removing cylinder head (left-side) 2 1.5 Removing cylinder head (right-side) ......... ce ce cee . 85 1.6 Installing cylinderhead ..... ee cee eee nee 38 1.7 Removing and installing intake manifold . . . . a . 92 1.8 Checking compression . a a ce a eee 95 2 Servicing valve gear beeen bette sete eee serene 9B 24 Exploded view- valve gear .... . nee cee . 98 22 Checking axial clearance of camshafts .. a cov teee teens 101 2.3 Renewing camshett oil seals 102 2.4 Renewing oil seal for Hall sender and sealing cap - cylinder head (left-side) 104 25am Renewing.cil seal for Hall sender - cylinder head (right-side) 104 26 Removing and installing camshafts and camshaft adjuster 107 27 | Ghedking hydrauligbucket tappets att 28 Renewingvalve.stem oil seals 112 2.9 Valve dimensions 417 2.10, ,. Checking valve guides 417 2.11 Machining vaive seats 118 B42 "“Checking Valves” ee ne et 120 3°) ICRBcking Variable Waive tinting 121 3.1 Checking function of variable valve timing. . ae ae ae . 121 3.2 Checking camshaft control valves (solenoid valves), betes steer eee 125 17 - Lubrication sec ee ences = 130 1 Removing and installing | parts ‘of lubrication system .. 130 1.1 Exploded view - lubrication system . fees fees + 130 1.2 Removing sump (bottom section) 132 1.3. Installing sump (bottom section) - engines with moulded gasket 133 1.4 Installing sump (bottom section) - engines with liquid gasket 134 1.5 Removing and installing sump (top section) 135 1,6 Removing and installing oil pump .... wee ce ee . 146 1.7 Checking chain tensioner ce ces 148 118 Removing and installing drive chain and chain tensioner for cil pump... - + 148 1.9 Renewing oil retention valves. . ae . . . 149 1.10 Checking oil pressure and oil pressure switch cee cee 150 1.11 Engine oil 153 4.12 Checking oil level 153 19=COOMING occ ee eee cece eee e eee eer e teeter ere 155 1. Removing and installing parts of cooling system 185 4.1. Connection diagram - coolent hoses 185 1.2 Draining and filing cooling system 187 1.3. Exploded view - coolant pump and thermostat 163 1.4 Removing and installing coolant pump 163 1.5 Removing, installing and checking thermostat 165 1.6 Exploded view coolant pipes .......... veceeeeee 168 Ti contents26 Audi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 1.7 Removing and installing coolant pipe (front) 169 1.8 Removing and installing coolant pipe (small) 71 1.9 Removing and installing coolant pipe (rear) 172 4.40 Exploded view - radiator and radiator fan 174 4.41 Removing and installing radiator 176 4.42 Removing and installing viscous fan 179 4.43. Removing and installing pulley for viscous fan 180 4.14 Checking continued coolant circulation pump V51 181 1.45. Removing and installing continued coolant circulation pump V51 181 1.46 Checking radiator fan 182 4.47 Checking cooling system for leaks 183 Exhaust system 2.0.0.0... cece cece cece eee ee eee ee eee - 185 1 Removing and instaling parts of exhaust system 185 4.1 Exploded view- exhaust system, vehicles with frontavheel drive 185 1.2. Exploded view - exhaust system, vehicles with four-wheel crive 191 1.3. Separating centre and rear silencers en 195 14 Stress-free alignment of exhaust system 196 15 Aligning tailpipes - vehicles with concealed tailpipes 197 16 Aligning tailpipes - vehicles with visible teilpipes 198 1.7 Checking exhaust system for leaks 198 2 Secondary air system - vehicles with engine code ALF, ALG, ALW, AML, AMM, AMX, AQD, ARJ, ARN, ASM, ATQ, BDV 199 24 Principle and function 199 22 Exploded view - secondary air system 201 23 Checking secondary air inlet valve N112 203 24 — Checking secondary air pump relay J299 and activation 206 25 Checking combination valve for secondary air system for proper operation and leakage .. 214 2.6 Removing and installing secondary air pump 213 27 falling combination valve for secondary air system (left-side) 214 28 taling combination valve for secondary air system (right-side) 216 consents HiiAudi A6 1998 > G-cylinder engine (2.4 itr. and 2.8 ltr 5-valve), mechanics - Edition 08.2019 IV contantsAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr. 5-valve), mechanics - Edition 08.2019 wy} Technical data 1 Technical data (ARLO06551; Edition 08.2019) 1A Engine number ‘© The engine number (‘engine code” and “serial number’) is stamped on the right inner side of the cylinder block between the cylinder head and power steering pump. There is also a sticker on the air duct showing the “engine code" and “serial number’ @ The engine code is also to be found on the vehicle data sticker. 1.2 Engine data [Code letters: ‘ACK AGA AGE ‘AHA AIG Capacity ltr [ 2.774 2.393 2774 2771 2.393 Power output kWat rpm| 42/6000 | 1215600 | 137/000 | 7142/6000 | 120/6000 Torque Nm at rpm|_280/3200 | 230/3600 | 260/3000 | 280/3200 | 230/320 Bore Zmm| 62.5 81.0 82.5 82.5 81.0 Stroke mm] 86.4 774 86.4 86.4 Ts Compression 106 10.5 40.4 10.6 108 ratio RON min. 98!) 952) 98!) 98) 95?) Injection/ignition system Motronic | Motronic _[ Motronic _| Motronic | Motronic Exhaust gas recirculation no. no. no. no. no {Turbocharging/supercharging no. no. no. no. no Catalytic converter Yes Yes Yes Yes Yes Knock control Yes Yes Yes Yes Yes Lambda control Yes Yes Yes Yes Yes ‘Secondary air system no. no. no. Yes no + In exceptional circumstances, fuel with not less than 05 RON can also be used, but this will cause a loss of power. + 2 In exceptional circumstances, fuel with not less than 91 RON can also be used, but this will cause a loss of power. [Code letters: 7 ALG ALW. AML AMI, Capacity ltr.[ 2.303 2.771 2.393 2.393 2.393 Power output RWatirpm| 1424/5600 0| »442/60002"] 400/575000] 4121/6000" | «4120/6000: Torque ‘Nmvat ppm 230/350) 280/820 ({ 1230/8200 = | '230/3200:»| 230/320 Bore mel 81.0 825 1.0, 24,0 81.0 Stroke mm] 77.4 86.4 774 774 774 1. Tochrical data 1Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 (Code letters ALE ALG ALW ANIL AMM ‘Compression 10.5 10.6 105 105 105 ratio RON min] 952 98) 352 952 359) Injection/ignition system Motronic | Motronic |" Motronic | Motronic | Motronic Exhaust gas recirculation no no no no no Turbocharging/supercharging no no no ne no Catalytic converter Yes Yes Yes Yes Yes [Knock control Yes Yes Yes Yes Yes Lambda control Yes Yes Yes Yes Yes [Secondary air system Yes Yes Yes Yes Yes In exceptional circumstances, fuel with not less than 95 RON can also be used, but this will cause 2 loss of power. + 2) In exceptional circumstances, fuel with not less than 91 RON can also be used, but this will cause a loss of power. (Code letters AMX APR APS APZ iCapacity tte] 2.774 2.303, 2.771 2.393 2.383 Power output kW at rpm| 142/600 | 11576000 | 142/600 | 1216000 | 120/600 Torque Nm at rpm] 280/320 | 230/320 | 20/3200 | 230/320 | 230/3200 Bore ‘mm 82.5 81.0 25 81.0 81.0 Stroke mom| 86.4 774 86.4 774 774 (Compression 103 105 10.4 105 105 ratio RON’ mip.| 98? 952) 98!) 954) 952) Injection/ignitignlpyateth Motronic | Motronic | Motronic | Motronic | Motronie Exhaust gas rBdirculation no no no no no Turbocharging/supercharging no no no no no (Catalytic converter Yes Yes. Yes Yes Yes [Knock contro} Yes, ‘Yes Yes Yes Yes [Lambda control Yes Yes Yes Yes Yes [Secondary air aystern Ves) fo no ie no ’) In exceptional circumstances, fuel with not less than 95 RON can also be used, but this will cause @ loss of power. 2) In exceptional circumstances, fuel with not less than 91 RON can also be used, but this will cause @ loss of power. [Code letters QD ARI ARN ASM. ATQ (Capacity tee] 2.774 2.393 2.393 2.393 2774 Power output KW at rpm] 142/6000 | 1216000 | 10/5750 | 100/750 | 142/6000 Torque Nm atrpm| 280/3200 | 230/3200 | 23013200 | 230/3200 | 2860/3200 Bore Zmm| 82.5 81.0 81.0 81.0 825 [Stroke mm) 86.4 774 174 774 86.4 [Compression 10.4 105 105 105 404 ratio RON min,| 98) 952) 954) 952) 98?) 2 Rep. 07: 00- Technical dataAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr. 5-valve), mechanics - Edition 08.2019 [Code letters: ‘AQD ARI ARN ‘ASM. ATO. Injection/ignition system Motronic _[ Motronic _[ Motronic _| Motronic | Motronic Exhaust gas recirculation no no no no no Turbocharging/supercherging no no no no no [Catalytic converter Yes Yes Yes Yes Yes Knock control Yes Yes Yes Yes Yes Lambda control Yes Yes Yes Yes Yes ‘Secondary air system Yes Yes Yes Yes Yes 1 In exceptional circumstances, loss of power. * 2) In exceptional circumstances, loss of power. fuel with not less than 95 RON can also be used, but this will cause a fuel with not less than 91 RON can also be used, but this will cause a [Code letters: ATX BDV, [Capacity Me] 2.71 2.393 Power Qutput| KW at rpnil_ 40/6000 | 1256/6000 Torque Nratrpm| 280/3200 | 230/3200 Bore @mm| 2.5 81.0 Stroke mmo 0864 Th [Compression 10.6 10.5. ratio RON min] ger) 35) Injection/ignition system Motronic | Motronic Exhaust gas recirculation no no Turbocharging/supercharging no no (Catalytic converter Yes ‘Yes Knock control Yes Yes Lambda control Yes) Yes) ‘Secondary air system no Yes loss of power. loss of power. *) In exceptional circumstances, fuel with not less than 95 RON can also be used, but this will cause a + 2) In exceptional circumstances, fuel with not less than 91 RON can also be used, but this will cause a 1. Tochrical data 3Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 2 Safety precautions 24 Working on the fuel system \When working on the fuel system note the following warnings: A WARNING The fuel system operates at extremely high pressure. This can cause injury. ¢ The fuel pressure in the high-pressure section of the in- ection system must be reduced fo a residual pressure ‘prior to opening the system. ¢ Wrap a clean cloth around the connection and carefully loosen the connection to allow the residual pressure to dissipate. ~ Procedure before opening high-pressure section of injection system = Rep. gr. 24 Observe the following to prevent injuries to persons and damage to the injection and ignition system: # Always switch off the ignition before connecting or discon- necting electrical wiring for the injection or ignition system or tester cables. + Always switch off ignition before washing engine. 4 Faults are stored in engine control units if electrical connectors ‘were unplugged and engine was started: "Generate readiness code’ in Guided Functions’ = Vehicle diagnostic tester Dy cum When alsconnecting the battery there is a risk of ireparable damage to electronic components. Observe gétes On proveureter dlconnecting the battery. # Alnays Shitch effthe ightion before disconnecting the battery. ~ Disconnect battery + Repygn! 27 22 Procedure before opsnirig high-pras* sure’section'of injection system ZX wane ¢ The injection system consists of a high-pressure section (maximum approx. 120 bar) and a low-pressure section (approx. 6 bar). ¢ The fuel pressure in the high-pressure section must be reduced to @ residual pressure of approx. 6 bar prior to mning the system. For details of procedure, refer to ep. of. 24 4 Rp. 07:00- Technical dataAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 23 Working on the cooling system Wien WeFling 6m TRéccooling system note the following warnings: A WARNING Risk of scalding due to hot steam and hot coolant. + The cooling system is under pressure when the engine ie ‘9 :\To alow pressure f0 dissipate, cover filer cep'on coolant expansion tank with loth and open carefully. 24 Using testers and measuring instru- ments during a road test Note the following if testers and measuring instruments have to be used during e road test: A WARNING Accidents can be caused if the driver is distracted by test equipment while road-testing, or if test equipment is not prop- erly secured. Persons sitting in the front passenger's seat could be injured if the airbag is triggered in an accident. + The use oftestequipment while driving causes distraction. There is an increased risk of injury if test equjoment is not secured. # Test equjoment must always be secured on the rear seat with a strap and operated from the rear seat by a second person. 25 Working on the exhaust system When working on the exhaust system please note the following: A Caution Risk of damage to fexible joint. '¢ Dornot bend flexible joint more than 10° ¢ Install flexible joint so that itis not under tension. ¢ Take care not to damage wire mesh on flexible joint. 2, Sataty precautions 5Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 3 General repair instructions 3.1 Rures for cleanliness when working on fuel supply system, injection system and turbocharger 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, injection system and turbocharger: # Carefully clean connection points and the surrounding area with engine cleaner orbrake eleanerand dry thoroughly before: opening. # Seal off open pipgs/lings andiconnections|immediately with clean plugs, e.g. from engine bung set - VAS 6122- # Place removed parts on.a clean surface and cover them. Use only lint-free cloths: # Carefully cover 6r S8al’Spén Componante if repairs Cannot be carried out immediately, # Only install clean components; replacement parts should only be unpacked immediately prior to installation. Do notuse 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. # Protect unplugged electrical connectors against dirt and mois- ture and make sure connections are dry when attaching, 3.2 Checking fuel system for leaks = Allow engine to run for several minutes at moderate rpm. — Switch off ignition. = Check complete fuel eystem for leaks = If leaks are found although the connections have been tight: tened to the correct torque, the relevant component must be renewed, = Road-test vehicle and accelerate with ful hrotle atleast once. Then inspect high-pressure section of fuel system again for leaks. 3.3 Foreign particles in engine # When working on the engine, all open inlet and exhaust ports must be sealed with suitable plugs (e.g. from engine bung set = VAS 6122- ) to prevent foreign patticles from entering the engine. 4 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. 3.4 Contact corrosion Contact corrosion cen occur if unsuitable fasteners are used (e.g, bolts, nuts, washers, etc.) For this reason, only fasteners wit a special surface costing are tte 6 op. o:00- Technical dataAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 ‘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 > Electroriic 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. 35 Routing and attachment of pipes, hoses and wiring © Mark fuel lines, hydraulic lines, vacuum lines, lines for activa ted charcoal filter and electrical wiring ete. before removal so they can be re-installed in the original positions and correctiy connected. Make sketches or take photographs if necessary ¢ Because of the limited space in the engine compartment, itis, important to ensure that there is adequate clearance to any moving or hot components to avoid damage to lines and wir- ing 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, aressecured withulocking fluid, Then in- stall bolts with locking flyid; for locking fluid refer to> Elec- tronic parts catalogue Threaded holes Which takerSelt-lockingHolts 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 étatéerapply to nohtoiledlHuts ahd bots. . oe . 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. 38 Use of impact wrenches In general, itis permitted to use an impact wrench to unscrew bolts and nuts. An exception to this is when work is performed. 8. Gonaralrepairinsrucions 7Audi A6 1998 > G-cylinder engine (2.4 itr_ and 2.8 ltr, 5-valve), mechanics, 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 ifthe following requirements are observed. In general, electric and compressed-air impact wrenches should be used. Requirements: + Only screwin bolt with locking fluid 6r’setf-latking nuts at low speed, + Use a suitable impact Wrench wih variable speed and adjust- able torque range. + Use suitable bits WREh Working/iA tHe Vidinity GF censitive Sur faces, e.g. plastic-coated. its 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: + Fitbolts/nuts by hand + Only use an impact wrench to screwin bolts/nuts until the head ofthe boltinut makes contact and then continue tightening with a torque wrench. + Clean threaded pins before unscrewing the bolt/nut. 3.9 Checking vacuum system ‘Special tools and workshop equipment required @ 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. — |fafaultis stored in the memory, check the vacuum lines lead- ing {o the corresponding component and also check the re~ maining vacuum lines in the system, wees - Edition 08.2019 8 Rep. 0: 00- Technical dataAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 — Ifitis not possible to build up pressure with the hand vacuum Pump - VAS 6213: or ifthe pressure drops again immediately, check the hand vacuum pump and connecting hoses for leaks. 310 installing radiators, condensers and chatge air coolers Even when theradiator, condenser and charge air cooler are cor- rectly installed, slight impressions may be visible on the fins of these components. This does not mean thet the components are damaged. If the fins are only vary slightly distorted, this does not Justify renewal of the radjator, condenser or charge air cooler. 8. Gonararepairinsrucions 9Audi A6 1998 > G-cylinder engine (2.4 itr. and 2.8 ltr 5-valve), mechanics - Edition 08.2019 10 joving and installing engine 1 Removing and installing engine 44 Removing. engine, Special tools and workshop equipment required VAG 1308, Support bracket - 10-222 A- Lifting tackle - 2024 A- Hose clamps up to @ 25 mm - 3084- Gearbox support - 3147- Workshop hoist - VAS 6100- or -V.AG 1202 A- Drip tray for workshop hoist - VAS 6208- or -V.A.G 1306- te eeeee 10.0075 10 ep. o.10-Removing and insaling engineAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 3204 3212 Locking pin - 3204- Pin wrench - 3212- Open-end spanner - 3312- Suppor bridge -30-211 A for vehicles wth automatic gearbox 1V 30-211 {2/Réemovng and instaling engine 11Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 # Used cil collection and extraction unit - V.A.G 1782- V.A.G 1782 Procedure (B) now, 4 The énginelis|rentoved fram the front without the gearbox. + Colectevained.coblantina.cian container for re-use or cs- posal % Ali cable ties which are released or cut open when removing ‘must be fitted in the same position when insialing. L\ \ Caston Observe notes on procedure for disconnecting the battery > Rep. gf. 27 = Detach rubber seal from plenum chamber cover in direction of arrow. — Detach plenum chamber cover -1- towards front. — With ignition switched off, disconnect battery earth cable “arrow 12 Rep. o.10-Removing and insaling engineAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 — Remove engine cover panel -arrows- A WARNING Hot steam or hot coolant can escape when expansion tank is opened: cover filler cap with cloth and open carefully. = Open filler cap on coolant expansion tank. = Vehicles with auxiliary heater: Remove bolts -arrows- securing exhaust pipe for auxiliary/supplementary heater to noise in- suletion. ~ Remove noise insulation -arrows-. ue I] & = Unbolt bracket fopneise insulation, -arraws- 1. Removing and instaling engine 13;Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 - Remove front bumper > Rep. gt. 63 — Unscrew cooling pipe for power steering hydraulic fluid -arrows- and mave clear to side do not open hydraulic fluid circuit = Place drip tray for workshop hoist - VAS 6208- under engine. = Turn drain plug -arrows on radiator anti-clockwise; fit drain hose to connection if necessary. — Also open coolant drain plug on engine -arrow. = Disengage retaining clip ~arrow- and disconnect coolent hose (bottom right) from radiator. 14 ep. o.10-Removing and instaling engineAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 Vehicles with multitronic gearbox 01J or automatic gearbox 01V: (a) Note Observe files fer bleanliness when working on gearbox > Rep. gr. OD or= Repior. 37 = Place used oil collection and extraction unit - V.A.G 1782- un- der connection =, Unscrew union nuts -2- and, disconnect. ATF lines. = Remove retainer for ATF lines (unsorew nuts.1-and :2:). All vehicles: — Remove cover -arrow- at power steering fluid reservoir. Unplug the electrical connectors -arrows- and move wiring harness clear. - Detach coolant hose (top) from radiator by releasing retaining clip -arrow= 1. Removing and instaling engine 15)Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 ~ Detach aipcleanencayersarrow, Remove bolts -arrows- — Remove air duct -1- and -2. = Unplug electrical connectors for headlights and headlight range control on both sides of vehicle -arrows-. = Tur bulb holders for turn signals anti-clockwise and remove from turn signal housing -left arrow.. = Unplug electrical connectors -1- and -2- on both horns. — Disengage wiring at retainer -arrows. 16 ep. o.10-Removing and instaing engineAudi a6 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr. 5-valve), mechanics - Ecition 08.2919 Vehicles with air conditioner: — Remove air ducts -4- (leit and right) from radiator — Unplug s'ectrical connavtor -%. at low pressure switch for air couiditioner - F°2- ZA, weaniye The air conditioner refrigerant efrcuitynust get be opened. (Fre To prevent demage to the condenser and refrigerant pjpes/hoses, ensure that the pipes and hoses are not stretched, kinked or bent. — Unscrew securing bolts -f- and -2- for condenser. — ull condenser up out of its bracket, pivot to side and secure to right-side front wheel with wire. All vehicles: — Pull bonnet seals away from lock carrier and wing panels. fa) Note Protect wing panels from damage. = Unscrew bolts (left and right) -arrows-. = Disconnect bonnet lock cable at bonnet lock. = Unscrew bolts -arrows- from impact dampers (left and right) fa) Note A second mechanic is required for removing the lock carrier. Remove lock carrier and place down in a secure position. — Detach coolant hoses -1- and -3. = Unbolt coolant expansion tank -2- -arrows- = Unplug electrical connector for coolant shortage indicator switch - F66- below coolant expansion tank 1. Removing and instaling engine 17Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 = On vehicles with secondary air system, turn connecting pipe through 45° to the right -arrow: and detach from air cleaner housing, = Remove ail intake hose between air mass meter - G70- and air intake elbow. — Unplug elsctricat connector at solendid val’ 1 for‘adtivated charcoal ing year NAQ: ans. atach aglaneis. valve, fam racket, Unplug electrical connector at air mass meter - G70- Unscrew and remove air cleaner housing. Dy waren The fuel system is pressurised. Before opening the system place a clean cloth around the connection. Then carefully loos- en the connection to relieve the pressure. = Detach fuel return line. ~ Disconnect fuel supply line at connection = Unscrew bolts -arrows- and take off cover for electronics box in plenum chamber. — Pry off retainer bar with a screwdriver -arrow- — Remove engine control unit from electronics box. The electri- cal wires remain connected. 18 ep. o.10-Removing and insaling engineAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 - Unplug electrical connectors -arrows- at connector console. = Release retainer -arrow- and pull auxiliary relay cartier in elec tronics box upwards to remove. — Detach earth connection -2- and retainer -1-for electrical con- rectors from plenum chamber. — Disengage engine wiring harness at electronics box and bulk- head -arrows- and move clear. - Detach two coolant hoses for heat exchanger at engine (re- lease retaining clamps on connecting flanges). = Detach electrical connectors at variable intake manifold change-over valve - N156- (blue), secondary air inlet valve - N112- (green) and intake air temperature sender - G42- (black) on air inlet connection = Cut open cable ties and move wiring clear. = Detach vacuum lines -arrows A... C- — Unscrew bolts -arrows 1 ... 3- and remove retaining plate. — Disconnectiines between suction-jet pump and air intake con- nection piece. 1. Removing and instaling engine 19)Audi A6 1998 > G-cylinder engine (2.4 itr_ and 2.8 ltr, 5-valve), mechanics, Vehicles with throttie cable and cruise control system: — Detach vacuum hose -2- at vacuum unit for cruise control — Unscrew bolts -1- and move vacuum unit downwards. All vehicles: =. Detach electrical connectors at camshaft control valves and injectors, — Detach wiring for solenoid valve 4 for activated charcoal filter = N80- from throttle valve unit ~ Move disconnected lines and wiring clear to one side, ~ Remove air intake elbow. Vehicles with throttle cable = Detach throttle cable from throttle valve module and from sup- port bracket (do not remove retainer). Move throttle cable clear to the side. Unplug electrical connector'atkickdewn switch hicles with automatic gearbox Frow- on ve All vehicles: = Detach connectors -1 to 4- from retainer at right of bulkhead, Unplug electrical connectors -1-, -3- and -4.. = Cut open cable tie on bracket for connectors. — Move Lambda probe wires clear. = Use hose clamps - 3094- to pinch off both hoses at hydraulic fluid supply pipe. = Disconnect supply line -arrow- below cylinder head (left-side) ff Note Place a cloth undemeath to catch any escaping oll. - Edition 08.2019 20 0p. or.10- Removing and installing engineAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Edition 08.2019 = Detach hydraulic pressure pipe at rear coolant pipe left arrow. = Disconnect hydraulic pressure pipe at cylinder head (right- side, -right arrow. = Use 2-hole pin wrench - 3212- to support viscous fan pulley and unscrew viscous fan with open-ended wrench - 3341- -arrow: (leftshand thread). Tensioning roller with-hexagon head: (Bre Before removing, mark direction of rotation of poly V-belt with ‘chalk or felt-tip pen. if the belt runs in the opposite direction when itis refitied, this can cause breakage. — Tumthe tensioner in the direction of the -arrow- using a 17 mm ring spanner to slacken the poly V-belt. = Lock tensioner in position by inserting locking pin - 3204- in locating holes -arrows- - Take off poly V-belt. 1. Removing and instaling engine 21Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 Tensioning roller with hexagon socket: ft} Note Before removing, mark direction of rotation of poly V-belt with chalk or felt-to pen. Ifthe belt runs in the opposite direction when itis refitted, this can cause breakage. = Tur the tensioner in the direction of the -arrow- using a 10 mm hexagon key to slacken the poly V-belt. = Lock tensioner in position by inserting locking pin - 32.:4- in locating holes -arrow 1- and -arrow 2. — Take off poly V-belt Both versions: = Unscrew engine/gearbox securing bolts that are accessible from above. Leave one bolt in place (hand-tight). — Unscrew nuts (accessible from above) securing e.:haust mani- fold to front exhaust pipe (left and right) Vehicles with automatic gearbox 01V: = Unbolt air duct for alternator from radiator cow (bottom left) and pull air duct off alternator. ~ lisconnect earth connection (engine / cross member) from enginesupperarrowm, ~ Open cableidud for sfaiter an alternator at longitudinal mem- Defelowerarrows = Unscrew alternator — Pivot alternator to side and unscrew electrical wires, Move alternator te front. — Detach wires “42 afd $2" at starter anid detath insulator at pos! itive connection of starter. Remove starter bolts -arrows- from gearbox side. — Unscrew clamp on right of top section of sump and move elec- trical wiring clear. = Take out starter downwards through gap leave alternator in vehicle. ~ Unscrew 3 bolts -arrovi for torque converter, working through ‘opening of removed starter (turn crankshaft '/3 turn each time), ca} Note When loosening torque converter bolts, counterhold crankshaft by applying spanner to central bolt on vibration damper. = Secure alternator back on its bracket with one bolt in order to remove engine. 22 ep. or.10- Removing and installing engineAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 - Tum locking lever -1- and detach electrical connector for gear- box. = Unplug electrical connector -2- at multiunction switch - F125. (F) ne Disregard -itern 3. Vehicles with multitronic gearbox 01J: = Release electrical connector -A- in direction of -arrow- and disconnect at gearbox — Move line clear. Vehicles with multitronic gearbox 01J or automatic gearbox 01V: — Remove brackets for ATF lines -arrows-. = Unscrew heat shields for drive shafts (left and right) -arrows- 1. Removing and instaling engine 23,Audi A6 1998 > G-cylindér engine 124 MBGrd 2S tt. 5-valve), mechanics - Edition 08.2019 = Unscrew engilé speed sefider = G28- -item 1- at front left of gearbox, = Unplug eledttical corinector 2. lat speedémeter sender e220 (B) wwe Observe rules for cleanliness whan working on gearbox + Rep. gf. O00r> Rep. gr. 37 = Remove bolt -2- and detach ATF lines from gearbox - Move ATF lines clear. Vehicles with manual gearbox: — Unclip and unplug electrical connector -3. = Unolip cover :or wiring connections. Unscrew earth cable + Unscrew wiring connection -2-. Unscrew clamp -4- and move wiring clear. = Detach electrical connector from speedometer sender - G22- arrow A. — Unplug electrical connector at reversing light switch - F4- -arrow B. Note ‘Shown in ilustration with gearbox removed. Vehicles with air conditioner: A WARNING The air conditioner refrigerant vir-uit must not be opened. = Unbolt bracket at front of engine securing refrigerant pipes and coolant pipes to sump -arrows- 24 0p. .10- Removing and instaling engineAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 = Place drip tray for workshop hoist - VAS 6208- under engine — Disconnect coolant hose at bottom of oil cooler -arrow- and drain off remaining coolent. — Place used oil collection and extraction unit - VAG 1782- un- der engine. — Remove oibfiteratcoil’cooler: = Unplug. connecter for magnetic clutch of air,conditioner com pressor. Ay wane The air conditioner refrigerant circuit must not be opened. — Unscrew air conditioner compressor from bracket -arrows-. Tie up air conditioner compressor to longitudinal member, with lines attached. All vehicles: — Unbott left ang right front exhaust pipes from exhaust mani- folds -arrows-. = Unscrew spring-loaded securing bolts on mounting brackets for catalytic converters. = Pullexhaust system rearwards off studs on exhaust manifolds - Mark positions of bolt connections -1- and locating sleeves. -2- on bottom of engine mountings (left and right), (B) nae Different mounting holes are provided for the different engine ver- ‘sions. — Remove bottom nuts -1- at engine mounting (left and right) 1. Removing and instaling engine 25)Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 Remove bottom engine/gearbox securing bolts -arrows-. — Set up support bracket - 10-222 A- behind gas-filled strut on wing panel flanges. The spindle must be at the front. —_ Insert gearbox support - 3147. into bolt hole in gearbox bell housing, = Connect the gearbox support - 3147- and support bracket - 10-222 A- fi Note Ilustration shows engine removed. 26 op. or.10- Removing ad installing engineAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 = Attach lifting tackle - 2024 A- to engine and workshop hoist - \VAS 6100- as shown in the illustration. @] Note To adjust to the centre of ravity ofthe assembly, the perforated rails of the support hooks must be positioned as shown, LX _ wornine The support hooks and retaining pins on the lifting tackle must be secured with locking pins -arrows-. = Unscrew remaining engineigearbox securing bolt (F) note Check that all hoses and other connections between engine and body have been detached, - Raise engine with workshop hoist - VAS 6100- until the studs of the engine mountings are cleer. = Tighten spindle of support bracket - 10-222 A- further. Note Make sure no wires/pipes are damaged on the bulkhead. Vehicles with automatic gearbox O1V: = Separate automatic gearbox from engine and simultaneously detach torque converter from drive plate All vehicles: - Detach engine from gearbox and lift engine forwards out of engine compartment. Vehicles with automatic gearbox 01V: — Secure the torque converter in the gearbox using support bridge - 30-211 A- to prevent it falling out, 1. Removing and instaling engine 27Audi A6 1998 > G:cylinder engine (2.4 itr_ and 2.8 It, S-valve), mechanics ~ 12 Securing engine to assembly stand Special tools and workshop equipment required % Engine and gearbox support - VAS 6095- Procedure = Secure engine to engine and gearbox support - VAS 6095- as ilustrated, 13 Installing engine Installation is carried out in the reverse order; note the following: (Fr Renew setlocking nuts and bolts when performing assembly wor + Renew bolts which are tightened to a specified angle as well as ol seals and gaskets. Secure all hose connections with the correct type of hose clips (same as original equioment) = Parts catalogue Fit all cable ties in the original positions when installing. Vehicles with manual gearbox: ~ Clean input shaft splines and (in the case of used clutch plates) the hub splines. Remove corrosion and apply only a very thin coating of grease for clutch plate splines - G 000 100- to the splines. Do not lubricate guide sieeve, = Check that clutch plate is correctly centred. = Check clutch release bearing for wear and make eure thet plastic ring is securely seated > Rep. gr. 30 - Aneedle bearing must be fitted in the crankshaft on vehicles ‘with manual gearbox. Install needle bearing if necessary > page 59 Vehicles with SAC pressure plate: = When fitting a new clutch plate together with @ used SAC pressure plate (self-adjusting clutch pressure plate), the ad- Edition 08.2019 VAS 6035 28 op. or.10- Removing and installing engineAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 [ustor ing inthe pressure pate has to be reset by turing it ack as far as it will go. if this is not done, the pressure plate ‘will operate with reduced clamping force, causing clutch slip = Rep. gr. 30 fa Note Ifthe clutch Plate is not being replated, itis not necessary to reset the adjuster ring. ¢ New SAC pressure plates are already pre-set accordingly; and do not have to be reset, Vehicles with miultitronie gearbox 019: — Clean input shaft splines and splines of damper unit on fly- Wiheel; remove corrosion and apply only a very thin coating of grease for clutch plate splines - G 000 100- to the splines. Remove any excess grease, Vehicles with automatic gearbox 01V: = Before installing an exchange engine in a vehicle with euto- matic gearbox, check whether the centralising bush -arrow- for the torque converter is fitted at the rear of the crankshaft. Checking installation depth of torque converter: If the torque converter has been correctly installed, the distance between the bottom contact surfaces at the attachment points on the torque converter and the contact surface on the torque con- verter bell housing (with automatic gearbox) is approx. 23 mm. A Caution If the torque converter is not installed correctly, the drive lugs of the torque converter and the ATF pump will be seriously damaged when the gearbox Is joined to the engine. 1. Removing and instaling engine 29)Audi A6 1998 > G:cylinder engine (2.4 itr_ and 2.8 It, S-valve), mechanics ~ = Before bringing engine and gearbox together, turn torque con- verter and drive plate on engine so that the holes for one securing bolt are in line with the opening for the starter motor -arrow- = To secure torque converter on drive plate, use only new ribbed bolts of the correct type (same as original equipment) as specified in = Parts catalogue . Ne Before end during tightening of bolts on engine/gearbox flange, continually check that the torque converter behind the drive plate can be tumed. If the converter cannot be tured, it must ‘be assumed that it has not been installed correctly and the drive lugs of the ATF pump and consequently the gearbox will ‘be damaged when the bolts are finaly tightened. All vehicles: — Check that dowel sleeves for centralising engine/gearbox are inthe cylinder biock: install if necessary. = Altach engine to gearbox and screw in one bolt finger-tight. = Release spindles of eupport bracket - 10-222 A- Lower engine, inserting studs of engine mountings into con- soles for engine mountings as you do so. fi Note Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. % Additional lubricant such as engine oil or gearbox oll may be used, but do not use lubricant containing graphite, + Do not use degreased parts. Tolerance for tightening torques is + 15% ‘Securing engine to manual gearbox Edition 08.2019 item Bolt Nm 4 M10x135 45 2 M12x110 ce 3.4.5 M12x67 cy 6 12x90 ") 6 7 M12x80 cy 8,9, 40 MA0Ka5 45 A Dowel sleeves for centralising +") Bolt with washer. 30 R09. 9:10- Removing and nsaling engineAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 ‘Securing engine to multitronic gearbox 01 Item Bolt Nm 4,10, 14 Mi10x45 45 2 M10x30 ") 65 3 M12«110 65 4,596 8 TA2x67 65 q Mg2x80 6 8 111 0x60 5 A Dowel sleeves for centralising + U°Boit with’ washer. 1. Removing and instaling engine 31Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 ‘Securing engine to automatic gearbox 01V Item Bolt Nm 1 M10x80 45 2 MA2x110 5 3.4.5 MA2x67 5 6 M12x90 ") 6 7 M12x75 cy 8 M10x60 5 9,40 M10x45 5 A Dowel sleeves for centralising F ) Batt withhwasher. All Versions: Remaining installation steps are carried out in reverse sequence; ‘ote the followings = ‘Ihstall engine imolintings free of stréss. To do $0, shake engine before tightening engine mountings: — Align exhaust system so its free of stress = page 196 ~ Install air conditioner compressor = Rep. gr. 87 = Install alternator > Rep. gr. 27 = Install viscous fan = page 179 = Install poly V-belt = page 37 = Install lock carrier > Rep. gr. 50 = Install front bumper > Rep. gr. 63 = Allow stop for torque reaction support to rest on rubber buffer for oraue reaction support under its own weight end tighten Vehicles with mutitronic gearbox 01V or automatic gearbox O1V: = Secure ATF lines to gearbox > Rep. gr. 37 Vehicles with throttle cable: = Check adjustment of throttle cable > Rep. gr. 20. All vehicles: ~ Connect vacuum hoses = page 34 = Electrical connections and routing > Current flow diagrams, Electrical fault finding and Fitting locations, = Observe notes on procedures required after connecting bat- tery= Rep. gr. 27 Do notuse a battery charger to boost starting. There is danger ‘of damaging the vehicle's control units. = Fill up with engine oil and check oil level > page 153 ~_ Fill cooling system = page 159 32. Rop. 9:10- Removing and instaling engineAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr. 5-valve), mechanics - Edition 08.2019 fa) Note ¢ Drained-off coolant may only be used again if the original cyl. inder head and cylinder block are re-installed. Contaminated or dity coolant must not be used again. ~ Top up power steering fluid and bleed steering system > Rep. or 48 Vehicles with multitronic gearbox 01J or automatic gearbox 01V: — Check ATF level = Rep. gr. 37 Tightening torques ¢ Tightening torques apply only to lightly greased, oiled, phosphated or black-finished nuts and bolts. ¢ Additional lubricant such as engine oil or gearbox oi/ may be used, but do not use lubricant containing graphite. © Donotuse degreased parts. © Tolerance for tightening torques: + 15% [Component Nm Bolte/nuts M6 10 M8 20 M10 5 Miz 65 Except for the following [Coolant drain plug to cylinder block 20 Fuel supply line to fuel rail 23 [Air duct to intake manifold 10 Power steering pressure pipe to pressure hose| 40 Drive plate to torque converter as) Engine speed sender to gearbox 10 Stop for torque reaction support to lock carrier 28 Torque reaction support to engine [40 Drive shaft heat shield to gearbox 23 Engine mounting to subframe 25. * 1) Use new genuine ribbed boits > Parts catalogue 1. Removing and instaling engine 33.Audi A6 1998 > G:cylinder engine (2.4 itr_ and 2.8 It, S-valve), mechanics ~ 1.4 Vacuum connections Vehicles without secondary air system (view from above) 1- To vacuum unit for intake manifold change-over 2- To vacuum reservoir 3+ To-connection on intake manifold 4- Non-return valve 5+ Variable intake manifold changeover valve - N156- 6- Fuel pressure regulator to T-connection 7 Toconnection on intake manifold 8- Intake manifold. Engine (rear) 1- Fuel presstiré regiilator 2+ Suction.jet pump 3- Non-return valve 4- To vacuum reservoir 5+ Air intake connection 6- Connection between air intake connectionithrottle valve unit 7+ Connection between suction jet pump/air intake connection Left side view 1+ Fuel pressure regulator 2- Suction-jet pump 3- To brake servo 4 Toair conditioning system 5- Airintake connection 6- Connection on throttle valve unit to activated charcoal filter solenoid valve 1 - N80- 7 Connection: suction-jet pumpintake manifold Vehicles with secondary air system: Edition 08.2019 34 op. 9:10- Removing and instaling engineAudi a6 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 1 - Combination valve for sec- ondary air system (right-side) On cylinder head (rear right) 2- To activated charcoal fiter Solenoid vaive 1 - N&0- On air cleaner 3. Throttle valve module - J338- 4 - Secondary air inlet valve - Ni12- 5- Non-return valve DscOn USA models 9- Combination valve for-sec: ondary air system (left-side), 10 - Fuel pressure regulator 41.- To vacuum reservoir In whee! housing (front right) 12- Intake manifold 13 - To actuator for intake manifold change-over 1. Removing and instaling engine 3DAudi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 4 Crankshaft 1 Servicing work on pulley end 14 Exploded view - poly V-belt drive 4-411Nm 8 9 10 11 12 13 14 15 2 - Fan wheel for viscous fan 1D Removing and installing > page 179 3 - Poly V-belt Before removing, mark direction of rotation with chalk or fett-tip pen. If the belt runs in the op- posite direction when it Is refitted, this can cause breakegen Removing anainstaling = page 3 4-22Nm 5 - Alternator Removing and installing > Rep. gr. 27 6 -45Nm 7 -22Nm 8 - Bracket for alternator 9-45 Nm. 10- Spacer sleeve 14-55Nm 12-22Nm 13 - Pulley for power steering pump To remove and install counterhold with pin wrench - 3212- > page 37, Marked “Vorne/Front” 24 23 (aos) 14 Pressure line 1D To power-assisted steering 15 - Banjo bolt: 40 Nm 16 - Seal O Renew 17-22Nm 18 - Power steering pump with bracket, Removing and installing = Rep. gr. 48 36 op. 9:15- Crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 19-22.Nm 20 - Pulley for viscous fan Removing and installing + page 180 21 - Tensioner for poly V-belt 22-25.Nm 23 - Air conditioner compressor Do not unscrew or disconnect refrigerant hoses or pipes. After removing compressor from mountings, secure it to longitudinal member with wire or similar. Do not leave it suspended from refrigerant pipes. 24+ M6: 10 Nm; MB: 22 Nm 25 - Belt pulley/vibration damper Removing and installing = page 39 26-22 Nm 27 - Viscous fen coupling 2 Removing and installing = page 179 Removing and installing power steering pump pulley + Poly V-belt must be removed = page 37 Use pin wrench - 3212- to counterhold when slackening and tightening bolts -arrows-. + Installation position: marking "Vorne/Front” faces in direction of travel + Tightening torque: 22 Nm 1.2 Removing and installing poly V-belt ‘Special tools and workshop equipment required # Locking pin -3204- 1. Servicing work on palsy ond 37Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 Removing — Remove engine cover panel -arrows- Remove bolts -arrows- — Remove air ducts -1- and -2.. ~ Vehicles with auxiliary heater: Remove bolts arrows. securing exhaust pipe for auxiliary/supplementary heater to noise in- ulation. Remove noise insulation -arrows- 38 op. o:15- Crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 Tensioning roller with hexagon head: (a) Note Before removing, mark direction of rotation of poly V-belt with ‘chalk or felt pen. Ifthe belt runs in the opposite direction when itis refitted, this can cause breakage. = Tum the tensioner in the direction of the -arrow- using a 17 mm ring spanner to slacken the poly V-belt. = Lock tensioner in position by inserting locking pin - 3204- in locating holes -arrows-. — Guide poly V-belt over viscous fan and detach belt. Tensioning roller with hexagon socket: (Bre Before removing, mark ditection of rotation of poly V-belt with chalk or felt-tip pen. Pthebelteursinthe-opposite direction when itis refitied, this can cause breakage. — Tumthe tensioner in the direction of the -aitoW- Using’a 10 mat hexagon key toslacken the poly Vabelt Lock tensioner in position:by:inserting:locking pin +:3204~in locating holes -arrow 1- and -arrow 2- - Guide poly V-belt over viscous fan and detach belt. Installing Installation is carried out in reverse order; note the following: Start by fitting poly V-belt onto crankshaft pulley. Push belt ‘onto tensioning roller last. Routing of poly V-belt D1 - without air conditioner D2- with air conditioner (B) note When installing poly V-belt, make sure it is property seated on pulleys. = Start engine and check that belt runs properly. 13 Removing and installing pulley/vibration damper Removing = Remove front bumper = Rep. of. 63 = Move lock carrier to service position = Rep. gr. 50 = Remove poly V-belt = paue 37 1. Servicing work on pulsy ond 3Q)Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 fw Note Central bolt does not have to be loosened when removing pulley/ vibration damper. = Unbott pulley/vibration damper. Installing Installation is carried out in reverse order; note the following + Ensure that notches -arrows- in pulleyivibration damper are aligned with locating lugs on toothed belt sprocket. = Install poly V-belt = page 37 = Install lock carrier > Rep. gr. 50 ~ Install front bumper = Rep. gr. 63 Tightening torque [Component Nm Belt pulley/vibration damper to crankshaft [22 sprocket 1.4 Exploded view - toothed belt drive 40 op or-13- crankshaft groupAudi a6 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 1-10Nm 2-10Nm 16 17 18 3- Washer 4-22Nm 5 - Tensioning lever with bear- ing bush 6 - O-ring Renew if damaged 2 Locates = Item 3 (page 41) , Siltem 4 (pace 41) and = tem (page 41) when assembled 7-22Nm. 8-55.Nm. 9- Washer 10 - Locating plate Side labelled “rear/hint- fen’ faces rear 11 - Camshaft sprocket (right- side) Removing and installing 31.5 Removing ang ine Sialing toothed bell page 43, 2 Remove using puller - T40001- 12 - Spacer 13-10Nm. 30 29 28 27 26 25 24 23 22 aaa) Install using locking flu- — id; for locking fluid refer to= Parts catalogue 14-10Nm 18 - Toothed belt cover (reer right) 16-10.Nm 17 - Coolant pump Removing and installing > page 163 18 - Gasket a Renew 19 - Toothed belt cover (rear left) 21 - Locating plate Dp Side labelled “tearihinten’ faces tah... 6 commercial purpose Inwhole, 22 - Toothed Belt oo. a. ih) py AUC J doe uarantee or a Before removing, mark direction of rotation with chalk or felttip pen, Ifthe belt runs in the opposite ction when itis refitted, this can cause breakage um 2 Check for wear 1. Servicing work on ploy ond 41Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 1D Removing = page 43 Installing (adjusting vaive timing) = page 46 23-55 Nm 24 - Idler roller 25 - Crankshaft sprocket Contact surface between sprocket and crankshaft must be free of cil Can only be installed in one position 26 - Tensioning roller with bearing bush 27-43Nm 28 - 200 Nm + 180° (v2 turn) further O Renew Do not additionally lubricate 2. Use locking pin - 3242- when loosening and tightening 1 Screwing in locking pin - 3242- > page 50 29- Tensioner 30 - Toothed belt cover (bottom) 42 Rep or-13- Crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 1.5 Removing and installing toothed belt Special tools and workshop equipment required Counterhols tool - 3036- Locking pin - 3242- Camshaft clamp - 3391- Puller - 40001- with claws - T40001/2- Locking pin - T40011- Removing + Engine in vehicle. tee ee = Remove front bumper = Rep. gt. 63 - Move lock carrier to service position > Rep. gr. 50 ~ Remove viscous fan = page 179 = Unscrew radiator cowl for viscous fan. 1. Servicing work on palsy ond 43,Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 = Remove poly V-belt > page 37 — Unscrew bolt -arrow- and remove tensioner for poly V-belt. = On vehicles with secondary air system, disconnect hose arrow. from seconde:y air connecting pipe. — Remove toothed belt cove. eft ana .ignt) L\ carton Engine must only be turned in direction of rotation (clockwise) via crankshaft. - Tum crankshaft by turning central bolt at crankshaft sprocket in.notmal direction of engine retation unt the marking is at + Notch -B-is ovposite mark -A-. = Check position of camshafts: + Large holes -arrows- in locating plates at camshaft sprockets must be opposite one another on inside. —_ If this is not the case, turn crankshaft one revolution further. 44 op or-13- Crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 = Vehicles with auxiliary heater: Remove bolts -arrows- securing exhaust pipe for auxiliary/supplementary heater to noise it sulation. Remove noise insulation -arrows- = Unscrew plug for TDC marking from cylinder block. [) we There is @ TDC dhiling in the crankshaft directly behind the sealing plug (itis possible to fee! the hole). A WARNING To avoid any risk of injury, do not rotate the crankshaft while feeling for the TOC hole with your finger. Sgerewlocking’ Sin 3242. into threaded hole where plug has been removed, and tighten = Remove pulleyivithation damper > page 39 Unbott toothed belt cover (bottom) and poly V-belt pulley for viscous fan -arrows- 1. Servicing work on palsy ond 45)Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 ~ Loosen both camshaft sprocket bolts using counterhold tool - 3036- ff Note Leave bolts screwed in loosely. = Pull camshaft sprockets (left and right) off their tapers using puller - T40001- with claws - T40001/2- (F noe % Before removing, mark rotation direction of toothed belt with chalk or felt-tip pen. 1f the belt runs in the opposite direction When it is refited, this can cause breakage. 4% The toothed belt tensioner is oil-damped and can therefore only be compressed slowly by applying constant pressure. — Tum toothed belt tensioning roller -1- clockwise in direction of -arrow- using an 8 mm Allen key until tensioning lever -2- ‘compresses tensioner -3- far enough for the pressure piston to be locked with locking pin - T40011- - Remove toothed belt Installing (adjusting valve tinting) + Crankshaft IGBK6S IM BOsitfor with fecking pin - 3242. + Camshatt sprockets free to tur. fw Note The crankshaft must not be at TDC at any cylinder when the camshaft is tumed. Otherwise, there is @ risk of damage to valves and piston cro we. + The valve timing must be adjusted as described below, even when the toothed belt has only been removed from the cam- shaft sprocket: ~ Fitboth camshaft sprockets with acting plates, washers and cls. + Installation position of locating plates: labelled side “front! vorne” faces front or marking ‘rear/hinten’ faces rear. ~ Tighten the two camshaft sprocket bolts until the sprockets can siill just be turned without axial movement = Position toothed belt as shown on all sprockets and finally on tensioning roller. G6 op or-13- Crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr. 5-valve), mechanics - Edition 08.2019 Fit camshaft clamp - 3391- onto the locating plates of the two camshafts, = Using an 8 mm Allen key, turn toothed belt tensioning roller 1- clockwise in direction of -arrow- until the locking pin - 740011- can be removed. — Proceed as follows to pre-tension tensioning roller before first starting engine: - Apply torque wrench at hexagon socket of tensioning roller and tension belt with a torque of 15 Nm, + This provides the correct amount of initial tension. = Tighten camshaft sprockets to 30. Nm. — Remove camshaft clamp - 3391-. = Tighten camshaft sprockets fully. To do so, apply counterhold tool - 3036- for support. = Remove locking pin - 3242- = Screw plug for TD.> marking into cylinder block with new O- ring. — Install pulley/vibfétionlampet= nae 38) = Install poly V-belt > page 37, = Install lock cartier > Rep. gr. 50 ~ Install front bumper = Rep. af, 63. Tightening torques, [Component Nm |Camshaft sprocket to camshaft 55. [Tensioner for poly V-belt to cylinder block [85 Toothed belt tensioning roller to oil pumpifront [22 sealing flange ‘Sealing plug in cylinder block 10 Toothed belt cover (bottom) to cylinder biock [10 \Viscous fan bracket to cylinder block M6|10 a |22 1. Servicing work on puloy ond 47Audi A6 1998 > G-cylinder engine (2.4 lr. and 2.8 ttt S-valve), mechanies - Edition 08.2019 2 Removing and installing sealing flanges.and.dual-mass flywheel/fly- Wwheel/drive plate 24 Exploded view - sealing flanges and dual-mass flywheel/flywheel/drive plate (Bie Senicing cluich > Rep. gr. 30 4-6: 10 Nm; M8: 30 Nm 2- Crankshaft oll seal Q_ Removing and installing = page 50 3-40Nm 4 - Stop for torque reaction support The version shown in the illustration differs from the version fitted in the vehicle. 5 -28Nm. 6 - Torque reaction support The version shown in the illustration differs from the version fitted in the vehicle. 7 = Sump (top section) Removing = page 135 O Installing = page 145 8-45 Nm 9-6 = 10. Nm; M7 - 16 Nm; M8 - 20 Nm 10- O-ring O Renew 14 - Dual-mass fiywheelifly- wheel/drive plate Removing and installing 32.4 Removing andin- stalling dual-mass fly- wheel - vehicles with manusl gearbox’ page 57, = "2.6 Removing and installing flywheel - vehicles with multitronic gearbox 01J", page 59 or = "2.7 Removing and installing orive plate - vehicles with automatic gearbox 01V", page 60 12 - Securing bolt for dual-mass flywheelfiywheel/drive plate Renew Tightening torque for dual-mass flywheel = page 57 Tightening torque for fywheel = page 59 4B op or-13- Crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 2 Tightening torque for drive plate > page 60 13 - Needle bearing Manual gearbox only Extracting and driving in > page 59 With automatic gearbox 01V, a bearing bush is pressed into the crankshaft instead of the needle bearing in the duel-mass flywheel = page 65 14 - Sealing flange (rear) with oil seal 2 Remove upper section of sump in order to remove and install = page 135 Lubricate sealing lip of oil seal lightly 15-10.Nm 169 CasKet a Renew 17&Cylinder-block. Removing and installing crankshaft = page 63 2... Dismantling and essembling pisions.and conrods 2.pace.69 18-40.Nm 10) Dipstick guide tube 20- Gasket a Renew 21 - Sealing flange (front) Removing and installing = page 51 2, Removing and instaling sealing anges and dual-mass fyuhoaltywhestive plas AQAudi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 22 Renewing crankshaft oil seal (pulley end) Special tools and workshop equipment required Fitting sieeve - 3202/1. # Oil seal extractor - 3203- Fitting sieeve - 3265- Procedure + Engine in vehicle. — Remove toothed belt + page 43 = Unscrew central bolt -3- for toothed belt sprocket -1- on crank- shaft. = Detach spacer -2- and toothed belt sprocket. 50 Rep. 9:15- Crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 — Unscrew inner section of cil seal extractor - 3203- 3 turns out of outer section and lock with knurled screw. = Lubricate threaded head of oll seal extractor, place itn posi- fion and screw into ol seal as far as possible (applying frm pressure) — Loosen knurled screw and turn inner part against crankshaft until cil seal is pulled out, = Clamp flats of oil seal extractor in vice = Remove oil seal with pliers. Clea tuning suffece ahd sealing surface. (a) tes Do not lubricate sealing'lig.and outer rit of oll seal before press ‘ng in. ~Pushion ipséa wag ting siseve'3202/11 Press in oil seal unti flush using the centre bolt and fiting sleeve - 3265- ~ Install crankshatt sprocket -1-with spacer 2-and new central alt -3.. © Contact surface between toothed belt sprocket and crankshaft must be free of ol, ¢ Do not additionally lubricate bolt for crankshaft toothed belt sprocket. — Install toothed belt (adjust valve timing) + page 46 Tightening torque [Component Nm Toothed belt sprocket to crankshaft 200 + 180° 12) +? Renew bott. + 2) 480: one half turn. 23 Removing and installing sealing flange (front) 2, Removing and instaling sealing langas and dua-mass fywhoaltywhosletive plats 51Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 Special tools and workshop equipment required Fitting sleeve - 3202/'- from fitting sleeves - 3202- 4 Fitting sleeve - 3265- # Used cil collection abd exttactionont V.A.G 1782- Electric drill with plastic brush attachment # Safety goggles # Sealant Perts catalogue Removing + Engine in vehicle. = Remove toothed belt > pege 43 = Unscrew central bolt -2- for toothed belt sprocket-1- on crank- shaft. — Detach spacer -2- and toothed belt sprocket. = Place used oil collection and extraction unit - V.AG 1782- un- der engine. =. Drain off engine oi 52 Rep or-13- Crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 Vehicles with multitronic gearbox 01J or automatic gearbox 01V: — Remove brackets for ATF lines -arrows-. All vehicles! = If fitted: unplug electrical connector -arrow- at oll level and oil temperature sender - G266- and move wiring clear — Remove sump (bottom section) -1- - Unscrew brackets for oil supply pipes -arrows- and detach front (long) oil supply pipe. 2, Removing and instaing sealing anges and dua-mass fyuhoaltywheauaive plats SSAudi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 = Unscrew 4 bolts -arrows- from sump (top section). = Remove idler roller -2-, tensioning roller -1-, tensioning lever ~4- and tensioner -3- (\ Remove bolts -1- and -2- and detach front sealing flange, — Drive out oil seal with flange removed, Installing Installation is carried out in reverse order; note the following: Remove sealant residue from sealing flange and bottom and top sections of sump with rotating plastic Brush or similer. A wane Put on safety goggles. — Clean sealing surfaces; they must bs free of oil and grease. 54 kop. :15- Crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 = Cutoff tube nozzle at front marking (nozzle approx. 3 mm 2), — Fit gasket onto dowel pins on sealing surfaces -A.. (a) nae Do hotapply.sealanttosealing surface ~A- on cylinder block. — After fiting gasket, apply a small sealant bead in each case to edges between “left arrows- and -right arrows ff} Note The sealing lange must be insialled within 5 minutes afer appiy- ing sealant = Apply sealant bead to clean sealing surface of sealing flange, as shown in illustration, + Thickness of sealant bead: 2 ... 3 mm. (B) nee © Sealant bead must not be wider than 3 mm, otherwise excess sealant could ingress into sump and clog strainer in oil intake pips. ¢ For hiting sealing flange with oil seal in position, attach fiting ‘sleeve - 3202/1- to end of crankshaft = Handctighten the 4 bolts -errows-. 2, Removing and instaing sealing anges and dua-mass fyuhoalfywheslisive plats SOAudi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 = Insert bolt -2- with locking fluid; Locking fluid = Parts cata- logue =. Tighten bolts -1- to 10 Nm and bolt -2- to 30 Nm. = Tighten the 4 bolts -arrows- fully. M6 - 10 Nm M7 -16Nm (E]) re Do not lubricate sealing lip and outer rim of oi! seal before press- ing in. = Push on oil seafusing fitting! sleev - 3202/1- — Press in oil seal untilfivsh Using the centre bolt and fitting sleeve - 3265-. Install comporlénts in the Specified sequende: Toothed belt tensicher item 3. Tensioning lever -item 4- Toothed belt tensioning roller item 4-. Idler roller item 2. Pay attention to shims beneath tensioning roller and tension- ing lever. 56 Rp. :15- Crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr. 5-valve), mechanics - Edition 08.2019 Install crankshaft sprocket -1- with spacer -2- and new central bolt -3- (a) Note © Contact surface between toothed belt sprocket and crankshaft must be free of of. © Do not additionally lubricate bolt for crankshaft toothed belt sprocket, = Install toothed belt (adjust valve timing) = page 46 Tightening torques [Component Nm Front sealing fangs to cylinder block M6 |10 Ma|30 Sealing flange (Front) tosump (opeec-__M6| 10 tion) M7 46 FToothed belt sprocket to crankshaft 200 + 180° Tensioner to sealing flange ({ront) 10 FTensioning lever to sealing flange (Font) 22 | Tensioning roller to sealing flange (front) 22 Idler roller to sealing flange (front) a3. + 1 Renew bolt. + 2) 480° = one half turn 24 Removing and installing dual-mass fly- wheel - vehicles with manual gearbox Special tools and workshop equipment required @ Locking pin - 3242- 2, Removing and instaling sealing anges and dual-mass fyuhoaltywheauaive plats STAudi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 Removing + Gearbox removed A Caution Engine must only be turned in direction of rotation (clockwise) via crankshaft. = Turn crankshaft by turning central bolt at crankshaft sprocket in normal direction of engine rotation until the marking is at TDC. + Notch -B-is opposite mark -A-. = Unscrew plug for TDC marking from cylinder block (B) nae There is.@ TOC drilingin th crankshaft directly bBhind the sealing plug (itis possible to fee/ the hole)s A wane To avoid any risk of tAjury.“do' Rot rotate the crankshaft White feeling for the TDC hale with your finger. = Screw locking pin - 3242. into threaded hole where plug has been removed, and tighten — Remove clutch pressure plate + Rep. gr. 30 ~ Mark installation position of dual-mass flywheel on crankshaft. = Unbolt dual-mass flywheel. Installing Installation is carried out in reverse order; note the following: Use new securing bolts. — Install clutch pressure plate > Rep. gr. 30 (a Note A needle bearing is fitted in the dual-mass flywheel; knock in the needle bearing when fiting a new flywheel = page 59. — Remove locking pin - 3242-. ~ Screw plug for TDC marking into cylinder block with new O- fing Tightening torques [Component Nm Dual-mass fiywheel to crankshaft (60 + 180° 92) + 1) Renew bolts. + 2) 480 one half turn. 58 op. :15- Crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 25 Extracting and driving in needle bearing for dual-mass flywheel Special tools and workshop equipment required Punch - 3264. 1- Internal puller - Kukko 21/1- @ 4 Counter-support - Kukko 22/1- Procedure — Remove needle bearing using internal puller- Kukko 21/1- and counter-support - Kukko 22/1- = Drive in needle bearing unti flush using punch - 3264- 26 Removing and installing flywheel - vehi- cles with multitronic gearbox O1J Special tools and workshop equipment required 2, Removing and instaling sealing anges and dual-mass fyuhoaltywheauaive plats SQ)Audi A6 1998 > G-cylinder engine (2.4 ltr and 28 tr. S-valve), mechanios - 4 Counterneidtoal -10-201- Removing + Engine or gearbox removed. =~ Remove damper unit -arrow-= Rep. gr. 13 — Mark installation position of flywheel -arrow- on crankshaft = Attach counterhold tool - 10-201- in order to loosen bolts. = Unbolt flywheel, Installing Installation is carried out in reverse order; note the following. = Use new securing bolts. — Reverse position of counterhold tool - 10-201- in order to tight- en bolts. = Install damper unit > Rep. gr. 13 Tightening torque [Component Nm Fiywhee! to crankshaft J60 + 90° 7) +) Renew bolts. + 2 90° = one quarter turn 27 Removing and installing drive plate - ve- hicles with automatic gearbox 01V ‘Special tools and workshop equipment required Edition 08.2019 10-201 60 op. or-13- crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr. 5-valve), mechanics - Ecition 08.2019 © Locking pin 932425 Removing + Gearbox removed A\ casion Engine must only be turned in direction of rotation (clockwise) via crankshaft = Tum crankshaft by turning central bolt et crankshaft eprocket in normal direction of engine rotation until the marking is at TDC. + Notch -B- is opposite mark -Ax = Unscrew plug for TDC marking from cylinder block. [) we There (s a TOC ariling in the crankshaftdirectly behind the sealing plug (itis possible to feel the hole). A WARNING To avoid any risk of injury, do not rotate the crankshaft while co feeling for the TDC hole with your finger. = Screw locking pin - 3242- into threaded hole where plug has been removed, and tighten = Mark installation position of drive plate on crankshaft. = Unbolt drive plate. Installing = Fit drive plate in position with packing plate -2- and shim-1- of *3.0 mm’ or "4.0 mm’ thickness. — Insert at least 3 old securing bolts and tighten to 30 Nm, 2, Removing and instaling sealing langas and dua-mass fywhoaltywhoslesive plats 61Audi A6 1998 > G:cylinder engine (2.4 itr_ and 2.8 It, S-valve), mechanics ~ = Measure distance -a- at three points and calculate average value. + Specification for automatic gearbox 01V: 18.1 ... 19.7 mm. If specification is not obtained: =, Remove drive plate again and install with different shim -1~ Re-tighten bolts fo 30'Nm — Repeat measurement procedure. If specification is obtained: = Renew bolts and tighten to final setting, — Remove locking pin - 3242-. = Screw plug for TDC merking into cylinder block with new O- ring Tightening torques [Component Nm Drive plate to crankshaft fe0 + 90° 0) [Sealing plug in cylinder block 10 +) Renew bolts. 2). 90° = one quarter turn Edition 08.2019 62 op or-13- Crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 3 Removing and installing crankshaft 3.1 Exploded view - crankshaft (B) Note Secure engine to engine and gearbox suoport - VAS 6095- prior to performing assembly work = page 28 1 - Dowel sleeve Insert in cylinder block 2- Chain sprocket 1D RBoviAG andiinstalling page or 3+ Crankshaft Measuring axial clear- ance = page 68 QMeasuring radial clear- ance = page 67 (Ax\Bo not rotate the-cranic. shaft when checking the radial clearance Crankshaft dimensions = page 65 4-- Bearing cap bolts 2 Renew Tightening sequence = page 65 5 - Bearing caps Note marking = page 64 Installing + page 65 6- Thrust washer Only fitted on 4th crank- shaft bearing Oil grooves face out- wards a Note location a Measuring axial clear- ance of crankshaft = page 66 7 - Bearing shell for bearing cap 2 Without oil groove Do not interchange used bearing shells (mark positions) Install new bearing shells for the bearing caps with the correct coloured markings =» page 65 8 - Bearing bush Automatic gearbox O1V only Driving in = page 65 9- Thrust washer Only fitted on 4th crankshaft bearing Removing and insialing erarkshan 3Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 Oil grooves face outwards Measuring axial clearance of crankshaft > page 66 10 - Bearing shell for cylinder block 1D With oil groove Do not interchange used bearing shells (mark positions) Install new bearing shells for the cylinder block with the correct coloured markings > page 64 11 - Bearing cap bolts Tightening sequence = page 65 Markings on crankshaft bearing caps Bearing -1-is on pulley end. % Bearing -4- is on flywheel end ‘Matching crankshaft bearing shells to bearings in cylinder block fi Note The -arrow- points to pulley Brid. # Bearing shells of the correct thickness are matched to the bearings in the cylinder block at the factory. Coloured dots on the bearing shells are used to identify the bearing shell thick- ness. # The allocation of the bearing shells to the cylinder block is identified by @ code letter next to the relevant bearing, Letter on cylinder block Colour coding of bearing Yellow Blue = Black 64 op, or-13- Crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 Matching crankshaft bearing shells to bearing caps Bearing shells of the correct thickness are assigned to the bearing caps at the factory. Coloured dots on the bearing shells are Used to identify the bearing shell thickness. ¢ The correct allocation of bearing shells to crankshaft is indi- cated by a sequence of letters on the crankshaft web. The number “1” -arrow- preceding the sequence of letters indicates the colour code for No. 1 bearing Letter on crankshaft Colour coding of bearing Yellow Blue = Black Installing crankshaft bearing caps = Renew bolts -1... &. Insert dowel sleeves in cylinder block. Tighten bearing cap bolts in following sequence: 1. SERA Bots AD ERRioht. Tighted bolts)+1 |, 8. to 60 Nm with torque wrench. ‘Tarboltst 8! 90™4Urther ("/4 turn) using a rigid wrench Ren Tighten bolts -A- to 25 Nm with torque wrench. Bearing bush for torque converter, (F) ne Short engines and reconditioned (exchange) engines, as well as new and reconditioned crankshafts, are supplied without bush -arrow.. The centring sleeve must therefore be knocked in before fitting drive plate on vehicles with automatic gearbox 01V. This ‘bush must not be fitted in vehicles with manual gearbox. 3.2 Crankshaft dimensions 2.4 Itr. engines Honing dimension | Crankshaft main] Crankshaft conrod (iamm) bearing journal 2 journal 2 Basic dimension 58.00 - 0.022 50,00 - 0.022 = 0.042 = 0.042 3, Removing and insialing erarkshan 5Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 [Honing dimension | Crankshaft main | Crankshaft conrod (in rom bearing journal 2 journal 2 Repair oversize 1 | 57.75 - 0.022 49.75 - 0.022 =0:042 =0:042 Repair oversize 2 | 87.50 - 0.022 49.50 - 0.022 = 0.042 =0.042 Repair oversize 3 | 87.25 - 0.022 49.25 - 0.022 = 0.082 = 0.042 2.8 itr. engines [Honing dimension | Crankshaft main | Crankshaft conrod (in mm) bearing journal & journal 2 [Basic dimension 65.00 - 0.022 84.00 - 0.022 = 0.042 ~0.042 Repair oversize | 64.75 -0.022. 53.75 - 0.022 = 0.042 = 01042 Repair oversize 2 | 64.50 -0.022 53.50 - 0.022 = 0.042 = 0.042 Repair oversize 64.25 - 0.022 53.25 - 0.022 = 0.042 = 0.042 3.3 Measuring axial clearance of crankshaft ‘Special tools and workshop equipment required # Universal dial gauge bracket - VW 387- + Dial gauge - VAS 6079- VAs 6979 66 op or-13- crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 Procedure Bolt dial gauge with universal dial gauge bracket - VW 387- onto cylinder block and apply gauge against crank web. Push crankshaft against ial gauge by hand and set gauge to Push crankshaft away from dial gauge and read off value for axial clearance: + New: 0.07 ... 0.23 mm. + Wear limit: 0.25 mm, 34 Measuring radial clearance of crank- shaft ‘Special tools and workshop equipment required © Plastigauge Procedure (F) ne Do not interchange used bearings. = Remove crankshaft bearing cap and clean bearing cap and journal — Place a length of Plastigauge corresponding to the width of the bearing on the bearing journal or bearing shell + The Plastigauge mustbe'Bositionedin’the centre of the bear- ing shell = Fitcrankshaft bearing Saps and tighten to 30 Nm. Donet rotate crankshaft = Remove crankshaft bearing cap again. = Compare width of Plastigauge with measurement scale: * Radial clearance (new): 0.018 ... 0.045 mm + Racial clearance (wear limit): 0.10 mm 35 Removing and installing drive chain sprocket for oil pump Special tools and workshop equipment required + Drift sleeve -30-100- 3, Removing and insti erarkshan OTAudi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 # Thrust plate - 40-105- # Two-arm puller, commercially available Protective cloves Removing = Remove chain for oll pump = page 148 — Pull drive chain sprocket off crankshaft with commercially available puller -2-; use a suitable washer -1- to protect end of crankshaft. Installing Installation is carried out in'teyersé ordef, note the séllowing: = Heat crive chain sprocket in an oven for approx. 15 minutes t0 220°C. A wn Wear protective gloves. = Using pliers, locate drive chain sprocket on end of crankshaft. + Installation position: lettering on drive chain sprocket must be visible. — Push drive chain sprocket onto crankshaft as far as the stop using drift sleeve - 30-100- 6B op or-13- Crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 4 Dismantling afd assembling pistons and conrods 44 Different versions of conrods and'con* rod bolts: New features were phased in as follows: ¢ Industrially cracked instead of sawn conrods from approx. 10.1997 onwards Distinguishing features of sawn and industrially cracked con- rods: ‘A.- Sawn conrods = smooth mating surface B - Industrially cracked conreds = rough mating surface (pro- duced by industrial cracking process) © Gradual introduction of M8.5 conrod bolts instead of M8 bolts. 4.2 Exploded view - sawn conrods (F) ne Oil spray jet for piston cooling = page 74 4, Dismanting and assomiing pistons and conroas QAudi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 1- Circlip 2- Piston pin IFdifficult to move, heat piston to approx. 80 °C Q Remove and install us- ing drift - VW 222 A- 3- Piston Q Mark installation posi- tion and eylinder num- ber > page 73 ‘Arrow on piston crown points to pulley.end Checking = Page 7% Install using\pistonyzing clamp Piston and cylinder di- mensions = pace 74 ‘Checking cylinder bore = page 73 4 - Piston rings Offset gaps by 120° Use piston ring pliers to remove and install “TOP” must face to- wards piston crown ‘Checking ring gap = page 72 Checking ring-to-groove clearance = page 72 5 - Conrod Only renew as a com- plete set Mark cylinder allocation -A-3 page 73 1D Installation position: Markings -B- face towards pulley end on cylinders 1 ... 3 and towards flywheel end on cylinders 4... 6 6 - Conrod bearing cap Note installation position 7 - Conrod bolt, 30 Nm + 90° (1/g turn) further Renew Lubricate threads and contact surface To measure radial clearance, tighten to 30 Nm but do not turn further 8 - Bearing shell Note installation position Do not interchange used bearing shells (mark positions) Measuring radial clearance = page 74 To measure radial clearance, tighten bolts = Item 7 (sage 70) to 30 Nm but do not turn further oo oo Oo oo co oooco 70 Rep. or-13- Crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 43 Exploded view - industrially cracked conrods (B) note Oil spray jet for piston cooling = page 74. 4 - Conrod bolt M8 = 30. Nm + further 90° (1/4) turn; conrod bolt M8.5= 40 Nm-+ further 90° (114) turn L\ cavion [oth M8 and M8.5 con- rod boits are used with industrially cracked con- rods. Fhe use of M8 bolts in [M8.5 threads wil cause serious engine damage. a Renew Lubricate threads and contact surface Tomeasure radial clear- ance, tighten to 30 Nm but do not turn further 2- Conrod bearing cap Note installation posi- tion: split contact surfa- ces on side of conrod must be in alignment 3- Bearing shell Note installation posi- tion 2 Do not interchange used bearing shells, (mark positions) 2 Measuring radial clear- | (as) ance = page 74 To measure radial clearance, tighten bolts = Item 1 (page 71) to 30 Nm but do not turn further 4-Conrod 2. Only renew es @ complete set 2 Mark cylinder allocation -A- = page 73 Note when fiting bearing cap: split contact surfaces on side of conrod must be in alignment -B- Installation position of conrod pairs = page 74 5-Circip 6 - Piston pirf If difficult 9 move, eat piston t0 approx. 60 °C A RemoVeandhinstallusingsdifté VW 222 A- 7- Piston 2. Markinstallation position arid cylinder number= page 73 2 Arrow.on piston crown points to pulley end. 4 Dismanting and assombing pistons and concods 741Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 D Checking = page 73 Install using piston ring clamp Piston and cylinder dimensions > page 74 Checking cylinder bore = page 73 8 - Piston rings Offset gaps by 120° Use piston ring pliers to remove and install “TOP” must face towards piston crown ‘Checking ring gap = page 72 ‘Checking ring-to-groove clearance = page 72 ooooo ‘Checking piston ring gap — Insert ring at right angle to cylinder wall from above and push down into lower cylinder opening approx. 15 mm from bottom of cylinder. Use a piston without rings to push ring into bore, 2.4 itr. engines Piston ring New Wear limit in mm), ‘1st compression ring 0.20 ... 0.40 0.98 [2nd compression ring 0.20 ... 0.40 0.98 [Ol scraper ring 0.25... 0.50 08 2.8 ir. engines Piston ring New Wear limit in mm), ‘1st compression ring O25 ..050 1.0 2nd compression ring 150 ...0/70 14 (Oil seraper ring 0.25... 0.50, 08 (Checking ring-to-groove cléaranice: = Clean groove in piston before checking clearance Piston ring New ‘Weer limit (in mm) ‘Compression rings 0.02... 0.08 0.10 [Oil scraper ring 0.02 ... 0.08 0.10 72. Rop.or-13- Crankshaft groupAudi AB 1998 > Gilindeb engite (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 Checking piston = Using a micrometer (75°.400'mm}, meastire approx. 40 mit from the lower edge, perpenuicuar to the piston pin axis. + Maxiinum deviation-trom rrominal dimension'0:04 mm Nominal dimension "4.4 Piston and cylinder dimensions’, page 74 Checking cylinder bore = Use 50 ... 100 mm internal dial gauge to take measurements at points in transverse direction -A- and longitudinal direction ‘+ Maximum deviation from nominal dimension: 0.08 mm, minal dimension ="4.4 Piston and cylinder dimensions’, page 74 Piston installation position and piston/cylinder allocation = Use chalk or waterproof felt-tip pen to mark installation posi- tion and cylinder aliocation on piston crown (a) Note Do not use @ centre punch or serber, as this would damage tie Cuating or ihe piston crown. + installation position: Arrow on piston rown points to pulley end. Marking conrods (Bre © Only renew conrods as a complete set. © Do not interchange conrod bearings - Betore removing, mark mating positions of conrods and con- rod Zearing caps with coloured pen -arrow. 4, Dismanting and assombing pistons and concods 73Audi A6 1998 > G:cylinder engine (2.4 itr_ and 2.8 ltr, 5-valve), mechanics ~ Installation position of conrod pairs with industrially cracked con- rods + The cast lugs -arrows- on the ground surfaces of the conrod pairs 1 and 2, 3 and 4, and 5 and 6 must face one another. Oil spray jet for piston cooling 1. Bolt, 10Nm 2+ Oilspray jet for piston cooling 44 Piston and cylinder dimensions 2.4 itr. engines [Honing dimension | Piston @mm [Cylinder bore mm| in mm) Basic dimension 80.965 80.05 2.8 itr. engines Honing cimansion [Piston im [Cyinder bore mm in mm Basic dimension 82.485 82.51 [nee Replacement pistons are only available with basic dimension. 4.5 Checking radial cleararice of cohrod bearings ‘Special tools and workshop equipment required + Plastigauge Test sequence - Remove conrod bearing caps. Edition 08.2019 —8 74. op or-13- Crankshaft groupAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 ~ Clean bearing caps and bearing journals. — Place Plastigauge onto bearing journal or into bearing shells: corresponding.to width ofbearing + ThePlasti¢auce mustfo8 positioned in the centre of the bear- ing shell Fit contéd beating ap an fighten to 30 Nm. Do not rotate crankshaft = Reftieve-coniou Bearing cape oneé more = Cofipard With GF Piastigalige With medsurerhant seaie® Radial Cleararice: + New: 0.015 ... 0.082 mm. + Wear limit: 0.12 mm, = Renew conrod bolts. 4, Dismanting and assomiing pistons and conods 75Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 Cylinder head, valve gea 1 Removing and installing cylinder head 44 Exploded - cylinder head 1- Cylinder head gasket Renewing 24.4 Removing oylin= der head (left-side page 82 and Installation position Part No. towardsi¢ylin- der head O Ifrenewed, refil system with fresh coolant 2- Cylinder head D Removing: leftside 2 page 82 ; right-side = page 85 Checking for distortion = page 17 Machining limit > page 77 Driving seating cap into cylinder head = page 78 O Installing = page 88 O Ifrenewed, refil system with fresh coolant 3 - Lifting eye 4-25Nm —23 5-Centring pin for intake mani- fold 6 - Cylinder head bolt O Renew O Different bolts = page 78 Note correct sequence when loosening = page 85 and = page 88 Note correct sequence when tightening = page 94 7 - Intake manifold gasket O Renew 8 - Intake manifold Removing and installing = page 92 9-10 Nm Tighten in stages and in diagonal sequence 76 6p. -18- Cylinder naad, vale gearAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 10- Sealing cap 11- Seal Renew if damaged or leaking 12- Rubber grommet 13 - Cover panel for cylinder head cover 44-10 Nm. Note correct sequence when tightening = page 80 or = page 82 415 - Cylinder head cover Removing and installing: left-side = page 79 , right-side = page 80 16 - Gasket/seals for cylinder head cover Renew if damaged or leaking Before fitting, apply sealant at sealing points = page 78 17 - Combination valve for secondanyzitsystem 18-10Nm 19 - Gasket a Renew 20-10 Nm 21 - Coolant pipe (rear) 22- O-ring a Renew 23 - Sealing cap Living sealing cap into cylinder head = page 104 Checking cylinder head for distortion — Use straight edge and feeler gauge to measure for distortion at several points. + Maximum permissible distortion: 0.1 mm. Cylinder head machining limit — Machining of the cylinder head (surface grinding) is only per- missible down to the minimum dimension -a- 39.25 mm + Minimum dimension: a 1. Removing andinstaling vind head 77Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 Different cylinder head bolts The cylinder head belts have been gradually converted fiom a ‘nulthpoint socket to Polydive. Itis necessary io esiablish the type of bolt heads installed betore slacl.ening off or ti,htening the cylinder head bolts. ‘A Multi-2oint socket head (use socket - 3410- ) B - Polydrive head (use special wrench, long reach - T0070.) Sealing points for bearing caps on cylinder head = Apply small quantity of sealant to sealing points -arrows- on top sealing surface of cylinder head; for sealant refer to = Parts catalogue Driving sealing cap into cylinder head. Replacement cylinder heads without camshafts can be used on booth the left and right-side and must be fitted with a sealing cap (on the appropriate,front side — Coat rim of sBaling/cap with seglant; sdalant = Parts cata- logue — Drive in sealing €&p with arift= VW'2S5- until outer rim of seal- ing cap is flush with end of chamfer in cylinder head. 7B 6p. o-15- Cylinder naad, val gearAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 1.2 Removing and installing cylinder head cover (left-side) Removing (F) v0 Allcable ties which ae released’or cut open when semoving must be fitted in the same postion wherrinstaling. = Remove engine;caver,panel -arrows- ~ Remove cover panel for cylinder head cover (left-side) -arrows- — Disconnect spark plug connectors -arrows-. = Remove crankcase breather hose from cylinder heed cover. — Unfasten cable tie and move wire clear. = Unscrew nuts -1- and -2- and remove cylinder head cover. 1. Ramoving and instaling evinderhead 79Audi A6 1998 > 6-cylinder engine (2.4 itr. and 2.8 ltr. 5-valve), mechanics - Edition 08.2019 Installing Installation is carried out in reverse order; note the following: (E) re Renew cvlinder head cover gaskets if damaged. Fit all cable ties in the criginal positions. when installig. + Apply stall quantity of -ealant to sealing points -arrows- on top sealing surface of cylinder head; for sealant refer to = Paris catalogue Tighten inner nuts -1- for cylinder head cover. Then tighten outer nuts -2- in stages and in diagonal se- quence. Tightening torque Component Nm [Gylinder head cover to cylinder head 70 13 Removing and installing cylinder head cover (right-side) Removing (Fre Allcable ties which are released or cut open when removing must ‘be fitted in the same position when instaliing. — Remove engine cover panel -arrows- 80 0p. or.15- Cyinder head. valve gearAudi AB 1998 > 6-cylinder engine (2.4 tr. and 2.8 itr 5-valve), mechanics - Ecition 08.2019 - Remove air intake hose between air mass meter - G70- and intake manifold -arrows- = Disengage 3 hoses -1- from bracket on cylinder heed cover. = Remove cover pane! for cylinder head cover (right-side) -arrows- — Unbolt bracket for power steering at cylinder head cover. — Disconnect spark plug connectors -arrows-. - Detach guide tube for dipstick at cylinder head -arrow.. (a) Note The guile tub& far the engine oil dipstick must not be lifted out completel,,as othensise the O-ring at the base of the guide tube ill have to be renewed. = Remove crankcase breather hose fron cylinder head coven ‘2 tUhfadten catile tie and MOve!Wird elder: 1. Ramovi'g andinsaling cyinderhead 81Audi A6 1998 > G:cylinder engine (2.4 itr_ and 2.8 It, S-valve), mechanics ~ = Unscrew nuts -1- and -2- and remove cylinder head cover. Installing Installation is carried out in reverse order; note the following: (F) ee # Renew gasket for cylinder head cover if damaged, Fit al cable ties in the original positions when installing. # Secure all hose connections with the correct type of hose clips (same as original equipment) > Parts catalogue = Apply small quantity of sealant to sealing points -arrows- on top sealing surface of cylinder head: for sealant refer to = Parts catalogue = Tighten inner nuts -1- for cylinder head cover. — Then tighten outer nuts -2- in stages and in diagonal se- quence. Tightening torques Edition 08.2019 [Component Nim [Cylinder head'gover'te cylinder Head 10 |Guide tube for dipstick to cylinder head 22 Bracket for power steering pine to ylinderhead| __10 14 Removing cylinder head (left-side) Note % The cylinder head bolts have been gradually converted from 4 muitr-point socket to Polyarive, Itis necessary to establish the type of bolt heads installed before slackening off or tight- ening the cylinder head batts + A-Muttzpoint socket head (use socket - 3410. ). # £- Polydrive head (use special wrench, long reach - T10070-) A B 82 rep or-15- Cynder noad. valve gear