Service: Audi Q5 2008

Service
Workshop Manual
Audi Q5 2008 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail -
generation II)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
CGL CGL CJCA CJCB CMG CJC
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Engine ID
CGL CMG CGL
A B A D
with respect to the correctness of information in this document. Copyright by AUDI AG.
C B D
Edition 07.2014
Service Department. Technical Information

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

No reproduction without prior agreement from publisher.
Copyright © 2014 Audi AG, Ingolstadt D3E802B1D38

Audi Q5 2008 ➤
4-cylinder TDI engine (2.0 ltr. 4-valve common rail - generation II) - Edition 07.2014
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine identification number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Safety precautions when working on the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 4
2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 4
2.4 Safety precautions when working on the subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.6 Safety precautions when working on the SCR system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.7 Safety precautions when working on the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Foreign particles in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Routing and
Protected attachment
by copyright. Copyingoffor pipes,
private or hoses
commercial and wiring
purposes, in part.or. in
. .whole,
. . . is. not
...................... 9
3.5 Installing
with respect to the correctness of information in this document. Copyright by AUDI AG. . . . . . . . . . . . . . . . . . . . . .
radiators and condensers . . . . . . . . . . . . . . . . . . . . . 9
3.6 Resetting SCR learnt values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Securing engine to engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.1 Exploded view - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2 Removing and installing engine mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.3 Removing and installing torque reaction support and cross member . . . . . . . . . . . . . . . . 46
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.1 Removing and installing engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.1 Exploded view - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.2 Exploded view - sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.4 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.5 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.6 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1.7 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.8 Removing and installing sealing flange (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2 Cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.1 Exploded view - cylinder block (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.3 Removing and installing sealing flange (gearbox end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.4 Renewing needle bearing in drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.1 Exploded view - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.5 Pulling spur gear off crankshaft and shrink-fitting new spur gear . . . . . . . . . . . . . . . . . . . . 82
Contents i
Audi Q5 2008 ➤
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

4.1 Exploded view - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.2 Removing and installing pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.3 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.4 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.5 Checking radial clearance of conrod bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.1 Exploded view - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.2 Exploded view - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.4 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.6 Removing and installing seals for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.1 Exploded view - toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.1 Exploded view - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.2 Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.3 Measuring radial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.4 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.5 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.6 Checking hydraulic valve compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.7 Removing and installing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.1 Machining valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.3 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.4 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1 Sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.1 Exploded view - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 155
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
2.1 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
3 Oil filter/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3.1 Exploded view - oil filter housing/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3.2 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.3 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3.4 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.5 Checking oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4 Balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.1 Removing and installing balance shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
19 - Cooling . Protected
. . . . .by. copyright.
. . . . .Copying
. . . .for.private
. . . or. commercial
. . . . . .purposes,
. . . . in. part
. . or. in. whole,
. . . is. not
. . . . . . . . . . . . . . . . . . 171
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
171
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.2 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1.3 Draining and filling cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
ii Contents
Audi Q5 2008 ➤
2 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

2.1 Exploded view - coolant pump and thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.2 Exploded view - continued coolant circulation pump V50 . . . . . . . . . . . . . . . . . . . . . . . . . . 185
2.3 Exploded view - pump for exhaust gas recirculation cooler V400 . . . . . . . . . . . . . . . . . . . . 186
2.4 Removing and installing coolant circulation pump V50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.5 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2.6 Checking thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2.7 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2.8 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 191
2.9 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 192
2.10 Removing and installing pump for exhaust gas recirculation cooler V400 . . . . . . . . . . . . 193
3 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.1 Exploded view - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.2 Removing and installing coolant pipe (top left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3.3 Removing and installing coolant pipe (bottom left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3.4 Removing and installing coolant pipe (rear right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
3.5 Removing and installing coolant pipe (rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4 Radiator/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.1 Exploded view - radiator/radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.2 Removing and installing radiator cowl with radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4.3 Removing and installing radiator cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4.4 Removing and installing radiator fan control unit J293 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.5 Removing and installing radiator fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
1 Turbocharger . . . . . . . . . . . . . . . . . .Protected . . . . . by. .copyright.
. . . . . Copying
. . . . .for. private
. . . . or. .commercial
. . . . . .purposes,
. . . . . in. .part
. .or. in. .whole,
219is not
1.1 Exploded view - turbocharger . . . . . .permitted .with
. . respect
. .unless
. . .to.authorised
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by AUDI AG. AUDI AG does not guarantee or accept any liability
the correctness of information in this document. Copyright by AUDI AG.
. . 219
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2.1 Overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
2.2 Exploded view - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
2.4 Removing and installing charge pressure sender G31 / intake air temperature sender G42
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
2.5 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
1.1 Overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
1.2 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.3 Filling and bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
1.4 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
2.1 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
3 Injectors/high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
3.1 Exploded view - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
3.2 Checking injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
3.3 Performing adaption of correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
3.4 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
3.5 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 255
3.6 Checking return flow rate of injectors at starter cranking speed . . . . . . . . . . . . . . . . . . . . 258
3.7 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
3.8 Removing and installing high-pressure pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
3.9 Removing and installing high-pressure reservoir (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3.10 Checking fuel pressure (low pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Contents iii
Audi Q5 2008 ➤
4 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

4.1 Exploded view - air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
4.2 Removing and installing air cleaner housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
5.1 Exploded view - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
5.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
5.3 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
6.1 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 282
6.2 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
6.3 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
6.4 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
6.5 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 287
6.6 Removing and installing NOx sender 2 G687 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
7 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
7.1 Wiring and component check with test box V.A.G 1598/42 . . . . . . . . . . . . . . . . . . . . . . . . 289
7.2 Removing and installing engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
8 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
8.1 Exploded view - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
8.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
8.3 Performing first fuel filling after installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . 297
9 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
9.1 Exploded view - Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
9.2 Removing and installing Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

1 Exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
1.1 Exploded view - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
1.2 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
1.3 Separating exhaust pipes/silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
1.4 Renewing tailpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
1.5 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
1.6 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
2 Emission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
2.1 Removing and installing SCR catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
2.2 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
3 SCR (selective catalytic reduction) system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
3.1 Exploded view - reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
3.2 Exploded view - control unit for reducing agent metering system . . . . . . . . . . . . . . . . . . . . 321
3.3 Exploded view - delivery unit for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
3.4 Exploded view - injector for reducing agent N474 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3.5 Exploded view - pump for reducing agent V437 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
3.6 Removing and installing reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3.7 Draining reducing agent tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
3.8 Removing and installing delivery unit for reducing agent . . . . . . . . . . . . . . . . . . . . . . . . . . 331
3.9 Removing and installing reducing agent supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
3.10 Removing and installing injector for reducing agent N474 . . . . . . . . . . . . . . . . . . . . . . . . 336
3.11 Removing and installing pump for reducing permittedagent V437 by.AUDI
unless authorised . . .AG.
. . AUDI
. . . AG
. . does
. . . not
. .guarantee
. . . . . or. .accept
. . . any
336liability
3.12 Removing and installing control unit for with reducing
respect toagent metering
the correctness system
of information in thisJ880
document.. Copyright
. . . . .by. AUDI
. 338AG.
3.13 Checking control unit for reducing agent metering system J880 . . . . . . . . . . . . . . . . . . . . 338
4 Exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
4.1 Exploded view - exhaust gas temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
4.2 Removing and installing exhaust gas temperature sender . . . . . . . . . . . . . . . . . . . . . . . . 341
5 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
iv Contents
Audi Q5 2008 ➤
5.1 Exploded view - exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

5.2 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 348
5.3 Checking exhaust gas recirculation cooler change-over . . . . . . . . . . . . . . . . . . . . . . . . . . 350
6 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
6.1 Exploded view - exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
6.2 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
1.1 Exploded view - glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
1.2 Removing and installing glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
1.3 Checking glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
1.4 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
1.5 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Contents v
Audi Q5 2008 ➤
vi Contents
Audi Q5 2008 ➤
00 – Technical data
1 Identification
(ARL003945; Edition 07.2014)
⇒ “1.1 Engine identification number/engine data”, page 1
1.1 Engine identification number/engine da‐

ta
♦ The engine number (“Engine code” and “Serial number”)
-arrow- can be found on the left side (seen in the direction of
travel) at the joint between engine and gearbox.
♦ Additionally there is a sticker on the toothed belt cover showing
the “engine code” and “serial number”.
♦ Starting with the letter “C”, the engine codes consist of 4 let‐
ters.
♦ The first 3 characters of the engine code stand for the engine
capacity and the mechanical construction and design. They
are stamped on the cylinder block, together with the serial
number.
♦ The 4th character indicates the power output and torque of the
engine, and is determined by the engine control unit.
Note
♦ The 4-character engine code can be found on the type plate

(in versions for some countries only) and on the vehicle data
sticker and the engine control
Protected unit.Copying for private or commercial purposes, in part or in whole, is not
by copyright.
♦ Fitting locations of the
with type
respectplate (certainofcountries
to the correctness information inonly) and Copyright by AUDI AG.
this document.
the vehicle data sticker ⇒ Maintenance ; Booklet 817 .
Code letters CGLA CGLB CJCD

Capacity ltr. 1.968 1.968 1.968
Power out‐ kW at rpm 120/4200 125/4200 110/4200
put
Torque Nm at rpm 350/1750 … 2500 350/1750 … 2500 350/1750 … 2500
Bore ∅ mm 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5
Compres‐ 16.5 16.5 16.5
sion ratio
CN at least 51 51 51
Firing or‐ 1-3-4-2 1-3-4-2 1-3-4-2
der
Exhaust gas recirculation yes yes yes
Exhaust gas temperature yes yes yes
control
Turbocharging/super‐ Turbocharger Turbocharger Turbocharger
charging
Glow plugs Steel glow plugs Steel glow plugs Steel glow plugs
Charge air cooling yes yes yes
Lambda control 1 Lambda probe 1 Lambda probe 1 Lambda probe
Particulate filter yes yes yes
1. Identification 1
Audi Q5 2008 ➤
Code letters CGLA CGLB CJCD

SCR catalytic converter yes/no 1) yes/no 1) yes/no 1)
Valves per cylinder 4 4 4
1) An SCR catalytic converter may be fitted depending on gearbox
type.
Code letters CJCA CJCB CMGA CGLC CGLD CMGB

Capacity ltr. 1.968 1.968 1.968 1.968 1.968 1.968
Power kW at rpm 105/4200 100/4200 125/4200 130/4200 120/4200 130/4200
output
Torque Nm at 320/1750 … 2 320/1750 … 350/1750 … 380/1750 … 380/1750 … 380/1750
rpm 500 2500 2500 2500 2500 … 2500
Bore ∅ mm 81.0 81.0 81.0 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5 95.5 95.5
Com‐ 16.5 16.5 16.5 16.5 16.5 16.5
pression
ratio
CN at least 51 51 51 51 51 51
Firing 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
order
Exhaust gas recir‐ yes yes yes yes yes yes
culation
Exhaust gas tem‐ yes yes yes yes yes yes
perature control
Turbocharging/su‐ Turbocharger Turbocharg‐ Turbocharg‐ Turbocharg‐ Turbocharg‐ Turbo‐
percharging er er er er charger
Glow plugs Steel glow Steel glow Steel glow Steel glow Steel glow Steel
plugs plugs plugs plugs plugs glow
plugs
Charge air cooling yes yes yes yes yes yes
Lambda control 1 Lambda 1 Lambda 1 Lambda 1 Lambda 1 Lambda 1 Lamb‐
probe probe probe probe probe da probe
Particulate filter yes yes yes yes yes yes
SCR catalytic con‐ yes/no 1) yes/no 1) no yes/no 1) yes/no 1) no
verter
Valves per cylinder 4 4 4 4 4 4
1) An SCR catalytic converter may authorised
permitted unless be fittedbydepending
AUDI AG. AUDIon AG gearbox
does not guarantee or accept any liability
type. with respect to the correctness of information in this document. Copyright by AUDI AG.
2 Rep. gr.00 - Technical data

Audi Q5 2008 ➤
2 Safety precautions
⇒ “2.1 Safety precautions when working on the fuel system”, page
3
⇒ “2.2 Safety precautions when working on vehicles with start/
stop system”, page 4
⇒ “2.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 4
⇒ “2.4
Protected by Safety precautions
copyright. Copying for privatewhen working
or commercial on inthe
purposes, part subframe”,
or in whole, is not
page unless
permitted 5 authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
⇒ “2.5 Safety precautions when working on the cooling system”,
page 5
⇒ “2.6 Safety precautions when working on the SCR system”,
page 6
⇒ “2.7 Safety precautions when working on the exhaust system”,
page 7
2.1 Safety precautions when working on the

fuel system
When working on the fuel system note the following warnings:
WARNING
Risk of injury - fuel system operates under pressure.

♦ Wrap a cloth around the connection before opening the
fuel system. Then release pressure by carefully loosening
the connection.
The fuel can become extremely hot. This can cause injuries.
♦ In extreme cases the temperature of the fuel lines and the
fuel can be up to 100 °C after the engine is switched off.
Allow the fuel to cool down before disconnecting the lines
- danger of scalding.
♦ Wear protective gloves.
♦ Wear safety goggles.
Observe the following points to prevent personal injuries and

damage to the injection and glow plug system:
♦ Always switch off the ignition before connecting or discon‐
necting tester cables or electrical wiring for the injection or
glow plug system.
♦ Always switch off ignition before washing engine.
♦ Faults are stored in event memory of engine control unit if
electrical connectors were unplugged and the engine was
started: Interrogate event memory in Vehicle self-di-
agnosis ⇒ Vehicle diagnostic tester.
2. Safety precautions 3
Audi Q5 2008 ➤
Caution
To prevent irreparable damage to the electronic components

when disconnecting the battery:
♦ Observe notes on procedure for disconnecting the battery.
♦ Always switch off the ignition before disconnecting the
battery.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and connecting battery .
2.2 Safety precautions when working on ve‐

hicles with start/stop system
When performing repairs on vehicles with start/stop system, note
the following:
WARNING
Risk of injury due to automatic engine start on vehicles with

start/stop system.
♦ On vehicles with activated start/stop system (this is indi‐
cated by a message in the instrument cluster display), the
engine may start automatically on demand.
♦ Therefore it is important to ensure that the start/stop sys‐
tem is deactivated when performing repairs (switch off
ignition, if required switch on ignition again).
2.3 Safety precautions when using testers

and measuring instruments during a
road test
Note the following if testers and measuring instruments have
Protected to
by copyright. Copying for private or commercial purposes, in part or in whole, is not
be used during a road test: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
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 of test equipment while driving causes distraction.
• There is an increased risk of injury if test equipment is not
secured.
♦ Test equipment must always be secured on the rear seat
with a strap and operated from the rear seat by a second
person.

Audi Q5 2008 ➤

subframe
When working on the subframe note the following warnings:
Caution
Risk of damage to running gear components.

♦ The vehicle must NOT be lowered onto its wheels if the
engine/gearbox mountings, steering rack or subframe
cross brace are not properly installed.
♦ The vehicle must NOT be supported by applying a trolley
jack or similar to the subframe or subframe cross brace.

cooling system
When working on the cooling system note the following warnings:
WARNING
Hot steam/hot coolant can escape - risk of scalding.

♦ The cooling system is under pressure when the engine is
hot.
♦ To allow pressure to dissipate, cover filler cap on coolant
expansion tank with cloth and open carefully.
Risk of injury as the radiator fans may start up automatically.
♦ Unplug electrical connectors before starting to work in the
area of radiator cowl.
Caution
Overheating can occur if the filler cap is not fitted properly.

♦ Close filler cap on coolant expansion tank (make sure it
engages).
Audi Q5 2008 ➤

SCR system
When working on the reducing agent metering system, note the
following warnings:
WARNING
Reducing agent can cause skin irritation.

♦ Avoid contact with the skin and eyes. Wear protective
gloves.
♦ If your skin has come into contact with reducing agent,
rinse it off with soap and water.
♦ If reducing agent gets into your eyes, rinse them out with
water for several minutes.
♦ Do not breathe in or swallow reducing agent.
♦ If you have swallowed reducing agent, rinse your mouth,
drink lots of water and consult a paramedic or doctor im‐
mediately.
When removing and installing components at the reducing agent

metering system, note the following:
♦ The reducing agent tank must be empty when you are working
on the reducing agent metering system. Refer to the corre‐
sponding work description to find out when the reducing agent
must be drained from the tank. Drain tank if necessary. Pro‐
cedure ⇒ page 329
When removing and installing the reducing agent tank, note the
following:
♦ The reducing agent tank must be empty. Drain the reducing
agent tank if necessary. Procedure ⇒ page 329
Automatic drawing back of reducing agent
• After the ignition is switched off, the reducing agent is auto‐
matically drawn back into the reducing agent tank from the
metering line leading to the injector for reducing agent - N474- .
• Before performing work in this area, you must therefore wait
until the reducing agent has been drawn back; this can take
up to 10 minutes after theProtected
ignition has been switched off.
• It is also important to wait permitted
until the reducing agent has been
unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
drawn back (i.e. 10 minutes after the ignition is switched off)

before disconnecting the battery ⇒ Electrical system; Rep. gr.

27 ; Battery; Disconnecting and connecting battery .
WARNING
Safety risk due to escaping reducing agent.

♦ To prevent large amounts of reducing agent from escap‐
ing when the metering line is opened, wait until the reduc‐
ing agent has been drawn back automatically ⇒ page 6 .

Audi Q5 2008 ➤

exhaust system
WARNING
Please note the following warnings when working on all parts

of the exhaust system:
♦ Wear gloves (e.g. rubber, not textile) and safety goggles
to avoid contact with eyes and skin - risk of injury.
♦ Do not dismantle exhaust gas temperature sender - risk
of injury.
Caution
Avoid damage to flexible joint.

♦ Do not bend flexible joint more than 10°.
♦ Install flexible joint so that it is not under tension.
♦ Take care not to damage wire mesh on flexible joint.
Audi Q5 2008 ➤
3 Repair instructions
⇒ “3.1 Rules for cleanliness”, page 8
⇒ “3.2 Contact corrosion”, page 8
⇒ “3.3 Foreign particles in engine”, page 9
⇒ “3.4 Routing and attachment of pipes, hoses and wiring”, page
9
⇒ “3.5 Installing radiators and condensers”, page 9
⇒ “3.6 Resetting SCR learnt values”, page 9
3.1 Rules for cleanliness

Even small amounts of dirt can cause faults in the injection sys‐
tem. For this reason, when working on the fuel supply system, the
injection system or the turbocharger, please observe the following
basic rules carefully:
♦ Carefully clean connection points and the surrounding area
with engine cleaner or brake cleaner and dry thoroughly before
opening.
♦ Seal off open pipes/lines and connections immediately with
clean plugs, e.g. from engine bung set - VAS 6122- .
♦ Place parts that have been removed on a clean surface and
cover them over. Do not use fluffy cloths.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation. Do not use parts
that have been previously unpacked and stored away loose
(e.g. in toolboxes, etc.).
♦ When the system is open: Do not work with compressed air.
Do not move the vehicle unless absolutely necessary.
♦ Protect unplugged electrical connectors against dirt and mois‐
ture and make sure connections are dry when attaching.
3.2 Contact corrosion

Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
used.
Additionally, all rubber and plastic parts and all adhesives are
made of non-conductive materials.
Always install new parts if you are not sure whether used parts
can be re-fitted ⇒ Electronic parts catalogue .
Note the following:
♦ We recommend using only genuine replacement parts; these
have been tested and are compatible with aluminium.
♦ We recommend the use of Audi accessories.
♦ Damage caused by contact corrosion is not covered under
warranty.

Audi Q5 2008 ➤
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 particles from entering the engine.
3.4 Routing and attachment of pipes, hoses

and wiring
♦ Mark fuel lines, hydraulic lines, vacuum lines, lines for activa‐
ted charcoal filter and electrical wiring etc. before removal so
they can be re-installed in the original positions and correctly
connected. Make sketches or take photographs if necessary.
♦ To prevent damaging pipes, hoses and wiring, ensure suffi‐
cient clearance from all moving or hot components in engine
compartment (little space in engine compartment).
3.5 Installing radiators and condensers

Even when the radiator, condenser andpermitted
chargeunlessair cooler
authorisedare cor‐AG. AUDI AG does not guarantee or accept any liability
by AUDI
rectly installed, slight impressions may bewithvisible
respect toon
thethe fins of
correctness of information in this document. Copyright by AUDI AG.
these components. This does not mean that the components are
damaged. If the fins are only very slightly distorted, this does not
justify renewal of the radiator, condenser or charge air cooler.
3.6 Resetting SCR learnt values

The learnt value in the engine control unit must be re-adapted
using the vehicle diagnostic tester if reducing agent has been
drained or any of the following components have been renewed.
♦ Reducing agent tank
♦ Pump for reducing agent
♦ Injector for reducing agent
♦ Reducing agent line
♦ Engine control unit
– Perform adaption using Guided Functions under 01 -
Adapting learnt values for reducing-agent tank
⇒ Vehicle diagnostic tester.
3. Repair instructions 9
Audi Q5 2008 ➤
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 10
⇒ “1.2 Securing engine to engine and gearbox support”,
page 32
⇒ “1.3 Installing engine”, page 33
1.1 Removing engine Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Caution
When installing a new base engine, it is essential that the

clamping pieces for the injectors are tightened to the specified
torque ⇒ page 259 after installing the high-pressure pipes. The
clamping pieces are only secured hand-tight at the factory so
the injectors can be aligned during installation. If these instruc‐
tions are not observed, the engine could be damaged.
Special tools and workshop

equipment required
♦ Support bracket - 10 - 222
A-
♦ Hook - 10 - 222 A /10-
♦ Removal lever - 80 - 200-
♦ Lifting tackle - 2024 A-
♦ Gearbox support - 3147-
♦ Workshop hoist -
VAS 6100-
10 Rep. gr.10 - Removing and installing engine

Audi Q5 2008 ➤
♦ Shackle - 10 - 222 A /12- for

vehicles with dual clutch
gearbox 0B5
♦ Used oil collection and ex‐
traction unit - V.A.G 1782-
for vehicles with dual clutch
gearbox 0B5
♦ Drip tray for workshop hoist
- VAS 6208-
♦ Hose clip pliers - VAS
6362-
♦ Lifting tackle - T40013- for
vehicles with dual clutch
gearbox 0B5
♦ Locking tool - T40098-
Procedure
Note
♦ The engine is removedProtected

upwards without
by copyright. gearbox.
Copying for private or commercial purposes, in part or in whole, is not
♦ Fit cable ties in the original

withpositions
respect to thewhen installing.
Caution

– Switch off ignition and take out ignition key.
1. Removing and installing engine 11

Audi Q5 2008 ➤
– Disconnect earth wire -arrow- from battery terminal ⇒ Electri‐

cal system; Rep. gr. 27 ; Battery, Disconnecting and connect‐
ing battery .
– Remove engine cover panel -arrows-.
WARNING

hot.
♦ To allow pressure to dissipate, cover filler cap on coolant
expansion tank with cloth and open carefully.
– Open filler cap on coolant expansion tank.

– Remove both front wheels.
– Remove wheel housing liners (front left and front right) ⇒
General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front) .

Audi Q5 2008 ➤
– Remove noise insulation -1- and -2- ⇒ General body repairs,

exterior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .
– Remove cross member (if one is fitted) ⇒ page 46 .
– Place drip tray for workshop hoist - VAS 6208- beneath en‐
gine.
– Open radiator drain tap -1- at connection andProtected

drain by offcopyright.
coolant; Copying for private or commercial purposes, in part or in whole, is not
then detach connection -2- from radiator (liftpermitted
retaining clip).
Note
Collect drained coolant in a clean container for re-use or disposal.
– Move coolant hose clear at longitudinal member.
– Release hose clip -arrow-, disconnect air hose and press to

one side.
– Remove nuts -arrows- for front exhaust pipe.

Audi Q5 2008 ➤
Vehicles with SCR catalytic converter:

– Unplug electrical connector -2- and move wiring clear.
– Release retaining clip -3- and detach injector for reducing
agent - N474- .
Caution
Always renew all clips that were detached to remove the re‐
ducing agent line.
Note
Disregard -item 1-.
– Move front exhaust pipe clear at mounting -2-.
Note
Disregard -item 1-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
All vehicles (continued):
Caution
Risk of damage to flexible joints in front exhaust pipe

♦ Do not bend flexible joints in front exhaust pipe more than
10°.
– Loosen bolts -arrows-, push back clamp and detach front ex‐
haust pipe.
– Remove bolt -2- on mounting for particulate filter.
Note
Disregard -item 1-.

Audi Q5 2008 ➤
– Unplug electrical connector -arrow- on steering rack.
– Detach bottom cover -1- from gearbox -arrow-.
– Detach cap from vibration damper.

– Counterhold crankshaft on central bolt for vibration damper
using angled ring spanner -1- when loosening bolts for drive
plate.
Note
When performing the next step, turn the crankshaft only in the
normal direction of rotation -arrow-.
– Remove bolts -arrow- (3x) for drive plate (turn crankshaft 120°
in normal direction of rotation each time via central bolt for vi‐
bration damper).

Audi Q5 2008 ➤
Vehicles with manual gearbox:

– Remove bolts -1, 7, 8, 9, 10- securing engine to gearbox.
Note
Disregard -item A-.
Vehicles with dual clutch gearbox 0B5:

– Remove bolt -1- for starter.
– Separate starter from gearbox and leave in position.
– Unscrew remaining bolts -6 ... 9- securing gearbox to engine.
Note
Disregard -item A-.
Caution
If a used belt runs in the opposite direction when it is refitted,

this can cause breakage.
♦ Before removing, mark direction of rotation of poly V-belt
with chalk or felt-tip pen for re-installation.
– Swivel tensioner in clockwise direction -arrow-, detach poly V-

belt from pulley for air conditioner compressor and lock ten‐
sioner using locking tool - T40098- .
– Take off poly V-belt.

Audi Q5 2008 ➤
– Unplug electrical connectors -1- and -2- and move electrical

wiring clear.
WARNING
Risk of injury caused by refrigerant.

♦ The air conditioner refrigerant circuit must not be opened.
– Remove bolts -arrows- for air conditioner compressor.
Caution
Danger of damage to refrigerant lines and hoses.

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Tie up air conditioner compressor together with lines to one

side (lines remain connected).
Note
Disregard -item 3-.

– Unplug electrical connector -2- at oil level and oil temperature
sender - G266- .
Note
Disregard -item 1-.
– Position used oil collection and extraction unit - V.A.G 1782-

below connection points.
– Unscrew union nuts -1- and -2-.

– Remove bolts -arrows- for ATF lines.

Audi Q5 2008 ➤
– Remove bolt -arrow-, detach ATF lines -1, 2- from gearbox and
push to one side.
– Seal off open pipes/lines and connections with clean plugs
from engine bung set - VAS 6122- .
Caution
Risk of irreparable damage to gearbox control unit (mecha‐

tronic unit) because of static discharge.
♦ Before unplugging or plugging in electrical
with respect connector, me‐
to the correctness of information in this document. Copyright by AUDI AG.
chanic must “discharge static” by briefly touching vehicle
earth, heater or lifting platform.
♦ Do NOT touch connector contacts in gearbox connector
with your hands.
– Turn retainer catch anti-clockwise -arrow- and unplug electri‐

cal connector at gearbox.
– Move clear electrical wiring harness.

– Take electrical connector -1- for radiator fan out of bracket and
unplug connector (push retainer to the rear -arrow- and press
down release catch).
– Move clear electrical wiring harness going to radiator fan con‐
trol unit.
– Remove bolt -arrow-, release fastener and move radiator fan

control unit - J293- -item 1- clear to one side.
Note
Disregard -items 2, 3-.

Audi Q5 2008 ➤
– Remove bolts -arrows- (counterhold at central bolt).

– Remove vibration damper.
– Pull off cover cap for idler roller.

– Remove bolt -arrow- and detach idler roller.
– Remove bolts -arrows- and move bracket -1- to the rear.
– Unscrew nut -arrow- on longitudinal member (right-side) and

move earth cables clear.

Audi Q5 2008 ➤
– Lift retaining clips -1- and -3- and disconnect coolant hoses.
Note
Ignore items marked -2- and -arrows-.
– Release hose clips -arrows- and remove air hose.

– Unplug electrical connector for charge pressure sender -
G31- / intake air temperature sender - G42- -item 1- and move
wiring clear.
– Remove bolts -1 and 2-.

– Release hose clip -3- and detach coolant hose.

Audi Q5 2008 ➤
– Unscrew terminal 30/B+ -item 1-.

– Unplug electrical connector -2-.
– Remove bolts -arrows-.

– Move coolant pipe (top left) to side and detach alternator -1-.
Note
♦ If alternator sticks in its bracket, screw bolts back in again

down to the last 2 turns.
♦ Tap carefully on bolt heads with flat side of hammer to release
bushes of alternator mountings.
Vehicles with power steering pump:
– Mark position of poly V-belt pulley for power steering pump

relative to hub -arrow- for re-installation.
– Remove bolts -arrows- and detach poly V-belt pulley for power
steering pump.

Audi Q5 2008 ➤
– Remove bolts -arrows- and tie power steering pump up to one

side (hydraulic lines remain connected).
– Lift retaining clip -2- and disconnect coolant hose.
Note
Disregard -item 1-.
– Remove bolt -1- and take off poly V-belt tensioner -2-
-arrow-.
– Open clips -arrows- and remove toothed belt cover.

Audi Q5 2008 ➤
– Detach air duct -arrow-.
– Unplug electrical connector -3- from air mass meter - G70- .

– Release hose clip -4- and detach air hose from air mass meter
- G70- .
– Disconnect vacuum hose -arrow-.
– Detach air cleaner housing -2- and, if fitted, unplug electrical
connector -1- at air filter bypass flap valve - N275- on reverse
side of air cleaner.
– Disconnect fuel supply hose -3- and fuel return hoses -1, 2-.
Caution
Protect fuel system against contamination.

♦ Rules for cleanliness when working on the injection sys‐
tem ⇒ page 8 .
– Remove body brace ⇒ Running gear, axles, steering; Rep.

gr. 40 ; Suspension strut, upper links; Removing and installing
body brace .

Audi Q5 2008 ➤
– Lift off foam plastic block -1- and -2- on both sides.
– Remove seal -3-.

– Unclip retaining clips -1- from mountings and detach plenum
chamber cover -2-.
– Release retainer -arrow A- and open cover -arrow B-.
– Remove nuts -1 ... 3- for electrical wiring.

– Detach electrical connector -4- from bracket and unplug.
– Remove bolt -5- and detach terminal 30 wiring junction 2 -
TV22- from plenum chamber partition panel -arrow-.

Audi Q5 2008 ➤
– If fitted, unplug electrical connector at brake servo pressure

sensor - G294- -arrow-.
– Working from wheel housing, release catches using a 5.5 mm

ring spanner -item 1- and remove wiring protector -2- from
above.
– Release wiring harness -3- leading to alternator and starter
using removal lever - 80 - 200- and move clear.
– Release catch -arrow- to open wiring duct -1- and move elec‐
trical wiring harness clear.
– Disconnect vacuum hose -2- on rear of plenum chamber par‐

tition panel -arrow- and detach vacuum connection -1- from
plenum chamber partition panel.

Audi Q5 2008 ➤
– Remove bolt -2- and nut -3-.

– Pull filler neck -1- with filler pipe out of washer fluid reservoir
and through opening in body -arrow-.
– Remove nut -5- and move earth wire clear.

– Remove bolts -1, 2, 4- and detach cover -3- for electronics box
in engine compartment -arrow-.
– Release catches -arrows A- and take out engine control unit

-arrow B-.
– If fitted, unplug electrical connector -2-.

– Unplug electrical connectors -4- and detach electrical wire
-3-.
– Release catches -arrow- and detach fuse holder B - SB-
-item 1-.
– Disengage engine wiring harness at electronics box and move
clear.

Audi Q5 2008 ➤
– Release catches -arrows A- and lift off wiring protector -2-

-arrow B-.
– Move wiring harness clear, place on engine and secure engine
control unit to prevent it from dropping.
Note
Disregard -item 1-.
Vehicles without auxiliary heater:

– Remove nut -5-.
– Lift retaining clips -1, 2- and disconnect coolant hoses.
– Guide coolant hoses through plenum chamber partition panel.
Vehicles with auxiliary heater:

– Remove nut -3-.
– Release hose clips -1, 2- and disconnect coolant hoses.
– Guide coolant hoses through plenum chamber partition panel
and move clear.
– Remove plenum chamber partition panel.
– Unplug electrical connector -3- for pressure differential sender

- G505- .
– Remove bolt -2- and move hoses -1- clear at bracket.
– Move pressure differential sender - G505- to rear.

Audi Q5 2008 ➤
– Move clear electrical wiring harness -arrow-.

– Remove nuts -1- and detach bracket -2-.
– Detach electrical connectors from bracket and unplug.

3 - For Lambda probe - G39-
4 - For exhaust gas temperature sender 3 - G495-
Note Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Disregard -items 1, 2-. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Remove Lambda probe - G39- -item 1- ⇒ page 300 .
– Remove nuts -arrows- and move particulate filter to rear.

Audi Q5 2008 ➤

– Unplug electrical connector -2- at reversing light switch - F4-
and move electrical wire clear.
Note
– Unclip electrical wiring from gearbox and unplug electrical

connector -C-.
Note
Disregard -item B-.
– Unplug electrical connector -arrow- for gearbox

Protected byneutral
copyright. posi‐
tion sender - G701- and move electrical permitted
wire clear.
– Remove bolts -2 ... 6- securing gearbox to engine.

Note
Disregard -item A-.

Audi Q5 2008 ➤
Note
Bolt -2- secures the starter to the gearbox and is provided with an
additional spacer sleeve -arrow-.
– Set up support bracket - 10 - 222 A- on suspension turrets (left

and right) as illustrated.
– Attach gearbox support - 3147- to gearbox and to hook - 10 -
222 A /2- using hook - 10 - 222 A /10- .
Note
For illustration purposes, the installation position is shown with
the engine removed.

– Take electrical connector -2- out of bracket, unplug it and
move electrical wiring clear.
– Remove bolts -2 ... 5- accessible from above securing gearbox

to engine.
Note
Disregard -item A-.

Audi Q5 2008 ➤
Note
Bolt -2- secures the starter to the gearbox and is provided with an
additional spacer sleeve -arrow-.
– Attach lifting tackle - T40013- to gearbox and close lock.

– Attach shackle - 10 - 222 A /12- to spindle - 10 - 222 A /11-
and to lifting tackle - T40013- .
Note

the engine removed.

– Take up weight of gearbox with spindle of support bracket.
– Remove lifting eye of lifting tackle - 2024 A- (pull out split pin
and press out pin).
– Reinsert lifting eye in 4thProtected
hole from frontCopying
by copyright. on lifting tackle.
for private or commercial purposes, in part or in whole, is not
– Secure pin with split pin again.
– Attach lifting tackle - 2024 A- to engine and workshop hoist -

VAS 6100- as shown in illustration.
WARNING
Accident risk from loose components of lifting tackle.

♦ The support hooks and retaining pins on the lifting tackle
must be secured with locking pins.

Audi Q5 2008 ➤
– Remove bolts -1- for engine mounting on both sides.

– Remove nut -2- and move bracket with electrical wiring clear.
– If fitted, remove electrical connectors -arrow- on both sides
from bracket and unplug connectors.
– Raise engine until engine mountings are clear.
– Tighten spindle of support bracket - 10 - 222 A- further.
Caution
Danger of damage to hoses, pipes and wiring connections and

to engine compartment.
♦ Check that all hoses and wiring connections between en‐
gine, gearbox, subframe and body have been detached.
♦ Carefully guide engine out of engine compartment when
lifting out.
Note
A second mechanic is required to carefully open bonnet as much

as possible when lifting engine out.
– Use small screwdriver to slightly lift retaining clip -arrow- at

both ends and detach gas strut -1- from ball stud -2- at top.
– Separate engine from gearbox and lift engine out of engine
compartment.
– Press gas struts back onto ball studs.
1.2 Securing engine to engine and gearbox

support
Special tools and workshop equipment required
♦ Engine and gearbox support - VW 540-

Audi Q5 2008 ➤
♦ Engine and gearbox support - VAS 6095-
Procedure
– Secure engine to engine and gearbox support - VW 540- .
– Secure engine to engine and gearbox support - VAS 6095-
using -VW 540- .
1.3 Installing engine

Special tools and
permitted workshop
unless authorised byequipment
AUDI AG. AUDI required
AG does not guarantee or accept any liability
♦ Assembly aid - T40169-
♦ Transport lock - T40170-

Audi Q5 2008 ➤
Tightening torques
Note
♦ Tightening torques apply only to lightly greased, oiled,

phosphated or black-finished nuts and bolts.
♦ Additional lubricants such as engine or gearbox oil may be
used, but do not use lubricants containing graphite.
♦ Do not use de-greased parts.
♦ Tolerance for tightening torques: ± 15 %.
Component Nm
Bolts/nuts M6 9
M7 15
M8 20
M10 40
M12 65
Assembly mountings
⇒ “2.1 Exploded view - assembly mountings”, page 42
Engine to manual gearbox
Item Bolt Nm
1 1) M10x50 2) 65
2 3) M12x100 4) 30 + 90°
3 5), 6 M12x75 4) 30 + 90°
4, 5 5) M12x120 4) 30 + 90°
7…9 M10x75 4) 15 + 90°
10 M12x50 4) 30 + 90°
A Dowel sleeves for centralising
• 1) Also secures starter
• 2) Property class 10.9. The steel bolt may be re-used as often
as necessary.
• 3)Also secures starter, with additional spacer sleeve be‐
tween starter and gearbox
• 4)Bolts must not be used more often than twice
⇒ page 35 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• 5) Also secureswith
wiring
respectretainer

Audi Q5 2008 ➤
Engine to dual clutch gearbox 0B5

Item Bolt Nm
1 1) M10x50 2) 65
2 3) M12x100 4) 30 + 90°
3 5), 6 M12x75 4) 30 + 90°
4, 5 M12x120 4) 30 + 90°
7, 8 M10x40 4) 15 + 90°
9 M12x50 4) 30 + 90°
A Dowel sleeves for centralising
• 1) Also secures starter.
• 2) Property class 10.9. The steel bolt may be re-used as often
as necessary.
• 3)Also secures starter, with additional spacer sleeve be‐
tween starter and gearbox.
• 4)Bolts must not be used more often than twice
⇒ page 35 .
♦ Aluminium bolts must not be used more often than twice. After
first use, bolts must therefore be identified with an “X” made
by two chisel marks -arrow-.
♦ To avoid damaging the bolts when making this mark, do bynot
Protected copyright. Copying for private or commercial purposes, in part or in whole, is not
clamp them directly in a vice. Clamp a 14 mm socket with
permitted 1/ authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
unless
" drive in a vice and insert the bolt as shown.

2
♦ Bolts already marked with an “X” must not be used again.
Procedure
Note
♦ Renew the bolts tightened with specified tightening angle.

♦ Renew self-locking nuts and bolts as well as seals, gaskets
and O-rings.
♦ Secure all hose connections with the correct type of hose clips
(same as original equipment) ⇒ Electronic parts catalogue .
♦ Fit all cable ties in the original positions when installing.
On vehicles with manual gearbox, a needle bearing must be fitted

in the drive plate. Before installing, check whether a needle bear‐
ing is fitted. Press needle bearing into drive plate ⇒ page 78 .

Audi Q5 2008 ➤
– The following preparations are required before joining engine

and gearbox.
– Insert assembly aid - T40169- into gearbox housing between
clutch module and gearbox housing from below, as illustrated.
• The assembly aid - T40169- must engage in the semi-circular
recess -1- and in the inspection hole -2-.
Note
There is only one inspection hole on the circumference; turn the

dual-mass flywheel accordingly.
– Insert pin of assembly aid into hole on gearbox housing.
– Insert transport lock - T40170- into gearbox housing from be‐

low and clamp onto flange shaft -1-.
– Check whether aluminium bolts securing engine to gearbox
can be reused; if so, apply marking
Protected ⇒
by page 35
copyright. . for private or commercial purposes, in part or in whole, is not
Copying

– Check whether dowel sleeves -A- for centring engine and
gearbox are fitted in cylinder block; install missing dowel
sleeves.
– Bring engine into position on gearbox, fit bolts -2 … 6- and
tighten.

Audi Q5 2008 ➤
Note
♦ Bolt -2- secures the starter to the gearbox and is provided with
an additional spacer sleeve -arrow-.
♦ The spacer sleeve must be fitted between starter and gearbox.
– Slacken hook - 10 - 222 A /10- .

– Lower workshop hoist and place engine/gearbox assembly
onto engine mountings.
– Install engine mountings ⇒ page 42 .
– Detach workshop hoist - VAS 6100- and lifting tackle - 2024
A- .
– Tighten bolts -1, 7, 8, 9, 10- to secure engine to gearbox.

– Remove transport lock - T40170- and assembly aid - T40169- .
Vehicles with dual clutch gearbox
with respect to the 0B5:
– Check whether dowel sleeves -A- for centring engine and

gearbox are fitted in cylinder block; install missing dowel
sleeves.

Audi Q5 2008 ➤
Note
♦ Bolt -2- secures the starter to the gearbox and is provided with
an additional spacer sleeve -arrow-.
♦ The spacer sleeve must be fitted between starter and gearbox.
– Slacken spindle - 10 - 222 A /11- .

– Lower workshop hoist and place engine/gearbox assembly
onto engine mountings.
– Install engine mountings ⇒ page 42 .
– Detach workshop hoist - VAS 6100- and lifting tackle - 2024
A- .
– Remove transport lock - T40170- and assembly aid - T40169- .
– Use assembly lever -1- to press dual-mass flywheel -2- slightly

against drive plate -3- in direction of -arrow-.
Note
This step is necessary to ensure that the dual-mass flywheel is

straight and that it makes even contact with the drive plate.
– Turn crankshaft at vibration damper with counterhold tool -

T10355- 360° in direction of engine rotation.

Audi Q5 2008 ➤
– The inspection hole -arrow- should be visible again in the re‐

cess on the gearbox housing.
– Bolt dual-mass flywheel onto drive plate as follows:

– Screw in first bolt -arrow-, tighten to 10 Nm and then slacken
again to 2 Nm (hand tight).
– Turn crankshaft at vibration damper with counterhold tool -
T10355- 120° further in direction of engine rotation.

Audi Q5 2008 ➤
– In this crankshaft position, screw in next bolt -arrow- and tight‐

en to 60 Nm.
– Turn crankshaft a further 120°, then screw in next bolt and
tighten to 60 Nm.
– Turn crankshaft a further 120° and tighten last bolt to 60 Nm.
Remaining installation steps are carried out in reverse sequence;
note the following:
Caution

– Install particulate filter ⇒ page 314 .

– Install injector for reducing agent - N474- ⇒ page 336 .
– Install pressure differential sender - G505- ⇒ page 287 .
– Install vibration damper
⇒ “1.5 Removing and installing vibration damper”,
page 59 .
– Install idler roller and tensioning roller
⇒ “1.1 Exploded view - poly V-belt drive”, page 50 .
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
– Install power steering pump (if one was originally fitted) ⇒
Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power
steering; Removing and installing power steering pump .
– Install ATF lines (if originally fitted) ⇒ Rep. gr. 37 ; ATF circuit;
Removing and installing ATF lines .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Detaching and at‐
taching air conditioner compressor at bracket .
– Install poly V-belt ⇒ page 55 .
– If previously fitted, re-install cross member ⇒ page 46 .
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting
Protectedlocations.
– Install engine control unit with respect to the correctness of information in this document. Copyright by AUDI AG.
⇒ “7.2 Removing and installing engine control unit J623 ”, page

290 .
– Install electrical wiring, terminal 30 wiring junction 2 - TV22-
and cover for electronics box in engine compartment ⇒ Elec‐
trical system; Rep. gr. 97 ; Relay carriers, fuse carriers,
electronic boxes; Overview of fitting locations - relay carriers,
fuse carriers, electronic boxes .
– Install body brace ⇒ Running gear, axles, steering; Rep. gr.
40 ; Suspension strut, upper links; Removing and installing
body brace .
– Install filler neck for washer fluid reservoir ⇒ Electrical system;
Rep. gr. 92 ; Windscreen washer system; Removing and in‐
stalling washer fluid reservoir .

Audi Q5 2008 ➤
– Observe steps required after re-connecting battery ⇒ Electri‐

cal system; Rep. gr. 27 ; Battery; Disconnecting and connect‐
ing battery .
Caution
Risk of irreparable damage to control units because of exces‐

sive voltage.
♦ Never use battery charging equipment for boost starting.
– Install air cleaner housing

⇒ “4.2 Removing and installing air cleaner housing”,
page 272 .
– Install air hoses with screw-type clips ⇒ page 231 .
– Check oil level ⇒ Maintenance ; Booklet 817 .
– Connect coolant hoses with plug-in connector ⇒ page 206 .
– Fill up with coolant
⇒ “1.3 Draining and filling cooling system”, page 175 .
– Bleed fuel system
⇒ “1.3 Filling and bleeding fuel system”, page 246 .
– Install noise insulation panels ⇒ General body repairs, exte‐
rior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .

Audi Q5 2008 ➤
2 Assembly mountings
⇒ “2.1 Exploded view - assembly mountings”, page 42
⇒ “2.2 Removing and installing engine mountings”, page 43
⇒ “2.3 Removing and installing torque reaction support and cross
member”, page 46
2.1 Exploded view - assembly mountings
1 - Bracket
❑ For electrical connector
2 - Bolt
❑ 20 Nm
3 - Bracket
❑ For engine mounting
❑ Renew bracket if engine
mounting is defective
❑ Check bracket on oppo‐
site
Protected side; renew
by copyright. Copyingif
fornec‐
private or commercial purposes, in part or in whole, is not
essary
4 - Bracket
❑ For hydraulic line
5 - Nut
❑ 9 Nm
6 - Bolt
❑ 40 Nm
7 - Engine support
❑ Version fitted in vehicle
may differ from illustra‐
tion
8 - Bolt
❑ 10 Nm
9 - Heat shield
tion
10 - Bolt
❑ Renew
❑ 90 Nm + turn 90° further
11 - Engine mounting
❑ With left electrohydraulic engine mounting solenoid valve - N144- (left-side only)
❑ Renew in pairs
❑ Removing and installing ⇒ page 43
12 - Subframe
13 - Bolt
❑ 55 Nm

Audi Q5 2008 ➤
Torque reaction support and cross member - tightening torques

1- Bolt, 25 Nm
2- Bolt, 40 Nm
2.2 Removing and installing engine mount‐

ings
Note
♦ To avoid repeat repairs, proceed as follows if an engine

mounting is defective:
♦ Renew engine mounting and corresponding bracket.
♦ Also renew engine mounting on opposite side; check corre‐
sponding bracket and renew if necessary.

♦ Support bracket - 10 - 222 A-
Removing
2. Assembly mountings 43
Audi Q5 2008 ➤

body brace .

- G505- .


– Attach spindles -10 - 222 A /11- to engine lifting eyes.
– Partly take up weight of engine with spindles.

Audi Q5 2008 ➤
– Remove wheel housing liner ⇒ General body repairs, exterior;

Rep. gr. 66 ; Wheel housing liner; Exploded view - wheel
housing liner (front) .
– Remove front noise insulation -1- ⇒ General body repairs,
insulation .
– Remove nut -2- and move bracket -1- clear.
– Move clear and unplug electrical connector -3- for electrohy‐

draulic engine mounting solenoid valve.
– Remove bolts -1, 4, 5- for engine mounting.
– Detach bracket -2- and engine mounting.
Installing
Installation is carried out in the reverse order; note the following:
• Tightening torques
⇒ “2.1 Exploded view - assembly Protected
mountings”, page
by copyright. 42 for private or commercial purposes, in part or in whole, is not
Copying
Note
Renew the bolts tightened with specified tightening angle.
– Install wheel housing liner and noise insulation (front) ⇒ Gen‐

eral body repairs, exterior; Rep. gr. 66 ; Wheel housing liners;
Exploded view - wheel housing liner (front) and ⇒ General
body repairs, exterior; Rep. gr. 66 ; Noise insulation; Exploded
view - noise insulation .
body brace .
Audi Q5 2008 ➤
2.3 Removing and installing torque reaction

support and cross member
Removing
insulation .
Vehicles with auxiliary heater:

– Remove nut -1-, loosen clamp -3- and detach exhaust pipe
-2- for auxiliary heater.

– Remove bolt -1- and nut -3- and detach strut -2- for lock carrier.

Audi Q5 2008 ➤
Vehicles with multitronic gearbox:

below connection point.
Note
Observe rules for cleanliness when working on gearbox ⇒ Rep.

gr. 00 ; Repair instructions; Rules for cleanliness .
– Unscrew bolts -arrows- and detach ATF lines from radiator.
Note
Tie ATF lines up onto longitudinal member to prevent fluid es‐

caping.

– Move electrical wiring -3- clear at cross member.

– Remove bolts -1- and take torque reaction support out of cross
member.
– Remove bolts -2- from cross member.
– Loosen subframe bolts -2- only as much as is necessary to be

able to move cross member -1- clear in direction of -arrow-.
WARNING
Accident risk if subframe mountings are detached.

♦ Subframe bolts must not be fully removed.
Audi Q5 2008 ➤
– Push cross member -1- to left side -arrow-.

– Detach cross member.
Installing
Note
♦ Renew bolts tightened with specified tightening angle.

♦ Remove and renew subframe bolts one after the other.
– Push torque reaction support -1- upwards -arrow- until it

makes contact with cross member.
– Push torque reaction support -1- upwards -arrow- until it

makes contact with cross member.
• The buffer stop -2- must be free of stress and must lie against
the cross member without play.
– Tighten bolts -3- in this position.
Tightening torques
♦ ⇒ Fig. ““Torque reaction support and cross member - tighten‐
ing torques”“ , page 43
♦ Subframe ⇒ Running gear, axles, steering; Rep. gr. 40 ; Sub‐
frame; Exploded view - subframe
♦ Lock carrier brace ⇒ General body repairs, exterior; Rep. gr.
50 ; Lock carrier; Exploded view - lock carrier
♦ Exhaust pipe for auxiliary heater ⇒ Auxiliary heater, supple‐
mentary heater; Rep. gr. 82 ; Overview of fitting locations -
auxiliary/supplementary heater; Overview of fitting locations -
components not located in passenger compartment
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Noise insulation; Exploded view - noise insulation .

Audi Q5 2008 ➤
3 Engine cover panel
3.1 Removing and installing engine cover

panel
Removing
– Carefully pull engine cover panel off retaining pins one after
the other -arrows-. Do not jerk engine cover panel away, and
do not try to pull on one side only.
Installing
– To avoid damage, do not strike the engine cover panel with
your fist or with any kind of tool.
– Observe oil filler neck when positioning engine cover panel.
– Press engine cover panel with both hands into the rubber
grommets at the rear and then into the grommets at the front.
3. Engine cover panel 49

Audi Q5 2008 ➤
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Exploded view - poly V-belt drive”, page 50
⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 54
⇒ “1.3 Removing and installing poly V-belt”, page 55
⇒ “1.4 Removing and installing tensioner for poly V-belt”,
page 58
⇒ “1.5 Removing and installing vibration damper”, page 59
⇒ “1.6 Removing and installing bracket for ancillaries”,
page 60
⇒ “1.7 Renewing crankshaft oil seal (pulley end)”, page 63
⇒ “1.8 Removing and installing sealing flange (pulley end)”, page
65
1.1 Exploded view - poly V-belt drive

Vehicles with power steering pump
Vehicles without power steering pump ⇒ page 52
1 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen. If
the belt runs in the op‐
posite direction when it
is refitted, this can
cause breakage.
❑ Removing and installing
⇒ page 55
❑ When installing, make
sure it is properly seated
on pulleys.
2 - Vibration damper
❑ Can only be installed in
one position
⇒ page 59
3 - Cap
❑ For vibration damper
4 - Bolt
❑ Renew Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5 - Bolt
❑ 22 Nm
6 - Poly V-belt pulley
❑ For power steering
pump
7 - Tensioner
❑ For poly V-belt
50 Rep. gr.13 - Crankshaft group

Audi Q5 2008 ➤
❑ Use locking tool - T40098- to lock tensioner.

8 - Bracket
❑ For ancillaries
9 - Bolt
❑ Tightening torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
10 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
11 - Bolt
❑ Renew
12 - Power steering pump
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power steering; Re‐
moving and installing power steering pump
13 - Bolt
❑ Renew
❑ Tightening torque and sequence ⇒ page 52
14 - Dowel sleeve
❑ Ensure correct seating in bracket
15 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant hoses or pipes.
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Detaching
and attaching air conditioner compressor at bracket
❑ Pay attention to dowel sleeves ⇒ Item 14 (page 51) when installing
16 - Bolt permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Tightening torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Exploded view
- air conditioner compressor drive unit
17 - Bolt
❑ Tightening torque ⇒ Running gear, axles, steering; Rep. gr. 48 ; Hydraulic power steering; Exploded
view - power steering pump
18 - Idler roller
❑ For poly V-belt
❑ With cover cap
❑ Note installation position
19 - Bolt
❑ Renew
1. Cylinder block (pulley end) 51

Audi Q5 2008 ➤
Bracket for ancillaries - tightening torque and tightening sequence
Note
– Fit bolts in the following sequence:

♦ Bolts -1, 5, 6- M10x60.
♦ Bolt -2- M10x40.
♦ Bolts -3, 4- M10x155.
– Tighten bolts in 4 stages in the sequence shown: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Stage Bolts Tightening torque/angle specification
1. -1 … 6- Screw in by hand until contact is made

2. -1 … 6- 40 Nm
3. -1- and -2- Turn 60° further
Vehicles without power steering pump
1 - Poly V-belt
❑ Check for wear
❑ Before removing, mark
direction of rotation with
chalk or felt-tip pen. If
the belt runs in the op‐
posite direction when it
is refitted, this can
cause breakage.
⇒ page 55
❑ When installing, make
sure it is properly seated
on pulleys.
2 - Bolt
❑ Renew
3 - Cap
❑ For vibration damper
4 - Vibration damper
one position
⇒ page 59
5 - Tensioner
❑ For poly V-belt
❑ Use locking tool -
T40098- to lock tension‐
er.
⇒ page 58

Audi Q5 2008 ➤
6 - Bolt
❑ Tightening torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; Exploded view - alternator
7 - Bracket
❑ For ancillaries
8 - Alternator
❑ Removing and installing ⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
9 - Bolt
10 - Bolt
❑ Renew
11 - Dowel sleeves
❑ Ensure correct seating in bracket
12 - Air conditioner compressor
❑ Do not unscrew or disconnect refrigerant hoses or pipes.
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Detaching
and attaching air conditioner compressor at bracket
❑ Pay attention to dowel sleeves ⇒ Item 11 (page 53) when installing
13 - Bolt
❑ Tightening torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Exploded view
- air conditioner compressor drive unit
14 - Idler roller
❑ For poly V-belt
❑ With cover cap
❑ Note installation position
15 - Bolt
❑ Renew
16 - Cap
❑ For idler roller

Audi Q5 2008 ➤
Bracket for ancillaries - tightening torque and tightening sequence
Note
– Fit bolts in the following sequence:

♦ Bolts -1, 5, 6- M10x60.
♦ Bolt -2- M10x40.
♦ Bolts -3, 4- M10x155.
– Tighten bolts in 5 stages in the sequence shown:
2. -1 … 6- 40 Nm
4. -3- and -4- Turn 180° further Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
5. -5- and -6- Turn 60° further permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
1.2 Exploded view - sealing flange (pulley end)

Audi Q5 2008 ➤
1 - Bolt
❑ Tightening torque
⇒ Item 27 (page 115)
2 - Crankshaft sprocket
❑ Contact surface be‐
tween sprocket and
crankshaft must be free
of oil
one position
3 - Oil seal
❑ For crankshaft (pulley
end)
❑ Renewing ⇒ page 63
❑ Do not lubricate with oil
4 - Sealing flange (pulley end)
❑ Should be positioned on
dowel pins
⇒ page 65
5 - Cylinder block
6 - Dowel pin
❑ 2x
7 - Bolt
❑ Tightening torque and
sequence ⇒ page 55
Sealing flange (pulley end) - tightening torque and sequence

– Tighten bolts in 3 stages in thepermitted
sequence shown:by AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
Stage Bolts Tightening torque
2. -1 … 6- Tighten in stages and in diagonal se‐
quence; final torque 15 Nm
3. -7 … 10- 15 Nm
1.3 Removing and installing poly V-belt


Audi Q5 2008 ➤
Removing
Vehicles with power steering pump
Caution


belt from alternator pulley and lock tensioner using locking tool
- T40098- .

Audi Q5 2008 ➤
Caution


belt from alternator pulley and lock tensioner using locking tool
- T40098- .
Installing
– Fit poly V-belt on all poly V-belt pulleys:
Vehicles with power steering
with respect to thepump
1- Vibration damper
2- Air conditioner compressor
3- Poly V-belt pulley for power steering pump
4- Idler roller
5- Poly V-belt tensioner
6- Alternator

1- Vibration damper
2- Air conditioner compressor
3- Idler roller
4- Poly V-belt tensioner
5- Alternator
Note
When installing poly V-belt, make sure it is properly seated on

pulleys.
– Start engine and check that belt runs properly.

Audi Q5 2008 ➤
1.4 Removing and installing tensioner for

poly V-belt
♦ Ratchet wrench 13 mm - T10384-
Removing
– Open clips -arrows- and remove toothed
with respect to the belt cover.
– Remove poly V-belt ⇒ page 55 .

Audi Q5 2008 ➤

insulation .
– Remove bolt -1- and take out poly V-belt tensioner -2- up‐
wards.
Installing
• Tightening torque
Note
– Install noise insulation (front) ⇒ General body repairs, exterior;

Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
1.5 Removing and installing vibration damp‐

er
Removing
– Remove cross member ⇒ page 46 .
– Remove radiator fan control unit - J293- ⇒ page 216 .

Audi Q5 2008 ➤
– Remove poly V-belt ⇒ page 55 .
Note

the engine removed.

– Counterhold on central bolt using ring spanner and loosen
bolts -arrows- for vibration damper.
– Remove bolts and take off vibration damper.
Installing
Note
• Installation position: hole -arrow- in vibration damper must be

positioned over raised section of crankshaft sprocket.
– Vehicles with four-wheel drive: Install radiator fan control unit
- J293- ⇒ page 216 .
– Install cross member ⇒ page 46 .
1.6 Removing and installing bracket for an‐

cillaries
♦ Pin wrench - 3212-

Audi Q5 2008 ➤
Removing
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
– Remove high-pressure pump ⇒ page 295 .
– Remove 4/2-way valve ⇒ page 188 .
– Remove bolt -arrow-.

– Remove bolts -1- and -2- and remove idler rollers for toothed
belt.
– Mark position of poly V-belt pulley for power steering pump

relative to hub -arrow- for re-installation.
– Remove bolts -arrows- and detach poly V-belt pulley for power
steering pump.

Audi Q5 2008 ➤
– Remove bolts -arrows- and tie power steering pump up to one

side (hydraulic lines remain connected).
– Unplug electrical connectors -1- and -2- and move electrical

wiring clear.
WARNING
Risk of injury caused by refrigerant.

♦ The air conditioner refrigerant circuit must not be opened.
– Remove bolts -arrows- for air conditioner compressor.
Caution
Danger of damage to refrigerant lines and hoses.

♦ Do NOT stretch, kink or bend refrigerant lines and hoses.
– Tie upwith
airrespect
conditioner compressor
to the correctness together
of information with Copyright
in this document. lines tobyoneAUDI AG.
side (lines remain connected).
Note
Disregard -item 3-.

Audi Q5 2008 ➤
– Remove bolts -1 ... 6- and detach bracket for ancillaries.

Installing
⇒ Fig. ““Bracket for ancillaries - tightening torque and tighten‐
ing sequence”“ , page 52
Note
– Check that dowel sleeves are fitted at top right between brack‐
et for ancillaries and cylinder block; insert dowel sleeves if
necessary.
– Tighten bolts for bracket for ancillaries ⇒ page 52 .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Detaching and at‐
taching air conditioner compressor at bracket .
– Install power steering pump ⇒ Running gear, axles, steering;
Rep. gr. 48 ; Hydraulic power steering; Removing and instal‐
ling power steering pump .
– Install high-pressure pump ⇒ page 295 .
– Install toothed belt (adjust valve timing) ⇒ page 119 .
– Install 4/2-way valve ⇒ page 188 .
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
1.7 Renewing crankshaft oil seal (pulley

end)
♦ Oil seal extractor - 3203-

Audi Q5 2008 ➤
♦ Counterhold tool - 3415-
♦ Assembly tool - T10053-
Procedure
– Remove toothed belt ⇒ page 116 .
– Loosen bolt for crankshaft sprocket using counterhold tool -
3415- .
– Remove bolt and detach crankshaft sprocket.
– Adjust inner section of oil seal extractor -3203- so it is flush

with the outer section and lock in position with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and screw it into oil seal as far as possible (applying firm
pressure).
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
– Clamp flats of oil seal extractor in vice and use pliers to remove
oil seal.
– Clean contact surface and sealing surface for oil seal.
– Remove oil residue from crankshaft journal with a clean cloth.
Note
Do not lubricate sealing lip and outer rim of oil seal before press‐
ing in.

Audi Q5 2008 ➤
– Fit guide sleeve -T10053/1- onto crankshaft journal.

– Push oil seal over guide sleeve onto crankshaft journal.
– Press in oil seal using bolt for crankshaft sprocket and thrust
sleeve of assembly tool - T10053- until flush.
– Install crankshaft sprocket ⇒ page 114 .
1.8 Removing and installing sealing flange

(pulley end)
♦ Counterhold tool - 3415-
♦ Electric drill with plastic brush attachment

♦ Safety goggles
♦ Sealant ⇒ Electronic parts catalogue
Removing
– Loosen bolt for crankshaft sprocket using counterhold tool -
3415- .
– Remove bolt and detach crankshaft sprocket.

Audi Q5 2008 ➤
– Remove bolts -1 ... 10- and carefully release sealing flange

from bonded joint.
– Drive out oil seal with sealing flange removed.
Installing
⇒ “1.2 Exploded view - sealing flange (pulley end)”, page 54
Caution
Make sure sealant residue does not enter lubrication system.

♦ Place a clean cloth over the exposed section of the sump.
– Carefully remove sealant residue on cylinder block and sump.
WARNING
Risk of eye injury.

– Use e.g. rotating plastic brush to remove sealant residue on

sealing flange.
– Clean
Protected sealing surfaces;
by copyright. they ormust
Copying for private be free
commercial of oil
purposes, and
in part or ingrease.
whole, is not
Note
Note the use-by date of the sealant.
– Cut off nozzle of tube at front marking (nozzle ∅ approx. 2

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

the cylinder block and the sump -arrows-.

Audi Q5 2008 ➤
Caution
Make sure lubrication system is not clogged by excess sealant.

♦ The bead of sealant must not be thicker than specified.
– Apply bead of sealant -arrow- onto clean sealing surface of

sealing flange as shown in illustration.
• Thickness of sealant bead: 2 ... 3 mm
– Apply a thin coat of sealant to bottom sealing surface

-shaded- on sealing flange.
Note
The sealing flange must be installed within 5 minutes after apply‐

ing the sealant.
– Carefully fit sealing flange onto dowel pins in cylinder block.
– Tighten sealing flange bolts ⇒ page 55 .

– Install crankshaft oil seal (pulley end) ⇒ page 63 .

Audi Q5 2008 ➤
2 Cylinder block (gearbox end)

⇒ “2.1 Exploded view - cylinder block (gearbox end)”, page 68
⇒ “2.2 Removing and installing drive plate”, page 69
⇒ “2.3 Removing and installing sealing flange (gearbox end)”,
page 70
⇒ “2.4.1 Renewing needle bearing in drive plate - vehicles with
manual gearbox”, page 78
2.1 Exploded view - cylinder block (gearbox

end)
Note
Servicing clutch ⇒ Rep. gr. 30 ; Clutch
1 - Cylinder block
2 - Dowel pins
3 - Engine speed sender -
G28-
⇒ page 357
4 - Bolt
⇒ page 355
5 - Sealing flange (gearbox
end)
❑ With oil seal
6 - Bolt
❑ 15 Nm
7 - Drive plate
❑ Lock with counterhold Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
tool - 3067- to slacken permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
off bolts with respect to the correctness of information in this document. Copyright by AUDI AG.
8 - Bolt
❑ Renew
9 - Needle bearing
❑ For vehicles with man‐
ual gearbox
⇒ page 78
10 - Intermediate plate
❑ Do not damage or bend
when assembling
❑ Installing ⇒ page 69

Audi Q5 2008 ➤
Installing intermediate plate

– Engage intermediate plate on sealing flange -top arrow- and
push onto dowel sleeves -bottom arrows-.
Sealing flange (gearbox end) - tightening torque and sequence

2. -1 … 6- Tighten in stages and in diagonal se‐
quence; final torque 15 Nm
2.2 Removing and installing drive plate

♦ Counterhold tool - 10 - 201-
2. Cylinder block (gearbox end) 69

Audi Q5 2008 ➤
Removing
• Gearbox removed.
– Insert counterhold tool - 10 - 201- in hole on cylinder block
-item B-, slacken bolts for drive plate.
Caution
Take care not to damage outer surface of bearing flange on

drive plate.
♦ Use a multi-point socket bit with a length of at least 40 mm
to slacken and tighten the drive plate bolts.
– Remove bolts and take off drive plate.

Installing
⇒ “2.1 Exploded view - cylinder block (gearbox end)”,
page 68
Note

♦ On vehicles with manual gearbox, a needle bearing is fitted in
the drive plate. Before installing, check that the needle bearing
is fitted. Removing and installing needle bearing in drive plate
(pressing in and out) ⇒ page 78 .
– Pay attention to dowel pin when installing drive plate.

– Insert counterhold tool - 10 - 201- in hole on cylinder block
-item A-, tighten bolts for drive plate.
2.3 Removing and installing sealing flange

(gearbox end)
♦ Open end spanner insert, AF 24 - V.A.G 1332/11-

Audi Q5 2008 ➤
♦ Depth gauge - VAS 6082-
♦ Bolt M6x35 (3x)

♦ Bolt M7x35 (2x)
Pressing out sealing flange with sender wheel
– Remove drive plate ⇒ page 69 .
Note
For illustration purposes, the following procedure is shown with

the engine removed.
– Remove engine speed sender - G28- -item 1- ⇒ page 359 .
Note
Disregard -item 2-.
– Pull intermediate plate off dowel pins -bottom

Protectedarrows- and
by copyright. de‐for private or commercial purposes, in part or in whole, is not
Copying
tach from sealing flange -top arrow-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi Q5 2008 ➤
– Rotate crankshaft by turning bolt for toothed belt sprocket until

crankshaft is positioned at “TDC”, as shown in illustration.
– Remove sump ⇒ page 150 .
– Remove bolts -1 ... 6- for sealing flange.
Note
The sealing flange is pressed off the crankshaft together with the
sender wheel.
– To press off, screw 3 bolts M6x35 -arrows- alternately into

sealing flange not more than 1/2 turn at a time.
– Take off sealing flange with sender wheel.
Pressing in sealing flange with sender wheel
Note
♦ The sealing
Protected flange
by copyright. withforPTFE
Copying oilcommercial
private or seal is purposes,
fitted with a orsealing
in part lipnot
in whole, is
support ring. authorised
permitted unless This support
by AUDIring actsAGas
AG. AUDI annotassembly
does guarantee or sleeve
accept anyand
liability
must not be removed before installation.
♦ Sealing flange and sender wheel must not be separated or

rotated out of position after removal from packaging.
♦ The sender wheel is held in its installation position by a locat‐
ing pin on the assembly tool - T10134- .
♦ The sealing flange and oil seal are one unit and must always
be replaced together with the sender wheel.
♦ The assembly tool - T10134- is held in the correct position rel‐
ative to the crankshaft by a guide pin which is inserted into a
hole in the crankshaft.

Audi Q5 2008 ➤
Construction of assembly tool - T10134-

A - Tightening flats
B - Hexagon nut
C - Assembly housing
D - Locating pin
E - Hexagon socket-head bolt
F - Guide pin for diesel engines
Protected by(black
copyright.handle)
G - Guide pin for petrol engines (red
with respect handle)
A - Fitting sealing flange with sender wheel onto assembly tool -

T10134- :
– Turn hexagon nut -B- on threaded spindle until it is just in front
of flats -A-.
– Clamp assembly tool - T10134- in a vice on tightening flats

-A- of threaded spindle.
– Press assembly housing -C- downwards so that it lies on hex‐
agon nut -B- -arrow-.
• Inner part of assembly device and assembly housing must
align (be level) with each other.
– Remove the securing clip -arrow- from new sealing flange.
Note
The sender wheel must not be taken out of the sealing flange or
rotated out of position.

Audi Q5 2008 ➤
• The locating hole -A- on the sender wheel -C- must align with
the marking -B- on the sealing flange.
– Place the sealing flange (with the front side downwards) on a
clean flat surface.
– Press the sealing lip support ring -A- downwards in direction

of -arrows- until it lies against the flat surface.
• The upper edge of the sender wheel and the front edge of the
sealing flange must align -arrows-.
– Place front side of sealing flange on assembly tool - T10134- ,

so that locating pin -B- can be inserted in hole -A- in sender
wheel.
• Ensure the sealing flange lies flat on the assembly tool.

Audi Q5 2008 ➤
– Press the sealing flange and sealing lip support ring -B- onto
the surface of the assembly tool - T10134- while tightening the
3 knurled screws -A- so that the locating pin will not slip out of
the hole in the sender wheel.
• Ensure that the sender wheel remains fixed on the assembly
tool when installing the sealing flange.
B - Installing assembly tool - T10134- with sealing flange on

crankshaft flange:
• Crankshaft flange must be free of oil or grease.
• Engine is at “TDC” position.
– Screw hexagon nut -B- to end of threaded spindle.
– Press the threaded spindle of assembly tool - T10134- in di‐
rection of -arrow- until the hexagon nut -B- lies on the assem‐
bly housing -A-.
– Position flat edge of assembly housing towards sealing sur‐

face for sump on cylinder block.
– Secure assembly tool - T10134- to crankshaft flange by screw‐
ing hexagon socket head bolts -A- approx. 5 threads into
crankshaft flange.
– Screw two bolts M7×35 mm -item A- into cylinder block to

guide sealing flange.

Audi Q5 2008 ➤
C - Securing assembly tool - T10134- onto crankshaft flange:

– Press the assembly housing -C- by hand in the direction of the
-arrow- until the sealing lip support ring -B- lies on the surface
of the crankshaft flange -A-.
Caution
Do not interchange components.

♦ The guide pin for PETROL engines (red handle) -F- MUST
NOT be inserted into the threaded hole in the crankshaft.
– Push guide pin for diesel engine (black handle) -D- into hole
in crankshaft. This brings the sender wheel into its final instal‐
lation position.
– Tighten the two hexagon socket head bolts on assembly tool
hand-tight.
– Screw hexagon nut -E- onto threaded spindle by hand until it
lies against the assembly housing -C-.
D - Pressing sender wheel onto crankshaft flange with assembly

tool - T10134- :
– Tighten hexagon nut on assembly tool - T10134- to 35 Nm.
• A small air gap must be present between cylinder block and
sealing flange after tightening hexagon nut to 35 Nm.
E - Checking installation position of sender wheel on crankshaft:

– Screw hexagon nut -E- to end of threaded spindle.
– Remove bolts -A- from cylinder block.
– Unscrew knurled screws -B- from sealing flange.
– Remove hexagon socket head bolts.
– Unbolt assembly tool - T10134- from crankshaft flange (re‐
move hexagon socket head bolts from crankshaft flange).
– Detach sealing lip support ring.
– Apply depth gauge - VAS 6082- to crankshaft flange.

Audi Q5 2008 ➤
– Measure distance between crankshaft flange -A- and sender

wheel -B-.
• Specification: Distance -a- = 0.5 mm.
– Press sender wheel in further if distance -a- is too small
⇒ page 77 .
– If reading matches specification, continue with assembly
⇒ page 78 .
F - Pressing sender wheel in further:

– Secure assembly tool - T10134- to crankshaft flange by tight‐
ening hexagon socket head bolts -A- hand-tight.
– Press assembly tool onto sealing flange by hand.
– Screw hexagon nut -E- onto threaded spindle by hand until it

lies against the assembly housing -C-.
– Tighten hexagon nut on assembly tool - T10134- to 40 Nm.

– Check installation position of sender wheel on crankshaft
again ⇒ page 76 .
– If distance “a” is still too small, tighten hexagon nut on assem‐
bly tool - T10134- to 45 Nm.
– Check installation position of sender wheel on crankshaft
again ⇒ page 76 .

Audi Q5 2008 ➤
Assembling:
– Tighten sealing flange bolts ⇒ page 69 .
– Install engine speed sender - G28- ⇒ page 359 .
– Install sump ⇒ page 150 .
– Install intermediate plate ⇒ page 69 .
– Install drive plate ⇒ page 69 .
2.4 Renewing needle bearing in drive plate

⇒ “2.4.1 Renewing needle bearing in drive plate - vehicles with
manual gearbox”, page 78
2.4.1 Renewing needle bearing in drive plate

- vehicles with manual gearbox
♦ Tube - VW 418 A-
♦ Tube - VW 421-

Audi Q5 2008 ➤
♦ Support - 40 - 103-
Procedure
– Remove drive plate ⇒ page 69 .
– Place support - 40 - 103- under drive plate when pressing out
and pressing in needle bearing.
– Use tube - VW 421- and workshop press and press out needle
bearing.
• Smaller diameter of tube -VW 421- faces drive plate.
– Carefully press in needle bearing as far as stop, using tube -

VW 418 A- and workshop press.
• Installation position: closed side of needle bearing faces en‐
gine.
– Install drive plate ⇒ page 69 .

Audi Q5 2008 ➤
3 Crankshaft
⇒ “3.1 Exploded view - crankshaft”, page 80
⇒ “3.2 Crankshaft dimensions”, page 81
⇒ “3.3 Measuring axial clearance of crankshaft”, page 81
⇒ “3.4 Measuring radial clearance of crankshaft”, page 82
⇒ “3.5 Pulling spur gear off crankshaft and shrink-fitting new spur
gear”, page 82 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3.1 Exploded view - crankshaft

Note
When carrying out repairs, secure engine with engine and gear‐
box support - VW 540- to engine and gearbox support
⇒ page 32 .
1 - Bearing shell
❑ For cylinder block (with
oil groove)
❑ Renew used bearing
shells
2 - Spur gear
❑ For balance shaft as‐
sembly
❑ Pulling spur gear off
crankshaft and shrink-
fitting new spur gear
⇒ page 82
3 - Bearing shell
❑ For bearing cap (without
oil groove)
shells
4 - Thrust washers
❑ For bearing No. 3
❑ Different types for cylin‐
der block and bearing
cap
❑ Note location
5 - Bolt
❑ Renew
❑ When measuring radial
clearance, tighten used
bolt to 65 Nm and turn
90° further
6 - Bearing caps
❑ Bearing cap 1: Pulley
end
❑ Bearing cap 3 with recesses for thrust washers
❑ Installation position: retaining lugs on bearing shells in cylinder block and bearing caps must be on the
same side

Audi Q5 2008 ➤
7 - Crankshaft
❑ Crankshaft dimensions ⇒ page 81
❑ Measuring axial clearance ⇒ page 81
❑ Measuring radial clearance ⇒ page 82
3.2 Crankshaft dimensions

Crankshaft Conrod
main bearing journal journal ∅
∅ mm mm
Basic dimension 54.00 -0.022 50.90 -0.022
-0.042 -0.042
3.3 Measuring axial clearance of crankshaft

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge - VAS 6079-
Procedure
– Bolt dial gauge - VAS 6079- with universal dial gauge bracket
- VW 387- onto cylinder block (as shown in illustration) and set
it against crank web.
– Press crankshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Push crankshaft away from dial gauge and read off value.
Axial clearance:
• New: 0.07 ... 0.17 mm.
• Wear limit: 0.37 mm
3. Crankshaft 81
Audi Q5 2008 ➤
3.4 Measuring radial clearance of crank‐

shaft
♦ Plastigage
Procedure
– Remove bearing cap and clean bearing journal.
– Place a length of Plastigage corresponding to the width of the
bearing on the bearing journal or in the bearing shell.
• The Plastigage must be positioned in the centre of the bearing
shell.
– Fit bearing cap and secure with old bolts ⇒ Item 5 (page 80)
without rotating crankshaft.
– Remove bearing cap again.
– Compare width of Plastigage with measurement scale.
Radial clearance:
• New: 0.03 ... 0.08 mm.
• Wear limit: 0.17 mm.
3.5 Pulling spur gear off crankshaft and

shrink-fitting new spur gear Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Fitting tool - 10 - 203-
♦ Temperature gauge - VAS 6519-

♦ Hotplate (commercially available)
Procedure
– Remove sealing flange (pulley end) ⇒ page 65 .

Audi Q5 2008 ➤
Note
If the balance shaft assembly does not have to be renewed, it is

sufficient just to remove the idler gear.
– Remove balance shaft assembly ⇒ page 164 .

Pulling off spur gear
– Insert thrust piece -T10392/1- in end of crankshaft.
– Insert puller -T10392- into holes in spur gear, turn clockwise

-arrow- and screw in locating
Protected pins
by copyright. -A-.for private or commercial purposes, in part or in whole, is not
Copying
– Counterhold crankshaft with ring spanner -A- and pull spur

gear off end of crankshaft by screwing in spindle with ring
spanner -B-.
Shrink-fitting spur gear
Note
♦ While heating up the new spur gear, monitor the temperature

with the temperature gauge -VAS 6519- .
♦ When the temperature reaches 200 °C, you have approx. 4
seconds to fit the spur gear on the crankshaft.
♦ A higher temperature increases the amount of time available
(220 °C = approx. 6 seconds).
♦ Make sure the end of the crankshaft is clean.
Caution
Do not exceed a maximum temperature of 240 °C; otherwise

the spur gear can become discoloured and distorted.
3. Crankshaft 83
Audi Q5 2008 ➤
– Place the new spur gear flat on a hotplate (commercially avail‐

able) and heat it to at least 200 °C, but not more than 240 °C.
The lettering must face upwards.
– Set temperature gauge - VAS 6519- to measuring range 2.
– Position temperature sensor -VAS 6519/1- on collar of spur
gear (as shown) and read off temperature at temperature
gauge.
WARNING
Risk of burns. Use suitable protective gloves for the following

steps.
– When the required temperature has been reached, pick up the

spur gear with pliers as illustrated.
Note with respect to the correctness of information in this document. Copyright by AUDI AG.
Take care not to damage the teeth of the spur gear.
– With the aid of fitting tool - 10 - 203- , slide spur gear by hand
onto end of crankshaft as far as stop. This must be done with‐
out delay, taking care to keep the gear straight.
– Wait a few minutes to allow the spur gear to cool down, and
then install the balance shaft assembly.
– Install sealing flange (pulley end) ⇒ page 65 .

Audi Q5 2008 ➤
4 Pistons and conrods

⇒ “4.1 Exploded view - pistons and conrods”, page 85
⇒ “4.2 Removing and installing pistons”, page 87
⇒ “4.3 Measuring piston projection at TDC”, page 89
⇒ “4.4 Checking pistons and cylinder bores”, page 91
⇒ “4.5 Checking radial clearance of conrod bearings”,
page 92
4.1 Exploded view - pistons and conrods

Note permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Oil spray jet and pressure relief valve ⇒ page 87
1 - Bolt
❑ Renew
❑ Lubricate threads and
contact surface
❑ When measuring radial
clearance, tighten used
bolt to 30 Nm and turn
90° further
2 - Conrod bearing cap
❑ Due to the cracking
method used to sepa‐
rate the bearing cap
from the conrod in man‐
ufacture, the caps only
fit in one position and
only on the appropriate
conrod
❑ Mark cylinder allocation
in colour -B-
❑ Installation position:
Markings -A- face to‐
wards pulley end
3 - Bearing shell
❑ Installation position
⇒ page 87
shells
❑ Note version: Upper
bearing shell (closest to
piston) is constructed
from a more wear-re‐
sistant material. Distin‐
guishing feature on new
bearing shells: black
marking on bearing sur‐
face near joint
❑ Check that it is securely seated
4 - Conrod
❑ Only renew as a complete set
4. Pistons and conrods 85

Audi Q5 2008 ➤
❑ With industrially cracked conrod bearing cap

❑ Separating parts of new conrod ⇒ page 87
❑ Mark cylinder allocation in colour -B-
❑ Installation position: Markings -A- face towards pulley end
❑ Axial clearance: wear limit: 0.37 mm
5 - Circlip
❑ 2x
❑ Renew
6 - Piston pin
❑ If difficult to move, heat piston to approx. 60 °C
❑ Remove and install using drift - VW 222 A-
7 - Piston
❑ With combustion chamber
❑ Version fitted in vehicle may differ from illustration
❑ Mark installation position and cylinder number ⇒ page 86
❑ Measuring piston projection at “TDC” ⇒ page 89
❑ Checking pistons and cylinder bores ⇒ page 91
8 - Piston rings
❑ Compression rings
❑ Measuring
Protected ring gap
by copyright. Copying ⇒ page
for private 91 purposes, in part or in whole, is not
or commercial
❑withMeasuring ring-to-groove
respect to the correctness clearance
of information ⇒ page
in this document. 92by AUDI AG.
Copyright
❑ Use piston ring pliers (commercially available) to remove and install

❑ Installation position: marking “TOP” or side with lettering faces towards piston crown
❑ Offset gaps by 120°
9 - Piston ring
❑ Oil scraper ring
❑ Measuring ring gap ⇒ page 91
❑ Measuring ring-to-groove clearance ⇒ page 92
❑ Use piston ring pliers (commercially available) to remove and install
❑ Installation position: marking “TOP” or side with lettering faces towards piston crown
❑ Offset gap 120° from bottom compression ring
Installation position of pistons and allocation of piston/cylinder

• Arrow on piston crown points to pulley end -arrows-.

Audi Q5 2008 ➤
Installation position of bearing shells in conrods

1- Bearing shell with oil drilling -arrow- for conrod.
2- Bearing shell without oil drilling for conrod bearing cap.
– Insert bearing shells centrally in conrod/conrod bearing cap.
• Distance -a- is the same on both sides.
Separating parts of new conrod

It is possible that the two parts of a new conrod are not completely
separated as intended. If it is not possible to take off the conrod
bearing cap by hand, proceed as follows:
– To avoid any risk of damage, the conrod should only be clam‐
ped lightly in a vice using jaw covers as shown in illustration.
• The conrod is clamped in position below the dotted line.
– Unscrew bolts -arrows- approx. 5 turns.
– Using a plastic hammer, carefully knock conrod bearing cap

loose -arrow-.
Oil spray jet and pressure relief valve

1- Bolt with pressure relief valve, 27 Nm
2- Oil spray jet (for cooling of pistons)
• Installation position: align locating edge of oil spray jet with
machined surface of cylinder block.
Caution
Risk of damage to oil spray jets.

♦ Do not bend oil spray jets.
♦ Always renew bent oil spray jets.
4.2 Removing and installing pistons


Audi Q5 2008 ➤
♦ Drift - VW 222 A-
♦ Piston ring clamp, commercially available

Removing
• Engine secured to engine and gearbox support ⇒ page 32 .
– Remove cylinder head ⇒ page 98 .
– Remove balance shaft assembly ⇒ page 164 .
– Mark installation position and matching of conrod bearing caps
to conrods for reinstallation ⇒ Item 2 (page 85) .
– Unbolt conrod bearing caps.
– Pull out pistons upwards with conrods.
Note
If piston pin is difficult to remove, heat piston to approx. 60 °C.
– Take circlip out of piston pin boss.

– Use drift - VW 222 A- to drive out piston pin.
Installing
⇒ “4.1 Exploded view - pistons and conrods”, page 85
Note
– Oil running surfaces of bearing shells.

– Install pistons using piston ring clamp.
Installation position:
• Pistons ⇒ page 86 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
• Bearing shells in conrods permitted
⇒with
page 87
respect to the correctness of information in this document. Copyright by AUDI AG.
– Install conrod bearing caps according to markings.
– Install balance shaft assembly ⇒ page 165 .
– Install balance shaft assembly ⇒ page 169 .
– Install cylinder head ⇒ page 98 .

Audi Q5 2008 ➤
4.3 Measuring piston projection at TDC
Note
Piston projection at “TDC” must be measured when installing new

pistons or a short engine.

equipment required
♦ Measuring bridge -
VW 382/7- from measuring
tool - VW 382-
♦ Measuring plate -
VW 385/17- from universal
measuring tool - VW 385-

Audi Q5 2008 ➤
Procedure
– Secure dial gauge - VAS 6079- with measuring bridge -
VW 382/7- and measuring plate -VW 385/17- to cylinder block
as shown in illustration.
– Measure piston projection at two points marked with
-arrows- for each piston.
Note
If the measured values for piston projection are not the same for
all pistons, use the highest value to determine the correct gasket
size.
– Depending on piston projection, install corresponding cylinder

head gasket according to following table:
Piston projection above top sur‐ Identification
face of cylinder block (No. of holes)
mm
0.91 … 1.00 1
1.01 … 1.10 2
1.11 … 1.20 3
Identification of cylinder head gasket

1- Part number
2- Holes
3- Ignore
Note
If the measured values for piston projection are not the same for
all pistons, use the highest value to determine the correct gasket
size.

Audi Q5 2008 ➤
4.4 Checking pistons and cylinder bores

Checking piston
– Using a micrometer (75 ... 100 mm), measure approx. 15 mm
from the lower edge, perpendicular to the piston pin axis.
• Maximum deviation from nominal dimension: 0.04 mm.
Note
Renew piston if cracking is visible on piston skirt.
Piston ∅
Nominal dimension 80.96 mm 1)
• 1)Dimensions including coating (thickness 0.02 mm). The
coating will wear down in service.
Measuring cylinder bore

– Use a cylinder gauge - VAS 6078- to take measurements at 3
points in transverse direction -A- and in longitudinal direction
-B-.
• Maximum deviation from nominal dimension: 0.10 mm.
Cylinder bore ∅
Nominal dimension 81.01 mm
Measuring piston ring gap

– Insert ring at rightwith
angle
respectto
to cylinder wall
the correctness from above
of information and push
in this document. Copyright by AUDI AG.
down into lower cylinder opening approx. 15 mm from bottom
of cylinder.
– To do so, use a piston without rings.
Piston ring new Wear limit
mm mm
1st compression ring 0.25 … 0.40 1.00
2nd compression ring 0.25 … 0.40 1.00
Oil scraper ring 0.25 … 0.50 1.00

Audi Q5 2008 ➤
Measuring ring-to-groove clearance

– Clean groove in piston before checking clearance.
Piston ring new Wear limit
mm mm
1st compression ring 0.06 … 0.09 0.25
2nd compression ring 0.05 … 0.08 0.25
Oil scraper ring 0.03 … 0.06 0.15
4.5 Checking radial clearance of conrod

bearings
♦ Plastigage
Procedure
– Remove conrod bearing cap. Clean bearing cap and bearing
journal.
bearing on the bearing journal or in the bearing shell.
– Fit conrod bearing cap and secure with old bolts
⇒ Item 1 (page 85) without rotating crankshaft.
– Remove conrod bearing cap again.
Radial clearance:
– Renew conrod bolts.

Audi Q5 2008 ➤
15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Exploded view - cylinder head”, page 93
⇒ “1.2 Exploded view - cylinder head cover”, page 95
⇒ “1.3 Removing and installing cylinder head”, page 98
⇒ “1.4 Removing and installing cylinder head cover”, page 108
⇒ “1.5 Checking compression”, page 111
⇒ “1.6 Removing and installing seals for injectors”, page 112
1.1 Exploded view - cylinder head
1 - Cylinder head gasket

❑ Identification of cylinder
head gasket
⇒ page 95
❑ If renewed, change
coolant and engine oil
2 - Bolt
❑ Apply locking fluid when
installing; refer to ⇒
Electronic parts cata‐
logue
❑ 10 Nm
3 - Hall sender - G40-
❑ For camshaft position
4 - Cylinder head
⇒ page 98
❑ To prevent damage to
glow plugs, always
placeCopying
Protected by copyright. cylinder heador on
for private a
commercial purposes, in part or in whole, is not
permitted unlesssoft foambysurface
authorised AUDI AG. AUDIafterAG does not guarantee or accept any liability
with respect removal.
❑ Checking for distortion

⇒ page 95
❑ Must not be machined
❑ Before installing, check
that the two dowel
sleeves for centring cyl‐
inder head are fitted on
cylinder block
❑ If renewed, change
coolant and engine oil
5 - Washer
6 - Bolt
❑ Renew
❑ Correct sequence when slackening ⇒ page 104
1. Cylinder head 93
Audi Q5 2008 ➤
7 - Oil pressure switch - F1-

❑ Opening/closing pressure 0.3 ... 0.6 bar
❑ Checking ⇒ page 160
❑ 20 Nm
8 - Seal
❑ Renew
9 - Bolt
❑ 20 Nm
10 - Engine lifting eye
11 - Seal
❑ Renew
12 - Screw plug
❑ 20 Nm
13 - Gasket
❑ Renew
14 - Vacuum pump
❑ Removing and installing ⇒ Brake system; Rep. gr. 47 ; Vacuum system; Removing and installing vacuum
pump
15 - Bolt
❑ Tightening torque ⇒ Brake system; Rep. gr. 47 ; Vacuum system; Exploded view - vacuum pump
16 - Connection
❑ For coolant hoses
❑ with coolant temperature sender - G62-
❑ Version fitted in vehicle may differ from illustration
17 - Bolt
❑ Tightening torque ⇒ Item 12 (page 195)
18 - Seal permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ Renew
19 - Bolt
❑ 20 Nm
20 - Engine lifting eye
Cylinder head - tightening torque and sequence
Note

1. -1 … 10- 30 Nm
2. -1 … 10- 50 Nm
3. -1 … 10- Turn 90° further
4. -1 … 10- Turn 90° further
94 Rep. gr.15 - Cylinder head, valve gear

Audi Q5 2008 ➤
Checking cylinder head for distortion

– Use straight edge 500 mm - VAS 6075- and feeler gauge to
measure cylinder head for distortion at several points.
• Max. permissible distortion: 0.1 mm.
Identification of cylinder head gasket

1- Part number
2- Holes
3- Ignore
Note
Cylinder head gaskets of different thicknesses are fitted depend‐

ing on the amount of piston projection ⇒ page 89 . When renewing
only the cylinder head gasket, the new gasket should have the
same identification as the old one.
1.2 Exploded view - cylinder head cover
Caution

1. Cylinder head 95
Audi Q5 2008 ➤
1 - Gasket
❑ Renew if damaged or
leaking
2 - Cylinder head cover
⇒ page 108
3 - Bracket
❑ For vacuum lines and
electrical wiring
4 - O-ring
❑ Renew
5 - Hose
❑ For crankcase breather
❑ Press release tabs to
detach
6 - Sealing bush
❑ For fuel rail
❑ Renew if damaged or
leaking
7 - Grommet
8 - Clamping piece
9 - Bolt
⇒ page 249
10 - Fuel rail
❑ Observe rules for clean‐
liness ⇒ page 8
❑ Do not attempt to bend
high-pressure pipes to a
different shape
❑ Installing high-pressure pipes ⇒ page 265
11 - Bolt
❑ Tightening torque ⇒ page 249
12 - Bolt
13 - Fuel return line
14 - O-ring
❑ Renew
15 - Injector
❑ Observe rules for cleanliness ⇒ page 8
16 - O-ring
❑ Renew
17 - Copper seal
❑ Renew
18 - Seal
❑ For injector

Audi Q5 2008 ➤
19 - Filler cap
20 - Seal
❑ For filler cap
21 - Grommet
22 - Bolt
❑ Renew if seal is damaged
Cylinder head cover - tightening torque

Protected and sequence
– Tighten bolts for cylinder head coverto in
with respect the the sequence
correctness -1 ...in 6-
of information this document. Copyright by AUDI AG.
to 9 Nm.
Note
Take care to keep cylinder head cover straight.
1. Cylinder head 97
Audi Q5 2008 ➤
1.3 Removing and installing cylinder head

equipment required
♦ Diesel injection pump lock‐
ing pin - 3359-
6362-
♦ Counterhold tool - T10051-
♦ Puller - T10052-
♦ Bit XZN 10 - T10385-
Removing
– Remove plenum chamber partition panel ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Bulkhead; Exploded view - plenum
chamber partition panel .
– Remove air cleaner housing ⇒ page 272 .
– Remove coolant pipe (top left) ⇒ page 196 .

Audi Q5 2008 ➤

- G505- .

– Remove bolt and nut -arrows-.

– Press coolant pipe (rear right) to one side.
Note

– Remove bolt -1-.
– Release hose clips -arrows- and disconnect coolant hoses
from rear coolant pipe.
– Move coolant pipe to rear.
Note
Disregard -item 2-.
1. Cylinder head 99
Audi Q5 2008 ➤
– Unplug electrical connector -2- at coolant temperature sender

- G62- .
Note
Disregard -item 1-.
– Remove bolt -1- for dipstick guide tube.

– Unplug electrical connector -3- at throttle valve module -
J338- .
Note
Disregard -item 2-.
– Remove cylinder head cover ⇒ page 108 .
– Lift retaining clip -arrow- and disconnect coolant line.

Audi Q5 2008 ➤
– Loosen bolt -1- for turbocharger.
Note
Disregard -item 2-.
– Slacken clamp -arrows-.

– Remove nuts -arrows- for turbocharger.
Note
– Move clear electrical wiring harness at cylinder head.
– Remove bolts -1- and -3- on exhaust gas recirculation cooler.
Note
Disregard -item 2-.
1. Cylinder head 101

Audi Q5 2008 ➤
– Remove bolts -1- and detach camshaft sprocket.
– Counterhold using counterhold tool - T10051- and loosen bolt

-1- for camshaft hub.
– Unscrew bolt approx. 2 turns.
– Apply puller - T10052- to camshaft hub and screw bolts -1- into
hub.
– Counterhold on hexagon flats (30 mm) of puller and screw in
bolt -2- to pull off camshaft hub.
– Detach hub from taper of camshaft.
– Remove bolt -arrow- for toothed belt cover (rear).

Audi Q5 2008 ➤
– Remove bolt for Hall sender - G40- -arrow- and move Hall
sender - G40- to one side.

Audi Q5 2008 ➤
– Slacken cylinder head bolts in the sequence -1 ... 10-.
Note
♦ A second mechanic is required for removal of the cylinder

head.
♦ Toothed belt tensioning roller is detached from stud when lift‐
ing out cylinder head.
– Swivel cylinder head towards front and out of rear toothed belt
cover and detach tensioning roller at the same time.
– Take care not to damage oil return line for turbocharger.
– Take care to place cylinder head down without bending oil re‐
turn line. If necessary, place a block of wood below exhaust
manifold.
Caution Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Risk of damage to glow plugs when putting down cylinder

head.
♦ After removal, the cylinder head must not be put down on
the gasket side with the glow plugs still installed, because
the glow plugs project slightly beyond the gasket surface.
Note
Audi Q5 models with a 2.0 ltr. 4-valve TDI engine (common rail)
are always equipped with steel glow plugs.
Installing

Audi Q5 2008 ➤
Caution
Avoid damage to sealing surfaces.

♦ Carefully remove sealant residue from cylinder head and
cylinder block.
♦ Ensure that no long scores or scratches are made on the
surfaces.
Avoid damage to cylinder block.
♦ No oil or coolant must be allowed to remain in the blind
holes for the cylinder head bolts in the cylinder block.
Risk of leaks at cylinder head gasket.
♦ Carefully remove any sealant residue from the cylinder
head and cylinder block. Ensure that no long scores or
scratches are made on the surfaces.
♦ Carefully remove any remaining emery and abrasive ma‐
terial.
♦ Do not remove new cylinder head gasket from packaging
until it is ready to be fitted.
♦ Handle the cylinder head gasket very carefully to prevent
damage to the silicone coating or the indented area of the
gasket.
Avoid damage
Protected to open
by copyright. valves.
♦ When installing
with respect an exchange
to the correctness cylinder
of information head,Copyright
in this document. the plastic
by AUDI AG.
protectors fitted to protect the open valves should not be
removed until the cylinder head is ready to be fitted.
Avoid damage to valves and piston crowns after working on
valve gear.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.
Note

♦ Renew self-locking nuts as well as seals, gaskets and O-rings.
♦ Cylinder heads must not be reworked on TDI engines.
♦ When installing an exchange cylinder head, the contact sur‐
faces between roller rocker fingers and cams must be oiled.
♦ After fitting a new cylinder head or cylinder head gasket,
change the engine oil and the coolant in the entire cooling
system.
– Before fitting cylinder head, remove crankshaft stop - T10050-

and turn crankshaft against normal direction of rotation until
all pistons are positioned approximately equally below “TDC”.
– If not already fitted, install dowel sleeves in cylinder block for
centring cylinder block and cylinder head.

Audi Q5 2008 ➤
– Note cylinder head gasket identification:

1- Part number
2- Holes
3- Ignore
Note
♦ If the cylinder head gasket or cylinder head have been re‐

placed, select the new cylinder head gasket according to the
number of holes on the old gasket.
♦ If parts of the crankshaft drive have been renewed, the new
cylinder head gasket must be selected by measuring the pis‐
ton projection at “TDC” ⇒ page 89 .
– Fit cylinder head gasket onto dowel sleeves -arrows- in cylin‐
der block.
• Installation position of cylinder head gasket: the word
“oben” (top) or the part number should face towards the cyl‐
inder head.
– Swivel cylinder head so that stud for toothed belt tensioning
roller is inserted into aperture in toothed belt cover (rear) and
attach tensioning roller at the same time.
Note
Make sure that electrical wiring to Hall sender - G40- is properly

routed.
– Fit cylinder head.
– Screw in cylinder head bolts by hand until they make contact.

– Tighten cylinder head bolts ⇒ page 94 .
– Install rear toothed belt cover, camshaft hub and sprocket
⇒ page 114 .

Audi Q5 2008 ➤
– Lock camshaft hub with diesel injection pump locking pin -

3359- .
Note
Disregard -arrows-.
– Lock high-pressure pump hub with diesel injection pump lock‐

ing pin - 3359- .
Note
Disregard -item 1-.
– Then turn crankshaft in direction of engine rotation until pin

-arrow- on crankshaft stop - T10050- engages in sealing
flange as crankshaft rotates.
note the following:
– Install cylinder head cover ⇒ page 108 .
– Install coolant pipe (rear) ⇒ page 201 .
– Install turbocharger ⇒ page 220 .
Electrical fault finding and Fitting locations.
– Install dipstick guide tube ⇒ page 146 .
– Install coolant pipe (rear right) ⇒ page 198 .
– Install coolant pipe (top left) ⇒ page 196 .
– Install air cleaner housing ⇒ page 272 .
– Install plenum chamber partition panel ⇒ General body re‐
– Change engine oil ⇒ Maintenance
Protected ; Booklet
by copyright. Copying for private817 .
or commercial purposes, in part or in whole, is not
– Fill cooling system with
with fresh
respect coolant
to the ⇒ ofpage
correctness 177in.this document. Copyright by AUDI AG.
information

Audi Q5 2008 ➤
1.4 Removing and installing cylinder head

cover
Removing
– Remove injectors ⇒ page 259 .
– Remove fuel rail ⇒ page 266 .
– Unplug electrical connectors -2, 3, 4- and move electrical wir‐

ing clear.
– Detach vacuum hose -1- and move clear.

Audi Q5 2008 ➤

- G505- .


– Release hose clips -2- and detach fuel hoses.
– Pull fuel lines upwards off cylinder head cover and press clear
to one side.
Note
Disregard -item 4-.
– Press release tabs and disconnect crankcase breather hose

-2-.
Note
Disregard -item 1-.

Audi Q5 2008 ➤
– Disconnect vacuum hose -2-.

– Detach bracket -1- for cylinder head cover and move clear to
one side.
Note
Disregard -item 3-.
– Slacken cylinder head cover bolts in the sequence -6 ... 1- and

remove.
Installing
⇒ Fig. ““Cylinder head cover - tightening torque and se‐
quence”“ , page 97
Note
♦ Fit new O-ring.

♦ Renew gasket for cylinder head cover and bolts for cylinder
head cover if damaged or leaking.
♦ Renew grommets and seals for injectors if damaged or leak‐
ing.
– Tighten cylinder head cover bolts ⇒ page 97 .
– Make sure that cylinder head cover is clipped properly to

toothed belt cover -arrows-.
Note

the camshaft sprocket removed.
– Make sure there is a clearance between hub and toothed belt

cover.
– Install fuel rail ⇒ page 266 and injectors ⇒ page 259 .
Electrical fault finding and Fitting locations.
– Bleed fuel system ⇒ page 246 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Audi Q5 2008 ➤
1.5 Checking compression

♦ Compression tester - V.A.G 1763- with adapter - V.A.G
1763/8-
Procedure
• Engine oil temperature approx. 80 °C
• Battery voltage at least 12.5 V.
– Unplug electrical connector -arrow- for fuel pressure regulat‐

ing valve - N276- at fuel rail.
– Briefly start engine to relieve fuel pressure in fuel rail.
– Remove all glow plugs ⇒ page 355 .

Audi Q5 2008 ➤
– Screw in adapter - V.A.G 1763/8- in place of corresponding

glow plug and connect compression tester - V.A.G 1763- .
Note
Using the compression tester ⇒ Operating instructions .
– Have a second mechanic operate starter until tester shows no

further pressure increase.
– Repeat procedure on each cylinder.
Compression pressure bar
When new 25.0 … 31.0
Wear limit 19.0
Maximum difference between cylinders 5.0
Assembling
– Install glow plugs ⇒ page 355 .
– Faults are stored in event memory of engine control unit be‐
cause electrical connectors were unplugged and the engine
was started: Interrogate event memory in Vehicle self-
diagnosis ⇒ Vehicle diagnostic tester.
1.6 Removing and installing seals for injec‐

tors
♦ Tool set for FSI engines - T10133-
♦ Socket, AF 24 mm - T10361-

Audi Q5 2008 ➤
♦ Oil seal extractor - T40195-
Procedure
– Remove corresponding injector ⇒ page 259 .
– Screw oil seal extractor - T40195- into seal -1-.
– Fit striker -T10133/3- with adapter -T10133/2- on oil seal ex‐
tractor, as shown in illustration, and pull out seal upwards by
tapping gently.
– Drive in new injector seal as far as stop using socket, AF 24 -

T10361- and short extension -1-.

Audi Q5 2008 ➤
2 Toothed belt drive

⇒ “2.1 Exploded view - toothed belt”, page 114
⇒ “2.2 Removing and installing toothed belt”, page 116
2.1 Exploded view - toothed belt
1 - Toothed belt
❑ Before removing, mark Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
direction of rotation with permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
chalk or felt-tip pen with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Check for wear

❑ Removing ⇒ page 116
❑ Installing (adjusting
valve timing)
⇒ page 119
2 - Idler roller
3 - Nut
❑ 20 Nm
4 - Stud
❑ 15 Nm
5 - Nut
6 - Tensioning roller
7 - Stud
❑ 15 Nm
8 - Bolt
❑ 20 Nm
9 - Idler roller
10 - Bolt
❑ 25 Nm
11 - Camshaft sprocket
12 - Bolt
❑ Slacken and tighten with
counterhold tool -
T10051-
❑ 100 Nm
13 - Hub
❑ For camshaft
14 - Plug
15 - Toothed belt cover (rear)
16 - Bolt
❑ 9 Nm
17 - Hub
❑ For high-pressure pump

Audi Q5 2008 ➤
18 - Nut
19 - High-pressure pump sprocket
20 - Bolt
21 - Idler roller
22 - Bolt
❑ Renew
23 - O-ring
❑ Renew
24 - Coolant pump
25 - Bolt
❑ Tightening torque ⇒ Item 2 (page 184)
26 - Crankshaft sprocket
❑ Contact surface between sprocket and crankshaft must be free of oil
❑ Can only be installed in one position
27 - Bolt
❑ Renew
❑ Slacken and tighten with counterhold tool - 3415-
❑ Do not additionally oil threads and shoulder
Tighten in three stages as follows:
♦ 1st stage: 180 Nm
♦ 2nd stage: Use rigid wrench to turn 90° further
♦ 3rd stage: Use rigid wrench to turn 45° further
Toothed belt cover (bottom) - tightening torque

– Tighten bolts -arrows-
permitted unless to 9 Nm.by AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
2. Toothed belt drive 115

Audi Q5 2008 ➤
2.2 Removing and installing toothed belt

equipment required
♦ 2x diesel injection pump
locking pin - 3359-
♦ Crankshaft stop - T10050-
♦ Special wrench, long reach
- T10264-
♦ Bit XZN 10 - T10385-

Audi Q5 2008 ➤
Removing
Caution


belt from alternator pulley and release tensioner.
Note
Ignore -T40098- .
– Remove vibration damper ⇒ page 59 .
– Release retaining clips

Protected by -arrows- and for
copyright. Copying detach toothed
private or belt
commercial cover
purposes, in part or in whole, is not
(top). permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

– Detach toothed belt cover (bottom).

Audi Q5 2008 ➤
Caution
Irreparable damage can be caused if the toothed belt slips.

♦ Turn crankshaft only in direction of engine rotation.
– Rotate crankshaft by turning bolt on crankshaft sprocket until

camshaft sprocket is positioned at “TDC”.
3359- .
Note
Disregard -arrows-.
– Lock crankshaft sprocket in position with crankshaft stop -

T10050- .
• The markings on the sprocket
Protected -2- and
by copyright. Copying for the crankshaft
private stop -1-in part or in whole, is not
or commercial purposes,
must align -arrow-. Theunless
permitted pin authorised
of the crankshaft stopAGmust
by AUDI AG. AUDI engage
does not guarantee or accept any liability
in the aperture inwith
therespect
sealing flange.
Note
The crankshaft stop can only be pushed onto the sprocket from
the front face of the teeth.
– Slacken bolts -arrows- for camshaft sprocket approx. 90°.
– Using bit XZN 10 - T10385- , loosen bolts -arrows- for toothed

belt sprocket on high-pressure pump by approx. 90°.

Audi Q5 2008 ➤
– Slacken nut -1- for tensioning roller.

– Turn eccentric adjuster of tensioning roller with special
wrench, long reach - T10264- anti-clockwise -arrow- until ten‐
sioning roller can be secured with locking tool - T10265- .
– Then use special wrench, long reach - T10264- to turn eccen‐

tric adjuster of tensioning roller clockwise -arrow- as far as stop
and tighten nut -1- by hand.
Caution

♦ Before removing, mark direction of rotation of toothed belt
– Take off toothed belt first from idler roller and then from re‐
maining sprockets.
Installing (adjusting valve timing)
⇒ “2.1 Exploded view - toothed belt”, page 114
Note
Perform adjustments on toothed belt only when engine is cold.
Caution
Avoid damage to valves and piston crowns.

♦ The crankshaft must not be at “TDC” at any cylinder when
the camshaft is turned.
Requirements:
• Tensioning roller is locked with locking tool - T10265- and se‐
cured at right stop with nut -1-.

Audi Q5 2008 ➤
• Camshaft hub locked with diesel injection pump locking pin -

3359- .
• Bolts -arrows- are fitted but not tightened.
• It should just be possible to turn the sprocket on the camshaft
without axial movement.
• Crankshaft is locked in position with crankshaft stop -

T10050- .
• Hub of high-pressure pump locked with diesel injection pump

locking pin - 3359- .
• Bolts -1- are fitted but not tightened.
• The high-pressure pump sprocket should still just turn, but
there must be no axial movement.
Note
If necessary, apply a screwdriver -arrows- to bolt heads -1- and

turn the high-pressure pump hub until it can be locked with the
locking pin.

Audi Q5 2008 ➤
– Turn the camshaft sprocket and high-pressure pump sprocket

in their elongated holes clockwise as far as the stop.
– Install toothed belt in the specified sequence:
1- Crankshaft sprocket
2- Tensioning roller
3- Camshaft sprocket
4- Coolant pump sprocket
5- High-pressure pump sprocket
6- Idler roller
– Loosen nut -1- for tensioning roller and detach locking tool -
T10265- .
Note
Disregard -arrow-.
Note
Ensure that tensioning roller is seated properly in toothed belt

cover (rear) -arrow-.
– Position counterhold tool - T10172- on camshaft sprocket as

shown in illustration.
– Apply force to counterhold tool in anti-clockwise direction
-arrow- and maintain tension.
– Tighten bolts -1- for camshaft sprocket and bolts -2- for high-
pressure pump sprocket in this position.
• Tightening torque: 20 Nm

Audi Q5 2008 ➤
– Carefully turn eccentric adjuster of tensioning roller clockwise

-arrow- using special wrench, long reach - T10264- until point‐
er -2- aligns with the centre of the slot on the base plate.
• Nut -1- must not turn.
– Hold tensioning roller in this position and tighten nut.
– Remove locking pins -3359- and crankshaft stop - T10050- .
Checking valve timing:
Caution

– Turn crankshaft two rotations in direction of engine rotation by

turning bolt for crankshaft sprocket until crankshaft is just be‐
fore “TDC”.
– Fit crankshaft stop - T10050- to crankshaft sprocket again.

– Turn crankshaft in direction of engine rotation until pin
-arrow- on crankshaft stop engages in sealing flange as crank‐
shaft rotates.
• It should now be possible to lock camshaft hub with diesel in‐

jection pump locking pin - 3359- .
Note
Disregard -arrows-.
• It is very difficult to reproduce the locking position of the high-

pressure pump hub. However, a slight deviation -arrow- does
not influence engine operation.

Audi Q5 2008 ➤
• Pointer -2- on tensioner roller must be centred between tabs

-1- and -3- on base plate.
Note
The maximum permissible sideways deviation from the specified

position is 5 mm.
♦ Re-adjust valve timing if requirements are not met

⇒ page 123 .
♦ If requirements are met, continue with procedure after adjust‐
ing valve timing correctly as described below ⇒ page 123 .
Re-adjusting valve timing:
– If camshaft hub cannot
Protectedbe locked,Copying
by copyright. withdraw crankshaft
for private or commercialstop - in part or in whole, is not
purposes,
T10050- until pin ispermitted
clearunless
of bore.
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Turn crankshaft in opposite direction of engine rotation slightly
past “TDC”.
– Now turn crankshaft slowly in direction of engine rotation until
it is possible to lock camshaft hub.
– Loosen bolts for camshaft sprocket after locking hub.
A - If pin of crankshaft stop - T10050- is on left side of bore:

– Turn crankshaft in direction of engine rotation until pin
-arrow- on crankshaft stop engages in sealing flange as crank‐
shaft rotates.
– Tighten camshaft sprocket bolts to 20 Nm.
B - If pin of crankshaft stop - T10050- is on right side of bore:
– Turn crankshaft slightly in opposite direction to engine rota‐
tion.
– Turn crankshaft in direction of engine rotation again until pin
of crankshaft stop engages in sealing flange as crankshaft ro‐
tates.
– Tighten camshaft sprocket bolts to 20 Nm.
Procedure after adjusting valve timing correctly:
– Remove diesel injection pump locking pin - 3359- and crank‐
shaft stop - T10050- .
– Turn crankshaft two rotations in direction of engine rotation by
turning bolt for crankshaft sprocket until crankshaft is just be‐
fore “TDC”.
– Check valve timing once again ⇒ page 122 .

Audi Q5 2008 ➤
– If camshaft hub can now be locked, tighten camshaft sprocket

bolts -1- to final torque ⇒ Item 10 (page 114) .
– Tighten bolts -2- for high-pressure pump sprocket to final tor‐
que ⇒ page 294 .
– Check valve timing once again ⇒ page 122 .
Assembling
Note
♦ Renew seals and/or gaskets.

– Install vibration damper ⇒ page 59 .

Audi Q5 2008 ➤
3 Valve gear
⇒ “3.1 Exploded view - valve gear”, page 125
⇒ “3.2 Measuring axial clearance of camshaft”, page 126
⇒ “3.3 Measuring radial clearance of camshaft”, page 127
⇒ “3.4 Removing and installing camshaft oil seal”, page 128
⇒ “3.5 Removing and installing camshaft”, page 130
⇒ “3.6 Checking hydraulic valve compensation elements”,
page 136
⇒ “3.7 Removing and installing valve stem oil seals”, page 137
3.1 Exploded view - valve gear
1 - Valve
❑ Must not be machined;
only grinding-in is per‐
missible
❑ Mark installation posi‐
tion for re-installation
❑ Valve dimensions
⇒ page 145
❑ Checking valve guides
⇒ page 144
2 - Cylinder head
3 - Valve stem oil seal
❑ Renewing with cylinder
head installed
⇒ page 137
❑ Renewing with cylinder
head removed
⇒ page 140
4 - Valve spring
5 - Valve spring plate
6 - Valve cotters
7 - Sealing cap
❑ Renew
❑ Removing sealing cap
with retaining frame in‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
stalled: pierce on one permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
side with an awl and pry with respect to the correctness of information in this document. Copyright by AUDI AG.
out
❑ Installing: drive in with‐
out sealant using suita‐
ble thrust piece
❑ Installation depth 1 ... 2
mm
8 - Oil seal
9 - Exhaust camshaft
3. Valve gear 125

Audi Q5 2008 ➤

10 - Bolt
❑ Correct sequence when slackening ⇒ page 132
11 - Retaining frame
❑ With integrated camshaft bearings
12 - Inlet camshaft
13 - Roller rocker finger
❑ Mark installation position for re-installation
❑ Check roller bearings for ease of movement
❑ Lubricate contact surfaces before installing
14 - Securing clip
❑ For hydraulic compensation element
15 - Hydraulic valve compensation element
❑ Mark installation position for re-installation
❑ Lubricate contact surfaces before installing
Retaining frame - tightening torque and sequence

• The retaining frame should make
contact with the cylinder head over
the full surface
2. -1 … 24- 10 Nm
3.2 Measuring axial clearance of camshaft


Audi Q5 2008 ➤
♦ Dial gauge - VAS 6079- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Procedure
– Remove retaining frame ⇒ page 130 .
– Secure dial gauge - VAS 6079- with universal dial gauge
bracket - VW 387- to retaining frame as shown in illustration.
– Press camshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
Axial clearance on inlet camshaft and exhaust camshaft:
• Specification: 0.048 … 0.118 mm.
3.3 Measuring radial clearance of camshaft

♦ Plastigage
Procedure
– Remove roller rocker fingers ⇒ page 130 .
– Clean bearings and bearing journals.
bearing on the bearing journal or bearing shell to be measured.
• The Plastigage must be positioned in the centre of the bearing.
– Fit retaining frame and tighten to 10 Nm without rotating cam‐
shafts ⇒ page 126 .
– Remove retaining frame again.
3. Valve gear 127

Audi Q5 2008 ➤
• Radial clearance: 0.035 ... 0.085 mm
3.4 Removing and installing camshaft oil

seal
♦ Oil seal extractor - 2085-
♦ Fitting sleeve - 3265-
♦ Bolt -T10071/2- from assembly tool - T10071-
♦ Fitting tool -T10132-

Audi Q5 2008 ➤
♦ Adapter 3/8” to 1/2”
♦ Washer 12x14
Procedure
– Remove camshaft sprocket and hub ⇒ page 130 .
– Insert adapter 3/8” to 1/2” -item 1- into oil seal extractor - 2085- .
– Screw inner section of oil seal extractor -2085- two turns (ap‐
prox. 3 mm) out of outer section and lock with knurled screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and screw it into oil seal as far as possible (applying firm
pressure).
– Loosen knurled screw andpermitted
turn inner
unlesssection
authorised against
by AUDI AG. camshaft
AUDI AG does not guarantee or accept any liability
until oil seal is pulled out. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Clamp flats of oil seal extractor in vice and use pliers to remove
oil seal.
– Clean contact surface and sealing surface.
Note
The sealing lip of the oil seal must not be additionally oiled or
greased.
– Apply guide sleeve -T10132/1- to camshaft as shown in illus‐

tration.
– Carefully push oil seal -1- over guide sleeve and onto cam‐
shaft.
– Use fitting sleeve - 3265- , bolt -T10071/2- and washer 12x14

-item 1- to pull in oil seal onto stop.
– Install camshaft sprocket and hub ⇒ page 130 .
3. Valve gear 129

Audi Q5 2008 ➤
3.5 Removing and installing camshaft

equipment required
♦ Puller - T10052-
♦ Camshaft fitting tool -
T40094-
♦ Camshaft fitting tool -
T40095-
♦ Clamping tool -T40096/1-
♦ Electric drill with plastic
brush attachment
♦ Safety goggles
♦ Sealant ⇒ Electronic parts
catalogue
Removing
• Cylinder head installed.

Audi Q5 2008 ➤

-2-.
– Loosen hose clip -1- and remove air hose.
– Remove bolts -1- and -3- on exhaust gas recirculation cooler.
Note
Disregard -item 2-.
– Take toothed belt off camshaft sprocket and high-pressure

pump sprocket ⇒ page 116 .
– Remove bolts -1- and detach camshaft sprocket.
3. Valve gear 131

Audi Q5 2008 ➤
– Counterhold using counterhold tool - T10051- and loosen bolt

-1- for camshaft hub.
– Unscrew bolt approx. 2 turns.
– If it is not possible to take off the hub by hand:

– Apply puller - T10052- to camshaft hub and screw bolts -1- into
hub.
– Counterhold on hexagon flats (30 mm) of puller and screw in
bolt -2- to pull off camshaft hub.
– Detach hub from taper of camshaft.
– Remove vacuum pump ⇒ Brake system; Rep. gr. 47 ; Vac‐
uum system; Removing and installing vacuum pump .
– Slacken retaining frame bolts in the sequence -24 ... 1-.

– Remove bolts and carefully release retaining frame from bon‐
ded joint.
– Mark fitting location of camshafts for re-installation and re‐
move.
Installing
Tightening torques:
• ⇒ “3.1 Exploded view - valve gear”, page 125 .
• ⇒ “5.1 Exploded view - exhaust gas recirculation system”,
page 347 .
Caution
Make sure axial bearings in retaining frame are not damaged.

♦ The camshafts MUST be installed using the camshaft fit‐
ting tool - T40094- as described in the following.

Audi Q5 2008 ➤
Caution
Protect lubrication system and bearings against contamina‐

tion.
♦ Cover exposed parts of the engine.
WARNING
Risk of eye injury.

– Remove remaining sealant from cylinder head and retaining

frame using rotating plastic brush or similar.
– Clean sealing surfaces; they must be free of oil and grease.
– Oil running surfaces of both camshafts.
Set up camshaft fitting tool - T40094- as follows:

– Secure supports -T40094/9- and -T40094/10- (with -
T40094/11- ) to base plate, as shown in illustration. If neces‐
sary, remove any supports already attached at these posi‐
tions.
– Fit support -T40094/1- onto position -F- and support -

T40094/2- onto position -A-.
3. Valve gear 133

Audi Q5 2008 ➤
– Place inlet camshaft in supports -T40094/1- and -T40094/2- .

– Turn inlet camshaft in such a way that it can be locked in “TDC”
position using locking device -arrow 1-.
• Recess -arrow 2- for cylinder head bolt must face outwards.
– Place exhaust camshaft in supports -T40094/9- and -

T40094/10- .
– Lock exhaust camshaft with top section -T40094/11- .
• The lug -1- on the top section must engage in the slot -2- in
the camshaft,
– Place clamping tool -T40096/1- on teeth of exhaust camshaft
in such a way that the two arms of the tool engage on the two
halves of the gear (one in each half, as shown in illustration).
• The wider arm must engage in the wider half of the gear.
– Tighten the clamping tool using the knurled wheel so that the
faces of the gear teeth are in alignment.
– Slide inlet camshaft towards exhaust camshaft, until gear
teeth engage -arrows-.
– Fit retaining frame on camshafts.

• All camshaft bearings must be seated on the camshafts.
– Position camshaft fitting tool - T40095- and fix camshafts in
position in retaining frame, as shown in illustration.
– Detach top section -T40094/11- .

Audi Q5 2008 ➤
Note

mm).
Caution
Make sure excess sealant does not contaminate camshaft

bearings.
♦ The beads of sealant must not be thicker than specified.
– Apply beads of sealant onto clean sealing surfaces of cylinder

head as shown in illustration.
• Thickness of sealant beads: 2 ... 3 mm
Note
♦ The retaining frame should be fitted and secured without de‐

lay, as the sealant starts hardening immediately.
♦ After installing the retaining frame, wait about 30 minutes for
the sealant to dry.
– Take camshafts together with retaining frame, camshaft fitting

tool - T40095- and clamping tool -T40096/1- out of camshaft
fitting tool - T40094- and insert components carefully into cyl‐
inder head.
3. Valve gear 135

Audi Q5 2008 ➤
– Screw in retaining frame bolts in the sequence -1 ... 24- evenly

by hand until they make contact.
• The retaining frame should make contact with the cylinder
head over the full surface.
– Tighten bolts ⇒ page 126 .
– Remove camshaft fitting tool - T40095- and clamping tool -
T40096/1- .
note the following:
– Install camshaft oil seal ⇒ page 128 .
– Drive new sealing cap ⇒ Item 7 (page 125) into cylinder head
to a depth of approx. 1 ... 2 mm using suitable thrust piece.
– Install vacuum pump ⇒ Brake system; Rep. gr. 47 ; Vacuum
system; Removing and installing vacuum pump .
Caution
Avoid damage to valves and piston crowns after working on

valve gear.
♦ The hydraulic tappets have to settle; wait for approx. 30
minutes after installing camshafts before starting engine.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.
3.6 Checking hydraulic valve compensation

elements
Note
♦ The hydraulic compensation elements cannot be serviced.

♦ Irregular valve noises when starting engine are normal.

♦ Feeler gauge
Procedure
– Start engine and run until radiator fan has started up once.
– Increase engine speed to approx. 2500 rpm for 2 minutes
(perform road test if necessary).
If irregular valve noise disappears but repeatedly re-occurs when
travelling short distances, renew oil retention valve. The oil re‐
tention valve is located in the oil filter bracket
⇒ Item 10 (page 157) .
– If the compensation elements are still noisy, locate the defec‐

tive compensation element as follows:

Audi Q5 2008 ➤
– Rotate crankshaft by turning bolt for toothed belt sprocket until

cam of supporting element to be tested is facing upwards.
– Press roller rocker finger down -arrow- to determine clearance
between cam and roller rocker finger.
– If it is possible to insert a feeler gauge of 0.20 mm between
cam and roller rocker finger, renew hydraulic compensation
element ⇒ page 130 .
Additional steps required
3.7 Removing and installing valve stem oil

seals
⇒ “3.7.1 Renewing valve stem oil seals with cylinder head instal‐
led”, page 137
⇒ “3.7.2 Renewing valve stem oil seals with cylinder head re‐
moved”, page 140
3.7.1 Renewing valve stem oil seals with cyl‐

inder head installed
♦ Valve stem seal puller - 3364-
♦ Valve stem seal fitting tool - 3365-
3. Valve gear 137

Audi Q5 2008 ➤
♦ Removal and installation device for valve cotters - VAS 5161-

with guide plate -VAS 5161/23- and sleeve -VAS 5161/23-1- .
♦ Bolt M6x30 (2x)

Procedure
– Remove all glow plugs ⇒ page 355 .
– Remove camshafts ⇒ page 130 .
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for reinstallation.

– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
– Set piston of appropriate cylinder to “bottom dead centre”.
– Fit guide plate -VAS 5161/23- onto cylinder head.
– Secure guide plate on intake manifold side with knurled screw
-VAS 5161/12- and 2 M6x30 bolts -item 1- by hand until they
make contact.
– Screw sealing pin -VAS 5161/10- into guide plate.

– Screw adapter -VAS 5161/11- hand-tight into corresponding
glow plug thread.

Audi Q5 2008 ➤
– Insert drift -VAS 5161/3- into guide plate and use plastic-head‐
ed hammer to release sticking valve cotters.
– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Slide sleeve -VAS 5161/23-1- onto assembly cartridge -
VAS 5161/8- .
– Connect adapter to compressed air line using a commercially
available connection piece, and apply constant air pressure.
• Minimum pressure: 6 bar
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move
Protected knurled
by copyright. Copyingscrew back
for private and forth
or commercial slightly;
purposes, the
in part or valve
in whole, cotters
is not
permittedare thus
unless forced
authorised apart
by AUDI AG.and
AUDItaken
AG doesup by the assembly
not guarantee cartridge.
or accept any liability
– Release pressure fork.
– Take off assembly cartridge with knurled spacer ring.
– Detach valve spring with valve spring plate.
– Pull off valve stem oil seal with valve stem seal puller - 3364- .
3. Valve gear 139

Audi Q5 2008 ➤
Caution
Make sure valve stem oil seals are not damaged when instal‐
ling.
♦ New valve stem oil seals -B- are supplied with plastic
sleeve; fit plastic sleeve -A- onto valve stem.
– Lightly oil sealing lip of valve stem oil seal.

– Slide valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide
permitted using
valve stem seal fitting tool - 3365- . with respect to the correctness of information in this document. Copyright by AUDI AG.
– Take off plastic sleeve.
If valve cotters have been removed from assembly cartridge, they

must first be inserted in insertion device -VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Insert valve spring and valve spring plate.
– Press assembly cartridge onto insertion device from above
and take up valve cotters.
– Insert assembly cartridge in guide plate -VAS 5161/23- again.

– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions - this will insert the valve
cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
Assembling
– Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly and are clipped onto their respec‐
tive hydraulic compensation elements.
– Install camshafts ⇒ page 130 .
– Install glow plugs ⇒ page 355 .
3.7.2 Renewing valve stem oil seals with cylinder head removed

Audi Q5 2008 ➤

equipment required
♦ Valve stem seal puller -
3364-
♦ Valve stem seal fitting tool -
3365-
♦ Removal and installation
device for valve cotters -
VAS 5161- with guide plate
-VAS 5161/23- and sleeve -
VAS 5161/23-1- .
♦ Engine and gearbox sup‐
port - VAS 6095-
♦ Cylinder head tensioning
device - VAS 6419-
♦ Bolt M6x30 (2x)
Procedure
– Remove camshafts ⇒ page 130 .
– Mark original positions of roller rocker fingers and hydraulic
compensation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and put down on a clean surface.
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095- .
– Secure cylinder head in cylinder head tensioning device, as
– Connect cylinder head tensioning device to compressed air.
– Using lever -arrow-, slide air pad under combustion chamber
where valve stem oil seal is to be removed.
– Apply just enough compressed air to bring air pad into contact
with valve heads.
3. Valve gear 141

Audi Q5 2008 ➤
– Fit guide plate -VAS 5161/23- onto cylinder head.

– Secure guide plate on intake manifold side with knurled screw
-VAS 5161/12- and 2 M6x30 bolts -item 1- by hand until they
make contact.
– Insert drift -VAS 5161/3- into guide plate and use plastic-head‐
ed hammer to release sticking valve cotters.
– Screw snap-in device -VAS 5161/6- with engaging fork -

VAS 5161/5- into guide plate.
– Slide sleeve -VAS 5161/23-1- onto assembly cartridge -
VAS 5161/8- .
– Attach pressure fork -VAS 5161/2- to snap-in device and push
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth slightly; the valve cotters
are thus forced apart and taken up by the assembly cartridge.
– Release pressure fork.
– Take off assembly cartridge with knurled spacer ring.
– Detach valve spring with valve spring plate.
– Pull off valve stem oil seal with valve stem seal puller - 3364- .

Audi Q5 2008 ➤
Caution
Make sure valve stem oil seals are not damaged when instal‐
ling.
♦ New valve stem oil seals -B- are supplied with plastic
sleeve; fit plastic sleeve -A- onto valve stem.
– Lightly oil sealing lip of valve stem oil seal.

– Slide valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Take off plastic sleeve.
If valve cotters have been removed from assembly cartridge, they

must first be inserted in insertion device -VAS 5161/18- .
• Larger diameter of valve cotters faces upwards.
– Insert valve spring and valve spring plate.
– Press assembly cartridge onto insertion device from above
and take up valve cotters.
– Insert assembly cartridge in guide plate -VAS 5161/23- again.

– Press down pressure fork and pull knurled screw upwards
while turning screw in both directions - this will insert the valve
cotters.
– Release pressure fork with knurled screw still in pulled posi‐
tion.
– Repeat procedure for each valve.
Assembling
– Ensure that all roller rocker fingers make contact with the ends
of the valve stems correctly and are clipped onto their respec‐
tive hydraulic compensation elements.
– Install camshafts ⇒ page 130 .
3. Valve gear 143

Audi Q5 2008 ➤
4 Inlet and exhaust valves

⇒ “4.1 Machining valve seats”, page 144
⇒ “4.2 Checking valve guides”, page 144
⇒ “4.3 Checking valves”, page 145
⇒ “4.4 Valve dimensions”, page 145
4.1 Machining valve seats
Valve seats may not be machined due to the very small toleran‐
ces.
4.2 Checking valve guides

Procedure
Note
♦ If the valve has to be renewed as part of a repair, use a new

valve for the measurement.
♦ Only insert inlet valve into inlet valve guide and exhaust valve
into exhaust valve guide, as the stem diameters are different.

Audi Q5 2008 ➤
– Attach dial gauge - VAS 6079- with dial gauge bracket - VW

387- to cylinder head.
– Insert valve into guide.
• End of valve stem must be flush with guide.
– Measure the amount of sideways play.
– If the wear limit is exceeded, repeat the measurement with
new valves.
– Renew cylinder head if wear limit is still exceeded.
Note
Valve guides cannot be renewed.
4.3 Checking valves

– Visually inspect for scoring on valve stems and valve seat sur‐
faces.
– Renew valve if scoring is clearly visible.
4.4 Valve dimensionsProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
Valves must not be machined. Only grinding-in is permitted.
Dimension Inlet valve Exhaust valve

∅a mm 28.10 26.00
∅b mm 5.975 5.965
c mm 99.30 99.10
α ∠° 45 45
4. Inlet and exhaust valves 145

Audi Q5 2008 ➤
17 – Lubrication
1 Sump/oil pump
⇒ “1.1 Exploded view - sump/oil pump”, page 146
⇒ “1.2 Engine oil”, page 150
⇒ “1.3 Removing and installing sump”, page 150
⇒ “1.4 Removing and installing oil pump”, page 154
⇒ “1.5 Removing and installing oil level and oil temperature send‐
er G266 ”, page 155
1.1 Exploded view - sump/oil pump
Note
♦ If large quantities of metal shavings or abrasion are found

when performing engine repairs, this may be an indication of
damage to the crankshaft or conrod bearings. To prevent fur‐
ther damage, the following steps are required after completion
of repair work: clean the oil galleries carefully and renew the
oil spray jets, engine oil cooler and oil filter.
♦ Refer to ⇒ Maintenance tables for engine oil capacity, oil
specifications and viscosity grades.
♦ Oil spray jet and pressure relief valve ⇒ page 87
146 Rep. gr.17 - Lubrication

Audi Q5 2008 ➤
1 - Seal
❑ Renew
2 - Oil drain plug
❑ 30 Nm
3 - Sump
⇒ page 150
4 - O-ring
❑ Renew
5 - Suction pipe
❑ Clean strainer if dirty
6 - Bolt
❑ 9 Nm
7 - Oil pump
⇒ page 154
❑ Before installing, check
that the two dowel
sleeves for centring oil
pump are fitted onto bal‐
ance shaft assembly
8 - Drive shaft
❑ For oil pump
9 - Circlip
❑ Must fit securely in
groove
❑ Renew circlip if dam‐
aged or stretched
10 - Spur gear permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ For balance shaftwith respect to the correctness of information in this document. Copyright by AUDI AG.
11 - Bolt
❑ Renew
12 - Thrust washer
❑ For idler gear
❑ Renew
❑ Installation position ⇒ page 149
❑ When installing idler gear, apply grease to hold washer on balance shaft assembly
13 - Idler gear
❑ Renew
❑ To achieve the correct backlash a suitably thick coating is already applied to the new idler gear; the
required clearance is achieved as the coating is worn down
❑ Installation position: Part No. must be visible.
❑ Make sure thrust washer is properly seated ⇒ page 149
14 - Bolt
❑ With washer
❑ Renew
1. Sump/oil pump 147

Audi Q5 2008 ➤
15 - Hub
❑ For idler gear
❑ Renew
16 - Crankshaft gear
17 - Cover
❑ Installation position for cover of oil level and oil temperature sender - G266- ⇒ page 149
18 - Dowel sleeves
19 - Balance shaft assembly
❑ Removing ⇒ page 164
❑ Re-installing "old" balance shaft assembly ⇒ page 169
❑ Installing new balance shaft assembly ⇒ page 165
❑ Before installing, check that the two dowel sleeves for centring balance shaft assembly are fitted on
cylinder block
20 - Bolt
❑ Renew
21 - Dowel sleeves
22 - Bolt
❑ 9 Nm
23 - Oil intake pipe
24 - Bolt
❑ 9 Nm
25 - Seal
❑ Renew
26 - Oil level and oil temperature sender - G266-
27 - Cover
❑ permitted
For oilunless
levelauthorised
and oilbytemperature
AUDI AG. AUDI AG sender - G266-or accept any liability
does not guarantee
28 - Bolt
❑ Self-locking
❑ Renew
❑ 9 Nm
29 - Bolt
❑ Renew

Audi Q5 2008 ➤
Installation position for cover of oil level and oil temperature send‐
er
– Clip in cover for oil level and oil temperature sender -arrow-,
as shown in illustration.
Note
For greater clarity, item -1- shows oil level and oil temperature
sender .
Sump - tightening torque and sequence

– Tighten bolts in stages:
1. -1 to 20- 5 Nm in diagonal sequence
2. -arrows- 15 Nm + turn 90° further (renew bolts)
3. -1 to 7-, Tighten in stages and in diagonal se‐
-9 and 10-, quence; final torque 13 Nm
-12 to 20-
4. -8 and 11- 23 Nm
Installation position of thrust washer
Caution
Thrust washer can slip out of position behind idler gear.

♦ Make sure that thrust washer -A- does not slip out of the
recesses in the balance shaft assembly -arrows- when fit‐
ting the idler gear. If this is neglected, the thrust washer
can become trapped. If necessary, apply grease to hold
washer on balance shaft assembly.

Audi Q5 2008 ➤
Balance shaft assembly - tightening torque and sequence
Note

1. -1 to 6- Screw in by hand until contact is made
2. -1 to 6- 6 Nm
3. -1 to 4- 20 Nm
4. -5 and 6- 13 Nm
5. -1 to 6- Turn 90° further
1.2 Engine oil

Refer to ⇒ Maintenance tables for engine oil capacity, oil speci‐
fications and viscosity grades.
1.3 Removing and installing sump

♦ Support bracket - 10 - 222 A-
♦ Engine and gearbox jack - V.A.G 1383 A-

Audi Q5 2008 ➤
♦ Engine bung set - VAS 6122-
♦ Special wrench - T10058-
Removing
• Engine oil drained ⇒ Maintenance ; Booklet 817
– Remove subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Exploded view - subframe .
– Unscrew nut -arrow- on longitudinal member (right-side) and

move earth cables clear.

Audi Q5 2008 ➤
– Unplug electrical connector -2- at oil level and oil temperature

sender - G266- .
Vehicles with front-wheel drive:
– Remove torque reaction support ⇒ page 46 .

Note

– Remove bolts securing sump to gearbox -arrows-.
– Slacken bolts -1 ... 20- in diagonal sequence and remove.
– Carefully release sump from bonded joint.
Installing
⇒ Fig. ““Sump - tightening torque and sequence”“ , page 149
Caution
Protect lubrication system and bearings against contamina‐

tion.
♦ Cover exposed parts of the engine.
WARNING
Risk of eye injury.


Audi Q5 2008 ➤
– Remove sealant residue from sump and cylinder block using

rotating plastic brush or similar.
– Clean sealing surfaces; they must be free of oil and grease.
Note

mm).
Caution

– Apply bead of sealant onto clean sealing surface of sump as

illustrated.
Note

mm).
Caution


Audi Q5 2008 ➤
– Apply bead of sealant onto clean sealing surface of sump as

illustrated.
• Thickness of sealant bead: 2 ... 3 mm
Note
♦ Take particular care when applying sealant bead in area of

rear sealing flange -arrows-.
♦ The sump must be installed within 5 minutes after applying the
sealant.
– Fit sump and tighten bolts ⇒ page 149 .
Note
♦ When installing sump with engine removed from vehicle, en‐

sure that sump is positioned flush with cylinder block at fly‐
wheel end.
♦ After fitting sump assembly, the sealant must dry for approx.
30 minutes. Then (and only then) fill the engine with engine
oil.
– Install subframe ⇒ Running gear, axles, steering; Rep. gr.

40 ; Subframe; Exploded view - subframe .
– Install electrical wiring ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
– Fill with engine oil and check oil level ⇒ Maintenance ; Booklet
817 .
1.4 Removing and installing oil pump

♦ Circlip pliers, commercially available
Removing
– Remove bolt -arrow- and detach suction pipe from oil pump.

Audi Q5 2008 ➤
– Remove circlip -1- using circlip pliers.

– Pull drive shaft -2- out of oil pump using a magnet -arrow-.
– Remove bolts -3, 4, 5- and detach oil pump.
Caution
The bolt on the idler gear must NOT be loosened.
Installing
Note
♦ Fit new O-ring.

♦ Renew circlip if damaged or stretched.
♦ Circlip must fit securely in groove.
– Insert dowel sleeves -arrows- in oil pump, if not fitted.

– If no dowel sleeves for centring the oil pump are fitted in the
balance shaft assembly, install missing dowel sleeves.
1.5 Removing and installing oil level and oil

temperature sender - G266-
Removing
• Engine oil drained ⇒ Maintenance ; Booklet 817
– Remove bolts -1- and detach oil level and oil temperature
sender - G266- -item 4-.
Installing
Note
Renew seal -2- and self-locking bolts -1-.
– Fill with engine oil and check oil level ⇒ Maintenance ; Booklet
817 .

Audi Q5 2008 ➤
2 Engine oil cooler

⇒ “2.1 Removing and installing engine oil cooler”, page 156
2.1 Removing and installing engine oil cool‐

er
Removing
– Drain coolant ⇒ page 175 .
Note
Place a cloth underneath to catch escaping coolant and engine

oil.
– Unscrew bolts -arrows- and detach engine oil cooler.

Installing
⇒ “3.1 Exploded view - oil filter housing/oil pressure switch”,
page 157
– Fill up cooling system (or change coolant if the engine oil cool‐
er has been renewed) ⇒ page 177 .

Audi Q5 2008 ➤
3 Oil filter/oil pressure switch

⇒ “3.1 Exploded view - oil filter housing/oil pressure switch”, page
157
⇒ “3.2 Removing and installing oil pressure switch F1 ”,
page 158
⇒ “3.3 Checking oil pressure and oil pressure switch”,
page 159
⇒ “3.4 Removing and installing oil filter housing”, page 161
⇒ “3.5 Checking oil level”, page 163
3.1 Exploded view - oil filter housing/oil pressure switch
1 - Sealing cap Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 25 Nm permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
2 - O-ring
❑ Renew
3 - O-ring
❑ Renew
4 - O-ring
❑ Renew
5 - Oil filter element
❑ See note ⇒ page 146
⇒ Maintenance ; Book‐
let 817
6 - Engine oil cooler
❑ See note ⇒ page 146
❑ Connection diagram -
coolant hoses
⇒ page 171
⇒ page 156
❑ If renewed, refill system
with fresh coolant
7 - Bolt
❑ 11 Nm
8 - Seals
❑ Renew
9 - Bolt
❑ Renew
❑ Tightening torque and
sequence ⇒ page 158
10 - Oil filter bracket
❑ With integrated oil retention valve
11 - Gaskets
❑ Renew
3. Oil filter/oil pressure switch 157

Audi Q5 2008 ➤
Oil filter bracket - tightening torque and sequence
Note
– Fit bolts at top left and bottom right first.

– Tighten bolts in 2 stages:
1. -arrows- 14 Nm in diagonal sequence
2. -arrows- Turn 90° further in diagonal sequence
3.2 Removing and installing oil pressure

switch - F1-
♦ Articulated wrench, 24 mm - T40175-
Removing

body brace .

Audi Q5 2008 ➤
– Remove bolts -2- and -3- and detach engine lifting eye -1-.
– Use articulated wrench, 24 mm - T40175- to unscrew oil pres‐
sure switch - F1- .
Installing
– Install coolant pipe (rear right)
⇒ “3.1 Exploded view - coolant pipes”, page 195 .
– Install engine lifting eye
⇒ “1.1 Exploded view - cylinder head”, page 93 .
body brace .
– Install air tocleaner housing

with respect the correctness of information in this document. Copyright by AUDI AG.
⇒ “4.2 Removing and installing air cleaner housing”,
page 272 .
3.3 Checking oil pressure and oil pressure

switch
⇒ “3.3.1 Checking oil pressure”, page 159
⇒ “3.3.2 Checking oil pressure switch F1 ”, page 160
3.3.1 Checking oil pressure

♦ Oil pressure tester - V.A.G 1342-
Procedure
• Oil level OK
– Remove oil pressure switch - F1- ⇒ page 158 .
– Connect oil pressure tester - V.A.G 1342- to threaded hole for
oil pressure switch - F22- .
– Screw a used oil pressure switch into threaded hole on oil
pressure tester - V.A.G 1342- to seal hole.
– Start engine.
• Oil pressure when starting and then at idling speed: at least
0.8 bar.

Audi Q5 2008 ➤
If specification is not obtained, switch off engine immediately; re‐

new oil pump
⇒ “1.4 Removing and installing oil pump”, page 154 .
If specification is obtained, let engine warm up.
• Oil pressure specification at operating temperature and 2000
rpm: at least 2.0 bar.
3.3.2 Checking oil pressure switch - F1-

♦ Oil pressure tester - V.A.G 1342-
♦ Voltage tester - V.A.G 1527B-
♦ Auxiliary measuring set - V.A.G 1594C-

Audi Q5 2008 ➤
Procedure
• Oil level OK
• Engine oil temperature approx. 80 °C
– Remove oil pressure switch - F1- ⇒ page 158 .
– Connect oil pressure tester - V.A.G 1342- to bore for oil pres‐
sure switch.
– Screw oil pressure switch - F1- -item 2- into threaded hole in
oil pressure tester.
– Connect brown wire -1- of oil pressure tester to earth (–).
– Connect voltage tester - V.A.G 1527B- with adapter leads from
auxiliary measuring set - V.A.G 1594C- to oil pressure switch
- F1- and battery positive (+).
• LED should not light up.
Note
Renew oil pressure switch - F1- if LED lights up at this stage.
Note
Observe oil pressure tester and LED while starting engine, as

switching point of oil pressure switch may already be exceeded
when starting.
• LED should light up at 0.3 ... 0.6 bar.

– Renew oil pressure switch - F1- if LED does not light up.
3.4 Removing and installing oil filter housing


Audi Q5 2008 ➤
♦ Used oil collection and extraction unit - V.A.G 1782-
♦ Drip tray for workshop hoist - VAS 6208-
♦ Hose clip pliers - VAS 6362-
Removing
– Remove oil filter element ⇒ Maintenance ; Booklet 817 .
– Remove coolant pipe (top left) ⇒ page 196 .
– Remove pump for exhaust gas recirculation cooler - V400-
⇒ page 193 .
– Pull oil dipstick out slightly and remove bolt -1-.
– Release clip -2- with removal lever - 80 - 200- .
– Pull guide tube for oil dipstick upwards out of cylinder block
and push to one side.

Audi Q5 2008 ➤
– Place drip tray for workshop hoist - VAS 6208- under connec‐
tion.
below engine.
– Unscrew bolts -arrows- and remove oil filter bracket with en‐
gine oil cooler.
Installing
⇒ Fig. ““Oil filter bracket - tightening torque and sequence”“ ,
page 158
Note

♦ Renew seals and/or gaskets.

– Install pump for exhaust gas recirculation cooler - V400-
⇒ page 193 .
– Install coolant pipe (top left) ⇒ page 196 .
– Install oil filter element, fill up with engine oil and check oil level
⇒ Maintenance ; Booklet 817 .
– Fill up with coolant ⇒ page 175 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3.5 Checking oil level
Check oil level ⇒ Maintenance ; Booklet 817 .

Audi Q5 2008 ➤
4 Balance shaft assembly

⇒ “4.1 Removing and installing balance shaft assembly”,
page 164
4.1 Removing and installing balance shaft

assembly
⇒ “4.1.1 Removing balance shaft assembly”, page 164
⇒ “4.1.2 Installing a new balance shaft assembly”, page 165
⇒ “4.1.3 Re-installing a used balance shaft assembly”,
page 169
4.1.1 Removing balance shaft assembly

♦ Diesel injection pump locking pin - 3359-
Procedure with respect to the correctness of information in this document. Copyright by AUDI AG.
– Pull out oil dipstick.

– Using angled ring spanner -1- at vibration damper, turn crank‐
shaft in normal direction of rotation -arrow- until crankshaft is
at “TDC”.

Audi Q5 2008 ➤
Caution


3359- .
Note
Disregard -arrows-.
– Loosen bolts in the sequence -6 ... 1-.

– Remove bolts and detach balance shaft assembly with oil
pump.
Note
♦ Installing a new balance shaft assembly ⇒ page 165 .

♦ Re-installing a used balance shaft assembly ⇒ page 169 .
4.1.2 Installing a new balance shaft assembly

4. Balance shaft assembly 165

Audi Q5 2008 ➤
♦ Bits - T10099-
♦ Insert tool, 14 mm - T10393-

Audi Q5 2008 ➤
Procedure
• Camshaft locked with diesel injection pump locking pin -
3359- .
Note
♦ The spur gear drive of the balance shaft assembly must be

installed with a backlash of 0.038 ... 0.072 mm.
♦ To achieve the correct backlash, a suitably thick coating is al‐
ready applied to the new idler gear. The coating is applied to
the teeth on parts of the circumference.
♦ The coating is worn down rapidly and the backlash is then
correct.
♦ A new balance shaft assembly must always be installed in
conjunction with a new idler gear which has the correct coat‐
ing.
Caution
Thrust washer can slip out of position behind idler gear.

♦ Before positioning balance shaft assembly, slacken off
bolt for idler gear as specified below, but not further. In‐
stallation position of thrust washer ⇒ page 149
– Loosen bolt -1- for idler gear approx. 45° using e.g. bits -
T10099- and insert tool, 14 mm - T10393- .
– If not already fitted, fit dowel sleeves into cylinder block for
centring balance shaft assembly.
– Attach balance shaft assembly to cylinder block.
• Take care not to damage the coating of the idler gear.

Audi Q5 2008 ➤
– Tighten bolts securing balance shaft assembly ⇒ page 150 .
– Lock balance shaft with locking tool - T10255- , turning bal‐

ance shaft as required.
• The lug of the locking tool must engage in the groove of the
balance shaft.
– Carefully fit balance shaft gear onto balance shaft; to do so,

push idler gear slightly to one side.
• Take care not to damage the coating of the idler gear.
• The threaded holes in the balance shaft should be aligned as
centrally as possible with the elongated holes in the balance
shaft gear.
Note
If it is not possible to align the elongated holes in the balance shaft

gear with the threaded holes, Protected
you must turn the
by copyright. gearforsome
Copying private orteeth
further as required and then fitpermitted
it again.
– Tighten bolts -arrows- for balance shaft gear.

– Remove locking tool - T10255- .

Audi Q5 2008 ➤
Note
The following three steps have to be performed simultaneously

(a second mechanic is therefore required):
– Push idler gear -3- firmly in direction of -arrow- into teeth on

spur gear -2- and balance shaft gear -1-. If necessary use a
wooden rod to do so.
– At the same time, turn balance shaft gear slightly anti-clock‐
wise.
– Tighten bolt securing idler gear.
– Remove diesel injection pump locking pin - 3359- .
Note
After installation the idler gear must have no backlash. This can
be checked by exerting light pressure by hand.

note the following:
4.1.3 Re-installing
Protected by copyright.a used
Copying balance
for private shaft
or commercial as‐
purposes, in part or in whole, is not
sembly


Audi Q5 2008 ➤
Procedure
• Camshaft locked with diesel injection pump locking pin -
3359- .
Note
♦ If re-installing the "old" balance shaft assembly and neither the

spur gear on the crankshaft nor the crankshaft itself have been
renewed, proceed as described in the following. It is also es‐
sential that the idler gear has NOT been slackened.
♦ If the bolt for the idler gear has been slackened or the spur
gear on the crankshaft or the crankshaft itself have been re‐
newed, you must install a new idler gear with the appropriate
coating. Procedure for installation ⇒ page 165 .
– Lock balance shaft with locking tool - T10255- , turning bal‐

ance shaft as required.
• The lug of the locking tool must engage in the groove of the
balance shaft.
– If not already fitted, fit dowel sleeves into cylinder block for
centring balance shaft assembly. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Attach balance shaft assembly to cylinder block. with respect to the correctness of information in this document. Copyright by AUDI AG.
• With the balance shaft locked in position, the idler gear must
engage in the spur gear on the crankshaft.
• Idler gear must have noticeable backlash.
– Tighten bolts securing balance shaft assembly ⇒ page 150 .

– Remove diesel injection pump locking pin - 3359- .
note the following:

Audi Q5 2008 ➤
19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 171
⇒ “1.2 Checking cooling system for leaks”, page 173
⇒ “1.3 Draining and filling cooling system”, page 175
1.1 Connection diagram - coolant hoses
Note
♦ Blue = Large coolant circuit.

♦ Red = Small coolant circuit.
♦ Brown = Heating circuit.
♦ Orange = Coolant circuit for exhaust gas recirculation.
1 - Non-return valve
❑ Arrow points in direction
of through-flow
2 - Radiator
with fresh coolant
3 - Coolant pump
4 - Cylinder head/cylinder
block
with fresh coolant
5 - Exhaust gas recirculation
cooler
❑ If renewed, refill system Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
with fresh coolant permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
6 - Radiator outlet coolant tem‐
perature sender - G83-
7 - Coolant temperature send‐
er - G62-
8 - Coolant circulation pump -
V50-
❑ On vehicles with start/
stop system only
❑ Different versions avail‐
able ⇒ Electronic parts
catalogue
9 - Coolant shut-off valve
❑ Activated by Climatronic
coolant shut-off valve -
N422- (negative pres‐
sure)
⇒ Heating, air conditioning; Rep. gr. 87 ; Overview of fitting locations - air conditioner; Overview of fitting
locations - components not located in passenger compartment
1. Cooling system/coolant 171

Audi Q5 2008 ➤
10 - Bleeder hole
11 - Heat exchanger for heater
❑ If renewed, refill system with fresh coolant
12 - Thermostat
❑ For exhaust gas recirculation cooler
❑ Arrow points in direction of through-flow
14 - Filler cap
❑ For coolant expansion tank
15 - Coolant expansion tank
❑ Checking cooling system for leaks ⇒ page 173
17 - Pump for exhaust gas recirculation cooler - V400-
18 - 4/2-way valve with thermostat
Vehicles with auxiliary heater

Note with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ Blue = Large coolant circuit.

♦ Red = Small coolant circuit.
♦ Brown = Heating circuit.
♦ Orange = Coolant circuit for exhaust gas recirculation.
172 Rep. gr.19 - Cooling

Audi Q5 2008 ➤
❑ Arrow points in direction
of through-flow
2 - Radiator
with fresh coolant
3 - Coolant pump
4 - Cylinder head/cylinder
block
with fresh coolant
cooler
with fresh coolant
6 - Radiator outlet coolant tem‐
perature sender - G83-
7 -permitted
Coolant temperature
unless send‐
authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
er - G62-
8 - Auxiliary heater
9 - Bleeder hole
10 - Heat exchanger for heater
with fresh coolant
11 - Heater coolant shut-off
valve - N279-
⇒ Auxiliary heater, sup‐
plementary heater; Rep.
gr. 82 ; Coolant circuit
with auxiliary/supple‐
mentary heater; Re‐
moving and installing heater coolant shut-off valve
12 - Thermostat
❑ For exhaust gas recirculation cooler
❑ Arrow points in direction of through-flow
14 - Filler cap
❑ For coolant expansion tank
15 - Coolant expansion tank
❑ Checking cooling system for leaks ⇒ page 173
18 - 4/2-way valve with thermostat
1.2 Checking cooling system for leaks


Audi Q5 2008 ➤
♦ Cooling system tester - V.A.G 1274 B-
♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Adapter for cooling system tester - V.A.G 1274/9-
Procedure
• Engine must be warm.
WARNING

hot.
♦ Cover filler cap on coolant expansion tank with a cloth and
open carefully to dissipate pressure.


Audi Q5 2008 ➤
– Fit cooling system tester - V.A.G 1274 B- with adapter -V.A.G

1274/8- onto coolant expansion tank.
– Using hand pump on cooling system tester, build up a pres‐
sure of approx. 1.0 bar.
– If this pressure is not maintained, locate and rectify leaks.
Checking pressure relief valve in filler cap

– Fit cooling system tester - V.A.G 1274 B- with adapter -
V.A.G 1274/9- onto filler cap.
– Build up pressure with hand pump on cooling system tester.
• The pressure relief valve should open at a pressure of
1.4 ... 1.6 bar.
– Renew filler cap if pressure relief valve does not open as de‐
scribed.
1.3 Draining and filling cooling system

Audi Q5 2008 ➤

equipment required
♦ Adapter for cooling system
tester - V.A.G 1274/8-
♦ Pipe for cooling system
tester - V.A.G 1274/10-
♦ Cooling system charge unit
- VAS 6096- with -
VAS 6096/1-
♦ Drip tray for workshop hoist
- VAS 6208-
6362-
♦ Refractometer - T10007 A-
Draining
WARNING

The cooling system is under pressure when the engine is hot.
Cover filler cap on coolant expansion tank with a cloth and

– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Protected
Noise insulation; Exploded
by copyright. Copying for privateview - noisepurposes,
or commercial insula‐in part or in whole, is not
tion . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi Q5 2008 ➤
gine.
– Remove drain plug -1- and drain off coolant.
Note
Disregard -item 2-.
Filling
Caution
Always use distilled water for mixing coolant additives as this

ensures optimum corrosion protection.

Audi Q5 2008 ➤
Note
♦ The effectiveness of the coolant is greatly influenced by the

quality of the water with which it is mixed. Because water may
contain different substances depending on the country or even
the region, the water quality to be used for cooling systems
has been specified. Distilled water meets all the requirements
and is therefore recommended for use when topping up or fill‐
ing up with coolant.
♦ Use only coolant additives listed in the ⇒ Electronic parts
catalogue (ETKA) . Other coolant additives could seriously
impair in particular the anti-corrosion properties. The resulting
damage could lead to loss of coolant and consequently to se‐
rious engine damage.
♦ Coolant with the recommended mixture ratio prevents frost
and corrosion damage and stops scaling. At the same time it
raises the boiling point of the fluid in the system. For this rea‐
son the cooling system must be filled all year round with the
correct coolant additive.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates.
♦ The refractometer - T10007A- MUST be used to determine the
current level of frost protection. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ The mixture must guarantee frost protection down to at least with respect to the correctness of information in this document. Copyright by AUDI AG.
-25 ℃ (in countries with arctic climate: down to -36 ℃). The
amount of antifreeze should only be increased if greater frost
protection is required in very cold climates. This must only be
down to -48 ℃, however, as otherwise the cooling efficiency
of the coolant is impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be provided to at least -25 ℃.
♦ Read off the level of frost protection on the scale for the rele‐
vant coolant additive.
♦ The temperature indicated on the refractometer - T10007A-
corresponds to the temperature at which the first ice crystals
can form in the coolant.
♦ Do not reuse coolant.
♦ Only use water/coolant additive as a lubricant for coolant ho‐
ses.
Recommended mixture ratio for coolant

• Coolant additive (40 %) and distilled water (60 %) for frost
protection to -25 ℃
• Coolant additive (50 %) and distilled water (50 %) for frost
protection to -36 ℃
• Coolant additive ⇒ Electronic parts catalogue
Procedure

Audi Q5 2008 ➤
– Close drain plug -1-.
– Fill reservoir of -VAS 6096- with at least 8 litres of premixed

coolant (according to recommended ratio):
– Fit adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank.
– Attach cooling system charge unit - VAS 6096- to adapter -
V.A.G 1274/8- .
– Run vent hose -1- into a small container -2-.
Note
The vented air draws along a small amount of coolant, which

should be collected.
– Close both valves -A- and -B- (turn lever at right angles to di‐
rection of flow).
– Connect hose -3- to compressed air.
• Pressure: 6 ... 10 bar.

Audi Q5 2008 ➤
– Open valve -B- by setting lever in direction of flow.

• The suction jet pump generates a partial vacuum in the cooling
system; the needle on the gauge should move into the green
zone.
– Also briefly open valve -A- (turn lever in direction of flow) so
that hose on reservoir of -VAS 6096- can fill with coolant.
– Close valve -A- again.
– Leave valve -B- open for another 2 minutes.
• The suction jet pump continues to generate a partial vacuum
in the cooling system; the needle on the gauge should remain
in the green zone.
– Close valve -B-.
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
Note
♦ If the needle does not reach the green zone, repeat the proc‐
ess.
♦ Check cooling system for leaks if the vacuum is not main‐
tained.
– Detach compressed air hose.

– Open valve -A-.
• The vacuum in the cooling system causes the coolant to be
drawn out of the reservoir of -VAS 6096- ; the cooling system
is then filled.
– Detach cooling system charge unit - VAS 6096- from adapter
-V.A.G 1274/8- on coolant expansion tank.
– Attach pipe -V.A.G 1274/10- onto adapter -V.A.G 1274/8- .

Audi Q5 2008 ➤
– Remove seal -3-.

– Unclip retaining clips -1- from mountings and detach plenum
chamber cover -2-.
– Release coolant hose going to heat exchanger for heater and

pull back hose until bleeder hole -arrow- in hose is no longer
blocked by connection.
– Fill up with coolant until it flows out at bleeder hole in coolant
hose.
– Push coolant hose back onto connection and secure with
spring-type hose clip.
– On vehicles with auxiliary heater, switch heater on (for about
30 seconds) and then off again.
– Close filler cap on coolant expansion tank (make sure it en‐
gages).
– Start engine.
– Set temperature to “HI” in all zones.
Time period Engine speed Air conditioner / heater setting

3 minutes 2000 rpm • Air conditioning system “OFF”, LED in AC button
not lit
• Heating at “HI”, select lowest possible blower
speed (= 0)
Until both large coolant Idling • Air conditioning system “OFF”

hoses on radiator be‐
come warm • Heating at “HI”
1 minute 2000 rpm • Air conditioning system “OFF”

• Heating at “HI”
– Switch off ignition and allow engine to cool down.
tion .

Audi Q5 2008 ➤
– Check coolant level.

• The coolant level must be between the “min” and “max” mark‐
ings when the engine is cold.
• The coolant level can be at the “max” marking when the engine
is warm.
– Top up with coolant again if necessary.

Audi Q5 2008 ➤
2 Coolant pump/thermostat assembly

⇒ “2.1 Exploded view - coolant pump and thermostat”,
page 183
⇒ “2.2 Exploded view - continued coolant circulation pump V50 ”,
page 185
⇒ “2.3 Exploded view - pump for exhaust gas recirculation cooler
V400 ”, page 186
⇒ “2.4 Removing and installing coolant circulation pump V50 ”,
page 186
⇒ “2.5 Removing and installing coolant pump”, page 188
⇒ “2.6 Checking thermostat”, page 188
⇒ “2.7 Removing and installing 4/2-way valve with thermostat”,
page 188
⇒ “2.8 Removing and installing coolant temperature sender G62
”, page 191
⇒ “2.9 Removing and installing radiator outlet coolant tempera‐
ture sender G83 ”, page 192
⇒ “2.10 Removing and installing pump for exhaust gas recircula‐
tion cooler V400 ”, page 193
2.1 Exploded view - coolant pump and thermostat
2. Coolant pump/thermostat assembly 183

Audi Q5 2008 ➤
1 - Coolant pump
⇒ page 188
2 - Bolt
❑ 15 Nm
3 - O-ring
❑ Renew
4 - O-ring
❑ Renew
5 - 4/2-way valve
❑ The thermostat is loca‐
ted in the interior of the
4/2-way valve and can‐
not be renewed sepa‐
rately
⇒ page 188
6 - Bolt
❑ 15 Nm

Audi Q5 2008 ➤
2.2 Exploded view - continued coolant circulation pump - V50-
1 - Bracket
2 - Mounting plate
3 - Coolant hoses
4 - Coolant circulation pump -
V50-
⇒ page 186
5 - Bolt
❑ 2.7 Nm
6 - Bolt
⇒ page 33

Audi Q5 2008 ➤
2.3 Exploded view - pump for exhaust gas recirculation cooler - V400-
1 - Nut
❑ 9 Nm
2 - Bracket
❑ For pump for exhaust
gas recirculation cooler
- V400-
3 - Spacer bush
4 - Bolt
❑ 2.7 Nm
5 - Grommet
6 - Pump for exhaust gas re‐
circulation cooler - V400-
⇒ page 193
2.4 Removing and installing coolant circula‐

tion pump - V50-
♦ Hose clamps, up to 25 mm - 3094-

Audi Q5 2008 ➤
Removing

– Clamp off coolant hoses using hose clamps -3094- , release
hose clips -1- and disconnect coolant hoses.
– Release fastener -arrow- and lift coolant circulation pump -
V50- off bracket.
Installing permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Install in reverse order.

Audi Q5 2008 ➤
2.5 Removing and installing coolant pump

Removing
– Unscrew bolts -1- and remove coolant pump -2-.
– Detach O-ring -3-.
Installing
⇒ “2.1 Exploded view - coolant pump and thermostat”,
page 183
Note
Fit new O-ring.
– Clean and smoothen sealing surface for O-ring.

– Lightly lubricate O-ring -3-Protected
with coolant.
– Fit coolant pump -2-. with respect to the correctness of information in this document. Copyright by AUDI AG.
• Installation position: Sealing plug in housing faces down‐

wards.
– Fill up with coolant ⇒ page 177 .
2.6 Checking thermostat

– Heat removed thermostat in water bath.
Starts to open Fully open Opening travel
approx. 92 °C approx. 107 ℃ 1) at least 7 mm
• 1) Cannot be tested.
2.7 Removing and installing 4/2-way valve

with thermostat

Audi Q5 2008 ➤
♦ T-bar and socket, 10 mm - 3185-
♦ Allen key, long reach - T10058-
♦ Multi-point bit XZN 8 - T10445- with respect to the correctness of information in this document. Copyright by AUDI AG.
Removing
Note
Disregard -item 1-.

Audi Q5 2008 ➤
– Remove bolt -2- for coolant pipe (bottom left) with multi-point
bit XZN 8 - T10445- .
– Detach coolant pipe from 4/2-way valve towards the rear and
place to one side.

– Remove nut -1- and move bracket with electrical connector to
one side.
– Pull oil dipstick out slightly and remove bolt -1-.

– Release clip -2- with removal lever - 80 - 200- .
– Pull guide tube for oil dipstick upwards out of cylinder block
and push to one side.

Audi Q5 2008 ➤
– Remove bolts -2-.

– Release hose clips -3-, lift retaining clip -1- and detach coolant
hoses.
– Detach 4/2-way valve.
Installing
Tightening torques:
• ⇒ “2.1 Exploded view - coolant pump and thermostat”,
page 183 .
• ⇒ “3.1 Exploded view - coolant pipes”, page 195 .
2.8 Removing and installing coolant temper‐

ature sender - G62-
Removing
• Engine cold.

body brace .
– To relieve residual pressure in cooling system, open filler cap

on coolant expansion tank briefly and then close cap again (it
should click into place).

Audi Q5 2008 ➤

– Pull off retaining clip -1- and pull out coolant temperature
sender - G62- .
Installing
Note
♦ Renew O-rings.
♦ Insert new coolant temperature sender - G62- immediately in‐
to connection to avoid loss of coolant.

body brace .
– Check coolant level ⇒ page 182 .
2.9 Removing and installing radiator outlet

coolant temperature
Protected by copyright. Copyingsender - G83-purposes, in part or in whole, is not
for private or commercial
Removing with respect to the correctness of information in this document. Copyright by AUDI AG.
• Engine cold.
– To relieve residual pressure in cooling system, open filler cap
on coolant expansion tank briefly and then close cap again (it
should click into place).

Audi Q5 2008 ➤
Note
Place a cloth underneath to catch escaping coolant.
– Unscrew radiator outlet coolant temperature sender - G83-

-item 1-.
Installing
⇒ “3.1 Exploded view - coolant pipes”, page 195
Note
♦ Fit new O-ring.

♦ Insert new radiator outlet coolant temperature sender - G83-
immediately into threaded hole to avoid loss of coolant.
2.10 Removing and installing pump for ex‐

haust gas recirculation cooler - V400-
♦ Hose clamps, up to 25 mm - 3094-

Audi Q5 2008 ➤
Removing

WARNING

hot.
♦ Cover filler cap on coolant expansion tank with a cloth and
– Remove nuts -2- and pull pump for exhaust gas recirculation
cooler - V400- off engine.
– Clamp off coolant hoses using hose clamps -3094- , release
hose clips -1- and disconnect coolant hoses.
– Remove bolts -3- and detach pump for exhaust gas recircula‐
tion cooler from bracket.
Installing
⇒ “2.3 Exploded view - pump for exhaust gas recirculation
cooler V400 ”, page 186

Audi Q5 2008 ➤
3 Coolant pipes
⇒ “3.2 Removing and installing coolant pipe (top left)”,
page 196
⇒ “3.3 Removing and installing coolant pipe (bottom left)”,
page 197
⇒ “3.4 Removing and installing coolant pipe (rear right)”,
page 198
⇒ “3.5 Removing and installing coolant pipe (rear)”, page 201
3.1 Exploded view - coolant pipes
1 - Bolt
❑ 9 Nm
2 - Coolant pipe (bottom left)
⇒ page 197
3 - O-ring
❑ Renew
4 - Thermostat
❑ For exhaust gas recircu‐
lation cooler
5 - Coolant pipe (rear right)
⇒ page 198
6 - Bolt
❑ 9 Nm
7 - Nut
❑ 9 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
8 - Retaining clip with respect to the correctness of information in this document. Copyright by AUDI AG.
9 - Coolant temperature send‐

er - G62-
⇒ page 191
10 - O-ring
❑ Renew
11 - Seal
❑ Renew
12 - Bolt
❑ 9 Nm
13 - Connection
❑ For coolant hoses
14 - Radiator outlet coolant temperature sender - G83-
❑ 2 Nm
15 - O-rings
❑ Different diameters
3. Coolant pipes 195

Audi Q5 2008 ➤
❑ Renew
16 - Nut
❑ 9 Nm
17 - Coolant pipe (rear)
18 - Bolt
❑ 9 Nm
19 - Bolt
❑ 9 Nm
20 - Bolt
❑ 9 Nm
21 - Coolant pipe (top left)
3.2 Removing and installing coolant pipe

(top left)
Removing

Audi Q5 2008 ➤
Note
Disregard -item 1-.

from coolant pipe (top left).
Installing
Note
Secure all hose connections with the correct type of hose clips


(bottom left)

Audi Q5 2008 ➤
Removing
Note
Disregard -item 1-.
– Release hose clip -3-, lift retaining clip -2- and detach coolant
hoses.
– Remove bolt -1- and pull coolant pipe (bottom left) off 4/2-way
valve.
Installing
Note

– Connect coolant hose with plug-in connector ⇒ page 206 .

(rear right)

Audi Q5 2008 ➤
Removing

– Remove front right wheel.

body brace .

Audi Q5 2008 ➤

- G505- .
– Remove front exhaust pipe ⇒ page 308 .
– Unplug electrical connector -4- for exhaust gas temperature

sender 3 - G495- .
Note
Disregard -items 1, 2, 3-.
– Unclip electrical connector -C- for exhaust gas temperature
sender 4 - G648- from bracket -B- and unplug connector.
Note
Disregard -item A- and -arrows-.
Note
Disregard -item 1-.

Audi Q5 2008 ➤
– Remove cover -1- for drive shaft in wheel housing (left-side).
– Remove nuts -arrows- and press particulate filter to rear.

– Release hose clips -1, 2, 3- and disconnect coolant hoses from
coolant pipe (rear right).
Installing
Note

body brace .
– Fit front wheel (right-side) ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres; Tightening torque for wheel bolts .

(rear)

Audi Q5 2008 ➤
Removing

body brace .

Audi Q5 2008 ➤

- G505- .


– Release hose clips -1, 2, 3- and disconnect coolant hoses from
coolant pipe (rear right).
– Press coolant pipe (rear right) to one side.

Audi Q5 2008 ➤

from rear coolant pipe.
Note
Disregard -item 2-.
Installing
Note

body brace .

Audi Q5 2008 ➤
4 Radiator/radiator fans
⇒ “4.1 Exploded view - radiator/radiator fans”, page 205
⇒ “4.2 Removing and installing radiator cowl with radiator fan”,
page 206
⇒ “4.3 Removing and installing radiator cowl”, page 211
⇒ “4.4 Removing and installing radiator fan control unit J293 ”,
page 216
⇒ “4.5 Removing and installing radiator fans”, page 217
4.1 Exploded view - radiator/radiator fans
WARNING

1 - Bolt
❑ 4.5 Nm
2 - Radiator fan control unit -
J293-
⇒ page 216
3 - Bolt
❑ 5 Nm
4 - Radiator cowl
⇒ page 206
5 - Radiator fan - V7-
⇒ page 217
6 - Bolt
❑ 3.5 Nm
7 - Washer
8 - Rubber bush
❑ For radiator
9 - Coolant hose
❑ Lift retaining clip to de‐
tach
❑ Connecting
⇒ page 206
10 - O-ring
❑ Renew
11 - Coolant Protected
hose by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Lift retaining clip to
with respect tothede‐
tach
❑ Connecting ⇒ page 206
4. Radiator/radiator fans 205

Audi Q5 2008 ➤
12 - O-ring
❑ Renew
13 - Coolant hose
❑ To coolant expansion tank
❑ Connecting ⇒ page 206
14 - O-ring
❑ Renew
15 - Radiator
❑ Different versions available ⇒ Electronic parts catalogue
❑ Remove and install together with radiator cowl ⇒ page 206
16 - Retaining pin
❑ Use screwdriver to release and pull off
17 - Rubber buffer
18 - Radiator bracket
19 - Bolt
❑ 5.5 Nm
20 - Radiator fan 2 - V177-
❑ Optional equipment
21 - Bolt
❑ 5 Nm
Connecting coolant hose with plug-in connector

– Remove old O-ring -2- from coolant hose -3-.
– Lightly lubricate new O-ring with coolant and fit O-ring in cool‐
ant hose.
– Press coolant hose onto connection -1- until it engages audi‐
bly.
– Press coolant hose in again and then pull to check that plug-
in connector is correctly engaged.
4.2 Removing and installing radiator cowl

with radiator fan
Note
♦ Radiator and radiator cowl are removed and installed together.

♦ Radiator cowl can also be removed separately ⇒ page 211 .


Audi Q5 2008 ➤
♦ Used oil collection and extraction unit - V.A.G 1782- for vehi‐
cles with dual clutch gearbox
♦ Engine bung set - VAS 6122- for vehicles with dual clutch
gearbox
Removing
insulation .
– Remove bumper cover (front) and bumper ⇒ General body
repairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded view
- bumper cover .
– Remove charge air cooler ⇒ page 231 .
– Remove condenser ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; Removing and installing condenser .

Audi Q5 2008 ➤
gine.
– Remove drain plug -1- and drain off coolant.
– Then disconnect coolant hose -2- from radiator (pull out re‐
taining clip).
WARNING

– Unplug electrical connector -1- for radiator fan (push retainer

to the rear -arrow- and press down release catch).

– Remove air duct -1- and intermediate flange -2-.
– Detach connections -1- and -2- from radiator (lift retaining clip).

Audi Q5 2008 ➤

Note
Observe rules for cleanliness when working on dual clutch gear‐

box ⇒ Rep. gr. 00 ; Repair instructions; Rules for cleanliness .


– Detach top air duct -1- (release catches -arrows-).
– Release catches -arrows A- and detach air duct -1- on left and
right -arrow B-.

Audi Q5 2008 ➤
– Release retaining pins for radiator on both sides and pull out
upwards -arrows-.
– Remove bolts -1- on both sides and detach radiator bracket

with radiator from lock carrier -arrow-.
– Slightly lower radiator.
– Detach radiator.

Audi Q5 2008 ➤
– Press locking tabs on left and right sides of radiator cowl

-arrow- and at the same time lift radiator cowl off radiator.
Note
If there are slight impressions on the fins, refer to ⇒ page 9 .
Installing
– Attach air duct to intermediate flange for air cleaner housing
⇒ page 271 .
– Install condenser ⇒ Heating, air conditioning; Rep. gr. 87 ;
Refrigerant circuit; Removing and installing condenser .
– Install charge air cooler ⇒ page 231 .
– Connect coolant hose with plug-in connector ⇒ page 206 .
– Install ATF lines ⇒ Rep. gr. 34 ; ATF circuit; Removing and
installing ATF lines .by AUDI AG. AUDI AG does not guarantee or accept any liability
permitted unless authorised
– Install bumper and bumper cover (front) ⇒ General body re‐
pairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded view -
bumper cover .
– Install noise insulation panels ⇒ General body repairs, exte‐
rior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .
Note
The coolant in the entire system must be changed if the radiator

is renewed.
4.3 Removing and installing radiator cowl


Audi Q5 2008 ➤
♦ Used oil collection and extraction unit - V.A.G 1782- for vehi‐
cles with dual clutch gearbox
♦ Engine bung set - VAS 6122- for vehicles with dual clutch
gearbox
Removing
insulation .
WARNING

– Unplug electrical connector -1- for radiator fan (push retainer

to the rear -arrow- and press down release catch).

Audi Q5 2008 ➤
– Remove closure plate for bumper cover (front) ⇒ General

body repairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded
view - bumper cover .
– Remove lock carrier cover ⇒ General body repairs, exterior;

Rep. gr. 50 ; Lock carrier .

– Detach air duct -1- from intermediate flange -2- for air cleaner
housing.

Note
Observe rules for cleanliness when working on dual clutch gear‐

box ⇒ Rep. gr. 00 ; Repair instructions; Rules for cleanliness .

from engine bung set - VASProtected
6122- by. copyright. Copying for private or commercial purposes, in part or in whole, is not
Note
Tie ATF lines up onto longitudinal member to prevent fluid es‐

caping.

Audi Q5 2008 ➤

– Use screwdriver -1- to release retaining hook -arrow A- on both
sides.
– Detach air intake grille -2- from bumper cover -arrow B-.
– Detach top air duct -1- (release catches -arrows-).

– Release catches -arrows A- and swivel air duct -1- on left and
right to centre of vehicle -arrow B-.

Audi Q5 2008 ➤
– If fitted, release retaining clips -arrow A- and swivel power

steering cooling pipe -1- to front -arrow B-.
– Lift power steering cooling pipe away from condenser and
place onto engine.
– Lift retaining clip -1- and detach connection from radiator.
Disregard -item 2-.
– Release retaining pins for radiator on both sides and pull out
upwards -arrows-.
– Pull top of radiator to the front.

Audi Q5 2008 ➤
– Press locking tabs on left and right sides of radiator cowl

-arrow- and at the same time lift radiator cowl off radiator.
Note
Installing
– Install ATF lines ⇒ Rep. gr. 34 ; ATF circuit; Removing and
installing ATF lines .
⇒ page 271 .
– Install lock carrier cover (⇒ General body repairs, exterior;
Rep. gr. 50 ; Lock carrier; Exploded view - lock carrier ) and
closure plate for bumper cover (⇒ General body repairs, ex‐
terior; Rep. gr. 63 ; Bumper (front); Exploded view - bumper
cover ).
tion .
4.4 Removing and installing radiator fan

control unit - J293-
Removing
Note
Fit all cable ties in the original positions when installing.

insulation .

Audi Q5 2008 ➤
– On vehicles with cross member -3-, remove bolts -1- for torque
reaction support.
– Remove bolts -2- from cross member -3- on both sides.
Note
♦ Due to the limited space available, the cross member cannot

be removed.
♦ Cross member must only be detached; leave it in installation
position.
– Take electrical connector -1- for radiator fan out of bracket and
unplug connector (push retainer to the rear -arrow- and press
down release catch).
– Move clear electrical wiring harness going to radiator fan con‐
trol unit.
– Unplug electrical connectors -2- and -3- (if fitted).

– Remove bolt -arrow-, release fastener and detach radiator fan
control unit - J293- -item 1-.
Installing
Tightening torques
♦ ⇒ “4.1 Exploded view - radiator/radiator fans”, page 205
tion .
4.5 Removing and installing radiator fans

Removing
Note
– Remove radiator cowl ⇒ page 211 .


Audi Q5 2008 ➤
Radiator fan - V7-

– Unscrew bolts -arrows- and remove radiator fan - V7- .
Radiator fan 2 - V177-

– Unscrew bolts -arrows- and remove radiator fan 2 - V177- .
Installing
– Install radiator cowl ⇒ page 211 .

Audi Q5 2008 ➤
21 – Turbocharging/supercharging
1 Turbocharger
⇒ “1.1 Exploded view - turbocharger”, page 219
⇒ “1.2 Removing and installing turbocharger”, page 220
1.1 Exploded view - turbocharger
Note
Observe rules for cleanliness ⇒ page 8 .
1 - Air hose
2 - Pulsation damper
3 - Oil return line
4 - Bolt
❑ 9 Nm
5 - Gasket
❑ Renew
6 - Threaded connection
❑ 40 Nm
7 - Gasket
❑ Renew
8 - Bolt
❑ 20 Nm
9 - Turbocharger
❑ Can only be renewed to‐
gether with vacuum unit
⇒ page 220
10 - Gasket
❑ Renew
11 - Nut
❑ Renew
❑ Coat thread with high-
temperature paste; for to the correctness of information in this document. Copyright by AUDI AG.
with respect
high-temperature paste
refer to ⇒ Electronic
parts catalogue
❑ 24 Nm
12 - Particulate filter
13 - Exhaust gas temperature sender 1 - G235-
❑ Exploded view ⇒ page 340
14 - Banjo bolt
❑ 30 Nm
1. Turbocharger 219
Audi Q5 2008 ➤
15 - Oil supply line

❑ Check for obstructions
❑ Before installing, fill turbocharger with engine oil at connection for oil supply line
❑ Tighten union nuts to 22 Nm.
16 - Bolt
❑ 9 Nm
17 - Seals
❑ Renew
18 - Exhaust manifold
19 - Nut
❑ Renew
❑ Coat thread with high-temperature paste; for high-temperature paste refer to ⇒ Electronic parts catalogue
❑ 24 Nm
20 - Vacuum hose
21 - Hose
❑ For crankcase breather
❑ Optional equipment for countries with cold climates: with heater element for crankcase breather - N79-
22 - Air pipe
23 - Support
❑ For turbocharger
24 - Bolt
❑ 40 Nm
25 - Bolt
❑ 9 Nm
1.2 Removing and installing turbocharger

220 Rep. gr.21 - Turbocharging/supercharging

Audi Q5 2008 ➤
Removing
Caution
If the turbocharger has suffered mechanical damage (e.g.

damaged compressor wheel), it is not sufficient merely to fit a
new turbocharger. The following work must be performed in
order to avoid further damage:
♦ Check air cleaner housing, air filter element and air hoses
for dirt and foreign particles. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Check the entire charge air system (including the charge
air cooler) for foreign matter.
♦ If foreign matter is found in the charge air system, clean
all relevant ducts and hoses and renew charge air cooler
if necessary.
1. Turbocharger 221
Audi Q5 2008 ➤
– Press release tabs, disconnect crankcase breather hose -2-

and move clear.

insulation .

sender 3 - G495- .
Note

Audi Q5 2008 ➤

Note

- G505- .

Note
– Move front exhaust pipe clear at mounting -2-.
Note
Disregard -item 1-.
1. Turbocharger 223
Audi Q5 2008 ➤

– Remove cover -1- for drive shaft in wheel housing (right-side).
Caution

10°.
– Loosen bolts -arrows-, push back clamp and tie up front ex‐
haust pipe.
Note
Disregard -item 1-.

one side.

Audi Q5 2008 ➤
– Remove bolts -1- and -2- and take out support for turbocharg‐
er.
– Remove union nut -2-.

– Detach electrical connector -3- for exhaust gas temperature
sender 1 - G235- from bracket, unplug connector and move
electrical wiring clear.
Note
Disregard -item 1-.
1. Turbocharger 225
Audi Q5 2008 ➤
– Remove union nut -2-.
Note
Disregard -item 1-.

Audi Q5 2008 ➤

– Disconnect vacuum hose -2-.
– Remove nuts -arrows- and detach turbocharger.
Caution
Risk of damage to oil supply line.

♦ Do not attempt to bend oil supply line to a different shape.

Installing
Tightening torques
• ⇒ “1.1 Exploded view - turbocharger”, page 219 .
• ⇒ “1.1 Exploded view - silencers”, page 302 .
Note
♦ Renew gasket/seal, nuts and O-ring.

♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ After installing the turbocharger, allow the engine to idle for
approx. 1 minute without pressing the accelerator to ensure
that the turbocharger is supplied with oil.

– Install front exhaust pipe ⇒ page 308 .
1. Turbocharger 227
Audi Q5 2008 ➤
2 Charge air system

⇒ “2.1 Overview - charge air system”, page 228
⇒ “2.2 Exploded view - charge air system”, page 230
⇒ “2.3 Removing and installing charge air cooler”, page 231
⇒ “2.4 Removing and installing charge pressure sender G31 / in‐
take air temperature sender G42 ”, page 234
⇒ “2.5 Checking charge air system for leaks”, page 234
2.1 Overview - charge air system
Note
♦ Check that all air pipes and hoses and vacuum lines are cor‐
rectly fitted and that there are no leaks before carrying out tests
or repairs.
♦ Hose connections and air pipes and hoses must be free of oil
and grease before assembly.
♦ To ensure that the air hoses can be properly secured at their
connections, spray rust remover onto the worm thread of used
hose clips before installing.
– Observe rules for cleanliness ⇒ page 8 .

Caution with respect to the correctness of information in this document. Copyright by AUDI AG.
Risk of engine malfunctions

♦ When routing vacuum lines, make sure they are not
kinked, twisted or crushed.

Audi Q5 2008 ➤
1 - Charge pressure control

solenoid valve - N75-
2 - Turbocharger
❑ With vacuum unit
❑ With position sender for
charge pressure posi‐
tioner - G581-
3 - Vacuum unit
❑ For change-over func‐
tion for exhaust gas re‐
circulation cooler
4 - Vacuum pump
5 - To brake servo
❑ Note installation posi‐
tion
7 - Cylinder head cover
❑ With vacuum reservoir
cooler change-over valve -
N345-
❑ Note installation posi‐
tion
2. Charge air system 229

Audi Q5 2008 ➤
2.2 Exploded view - charge air system
1 - Charge air cooler

⇒ page 231
2 - Hose clip
3 - Air hose
❑ To turbocharger
4 - Hose clip
5 - Hose clip
6 - Air hose
❑ To intake manifold
7 - Hose clip
8 - O-ring
❑ Renew
9 - Charge pressure sender -
G31- / intake air temperature
sender - G42-
❑permitted
Removing and installing
⇒ respect
with pageto234the correctness of information in this document. Copyright by AUDI AG.
10 - Bolt
❑ 5 Nm
11 - Rubber grommet
12 - Bush
13 - Nut
❑ 9 Nm
14 - Rubber grommet
15 - Hose clip
16 - Air pipe
17 - Hose clip
18 - Air hose
❑ From charge air cooler
19 - Hose clip
20 - Bolt
❑ 7 Nm
21 - Resonator
22 - Rubber grommet
23 - Hose clip
24 - Air hose
❑ To resonator

Audi Q5 2008 ➤
Installing air hoses with screw-type clips
Note
♦ To ensure that unless
permitted the air hoses
authorised can AG.
by AUDI beAUDI
properly
AG doessecured atortheir
not guarantee accept any liability
connections, spraytorust
with respect remover
the correctness onto theinworm
of information thread
this document. of used
Copyright by AUDI AG.
hose clips before installing.
Tightening torque for

1- Hose clip -a- = 13 mm wide: 5.5 Nm
2- Hose clip -b- = 9 mm wide: 3 Nm
2.3 Removing and installing charge air cool‐

er
Removing
– Detach air intake grille -2- from bumper cover -arrow B-.

insulation .

Audi Q5 2008 ➤
– Remove closure plate for bumper cover (front) ⇒ General

body repairs, exterior; Rep. gr. 63 ; Bumper (front); Exploded
view - bumper cover .
– Remove lock carrier cover ⇒ General body repairs, exterior;

Rep. gr. 50 ; Lock carrier .

– Detach air duct -1- from intermediate flange -2- for air cleaner
housing.
– Release catches -arrows A- and swivel airProtected

duct -1- on leftCopying
by copyright. and for private or commercial purposes, in part or in whole, is not
right to centre of vehicle -arrow B-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability

Audi Q5 2008 ➤
– Release hose clip -arrow- and detach air hose from charge air
cooler.
– Release hose clip -1- and detach air hose from charge air
cooler.
– Push catch down -arrow A- and move top of charge air cooler
slightly in direction of -arrow B-.
Note
For illustration purposes, the installation
permitted position
unless authorised by AUDI AG.is AUDI
shown withnot guarantee or accept any liability
AG does
the bumper cover removed. with respect to the correctness of information in this document. Copyright by AUDI AG.
– Lift charge air cooler off radiator -arrows A- and press in di‐
rection of -arrow B-.
– Pull bumper cover to front and detach left side of charge air
cooler downwards -arrow C-.
Note
Installing
⇒ page 271 .
– Install lock carrier cover (⇒ General body repairs, exterior;
Rep. gr. 50 ; Lock carrier; Exploded view - lock carrier ) and
closure plate for bumper cover (⇒ General body repairs, ex‐
terior; Rep. gr. 63 ; Bumper (front); Exploded view - bumper
cover ).
tion .

Audi Q5 2008 ➤
2.4 Removing and installing charge pres‐

sure sender - G31- / intake air tempera‐
ture sender - G42-
Removing
– Remove bolts -arrows- and pull charge pressure sender -
G31- / intake air temperature sender - G42- out Protected
of air pipe.
Installing

Note
Fit new O-ring.
2.5 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-
Procedure
insulation .

Audi Q5 2008 ➤

one side.
– Insert adapter - 1687/12- into air hose -1- and secure with hose
clip.
– Connect charge air system tester - V.A.G 1687- as shown on
illustration.
Prepare charge air system tester - V.A.G 1687- as follows:

– Unscrew pressure control valve -2- completely and close
valves -3- and -4-.
Note
Make sure knob is pulled out before turning pressure control valve
-2-.

Audi Q5 2008 ➤
– Using a commercially available connection piece, connect

charge air system tester - V.A.G 1687- to compressed air -1-.
Note
If there is water in sight glass, remove drain plug -6- and drain
water.
– Open valve -3-.
Caution
Risk of damage if pressure is set too high.

♦ The pressure must not exceed 0.5 bar.
– Adjust pressure to 0.5 bar via pressure control valve -2-.

– Open valve -4- and wait until test system is pressurised. If
necessary, adjust pressure to 0.5 bar again.
– Check charge air system for audible leaks or leaks that can be
felt with the hand; apply commercially available leak detecting
spray or use ultrasonic tester - V.A.G 1842- .
Note
♦ A small amount of air escapes through the valves and enters

the engine. Therefore it is not possible to perform a pressure
retention test.
♦ For operation of ultrasonic tester -V.A.G 1842- , refer to ⇒
Operating instructions .
♦ Release pressure in test circuit by detaching hose coupling
from adapter before removing adapter.
Assembling
Note
Renew gasket and O-rings.

tion .

Audi Q5 2008 ➤
23 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Overview - fuel system”, page 237
⇒ “1.2 Overview of fitting locations - injection system”,
page 239
⇒ “1.3 Filling and bleeding fuel system”, page 246
⇒ “1.4 Checking fuel system for leaks”, page 247
1.1 Overview - fuel system
Caution
Risk of malfunctions caused by dirt.

♦ Observe
⇒ “2.1 Safety precautions when working on the fuel sys‐
tem”, page 3 .
The high-pressure fuel pump has very close tolerances and
must not be allowed to run without fuel. To prevent this and to
enable the engine to start quickly after parts have been re‐
newed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank
and the high-pressure pump are removed or renewed, the
first fuel filling operation must be performed.
♦ If a fuel pump, fuel line (between fuel tank and high-pres‐
sure pump) or fuel filter is removed or renewed, the fuel
system must be bled before the engine is started for the
first time.
♦ If the high-pressure pump is removed or renewed, the fuel
first time.
Procedure for first fuel filling ⇒ page 297
The high-pressure pump will be damaged if the first fuel filling
operation is not performed.
1. Injection system 237

Audi Q5 2008 ➤
1 - Fuel tank
❑ With fuel system pres‐
surisation pump - G6-
2 - Fuel filter
❑ Exploded view ⇒ Fuel
supply system; Rep. gr.
20 ; Fuel filter; Exploded
view - fuel filter
3 - Not fitted
4 - Filter strainer
5 - Fuel temperature sender -
G81-
6 - High-pressure pump
❑ After renewing high-
pressure pump or fuel
pressure regulating
valve - N276- , learnt
values must be re-adap‐
ted using ⇒ Vehicle di‐
agnostic tester
❑ Exploded view
⇒ page 294
7 - Fuel metering valve - N290-
❑ Do not unscrew
8 - Fuel pressure regulating
valve - N276-
❑ Exploded view
⇒ page 249
9 - Fuel rail
10 - Fuel pressure sender -
G247-
❑ Exploded view
⇒ page 249
11 - Restrictor
12 - Injector permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
238 Rep. gr.23 - Mixture preparation - injection

Audi Q5 2008 ➤
1.2 Overview of fitting locations - injection system
1 - Air mass meter - G70-

⇒ page 287
2 - Air filter bypass flap valve -
N275-
❑ Country-specific version
3 - Electrical connectors
❑ For Lambda probe -
G39-
❑ For exhaust gas tem‐
perature sender 3 -
G495-
❑ Fitting location
⇒ page 244
4 - Lambda probe - G39- with
Lambda probe heater - Z19-
⇒ page 244
❑ Exploded view
⇒ page 299
control motor - V338- with ex‐
haust gas recirculation poten‐
tiometer Protected
- G212-by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Integrated intoauthorised
permitted unless exhaust by AUDI AG. AUDI AG does not guarantee or accept any liability
gas recirculation cooler of information in this document. Copyright by AUDI AG.
with respect to the correctness

exhaust gas recircula‐
tion cooler ⇒ page 348
6 - Exhaust gas temperature
sender 3 - G495-
⇒ page 244
7 - Radiator outlet coolant temperature sender - G83-
❑ Fitting location ⇒ page 243
8 - Pressure differential sender - G505-
9 - Coolant circulation pump - V50-
❑ Vehicles with start/stop system only
11 - Coolant temperature sender - G62-
12 - Fuel pressure regulating valve - N276-

Audi Q5 2008 ➤
13 - Gearbox neutral position sender - G701-

❑ Vehicles with start/stop system only
14 - Brake servo pressure sensor - G294-
15 - Accelerator position sender - G79- and accelerator position sender 2 - G185-
16 - Brake light switch - F- and brake pedal switch - F47-
17 - Clutch position sender - G476-
❑ With clutch pedal switch for engine with
start - F194-
respect and clutch
to the correctness pedalinswitch
of information - F36-
this document. (manual
Copyright gearbox
by AUDI AG. only)
❑ Only on vehicles with manual gearbox
18 - Engine control unit - J623-
19 - Engine speed sender - G28-
21 - Throttle valve module - J338- with throttle valve potentiometer - G69-
22 - Left electrohydraulic engine mounting solenoid valve - N144-
❑ On left side only
23 - Charge pressure sender - G31- / intake air temperature sender - G42-
24 - Fuel temperature sender - G81-
25 - Fuel metering valve - N290-
26 - Glow plugs
❑ Glow plug 1 - Q10-
27 - Fuel pressure sender - G247-
29 - Injectors
❑ Injector, cylinder 1 - N30-

Audi Q5 2008 ➤

30 - Charge pressure control solenoid valve - N75-
31 - Exhaust gas recirculation cooler change-over valve - N345-
❑ Electrical connector ⇒ page 245
32 - Position sender for charge pressure positioner - G581-
Installed on vehicles with reducing agent system (AdBlue sys‐

tem): injector for reducing agent - N474-
Removing and installing ⇒ page 336
Installed on vehicles with reducing agent system (AdBlue system)

1 - Control unit for NOx sender 2 - J881-
2 - Control unit for reducing agent metering system - J880-
3 - NOx sender 2 - G687-

1 - Electrical connector for tank sender for reducing agent - G684-
and temperature sender for reducing agent - G685-
2 - Electrical connector for heater for reducing-agent line - Z104-
3 - Electrical connector for heater for reducing-agent tank - Z102-
4 - Connector for pipe heater
5 - 14-pin connector
6 - 8-pin connector
7 - Electrical connector
with respect for pump
to the correctness for reducing
of information agent
in this document. - V437-
Copyright andAG.
by AUDI
pressure sender for reducing agent metering system - G686-

Audi Q5 2008 ➤
Fitting location of engine control unit - J623-

♦ In electronics box in plenum chamber (left-side)
Fitting location: accelerator position sender - G79- and accelera‐

tor position sender 2 - G185-
♦ In accelerator pedal module
Note
The accelerator position sender - G79- and accelerator position

sender 2 - G185- are integrated in the accelerator pedal module
and cannot be renewed individually.
Removing and installing ⇒ Fuel supply system; Rep. gr. 20 ;

Accelerator mechanism; Exploded view - accelerator pedal mod‐
ule
Fitting location of brake light switch - F- and brake pedal switch -

F47- / clutch position sender - G476-
1- Brake light switch - F- and brake pedal switch - F47-
2- Clutch position sender - G476- with clutch pedal switch for
engine start - F194- and clutch pedal switch - F36- (manual
gearbox only)
Fitting locations
2 - Fuel temperature sender - G81-

Audi Q5 2008 ➤
Fitting location of pump for exhaust gas recirculation cooler -

V400-
4 - Electrical connector for pump for exhaust gas recirculation
cooler - V400-
♦ At rear left of engine
Fitting location of coolant temperature sender - G62-

2 - Electrical connector for coolant temperature sender - G62-
♦ At rear of engine
Fitting location of radiator outlet coolant temperature sender -

G83-
♦ -Item 1- in coolant pipe (rear)
Fitting location of Hall sender - G40-

♦ At front of engine next to camshaft sprocket -arrow-

Audi Q5 2008 ➤
Fitting locations
1 - Lambda probe - G39-
3 - Electrical connector for Lambda probe - G39-
4 - Electrical connector for exhaust gas temperature sender 3 -
G495-
Fitting location of pressure differential sender - G505-

♦ At rear of engine
3 - Electrical connector for pressure differential sender - G505-
Fitting location of engine speed sender - G28-

1- Electrical connector for engine speed sender - G28-
Fitting location of charge pressure sender - G31-permitted
with intake air
temperature sender - G42- with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ In engine compartment (front left)

1- Electrical connector for charge pressure sender - G31- with
intake air temperature sender - G42-

Audi Q5 2008 ➤
Fitting location of position sender for charge pressure positioner

- G581-
♦ On turbocharger on right side of engine
1- Electrical connector for position sender for charge pressure
positioner - G581-
Fitting location of charge pressure control solenoid valve - N75-

♦ At front right of engine -arrow-
Fitting location of gearbox neutral position sender - G701-

♦ On left of gearbox -arrow-
Only installed on vehicles with start/stop system
Electrical connectors
2 - Exhaust gas recirculation cooler change-over valve - N345-

Audi Q5 2008 ➤
Fitting location of left electrohydraulic engine mounting solenoid

valve - N144-
♦ On engine mounting (left-side) -arrow- (electrical connector)
Fitting location of brake servo pressure sensor - G294-

♦ In vacuum line leading to brake servo -arrow-
1.3 Filling and bleeding fuel system

♦ Vehicle diagnostic tester
Caution
If a fuel pump, fuel line (between fuel tank and high-pressure

pump) or fuel filter is removed or renewed, the fuel system must
be bled before the engine is started for the first time.
Proceed as follows to fill fuel system with fuel:

– Connect a ⇒ Vehicle diagnostic tester.
– Switch on ignition.
– Select “Engine electronics” in vehicle self-diagnosis.
– Then select “Basic setting”.
– permitted
Selectunless
“Checking
authorised fuel system
by AUDI AG. AUDIpressurisation pump”
AG does not guarantee from
or accept the
any liability
list.
– Press “Start” button.

– The fuel pump starts running.
– The fuel pump must run for approx. 2 minutes to ensure that
the fuel system is filled sufficiently with fuel.
Note
To repeat basic setting, switch ignition off and on once. Then start
basic setting again.
– Start engine after filling fuel system.

Audi Q5 2008 ➤
– Run engine at moderate speed for several minutes and then

switch off.
– Check fuel system for leaks.
– Erase entry in event memory using diagnostic tester.
– After completing the repair, road-test the vehicle. Accelerate
with full throttle at least once. Then check the high-pressure
section of the fuel system again for leaks.
Note
If there is any air left in the fuel system, the engine may switch to
the backup mode ('emergency running' mode) during the road
test. Switch off the engine and erase the event memory. Then
continue the road test.
– Interrogate event memory.
1.4 Checking fuel system for leaks

– Run engine at idling speed for several minutes (do not press
accelerator) and then switch off. Fuel system will bleed itself
automatically.
– Check the entire fuel system for leaks.
Renew affected component if leakage still occurs after tightening
to correct torque.
Note

Audi Q5 2008 ➤
2 Vacuum system
⇒ “2.1 Checking vacuum system”, page 248
2.1 Checking vacuum system

♦ 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
♦ Lines porous or leaking
– Check vacuum line to solenoid valve and from solenoid valve
to corresponding component.
– If a fault is stored in the event memory, check all vacuum lines
leading to the corresponding component, and also check the
remaining vacuum lines leading to other components.
– If it is not possible to build up a vacuum with the hand vacuum
pump - VAS 6213- or if the vacuum pressure drops again im‐
mediately, check the hand vacuum pump and connecting
hoses for leaks.

Audi Q5 2008 ➤
3 Injectors/high-pressure reservoir
(rail)
⇒ “3.1 Exploded view - injectors”, page 249
⇒ “3.2 Checking injectors”, page 252
⇒ “3.3 Performing adaption of correction values for injectors”,
page 253
⇒ “3.4 Checking for injectors sticking open”, page 253
⇒ “3.5 Checking return flow rate of injectors with engine running”,
page 255
⇒ “3.6 Checking return flow rate of injectors at starter cranking
speed”, page 258
⇒ “3.7 Removing and installing injectors”, page 259
⇒ “3.8 Removing and installing high-pressure pipes”, page 265
⇒ “3.9 Removing and installing high-pressure reservoir (rail)”,
page 266
⇒ “3.10 Checking fuel pressure (low pressure)”, page 268
3.1 Exploded view - injectors

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

3. Injectors/high-pressure reservoir (rail) 249

Audi Q5 2008 ➤
1 - Seal
❑ In cylinder head cover
❑ Renew if leaking
⇒ page 112
2 - Copper seal
❑ Always renew copper
seal when removing and
installing
3 - O-ring
❑ Renew
4 - Injector
❑ Use a coloured pen to
mark allocation of injec‐
tors to corresponding
clamping piece and
high-pressure pipe, and
to corresponding cylin‐
der for re-installation;
pay attention to mark‐
ings when installing
❑ Always renew copper
seal when removing and
installing
❑ To remove carbon de‐
posits from the injector
sealing surface, clean
the injector bore in the
cylinder head with
cleaning kit - VAS 6811-
(it is important to do this
to avoid leaks)
⇒ page 259
5 - O-ring
❑ Renew
❑ To fuel tank
❑ With restrictor
❑ Must not be kinked, damaged or clogged
❑ Do not dismantle
❑ The restrictor maintains a constant residual pressure in the fuel return lines
❑ This residual pressure is required for the control function of the injectors
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system. Then
check fuel return lines for leaks
7 - Bolt
❑ Renew
❑ Tighten initially to 2 Nm, then screw on union nuts for high-pressure pipes hand-tight and align injectors
❑ Then tighten to final torque (8 Nm + 180°)

Audi Q5 2008 ➤
8 - Clamping piece
Caution
Risk of damage to en‐
gine.
When
♦ installing a new
base engine, it is essen‐
tial that the clamping
pieces for the injectors
are tightened to the
specified torque
⇒ Item 7 (page 250) after
installing the high-pres‐
sure pipes. The clamping
pieces are only secured
hand-tight at the factory
so the injectors can be
aligned during installa‐
tion.
❑ Use a coloured pen to mark injectors and corresponding clamping piece and cylinder for re-installation;
pay attention to markings when installing
❑ The clamping pieces can be re-used when installing new injectors
❑ Each clamping piece secures two injectors
9 - High-pressure pipe
❑ Between fuel rail and injectors
Note
♦ The high-pressure pipe can be

re-used after performing the fol‐
lowing checks:
♦ Check taper seat for deformation
and cracks.
♦ The bore of the pipe must not be
distorted, restricted or otherwise
damaged.
♦ Corroded pipes must not be
used again.
❑ Install free of stress
❑ Lubricate threads of union nuts with clean engine oil
❑ 25 Nm
10 - Bolt
❑ 22 Nm
11 - Fuel rail
12 - Fuel return hose with respect to the correctness of information in this document. Copyright by AUDI AG.

❑ Always renew after removing
❑ 80 Nm
❑ After renewing high-pressure pump or fuel pressure regulating valve - N276- , learnt values must be re-
adapted; see “Guided Functions” in ⇒ Vehicle diagnostic tester

Audi Q5 2008 ➤
14 - O-ring
❑ Renew
❑ Between high-pressure pump and fuel rail
Note
♦ Note identification marks for cyl‐

inder allocation when re-instal‐
ling high-pressure pipes.
The high-pressure pipes can be
♦copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected by
lowing checks:
♦ Check taper seats of high-pres‐

sure pipes for deformation and
cracks.
damaged.
used again.
❑ Install free of stress
❑ 25 Nm
16 - Bolt
❑ 8 Nm
❑ 100 Nm
18 - Grommet
❑ In cylinder head cover
Installation position of clamping piece

• Each clamping piece secures two injectors.
• The bulge -arrow- of the clamping piece should point down‐
wards.
3.2 Checking injectors

There are four different tests for checking the operation of the
injectors.
• Checking adaption of “Injector delivery calibration values” and
“Injector voltage calibration values” ⇒ page 253
• Checking for injectors sticking open ⇒ page 253

Audi Q5 2008 ➤
• Checking return flow rate of injectors with engine running

⇒ page 255
• Checking return flow rate of injectors at starter cranking speed
⇒ page 258
Only perform the following tests if the engine does not start at all:
♦ Checking for injectors sticking open ⇒ page 253
♦ Checking return flow rate of injectors at starter cranking speed
⇒ page 258
♦ Checking fuel pressure regulating valve - N276-
3.3 Performing adaption of correction val‐

ues for injectors
The “Injector delivery calibration values” function serves to correct
the injection rates for each cylinder of a common rail system in‐
dividually across the entire operating range.
The 7-digit adaption values -1- (details in illustration are only an
example) are marked separately on each injector. The values
may consist of letters and/or numbers.
Injector (view from above)
1 - Checksum
2 - Data matrix code
3 - Part number
When a new injector is installed, the adaption value must be writ‐
ten into the engine control unit.
When a new engine control unit is installed, the “Adaption values
for injectors” must be written into the new control unit.
Additionally, check that the “injector delivery calibration values”
are correctly entered for all the other injectors. Do NOT attempt
to re-enter these values if the correct values are already stored in
the engine control unit.
The adaption procedure is described in the Guided Fault Finding.
(The procedure is also described in Guided Functions.)
3.4 Checking for injectors sticking open

If one of the injectors is sticking open, this means that the injector
needle is not closing fully and fuel escapes into the cylinder.

Audi Q5 2008 ➤
♦ Use a return line to make an -adapter-.
Caution

♦ Observe ⇒ page 3 .
– Pull off engine cover panel ⇒ page 49 .

– Clean all connections (with commercial cleaning solution or
similar) before removing.
Note
♦ Make sure all parts are clean; no dirt must be allowed to enter
the fuel system.
♦ Check all cylinders in turn.
– Dry all components after cleaning.

Start with cylinder No. 1.
– Pull return line connections off injectors; to do so, press tabs
-1- and -2- down and at the same time pull release pin upwards
-arrow-.
– Connect adapter to return line connection of injector to be tes‐
ted after adapter has been cleaned and blown out.

Audi Q5 2008 ➤
– Generate a vacuum of -500 mbar using the hand vacuum

pump - VAS 6213- .
If the vacuum reading remains the same for 30 seconds, the in‐
jector is OK.
If the injector is faulty, the vacuum reading will fall back to 0 bar
within 2 to 3 seconds.
Repeat test if necessary; note drop in vacuum reading on hand
vacuum pump - VAS 6213- .
– Renew faulty injectors ⇒ page 259 .
Installing fuel return lines
– Check O-ring for fuel return line connection for damage and
deformation.
If O-ring is damaged or deformed, renew O-ring.
Note
Lubricate all seals with engine oil or assembly oil before installing.
– Push return line connections carefully over seals and onto in‐
jectors. The catch should engage audibly. Then press release
pin down carefully.
Checking fuel system for leaks
automatically.
Renew the affected component if leakage occurs.
– Install engine cover panel ⇒ page 49 .
3.5 Checking return flow rate of injectors

with engine running
Checking return flow rate if engine does not start ⇒ page 258
♦ Hose clamps, up toProtected
25 mm - 3094-Copying for private or commercial purposes, in part or in whole, is not
by copyright.

Audi Q5 2008 ➤
♦ Return flow meter - VAS 6684-
♦ Fuel-resistant measuring container

Checking return flow rate of all injectors
Caution


– Disconnect hose connection at fuel line.
– Seal off open return line connection with a clean plug -2-.
– Hold end of fuel return hose -1- (lengthen if necessary) in a
measuring container to measure the total return flow rate.
– Start engine and let it idle for 2 minutes.
• Specification for 2 minutes: 0 ml to 50 ml
– If specification is attained, increase engine speed to 2000 ...
2500 rpm for approx. 2 minutes and then check return flow rate
again.
• Specification for 2 minutes: less than 250 ml
Note
1000 ml = 1 litre
If specification is exceeded, this indicates that one or more injec‐

tors are defective. Check return flow rate from each injector
individually.
Checking return flow rate of individual injectors
Each injector normally has a relatively low return flow rate. If the
return flowwith
rate at one
respect injector is
to the correctness relatively
of information high
in this compared
document. Copyrightto the AG.
by AUDI
other injectors, that injector is probably defective.
– Clean all return line connections (e.g. with commercial clean‐
ing solution etc.) before removing.
– Dry all components after cleaning.

Audi Q5 2008 ➤
– Clamp off fuel return hose -arrow- using hose clamp up to

25 mm - 3094- .

-arrow-.
– Connect hoses of return flow meter - VAS 6684- to return line
connections of all four
Protected by copyright. injectors.
Caution
Risk of damage to injectors when return lines are disconnec‐

ted.
♦ Do NOT press the accelerator during this test; the engine
must only run at idling speed.
– Start engine and let it idle for several minutes.

Audi Q5 2008 ➤
Evaluating return flow rate

– When the engine is warm and running at idling speed, the re‐
turn flow rates at each of the 4 return lines must not differ by
more than a small amount.
If one injector has a significantly higher return flow rate than the
others (example -2-), it must be renewed ⇒ page 259 .
Installing fuel return lines
deformation.
Note
Lubricate all seals with engine oil or assembly oil before installing.
– Push return line connections carefully onto injectors. The

catch should engage audibly. Then press release pin down
carefully.
automatically.
3.6 Checking return flow rate of injectors at

starter cranking speed
Only perform this test if the engine does not start at all.
♦ Return flow meter - VAS 6684-
Caution


Audi Q5 2008 ➤
Each injector normally has a relatively low return flow rate. If the
return flow rate at one injector is relatively high compared to the
other injectors, that injector is probably defective.
– Clean all return line connections with engine cleaner or brake
cleaner and dry.
– Disconnect fuel return hoses from injectors; to do so, press
down both tabs -1 and 2- and at the same time pull centre
piece up to release connection -arrow-.
Note
No dirt must be allowed to get into the disconnected return lines

or the open connections on the injectors.
– Connect hoses of return flow meter - VAS 6684- to all return

line connections of the four injectors.
– Operate starter three times (wait approx. 20 seconds each
time after operating starter to prevent it from overheating).
• Specification of return flow rate: 0 ml
– If fuel comes out of an injector, that injector must be renewed.
Installing fuel return lines permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
deformation.
Note
Lubricate all O-rings with engine oil or assembly oil before instal‐
ling.
– Push return line connections carefully onto injectors. The

catch should engage audibly. Then press release pin down
carefully.
automatically.
3.7 Removing and installing injectors

♦ Cleaning kit - VAS 6811-

Audi Q5 2008 ➤
♦ Puller - T10055-
♦ Assembly sleeve - T10377-
♦ Puller - T10415-
Removing
Caution

Caution
♦ Mark cylinder numbers on injector units. They must al‐

ways be re-installed on the same cylinders.
♦ Observe rules for cleanliness when working on the injec‐
tion system. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Plug open connections with suitable sealing with
caps imme‐
diately.

Audi Q5 2008 ➤

-arrow-.
– Unplug electrical connectors -arrows- at injectors.

– Loosen union nuts of high-pressure pipes -1 to 4-.

Audi Q5 2008 ➤
– Unscrew bolt -1- for clamping piece.
Note
Leave clamping piece in position until adjacent injector is detach‐

ed.
Caution
Risk of damage to injector if clamping piece is not kept straight.

♦ First detach injectors for cylinders 2 and 4; then detach
injectors for cylinders 1 and 3, and at the same time detach
clamping pieces.
– Apply puller - T10055- with puller - T10415- as shown in illus‐

tration, and pull out injector upwards.
Note
To avoid damaging the sealing lip, rotate the injector while pulling
it out.
– After removal, lay injectors on a clean cloth.

Important instructions for installing injectors:
When installing injectors, the following components must be re‐
newed:
♦ Bolt for clamping piece
♦ Copper seal with respect to the correctness of information in this document. Copyright by AUDI AG.
♦ O-ring for injector bore

♦ O-ring for fuel return line connection
Note
♦ Note identification marks for cylinder allocation when re-in‐

stalling high-pressure pipes.
♦ The high-pressure pipes can be re-used after performing the
following checks:
♦ Check taper seats of high-pressure pipes for deformation and
cracks.
♦ The bore of the pipe must not be distorted, restricted or oth‐
erwise damaged.
♦ Corroded pipes must not be used again.
If a used injector is being re-installed:

– Spray tip of injector nozzle with rust-releasing spray. Wait ap‐
prox. 5 minutes and wipe off soot particles and oil with a cloth.
– To remove the old copper seal from the injector, clamp the seal
carefully in a vice so that it is just held between the jaws without
turning. Then carefully pull and twist the injector out of the
copper seal by hand.
– Clean off deposits under the copper seal using a suitable scra‐
per.

Audi Q5 2008 ➤
– Fit new copper seal.

– Lubricate all O-rings with engine oil or assembly oil before in‐
stalling.

Audi Q5 2008 ➤
– Renew O-ring for injector bore using assembly sleeve -

T10377- .
Continued (same procedure for used and new injectors):
Note
♦ If injector seals in cylinder head cover are damaged, they must

be renewed ⇒ page 112 .
♦ Lubricate all O-rings with assembly oil, engine oil or diesel fuel
before installing.
Caution
Risk of damage to injector sealing surface.

♦ To remove carbon deposits from the injector sealing sur‐
face, clean the injector bore in the cylinder head with
cleaning kit - VAS 6811- .
– Install injectors.
– Slide clamping piece onto injectors; observe installation posi‐
tion.
– Always insert 2 injectors with clamping piece carefully into
bores in cylinder head.
– Hand-tighten union nuts on high-pressure pipes. Make sure
that connections are not under tension.
– Tighten clamping piece to specified torque.
Tightening torques:
♦ ⇒ “3.1 Exploded view - injectors”, page 249
– Hand-tighten union nuts on high-pressure pipes. Make sure
that connections are not under tension.
– Press return line connections carefully over seals and onto in‐
jectors (check seal for damage before connecting return line).
The catch should engage audibly. Then press release pin
down carefully.
After renewing one or more injectors, the “injector delivery cali‐
bration values” and “injector voltage calibration values” for the
new injectors must be written into the engine control unit.
Additionally, check that the “injector delivery calibration values”
and “injector voltage calibration values” are correctly entered for
all the other injectors. Do NOT attempt to re-enter these calibra‐
tion values if the correct values
Protected are already
by copyright. Copying forstored
private orin the engine
control unit. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Bleeding fuel system and checking for leaks
Note
The fuel system is self-bleeding; do not open the high-pressure

connections.
– Run engine at idling speed for several minutes and then switch
off.
– Switch off ignition.

Audi Q5 2008 ➤
– Check the complete fuel system including all 4 return line con‐
nections for leaks.
Renew affected component if leakage still occurs after tightening
to correct torque.
Note
3.8 Removing and installing high-pressure

pipes
♦ Open end spanner insert, AF 17 - V.A.G 1331/6-
Procedure
Note

following checks:
♦ Check taper seats of high-pressure pipes permitted
for deformation andby AUDI AG. AUDI AG does not guarantee or accept any liability
unless authorised
cracks. with respect to the correctness of information in this document. Copyright by AUDI AG.

erwise damaged.
– Use vacuum cleaner to remove dirt from taper seat at fuel rail.
– Clean fuel pipe and end of pipe using cleaning solution and
dry with compressed air.
– Lubricate threads of union nuts with fuel.
– Hand-tighten union nuts on high-pressure pipes (ensure that
pipes are not under tension).

Audi Q5 2008 ➤
– To tighten unions of high-pressure pipes to fuel rail and injec‐

tors, use torque wrench - V.A.G 1331- with open end spanner
insert, AF 17 - V.A.G 1331/6- .
– Check fuel system for leaks ⇒ page 247 .

reservoir (rail)
♦ Ratchet - V.A.G 1331/1- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
♦ Socket - T40055-
Removing
Caution


Audi Q5 2008 ➤
– Unplug electrical connector -arrow- at fuel pressure regulating

valve - N276- .
– Remove bolt -2- and union nuts -1 and 3- and detach high-
pressure pipe.
– Release hose clip -arrow- and detach fuel return hose from
fuel rail.
– Seal off open fuel return hose with a clean plug.
– Detach vacuum hose -3- and move clear.
Note
– Unplug electrical connectors on glow plugs ⇒ page 355 .

Audi Q5 2008 ➤
– Unplug electrical connectors -1, 2, 3-.

– Remove bolt -arrow- from bracket.
– Unscrew union nuts for high-pressure pipe between high-
pressure pump and fuel rail using socket - T40055- .
– Move clear wiring guide with electrical wiring harness and
press to one side.
– Remove union nuts -1- and bolts -arrows- and detach fuel rail.
– Set removed fuel rail (with high-pressure pipes attached)
down on a clean cloth.
– Seal off openings in fuel rail with clean plugs.
Installing
– Install high-pressure pipes free of stress.
Note

following checks:
♦ Check taper seats of high-pressure pipes for deformation and
cracks.
erwise damaged.
3.10 Checking fuel permitted
pressure (low pressure)

♦ K-Jetronic pressure tester - V.A.G 1318-
Test conditions:
• Battery voltage at least 12.5 V

Audi Q5 2008 ➤
• Fuel filter OK.

• Fuel tank at least 1/2 full.
• Ignition off.
Checking residual pressure
Caution

♦ To reduce the pressure in the fuel system, wrap a clean
cloth around the connection and carefully loosen the con‐
nection.
– Release hose clip and detach fuel supply line -arrow- from
high-pressure pump.
– Connect K-Jetronic pressure tester - V.A.G 1318- to fuel sup‐

ply line -2- with suitable adapter -3-.
– Connect second hose -1- (from -V.A.G 1318- ) to open con‐
nection on high-pressure pump, as shown in illustration below.

Audi Q5 2008 ➤
Note
In this way the K-Jetronic pressure tester - V.A.G 1318- is con‐

nected into the fuel supply line.

– Select “Checking fuel system pressurisation pump” from the
list.
– Let fuel pump run until maximum fuel pressure has built up.
• Specification: at least 3.5 bar
If specification is not obtained:
♦ Leak in union between pressure tester and fuel line.
♦ Leak in pressure tester.
♦ Leak in fuel lines and their connections.
♦ Fuel filter is blocked.
– Check delivery rate of fuel pump ⇒ Fuel supply system; Rep.
gr. 20 ; Fuel pump; Checking fuel system pressurisation pump
- G6- .
Note
Check fuel system for leaks.

Audi Q5 2008 ➤
4 Air cleaner
⇒ “4.1 Exploded view - air cleaner housing”, page 271
⇒ “4.2 Removing and installing air cleaner housing”, page 272
4.1 Exploded view - air cleaner housing
1 - Hose clip
❑ 3.5 Nm
2 - Air hose
3 - Hose clip
❑ 3.5 Nm
4 - Air duct
❑ Clipped into air cleaner
housing
❑ Clean out dirt, leaves
and salt deposits
5 - Air duct
and salt deposits
6 - Air duct
❑ Secure to lock carrier
(2 Nm)
and salt deposits
7 - Rubber grommet
8 - Water drain hose Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Clean any leaves and permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
dirt out of water drain with respect to the correctness of information in this document. Copyright by AUDI AG.
hose (important)
9 - Guide for water drain hose
10 - Hot air intake (countries
with cold climates only)
❑ Slide hot air intake into
air cleaner as far as
stop; then turn clock‐
wise until it engages no‐
ticeably
11 - Air cleaner (bottom section)
❑ Clean out dirt, leaves and salt deposits
❑ Check for dirt in water drain and clean as required (important)
12 - Retainer for air cleaner (bottom section)
❑ Must engage positively
❑ Do not use any lubricants
13 - Air filter bypass flap valve - N275-
❑ With flap for variable intake manifold change-over
14 - Bolt
❑ For air filter bypass flap valve - N275-
15 - Air filter element
❑ Use genuine air filter element ⇒ Electronic parts catalogue
4. Air cleaner 271

Audi Q5 2008 ➤
❑ Change intervals ⇒ Maintenance tables

❑ Also clean snow screen (if fitted)
16 - Frame insert for air cleaner (bottom section)
17 - Air cleaner (top section)
❑ Clean out dirt, leaves and salt deposits
18 - Bolt
❑ 1.5 Nm
19 - O-ring
❑ Renew if damaged
20 - Air mass meter - G70-
4.2 Removing and installing air cleaner

housing
⇒ “4.2.1 Removing and installing air cleaner (bottom section)”,
page 272
⇒ “4.2.2 Removing and installing air filter element”, page 274
4.2.1 Removing and installing air cleaner (bot‐

tom section)
Removing
– Unplug electrical connector -1- at air mass meter - G70- .
– Release hose clip -2- securing air hose (going to turbocharger)
and disconnect hose from air mass meter - G70- .

– Remove air duct -3-.
– Detach vacuum hose -arrow- (if fitted).

Audi Q5 2008 ➤
– Release retainer -4- for bottom section of air cleaner (press in

rubber on left and right side and pull upwards).
Note
♦ The air filter bypass flap valve - N275- -item 1- is not installed
on all equipment versions / country-specific versions.
♦ Do not use lubricant when installing retainer.
– Unplug electrical connector at air filter bypass flap valve -

N275- (if fitted).
– Carefully take out complete air cleaner housing.
Installing
To ensure the proper function of the air mass meter - G70- it is
important to observe the following instructions.
Note
♦ The air cleaner housing MUST be clean.

♦ To prevent malfunctions, cover critical parts of the engine air
intake (air mass meter, air pipes, etc.) with a clean cloth when
blowing out the air cleaner housing with compressed air.
♦ Use a silicone-free lubricant when installing the air hoses.
♦ Secure
permittedall hose connections
by AUDI AG.with
AUDIthe correct type of hoseanyclips
unless authorised AG does not guarantee or accept liability
(same as original
with respect equipment)
to the correctness ⇒ Electronic
of information parts
in this document. catalogue
Copyright .
by AUDI AG.
– If hot air intake is fitted (for countries with cold climates only),
make sure that air intake connection has engaged properly
-arrows- (pay attention to markings).
– Check water drain hose -1- in air cleaner (bottom section) for
dirt and other obstructions (clean if necessary).
– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections); use a vacuum cleaner if necessary.
– Check for salt residue, dirt and leaves in air hose (engine in‐
take side).
– Check for dirt and leaves in air duct going from lock carrier to
air cleaner housing.
– Plug electrical connector at air filter bypass flap valve - N275-
in again (if fitted).
– Re-install air cleaner (bottom section).
Note
The water drain hose must be routed straight downwards and

must not be kinked.
4. Air cleaner 273

Audi Q5 2008 ➤
– Slide vacuum hose -3- (if fitted) back onto connection of air
filter bypass flap valve - N275- -item 1-.
– Ensure secure fit of air hose at air mass meter - G70- .
The remaining installation steps are carried out in the reverse se‐
quence.
4.2.2 Removing and installing air filter ele‐

ment
Removing
– Release hose clip -2- securing air hose (going to turbocharger)
and disconnect hose from air mass meter - G70- .
– Unscrew bolts -arrows- and detach air cleaner (top section).
– Take out old filter element.
Installing
⇒ “4.1 Exploded view - air cleaner housing”, page 271
To ensure that the air mass meter -G70- functions properly, it is
important to observe the following notes and instructions.
Note
♦ If the air filter element is very dirty or wet, dirt or water could
reach the air mass meter and affect the air mass value. This
would lead to loss of power, since a smaller injection quantity
is calculated.
♦ Always use genuine part for air filter element.
♦ The air cleaner housing MUST be clean.
♦ Hose connections and
Protected air pipes
by copyright. and
Copying for hoses
private or must be purposes,
commercial free of inoilpart or in whole, is not
♦ To prevent malfunctions, cover critical parts of the engine air
intake (air mass meter, air pipes, etc.) with a clean cloth when
blowing out the air cleaner housing with compressed air.
♦ Observe environmental requirements for disposal.

Audi Q5 2008 ➤
– Clean salt residue, dirt and leaves out of air cleaner housing
(top and bottom sections) using a vacuum cleaner.
– Blow out water drain -arrow- with compressed air.
– Check for salt residue, dirt and leaves in air mass meter and
air hose (engine intake side).
– Check for dirt and leaves in air duct going from lock carrier to
air cleaner housing.
– When installing air filter element, check that it is properly cen‐
tred in retainer in air cleaner (bottom section).
– Fit the top section of the air cleaner carefully on the bottom
section, without using force. Make sure the top section of the
air cleaner is fitted straight on the air filter element (note posi‐
tion of sealing lip on air filter element).
– Ensure secure fit of intake hose at air mass meter - G70- .
quence.
4. Air cleaner 275

Audi Q5 2008 ➤
5 Intake manifold
⇒ “5.1 Exploded view - intake manifold”, page 276
⇒ “5.2 Removing and installing intake manifold”, page 277
⇒ “5.3 Removing and installing throttle valve module J338 ”, page
280
5.1 Exploded view - intake manifold
1 - Guide tube
❑ For oil dipstick
2 - Seal
❑ Renew
3 - Gasket
❑ Renew
4 - Bolt
❑ 8 Nm
tion
6 - Bolt
❑ 9 Nm
7 - Intake manifold
⇒ page 277
8 - Not fitted
9 - Not fitted
10 - Not fitted
11 - Gasket
❑ Renew
12 - Bolt
❑ 9 Nm
13 - Connecting pipe
❑ To exhaust gas recircu‐
lation cooler
14 - Clamp
❑ Renew
❑ 5 Nm
15 - Connection permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
❑ For exhaust gas recirculation
16 - Bolt
❑ 8 Nm
17 - Seal
❑ Renew
18 - Throttle valve module - J338-
❑ With throttle valve potentiometer - G69-

Audi Q5 2008 ➤

19 - Bolt
❑ 8 Nm
20 - Bolt
❑ 9 Nm
21 - Clip
5.2 Removing and installing intake manifold

♦ Ratchet - V.A.G 1331/1-
♦ Socket - T40055-
♦ Protected
Socket Torx T30 - T10405-
5. Intake manifold 277

Audi Q5 2008 ➤
Removing
Caution


– Unplug electrical connectors on glow plugs ⇒ page 355 .
pressure pipe.
– Unplug electrical connectors -2 and 3-.
– Remove bolt -arrow- and push wiring retainer to the side.
Note
Disregard -item 1-.
– Release hose clips -2 and 4- and detach fuel hoses.

Audi Q5 2008 ➤
– Unscrew bolt -2- and detach pressure differential sender -

G505- .
to one side.
Note
Do not bend fuel lines.
Caution
♦ Observe rules for cleanliness when working on the injec‐

tion system.
♦ Plug open connections with suitable sealing caps imme‐
diately.
– Open clamp -1- and detach.
Note
Disregard -item 2-.
– Release hose clip -2- and detach air hose.

– Unplug electrical connector -3- at throttle valve module -
J338- .
5. Intake manifold 279

Audi Q5 2008 ➤
– Unscrew intake manifold bolts -arrows- in diagonal sequence

starting from outside and working inwards using socket Torx
T30 - T10405- .
Installing
Note
Renew seals and/or gaskets.
– Tighten intake manifold bolts in diagonal sequence, working

from inside to outside.
– Install high-pressure pipe ⇒ page 265 .
5.3 Removing and installing throttle valve
module - J338-
Removing
– Release hose clip -arrow- and detach air hose downwards.

– Remove bolts -arrows- and detach throttle valve module -
J338- .
Installing
Note
Fit new O-ring.

Audi Q5 2008 ➤
6. Senders and sensors 281

Audi Q5 2008 ➤
6 Senders and sensors

⇒ “6.1 Removing and installing fuel pressure regulating valve
N276 ”, page 282
⇒ “6.2 Checking fuel pressure regulating valve N276 ”,
page 283
⇒ “6.3 Removing and installing fuel pressure sender G247 ”, page
284
⇒ “6.4 Removing and installing air mass meter G70 ”, page 287
⇒ “6.5 Removing and installing pressure differential sender G505
”, page 287
⇒ “6.6 Removing and installing NOx sender 2 G687 ”,
page 288
6.1 Removing and installing fuel pressure

regulating valve - N276-
The fuel pressure regulating valve - N276- -arrow- is located in
the fuel rail. It maintains a constant pressure in the fuel rail and
the injector pipes (high-pressure fuel circuit).
If the pressure in the high-pressure fuel circuit is too high, the
regulating valve opens to allow some of the fuel to flow back from
the fuel rail to the fuel tank via a return line.
If the pressure in the high-pressure fuel circuit is too low, the fuel
pressure regulating valve - N276- closes and seals off the high-
pressure section of the system from the low-pressure section.
Note
Fuel pressure regulating valve - N276- must always be renewed

after it has been removed.
Removing
Caution

– Remove fuel rail ⇒ page 266 .

– Before removal, clean
Protected area around
by copyright. thread
Copying for private orfor fuel pressure
regulating valve - N276-
permitted unlessusing commercial
authorised by AUDI AG. AUDI cleaning
AG does notsolution
guarantee or accept any liability
or similar (no dirt must enter opening in fuel rail).
Note
Clean carefully; cleaning solution must not enter the electrical

connector.
– Dry off fuel pressure regulating valve - N276- .

– Slacken union nut (counterhold at hexagon flats on housing).
Then unscrew and remove by hand.
– Extract dirt from opening in fuel rail (thread and sealing sur‐
face) using a vacuum cleaner. Do not use metal tools, etc.

Audi Q5 2008 ➤
– Seal off opening in fuel rail with a clean plug.

Installing
Note
♦ The fuel pressure regulating valve - N276- has a deformable

sealing lip and no separate seal; it can therefore be used only
once.
♦ Check that sealing surfaces (deformable sealing lip) and
threads on new fuel pressure regulating valve - N276- are not
damaged.
♦ Check sealing surface at opening in fuel rail.
♦ The beginning of the thread, the deformable sealing lip and
the O-ring of the fuel pressure regulating valve - N276- must
be coated with diesel fuel.
– Screw on union nut by hand.

– Align new regulating valve so that connecting wire is free of
tension after connector is attached.
– Hold regulating valve in this position by counterholding hexa‐
gon flats on housing of regulating valve with open-end spanner
or pliers (water pump pliers or similar).
– Use suitable torque wrench with an open-end spanner insert
(30 mm) to tighten union nut.
– Install fuel rail ⇒ page 266 .
After renewing high-pressure pump or fuel pressure regulating
valve - N276- , learnt values must be re-adapted; see “Guided
Functions” in ⇒ Vehicle diagnostic tester
– After installation, run engine at moderate speed for several
minutes and then switch off.
– Interrogate event memory again.
6.2 Checking fuel pressure regulating valve

- N276-
♦ Fuel-resistant measuring container

Audi Q5 2008 ➤
Caution

♦ To reduce the pressure in the fuel system, wrap a clean
cloth around the connection and carefully loosen the con‐
nection.

– Release hose clip -arrow- and detach fuel return hose from
fuel rail.
– Seal off open fuel return hose with a clean plug.
– Connect test hose -2- to return line connection of fuel rail -3-.
– Seal off open fuel return hose -1- with a clean plug.
– Hold end of test hose into measuring container -4- to measure
return flow rate.
1) Checking while engine is running
– Start the engine and run at idling speed.
• Specification: more than 75 ml in 30 seconds
If specification is not obtained, fuel pressure regulating valve -
N276- is defective.
2) Checking while engine is running
If condition for 1) is met, increase engine speed to ≥ 2000 rpm.
• Specification of return flow rate: 0 ml
• Drip leaks are permissible
• If specification is not obtained, fuel pressure regulating valve
- N 276- is defective.
3) If engine can no longer be started
Perform check at cranking speed.
• Specification of return flowProtected
rate: 0 by ml
copyright. Copying for private or commercial purposes, in part or in whole, is not
• Drip leaks are permissible with respect to the correctness of information in this document. Copyright by AUDI AG.
• If specification is not obtained, fuel pressure regulating valve

- N 276- is defective.
6.3 Removing and installing fuel pressure

sender - G247-

Audi Q5 2008 ➤
♦ Bit (27 mm) - T40218- or commercially available socket

(27 mm)
♦ Torque wrench
Note
♦ The fuel pressure sender - G247- continuously measures the
fuel pressure in the high-pressure system. It transmits a cor‐
responding voltage signal to the engine control unit - J623- .
♦ Should the fuel pressure sender fail, the engine control unit
will control the fuel pressure via a mapped open-loop backup
function. Maximum engine speed in this mode is restricted.
♦ The fuel pressure sender - G247- has a deformable sealing
lip.
Removing
Caution


– Before removal, clean area around thread for fuel pressure
sender using commercial cleaning solution etc. (no dirt must
enter opening).
Note
Clean carefully; cleaning solution must not enter the electrical

connector.
– Dry off fuel pressure sender - G247- .

Audi Q5 2008 ➤
– Unplug electrical connector -1- at fuel pressure sender -

G247- .
– Unscrew fuel pressure sender - G247- using socket, 27 mm -
T40218- .
Note
An open-end spanner must not be used for loosening or tighten‐

ing.
– Extract dirt from opening in fuel rail (thread and sealing sur‐
face) using a vacuum cleaner. Do not use metal tools, etc.
Note
Disregard -item A-.
Installing
Note
♦ The fuel pressure sender - G247- does not have a seal; in‐
stead, it has a deformable sealing lip.
♦ Check that sealing surfaces (deformable sealing lip) and
threads on fuel pressure sender - G247- are not damaged. If
inspection of fuel pressure sender - G247- shows that it is OK,
it can be used again.
♦ Also check sealing surface at opening in fuel rail.
♦ The beginning of the thread and the deformable sealing lip of
the fuel pressure regulating valve - N276- must be coated with
diesel fuel.
– Screw in fuel pressure sender - G247- by hand.

– Then tighten fuel pressure sender - G247- to specified torque.
– After installing fuel pressure sender - G247- , leave engine
running at moderate
with respect speed
to the correctness for a infew
of information minutesCopyright
this document. whenbybleeding
AUDI AG.
fuel system and then switch off again.
Note
The fuel system is “self-bleeding”; do NOT open the high-pres‐

sure connections.
– Interrogate event memory and erase it if necessary.

– Carefully check the entire fuel system for leaks.
– Renew affected component if leakage still occurs after tight‐
ening to correct torque.

Audi Q5 2008 ➤
Note
– After road test, interrogate event memory again.
6.4 Removing and installing air mass meter

- G70-
Removing
– Release hose clip securing air hose (coming from turbocharg‐
er) and disconnect hose from air mass meter - G70- .
– Unscrew both bolts from air mass meter - G70- .
– Then carefully pull air mass meter - G70- out of guide on air
cleaner housing.
Installing
To ensure that the air mass meter - G70- functions properly, it is
important to observe the following notes and instructions.
Note
♦ If the air filter element is very dirty or wet, dirt or water could
reach the air mass meter and affect the air mass value. This
would lead to loss of power, since a smaller injection quantity
is calculated.
– Check for salt residue, dirt and leaves in air mass meter and
air hose (engine intake side).
– Check for dirt in air duct leading to air filter element. If neces‐
sary, clean salt residue, dirt and leaves out of air cleaner
housing (top and bottom sections); wash out or use a vacuum
cleaner as required. Removing and installing air cleaner
⇒ page 272 .
quence.
6.5 Removing and installing pressure differ‐

ential sender - G505-
The pressure differential sender - G505- detects the amount of

deposits in the particulate filter.


Audi Q5 2008 ➤
Removing
– Unscrew bolt -2- and detach pressure differential sender -
G505- .
– Before disconnecting, spray hoses coming from exhaust gas
pressure sensor 1 - G450- with suitable release agent.
– Carefully disconnect the hoses from their connections (take
care to keep the hoses straight: the connections on pressure
sensor can break off easily).
Installing
⇒ “9.1 Exploded view - Lambda probe”, page 299
Note
♦ Before installing, blow out pressure pipes from pressure dif‐

ferential sender - G505- to particulate filter towards particulate
filter with compressed air (pipes can become obstructed or
may ice up due to condensation).
♦ Make sure that hoses are securely fitted and that there are no
leaks.
♦ If pressure pipes are detached from particulate filter, tighten
pressure pipe connections ⇒ page 314 .
– “Adaption” must be performed after renewing pressure differ‐

ential sender ⇒ Vehicle diagnostic tester.
After renewing pressure differential sender - G505- and/or par‐
ticulate filter, adaption must be performed in order to reset learnt
values. The adaption procedure is described in the Guided Fault
Finding or Guided Functions; use ⇒ Vehicle diagnostic tester.
6.6 Removing and installing NOx sender 2 -

G687-
Removing
– Remove aerodynamic fairing (left-side) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded view -
underbody trim .
– Unplug electrical connector -1- at control unit for NOx sender 2
- J881- .
– Remove nuts -arrows-.
– Remove NOx sender 2 - G687- -2-.
Installing
Installation
with is carried
respect out in the
to the correctness reverseinorder;
of information noteCopyright
this document. the following:
by AUDI AG.
– Install aerodynamic fairing (rear left) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody trim; Exploded view - un‐
derbody trim .

Audi Q5 2008 ➤
7 Engine control unit

⇒ “7.1 Wiring and component check with test box V.A.G 1598/42
”, page 289
⇒ “7.2 Removing and installing engine control unit J623 ”,
page 290
7.1 Wiring and component check with test

box - V.A.G 1598/42-
♦ Adapter cable - V.A.G 1598/39-1-
♦ Adapter cable - V.A.G 1598/39-2-
♦ Test box - V.A.G 1598/42-
7. Engine control unit 289

Audi Q5 2008 ➤
Note
♦ The test box has 105 sockets. The connecting cable can be
disconnected from the test box. This means that only the cable
(and not the test box) has to be purchased for future engine
control units with different types of connectors.
♦ The smaller of the two connectors on the engine control unit
has the contacts 1 to 60. The larger of the two connectors has
the contacts 1 to 94.
♦ To carry out tests on the 60-pin wiring harness connector, the
adapter cable - V.A.G 1598/39-1- is connected to connector
“A” on the test box. For components connected to 60-pinwithwiring
harness connector ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
♦ To carry out tests on the 94-pin wiring harness connector, the
adapter cable - V.A.G 1598/39-2- must be connected to con‐
nectors -A- and -B- on the test box. For components connec‐
ted to 94-pin wiring harness connector ⇒ Current flow
diagrams, Electrical fault finding and Fitting locations.
♦ The test box - V.A.G 1598/42- is designed so it can be con‐
nected both to the wiring harness for the engine control unit
and to the engine control unit itself at the same time.
♦ The advantage of this is that the electronic engine control sys‐
tem remains fully functional when the test box is connected
(for example, for measuring signals when the engine is run‐
ning).
♦ The relevant test procedure will state whether it is necessary
to also connect the engine control unit to the test box.
WARNING
To prevent irreparable damage to the electronic components,

select appropriate measuring range before connecting the
measuring cables and observe the test requirements.
– Remove engine control unit ⇒ page 290 .

– Connect test box - V.A.G 1598/42- to wiring harness with
adapter cable - V.A.G 1598/39-1- or adapter cable - V.A.G
1598/39-2- . Connect earth clip of test box to negative terminal
of battery. The instructions for performing the individual tests
indicate whether or not the engine control unit itself also needs
to be connected to the test box.
– Carry out test as described in appropriate repair procedures.
Installing engine control unit
Installation is performed in the reverse sequence; the engine con‐
trol unit must be installed with the protective housing. New shear
bolts must be used.
Perform the following after reconnecting engine control unit:
– Interrogate event memory and erase if necessary.
7.2 Removing and installing engine control

unit - J623-

Audi Q5 2008 ➤
♦ Hot air blower - VAS 1978/14A- -item 1- with nozzle attach‐

ment -2- from wiring harness repair set - VAS 1978 B-
♦ Small, commercially available mole grips -3-
Note
♦ Not every engine control unit is bolted to a protective housing.

Whether a protective housing is fitted depends on the engine/
gearbox combination.
♦ The engine control unit -1- is bolted to the protective housing
-5-. To make it more difficult to unscrew the shear bolts -4- for
locking plate -2-, their threads have been coated with locking
fluid.
♦ The protective housing has to be removed before the connec‐
tors can be unplugged from the engine control unit (e.g. to
connect the test box or renew the engine control unit).
Removing
– Before removing the engine control unit - J623- , the adaption
values of the injectors and the ash deposit mass must be read
out. Use ⇒ Vehicle diagnostic tester.
The adaption values for the injectors in the old (defective) engine
control unit can be read out via the Guided Fault Finding or Gui‐
ded Functions mode and can be stored as an electronic file in the
⇒ Vehicle diagnostic tester.
– Switch off ignition and remove ignition key after storing elec‐
tronic file containing adaption values.
Note
If the adaption values of the injectors cannotpermitted
be read out
unless of theby AUDI AG. AUDI AG does not guarantee or accept any liability
authorised
old (defective) engine control unit, they must be entered
with respect to theinto the of information in this document. Copyright by AUDI AG.
correctness
new engine control unit manually and the adaption procedure
must be performed accordingly.

Audi Q5 2008 ➤
– Remove nut -3- and bolt -2-.

– Pull filler neck -1- with filler pipe out of washer fluid reservoir
and through opening in body -arrow-.
– Unscrew bolts -arrows- and take off lid for electronics box.
Note
Disregard -item 1-.
– Release retainers -arrows A- and pull out engine control unit

- J623- -arrow B-.
Note
Cover painted surfaces with a cloth to prevent scratching.
The threads of the two shear bolts -4- which are not screwed into
the engine control unit are secured with locking fluid. To unscrew
these two bolts, the threads must therefore be heated with the hot
air blower.
The threads of the two shear bolts -3- which are screwed into the
engine control unit are not secured with locking fluid. Do not apply
heat to the threads in the control unit housing; this is not neces‐
sary and would cause overheating of the control unit.

Audi Q5 2008 ➤
– Select settings on hot air blower as shown in illustration, i.e.

set temperature potentiometer -2- to maximum heat output
and two-stage air flow switch -3- to position 3.
WARNING
Heating the thread of the locking plate also heats up the shear
bolts and parts of the metal housing. Take care to avoid burns.
It is also important to ensure that only the thread is heated and
none of the surrounding components if at all possible. These
should be covered if necessary.
Switch on the hot air blower and heat the bolt for approximately
20 ... 30 seconds.
– Unscrew shear bolts using suitable vice-grip pliers (see arrow

in illustration).
– The two shear bolts screwed into the engine control unit do
not need to be heated. They should be removed without being
heated.
– Detach protective housing from control unit connectors.
– Release connectors on engine control unit and unplug con‐
nectors.
– Take out old engine control unit - J623- and install new engine
control unit - J623- .
Installing
Installation is performed in the reverse sequence.
– After installation, the protective housing must be re-fitted on
the engine control unit - J623- .
– Clean threaded holes for shear bolts
Protected to remove
by copyright. any
Copying residue
for private or commercial purposes, in part or in whole, is not
from locking fluid. This can be doneunless
permitted using a thread
authorised by AUDItap.
AG. AUDI AG does not guarantee or accept any liability
– Always use new shear bolts.
The procedure required after connecting the new engine control
unit is described in the Guided Fault Finding or Guided Functions.
Use ⇒ Vehicle diagnostic tester.

Audi Q5 2008 ➤
8 High-pressure pump
⇒ “8.1 Exploded view - high-pressure pump”, page 294
⇒ “8.2 Removing and installing high-pressure pump”, page 295
⇒ “8.3 Performing first fuel filling after installing high-pressure
pump”, page 297
8.1 Exploded view - high-pressure pump
1 - Bracket for ancillaries

⇒ page 60
2 - Bolt
❑ 2x
❑ Renew
❑ 20 Nm + 180°
3 - Hub
❑ Use counterhold tool -
T10051- when loosen‐
ing and tightening
❑ To remove, use puller -
T40064-
sprocket
5 - Bolt
❑ 3x
❑ Renew
❑ 20 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6 - Nut with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ 95 Nm
7 - Bolt
❑ Renew
❑ 20 Nm + 45°
❑ With fuel metering valve
- N290- (do not open)
❑ After renewing, first fuel
filling operation MUST
be performed (it is im‐
portant not to allow
pump to run while it is still empty) ⇒ page 297
❑ After renewing high-pressure pump or fuel pressure regulating valve - N276- , learnt values must be re-
adapted; see “Guided Functions” in ⇒ Vehicle diagnostic tester
9 - Fuel supply hose
10 - Fuel return hose
❑ Between high-pressure pump and fuel rail

Audi Q5 2008 ➤
Note
♦ The high-pressure pipes can be

lowing checks:
♦ Check taper seat for deformation
and cracks.
damaged.
used again.
❑respect
with Install
to thefree of stress

❑ 25 Nm

pump
Caution

The high-pressure fuel pump has very close tolerances and
must not be allowed to run without fuel. To prevent this and to
enable the engine to start quickly after parts have been re‐
newed, it is important to observe the following:
♦ If components of the fuel system between the fuel tank
and the high-pressure pump are removed or renewed, the
first fuel filling operation must be performed.
♦ If a fuel pump, fuel line (between fuel tank and high-pres‐
sure pump) or fuel filter is removed or renewed, the fuel
first time.
♦ If the high-pressure pump is removed or renewed, the fuel
first time.
Procedure for first fuel filling ⇒ page 297
Removing
– Remove toothed belt from camshaft and high-pressure pump
⇒ page 116 .
8. High-pressure pump 295

Audi Q5 2008 ➤
pressure pipe.

– Release hose clips -2- and detach fuel hoses.
to one side.
Note
Disregard -item 4-.
– Unplug electrical connector -arrow- at fuel metering valve -

N290- .
– Using bit XZN 10 - T10385- , unscrew bolts -arrows- for high-

pressure pump sprocket.

Audi Q5 2008 ➤
– Counterhold using counterhold tool - T10051- and remove nut

-1- at hub of high-pressure pump.
– Apply puller - T40064- with thrust piece - T40064/1- and pin -

T40064/2- as shown in illustration and pull hub off high-pres‐
sure pump. If necessary, counterhold using an open-end
spanner (24 mm).
– Unscrew securing bolts -arrows- for high-pressure pump.

– Carefully take out high-pressure pump.
Installing
⇒ “8.1 Exploded view - high-pressure pump”, page 294
– Install toothed belt for high-pressure pump ⇒ page 116 .
– Install high-pressure pipe ⇒ page 265 .
Caution
♦ The high-pressure pump must first be filled with fuel before

the engine is started. The high-pressure pump must not
be allowed to run while still empty. First fuel filling
⇒ page 297 .
♦ Running when dry causes irreparable damage to high-
pressure pump.
After renewing high-pressure pump and/or fuel pressure regulat‐

ing valve - N276- , adaption must be performed. The adaption
procedure is described in the Guided Fault Finding or Guided
Functions; use ⇒ Vehicle diagnostic tester.
8.3 Performing first fuel filling after installing
high-pressure pump
8. High-pressure pump 297

Audi Q5 2008 ➤
Caution
Running when dry causes irreparable damage to high-pres‐

sure pump.
♦ The high-pressure pump must first be filled with fuel before
the engine is started. The high-pressure pump must not
be allowed to run while still empty.
Note
♦ When installing the high-pressure fuel pump, it is essential to

ensure that no dirt enters the fuel system.
♦ Only remove sealing plugs immediately prior to installation of
fuel lines.
Proceed as follows to fill fuel system with fuel:

• Check fuel gauge in instrument cluster; fuel gauge needle
must indicate that fuel is above reserve level.
– Select “Checking fuel system pressurisation pump” from the
list.
– The fuel pump starts running.
– The fuel pump must run for approx. 3 minutes to ensure that
the high-pressure pump is filled with sufficient fuel.
– Start engine after filling fuel system.
– Run engine at moderate speed for several minutes and then
switch off.
– Erase entry in event memory using
Protected by ⇒ Vehicle
copyright. Copying for diagnostic test‐purposes, in part or in whole, is not
private or commercial
er. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
Note

Audi Q5 2008 ➤
9 Lambda probe
⇒ “9.2 Removing and installing Lambda probe”, page 300
9.1 Exploded view - Lambda probe
1 - Centre silencer
2 - Nut
3 - NOx sender 2 - G687-
⇒ page 288
sender 4 - G648-
⇒ page 346
5 - Pressure line
❑ For pressure differential
sender - G505-
❑ 45 Nm
6 - Nut
❑ Tightening torque: 4.5
Nm
sender 1 - G235-
⇒ page 341
8 - Turbocharger
❑ With position sender for
charge pressure posi‐Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
tioner - G581- permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
9 - Pressure differential sender
- G505-
⇒ page 287
❑ Pressure pipes to partic‐
ulate filter: 45 Nm
❑ Tighten bolt to 4.5 Nm
10 - Pressure line
❑ For pressure differential sender - G505-
❑ 45 Nm
11 - Lambda probe - G39- with Lambda probe heater - Z19-
❑ New Lambda probes are coated with an assembly paste
❑ If you are re-using Lambda probe, coat only thread with high-temperature paste; refer to ⇒ Electronic
parts catalogue for high-temperature paste
❑ The assembly paste/high-temperature paste must not get into the slots on the Lambda probe body
❑ 55 Nm
9. Lambda probe 299

Audi Q5 2008 ➤
❑ Adaption must be performed after renewing particulate filter. Use ⇒ Vehicle diagnostic tester
14 - Front exhaust pipe
15 - SCR catalytic converter
Only installed on vehicles with reducing agent system (AdBlue

system): injector for reducing agent - N474-

1 - Control unit for NOx sender 2 - J881-
2 - Control unit for reducing agent metering system - J880-
3 - NOx sender 2 - G687- (tightening torque 50 Nm)
9.2 Removing and installing Lambda probe

♦ Lambda probe open ring spanner set - 3337-

Audi Q5 2008 ➤
Removing
– Unplug electrical connector -3- for Lambda probe - G39- and
move electrical wiring clear.
– Unscrew Lambda probe - G39- -item 1- using a tool from
Lambda probe open ring spanner set - 3337- .
Note
Installing
Note
♦ Threads of new Lambda probes are already coated with as‐

sembly paste; the paste must not get into the slots on the probe
body.
♦ In the case of a used Lambda probe grease only the thread
with high-temperature paste. The paste must not get into the
slots on the Lambda probe body. For high-temperature paste
refer to ⇒ Electronic parts catalogue
♦ When installing, the Lambda probe wiring must always be re‐
attached at the same locations to prevent it from coming into
contact with the exhaust pipe.
9. Lambda probe 301

Audi Q5 2008 ➤
26 – Exhaust system
1 Exhaust pipes/silencers
⇒ “1.1 Exploded view - silencers”, page 302
⇒ “1.2 Removing and installing front exhaust pipe”, page 308
⇒ “1.3 Separating exhaust pipes/silencers”, page 309
⇒ “1.4 Renewing tailpipes”, page 310
⇒ “1.5 Stress-free alignment of exhaust system”, page 311
⇒ “1.6 Checking exhaust system for leaks”, page 313
1.1 Exploded view - silencers
Note
After working on the exhaust system, ensure that the system is

not under stress and that it has sufficient clearance from the body.
If necessary, loosen clamp and align silencers and exhaust pipe
so that sufficient clearance is maintained to the body at all points
and the mountings are evenly loaded.
Vehicles without SCR catalytic converter
302 Rep. gr.26 - Exhaust system

Audi Q5 2008 ➤
1 - Gasket
❑ Renew
❑ With catalytic converter
❑ With pressure line for
pressure differential
sender - G505-
⇒ page 314
❑ Mounting components
⇒ page 307
❑ After renewing, perform
Adaption in Guided
Functions ⇒ Vehicle
diagnostic tester Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - Gasket with respect to the correctness of information in this document. Copyright by AUDI AG.
❑ Renew
4 - Nut
❑ Renew
❑ 25 Nm
❑ With flexible joint; do not
bend flexible joint more
than 10° – otherwise it
can be damaged
❑ Protect against knocks
and impact
⇒ page 308
❑ Align exhaust system so
it is free of stress
⇒ page 311
6 - Clamp (front)
❑ Before tightening, align exhaust system so it is free of stress ⇒ page 311
❑ Tighten bolted connections evenly
7 - Nut
❑ 23 Nm
8 - Rear silencer
❑ Combined in one unit with centre silencer as original equipment. Can be renewed individually for repair
purposes
❑ On vehicles from model year 2013 onwards, the rear silencer has only one tailpipe
❑ Cutting point: centre silencer / rear silencer ⇒ page 309
❑ Renewing tailpipes ⇒ page 310
❑ Align exhaust system so it is free of stress ⇒ page 311
9 - Mounting
❑ Check preload ⇒ page 311
10 - Bolt
❑ 20 Nm
11 - Rubber mounting
1. Exhaust pipes/silencers 303

Audi Q5 2008 ➤
12 - Bracket
13 - Bolt
❑ 23 Nm
14 - Tailpipe
❑ Can be renewed separately for repair purposes ⇒ page 310
❑ Cutting point between rear silencer and tailpipes ⇒ page 310
15 - Clamp
❑ 23 Nm
16 - Nut
❑ 23 Nm
17 - Clamp (rear)
❑ For separate replacement of centre and rear silencers
18 - Centre silencer
❑ Combined in one unit with rear silencer as original equipment. Can be renewed individually for repair
purposes
❑ Cutting point: centre silencer / rear silencer ⇒ page 309
❑ Align exhaust systemProtected
so it isbyfree of stress ⇒ page 311
19 - Mounting with respect to the correctness of information in this document. Copyright by AUDI AG.
20 - Bolt
❑ 23 Nm
21 - Nut
❑ 23 Nm
22 - Bracket
23 - Bolt
24 - Nut
❑ Renew
❑ 23 Nm
Vehicles with SCR catalytic converter

Audi Q5 2008 ➤
1 - Nut
❑ 23 Nm
2 - Clamp (front)
❑ Before tightening, align
exhaust system so it is
free of stress
⇒ page 311
❑ Installation position
⇒ page 307
❑ Tighten bolted connec‐
tions evenly
3 - Centre silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed individually
for repair purposes
❑ Cutting point: centre si‐
lencer / rear silencer
⇒ page 309
⇒ page 311
❑ With flexible joint; do not
bend flexible joint more
than 10° – otherwise it
can Protected
be damagedby copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Protectwithagainst
respect to knocks
the correctness of information in this document. Copyright by AUDI AG.
and impact
⇒ page 308
⇒ page 311
5 - Gasket
❑ Renew
6 - Turbocharger
7 - Gasket
❑ Renew
8 - Nut
❑ Renew
❑ 23 Nm
❑ With catalytic converter
❑ With pressure line for pressure differential sender - G505-
❑ After renewing, perform "Adaption" in “Guided Functions” mode ⇒ Vehicle diagnostic tester.
10 - Nut
❑ Renew
❑ 23 Nm

Audi Q5 2008 ➤
11 - Nut
❑ 23 Nm
12 - Mounting
13 - Gasket
❑ Renew
15 - Nut
❑ Renew
❑ 23 Nm
16 - Mounting
17 - Bolt
❑ 23 Nm
18 - Clamp
❑ 23 Nm
19 - Tailpipe
❑ Aligning ⇒ page 310
20 - Mounting
21 - Bolt
❑ 23 Nm
22 - Rear silencer
❑ Tailpipes can be renewed separately as required
❑ On vehiclespermitted
from model year 2013
unless authorised by AUDIonwards,
AG. AUDI AG the does rear silencer
not guarantee hasany
or accept only one tailpipe
liability
❑ Cutting point between rear silencer and tailpipe ⇒ page 310
❑ Align exhaust system so it is free of stress ⇒ page 311
23 - Clamp (rear)
❑ For separate replacement of centre and rear silencers
24 - Nut
❑ 23 Nm
25 - Bolt
❑ 23 Nm
26 - Mounting

Audi Q5 2008 ➤
Installation position of front clamp

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

– Install clamps so that the bolt ends do not protrude beyond
bottom of clamp.
• Bolted connection faces to left.
Components of mountings for particulate filter

1- Spacer sleeve
2- Compression spring
3- Washer
4- Bolt, 23 Nm
5- Bolt, 23 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
6- Spacer sleeve with respect to the correctness of information in this document. Copyright by AUDI AG.
7- Buffer
8- Bracket
9- Bolt, 23 Nm
10 - Bracket
11 - Nut

Audi Q5 2008 ➤
1.2 Removing and installing front exhaust

pipe
Removing
– Remove rear noise insulation -2- ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Exploded view - noise
insulation .
Vehicles without SCR catalytic converter:
Caution

10°.
– Loosen bolts -arrows-, push back clamp and detach front ex‐
haust pipe.

Audi Q5 2008 ➤

agent - N474- .
Caution
Always renew all clips that were detached to remove the re‐
ducing agent line.

– Move front exhaust pipe clear of mounting -1- and detach.
Installing
Note
Renew gasket and nuts.
– Install injector for reducing agent - N474- ⇒ page 336 .

– Align the exhaust system so it is free of stress ⇒ page 311 .
tion .
1.3 Separating exhaust pipes/silencers

♦ The connecting pipe can be cut through at copyright.
Protected by the cutting location
in order to renew the centre and rear silencers
permitted separately.
♦ The cutting point is marked by an indentation on the circum‐
ference of the exhaust pipe.
♦ Chain pipe cutter - VAS 6254-

Audi Q5 2008 ➤
Procedure
– Cut through the exhaust pipe at a right angle at the position
marked -arrow- using chain pipe cutter - VAS 6254- .
– Position centre of clamps -arrow- over cutting location.
Note
On vehicles from model year 2013 onwards, the rear silencer has
only one tailpipe
– Install clamp so that ends of bolts do not protrude beyond bot‐

tom of clamp.
• Bolted connection faces to left.
1.4 Renewing tailpipes

♦ The tailpipes can be cut through at the point marked so that
the tailpipes can be renewed separately.
♦ The cutting point is marked by an indentation on the circum‐
ference of the tailpipe.
♦ Chain pipe cutter - VAS 6254-

Audi Q5 2008 ➤
Procedure
– Cut through tailpipe at right angle at the position marked by
-arrows- using chain pipe cutter - VAS 6254- .
Note
On vehicles from model year 2013 onwards, the rear silencer has
only one tailpipe
– Fit tailpipes.
– Check clearance between tailpipes and bumper:

• Dimension -x- (left-side) = dimension -x- (right-side)
– Tighten bolt connections on by
Protected clamps.
1.5 Stress-free alignment of exhaust system

Procedure
• The exhaust system must be aligned when it is cool.
• Tightening torques ⇒ page 302
Vehicles without clamps between centre silencer and rear silenc‐
er
– Loosen bolt connections on front clamp.
– Push exhaust system towards front of vehicle -arrow- so that
rear mountings for rear silencer are preloaded by -a- = 11 ... 15
mm.
– Align rear silencer so it is horizontal.
– Check clearance between tailpipes and bumper.
Vehicles with double tailpipe:


Audi Q5 2008 ➤
Vehicles with single tailpipe, version 2:

– Check clearance between tailpipes and bumper on both sides:
• Dimension -a- = 18 mm
• Dimension -b- is the same on both sides.
– Tighten bolt connections on clamp evenly.
Vehicles with clamps between centre silencer and rear silencer
– Loosen bolt connections on front and rear clamps.
– Push centre silencer towards front of vehicle -arrow- until

mounting for centre silencer is preloaded by -a- = 6 ... 10 mm.
– Tighten bolt connections on front clamp evenly.
– Push rear silencer towards front of vehicle -arrow- so that rear

mounting for rear silencer is preloaded by -a- = 11 ... 15 mm.
– Align rear silencer so it is horizontal.
– Check clearance between tailpipes and bumper.
Vehicles with double tailpipe:


Audi Q5 2008 ➤
Vehicles with single tailpipe, version 2:

– Check clearance between tailpipes and bumper on both sides:
• Dimension -a- = 18 mm
• Dimension -b- is the same on both sides.
– Tighten bolt connections on rear clamps evenly.
1.6 Checking exhaust system for leaks

– Start the engine and run at idling speed.
– Plug tailpipes during leak test (e.g. with cloth or plug).
– Listen for noise at connection points of cylinder head/exhaust
manifold, turbocharger/exhaust manifold, turbocharger/partic‐
ulate filter etc. to locate any leaks.
– Rectify any leaks that are found.

Audi Q5 2008 ➤
2 Emission control system

⇒ “2.1 Removing and installing SCR catalytic converter”,
page 314
⇒ “2.2 Removing and installing particulate filter”, page 314
2.1 Removing and installing SCR catalytic

converter
Removing
Note
Disregard -item 1-.
– Unfasten connections -arrows-, push clamp towards rear and

detach SCR catalytic converter.
Installing
Renew seals, gaskets and self-locking nuts.
2.2 Removing and installing particulate filter

♦ Engine and gearbox jack - V.A.G 1383 A-

Audi Q5 2008 ➤
♦ Gearbox support - T10337-
Removing
Note
♦ Fit all cable ties in the original positions when installing.

♦ Exhaust gas temperature senders are not fitted on vehicles
complying with emission standard EU4.


– Remove exhaust gas temperature sender 3 - G495- -item 2-
⇒ page 344 .
– Remove exhaust gas temperature sender 4 - G648-
⇒ page 346 .
– Remove plenum chamber partition panel ⇒ General body re‐
– Remove union nuts -1, 2-.

– Move pipes -arrows- clear and swivel to one side.
2. Emission control system 315

Audi Q5 2008 ➤
Note
Disregard -item 1-.

– Remove bolt -3- and pivot push rod to one side.
Note

Audi Q5 2008 ➤

– Fit gearbox support - T10337- onto engine and gearbox jack
- V.A.G 1383 A- and position underneath gearbox.
– Raise gearbox slightly.
WARNING
Risk of accident.
♦ Engine and gearbox jack - V.A.G 1383 A- must remain in
position when work is being carried out and must not be
left unattended.
– Remove bolts -arrows- on tunnel cross member.
2. Emission control system 317

Audi Q5 2008 ➤
– Lower engine/gearbox assembly using engine and gearbox

jack - V.A.G 1383 A- only as far as distance -a-.
• Dimension -a- = 65 mm (maximum).
– Place particulate filter on gearbox.
– Then again lift gearbox and secure tunnel cross member.
– Lift out particulate filter.
Installing
Tightening torques
• ⇒ “1.1 Exploded view - silencers”, page 302 .
• ⇒ “4.1 Exploded view - exhaust gas temperature control”, page
340 .
Note
Renew gaskets and nuts.
– Install tunnel cross member and push rod ⇒ Rep. gr. 34 ;

Assembly mountings; Exploded view - assembly mountings .
– Install plenum chamber partition panel ⇒ General body re‐
– Install exhaust gas temperature sender 4 - G648-
⇒ page 346 .
– Install exhaust gas temperature sender 3 - G495-
⇒ page 344 .
– Install Lambda probe - G39- ⇒ page 300
– After renewing particulate filter, perform Adaption in Guided
Functions ⇒ Vehicle diagnostic tester.

Audi Q5 2008 ➤
3 SCR (selective catalytic reduction)

system
⇒ “3.1 Exploded view - reducing agent tank”, page 319
⇒ “3.2 Exploded view - control unit for reducing agent metering
system”, page 321
⇒ “3.3 Exploded view - delivery unit for reducing agent”,
page 321
⇒ “3.4 Exploded view - injector for reducing agent N474 ”,
page 324
⇒ “3.5 Exploded view - pump for reducing agent V437 ”,
page 324
⇒ “3.6 Removing and installing reducing agent tank”, page 326
⇒ “3.7 Draining reducing agent tank”, page 329
⇒ “3.8 Removing and installing delivery unit for reducing agent”,
page 331
⇒ “3.9 Removing and installing reducing agent supply line”, page
334
⇒ “3.10 Removing and installing injector for reducing agent N474
”, page 336
⇒ “3.11 Removing and installing pump for reducing agent V437 ”,
page 336
⇒ “3.12 Removing and installing control unit for reducing agent
metering system J880 ”, page 338
⇒ “3.13 Checking control unit for reducing agent metering system
J880 ”, page 338
3.1 Exploded view - reducing agent tank
Note
Fitting location: Beneath left rear seat on underside of vehicle.
3. SCR (selective catalytic reduction) system 319

Audi Q5 2008 ➤
1 - Bolt
❑ 4.2 Nm
2 - Aerodynamic fairing (rear
left)
⇒ General body repairs,
exterior; Rep. gr. 66 ;
Underbody trim; Explo‐
ded view - underbody
trim
3 - Heat shield Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ For reducing agent tank permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4 - Reducing agent tank
⇒ page 326
5 - Filler line
❑ Disconnecting reducing
agent lines ⇒ page 334
❑ From filler neck
WARNING
Safety risk due to escap‐
ing reducing agent.
Observe
♦ safety meas‐
ures for handling reduc‐
ing agent ⇒ page 6 .
6 - Breather line
❑ From filler neck
WARNING
ing reducing agent.
Observe
♦ safety meas‐
7 - Sleeve
8 - Grommet
9 - Sleeve
10 - Bolt
❑ 20 Nm
11 - Nut
❑ Tightening torque ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded view -
underbody trim

Audi Q5 2008 ➤
3.2 Exploded view - control unit for reducing agent metering system
Note
Fitting location: control unit for reducing agent metering system - J880- is underneath tank.
❑ For control unit for re‐
ducing agent metering
system - J880-
❑ Depending on vehicle
version, electrical con‐
nector may have two
parts
2 - Control unit for reducing
agent metering system - J880-
⇒ page 338
3 - Nut
❑ 4.5 Nm
3.3 Exploded view - delivery unit for reduc‐

ing agent
Different types may be installed, depending on vehicle version.
Version A:

Audi Q5 2008 ➤

2 - Seal
❑ Renew
❑ Install dry
3 - Supply line
❑ With heater
WARNING
ing reducing agent.
Observe
♦ safety meas‐
ures for handling reduc‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
ing agent ⇒ page 6 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4 - Return line
❑ With heater
WARNING
ing reducing agent.
Observe
♦ safety meas‐
5 - Reservoir
❑ With tank sender for re‐
ducing agent - G684-
❑ With temperature send‐
er for reducing agent -
G685-
❑ With heater for reducing-agent tank - Z102-
❑ With filter
6 - Union nut
❑ Remove and install using special wrench - T40283-
❑ Tightening ⇒ page 334
Version B:

Audi Q5 2008 ➤

2 - Seal
❑ Renew
❑ Install dry
3 - Reservoir
❑ With pump for reducing
agent - V437-
❑ With tank sender for re‐
ducing agent - G684-
❑ With temperature send‐
er for reducing agent -
G685-
❑ With heater for reduc‐
ing-agent tank - Z102-
❑ With filter
❑ Removing and installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
⇒ page 331 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
4 - Union nut
❑ Remove and install us‐
ing special wrench -
T40283-
❑ Tightening ⇒ page 334
5 - Reducing agent line
❑ To injector for reducing
agent - N474-

Audi Q5 2008 ➤
3.4 Exploded view - injector for reducing agent - N474-
1 - Bolt
❑ 5 Nm
2 - Retaining clamp
❑ Renew
3 - Seal
❑ Renew
4 - Injector for reducing agent -
N474-
⇒ page 336
5 - Reducing agent line
Caution
Always renew all clips
that were detached to re‐
move the reducing agent
line.
Disconnecting reducing agent lines ⇒ page 334
WARNING

♦ Observe safety measures for handling reducing agent
⇒ page 6 .
3.5 Exploded view - pump for reducing

agent - V437-
Note
Depending on vehicle version, pump for reducing agent - V437-

may also be fitted in reservoir for reducing agent ⇒ page 331 .

Audi Q5 2008 ➤
1 - Grommet
2 - Sleeve
3 - Bolt
❑ 5 Nm
4 - Supply line
❑ With heater
WARNING
ing reducing agent.
Observe
♦ safety meas‐
6 - Pump for reducing agent -
V437-
❑ With heater for reduc‐
ing-agent pump - Z103-
❑ With pressure sender
for reducing agent me‐
tering system - G686-
❑ Depending on vehicle
version, pump for reduc‐
ing agent - V437- may permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
also be fitted in reservoir
for reducing agent
❑ Refer to exploded view,
version A ⇒ page 321
♦ Removing and installing
pump for reducing agent -
V437- ⇒ page 336
❑ Refer to exploded view, version B ⇒ page 322
♦ Removing and installing reservoir with pump for reducing agent - V437- ⇒ page 331
7 - Return line
❑ Disconnecting reducing agent lines ⇒ page 334
❑ With heater
WARNING
ing reducing agent.
Observe
♦ safety meas‐
8 - Metering line
❑ From pump for reducing agent - V437- to injector for reducing agent - N474-
❑ With heater
❑ Clip onto fuel tank

Audi Q5 2008 ➤
WARNING
ing reducing agent.
To
♦ prevent large
amounts of reducing
agent from escaping
when the metering line is
opened, wait until the re‐
ducing agent has been
drawn back automatically
⇒ page 6 .
9 - Grommet
10 - Washer
11 - Bolt
❑ 2 Nm
3.6 Removing and installing reducing agent

tank
Removing
Observe safety precautions ⇒ page 6 .
WARNING

– Drain reducing agent tank ⇒ page 329 .

Audi Q5 2008 ➤
– Remove bolts -arrows- and detach heat shield -1-.
WARNING

♦ Avoid contact with the skin and eyes. Wear gloves and
safety goggles.
mediately.

Type A:
– Disconnect line -3- ⇒ page 334 .

– Unplug electrical connectors -1, 2, 4- and move wiring harness
clear.
– Release -arrow- and unplug electrical connector -2- on control

unit for reducing agent metering system - J880- and move
wiring clear.
Note
Type B:

Audi Q5 2008 ➤
– Unplug electrical connectors -2, 3- and move electrical wiring

harness clear.
– Disconnect reducing agent line -1- and move it clear
⇒ page 334 .
Both types:
WARNING
Risk of accident caused by weight of tank

♦ Tank must be empty when it is removed.
– Position engine and gearbox jack - V.A.G 1383 A- underneath

vehicle with a soft foam surface to support tank.
– Remove bolts -arrows- (have a second mechanic support the

tank by hand).
Note
For greater clarity the tank is shown without the engine and gear‐
box jack.
– Lower tank by about 100 mm using engine and gearbox jack

- V.A.G 1383 A- (guide tank down by hand).

Audi Q5 2008 ➤
Note
Hold a clean cloth under the separating point to catch escaping

reducing agent.
– Press release tab and disconnect filler line -1- and breather
line -2-.
– Continue lowering tank using engine and gearbox jack -
V.A.G 1383 A- (also guiding tank down by hand).
Installing
⇒ “3.1 Exploded view - reducing agent tank”, page 319
– Check that lines are clipped onto tank.
– Adapt learnt value after draining reducing agent or renewing
components ⇒ page 9 .
3.7 Draining reducing agent tank

♦ Drip tray
Procedure
– Open tank flap.
– Unscrew filler cap -2- from filler neck for reducing agent.
Note
Disregard -item 1-.

Audi Q5 2008 ➤
– Remove bolt and nuts -arrows- and detach cover for reducing
agent tank.
WARNING

safety goggles.
mediately.
– Place drip tray underneath.
Note

reducing agent.
Type A:
– Disconnect supply line -1- from reservoir ⇒ page 334 .
– Attach auxiliary hose -2- to connection -arrow- on reservoir
and drain off reducing agent into drip tray.

Audi Q5 2008 ➤
Type B:
– Remove sealing cap -1- on reducing agent tank
⇒ page 334 .
– Attach auxiliary hose -2- to connection and drain off reducing
agent into drip tray.
Both types:
After re-filling, the following step must be carried out:
3.8 Removing and installing delivery unit for

reducing agent
♦ Special wrench - T40283-
Removing
– Remove reducing agent tank ⇒ page 326 .
Type A:
– Unplug electrical connectors -1- and -2- and unclip connectors
from bracket.

Audi Q5 2008 ➤
WARNING

⇒ page 6 .
Note
Hold a clean cloth under the separating point to catch

Protected escaping
reducing agent. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
– Disconnect return line -2- and supply line -3- ⇒ page 334 .
– Move electrical wiring clear.
– Unscrew union nut -4- using special wrench - T40283- and
carefully lift off reservoir -1-.
Type B:
– Unscrew union nut -2- using special wrench - T40283- and
carefully lift off reservoir -1-.
Both types:
WARNING

♦ Keep in mind that the tank and the reservoir still contain a
small amount of reducing agent.
Installing
⇒ “3.3 Exploded view - delivery unit for reducing agent”, page
321
Note
♦ Renew seal.
♦ Thoroughly clean sealing surfaces for seal.

Audi Q5 2008 ➤
Type A:
– Insert reservoir -2- in tank; while doing so, carefully slide heat‐
ing element into tank through gap between reservoir and
installation opening.
– Slip new seal -1- onto reservoir and press it until it makes con‐
tact at installation opening.
• The seal must not be twisted.
– Move reservoir into installation position:
• Lug -arrow A- on reservoir must engage in groove -arrow B-
on edge of installation opening of tank.
Note
Reservoir must be held in place in its installation position when

tightening union nut to prevent damage to the lug on the reservoir.
Type B:
– Insert reservoir -2- in tank; while doing so, carefully slide heat‐
ing element into tank through gap between reservoir and
installation opening.
– Slip new seal -1- onto reservoir and press it until it makes con‐
tact at installation opening.
• The seal must not be twisted.
– Move reservoir into installation position:
• Connection for reducing agent line -arrow A- must align with

installation marking (square recess) -arrow B- on reducing
agent tank.

Audi Q5 2008 ➤
Both types:
– Position union nut -2- so that mark -3- is positioned above start
of first thread -4-. At this position there is an arrow -1- on the
tank.
– First tighten union nut by hand and then use special wrench -
T40283- to tighten it a total of 5/4 turns (450°).
Caution
When tightening union nut, make sure that reservoir does not
rotate.
The reservoir must not be rotated out of its installation position.
• Mark -3- on union nut -2- and mark -1- (arrow with a line on
each side) must be aligned.
note the following:
– Install reducing agent tank ⇒ page 326 .
3.9 Removing and installing reducing agent

supply line
♦ Release tool - T40278- should be used for version 2 only.

Audi Q5 2008 ➤
WARNING

⇒ page 6 .
Different connectors may be installed, depending on vehicle ver‐

sion.
Version 1
– Press release catches in direction of -arrows- and detach re‐
ducing agent line.
Version 2
– Push release tool - T40278- onto connector in direction of
-arrows-, as shown in illustration A.
– Pull release tool - T40278- by retainer -1- in direction of
-arrow-, as shown in illustration B.
– Use a small screwdriver to detach release tool - T40278- , as


Audi Q5 2008 ➤
3.10 Removing and installing injector for re‐

ducing agent - N474-
Removing
WARNING

♦ Observe safety measures when handling reducing agent
⇒ page 6 .
Note

reducing agent.
– Press release catches ⇒ page 335 and disconnect hose -1-

from injector for reducing agent - N474- .
agent - N474- .
Installing
⇒ “3.4 Exploded view - injector for reducing agent N474 ”, page
324
Note
♦ Renew gasket and retaining clip.

♦ Always renew all clips that were detached to remove the re‐
ducing agent line.
• Installation position: lugs in injector for reducing agent - N474-

-item 2- must be inserted in corresponding mountings in front
exhaust pipe -1-.
3.11 Removing and installing pump for re‐
ducing agent - V437-
Note
♦ Depending on vehicle version, pump for reducing agent -

V437- may be fitted outside reducing agent tank or combined
as one unit with reservoir in reducing agent tank
⇒ page 331 .
♦ Refer to exploded view, version A ⇒ page 321 .
♦ Refer to exploded view, version B ⇒ page 322 .

Audi Q5 2008 ➤
Removing
– Switch off ignition and take out ignition key.
WARNING

– Drain
permitted reducing
unless agent
authorised by AUDI AG. tank
AUDI⇒AG page 329
does not .
guarantee or accept any liability
– Unscrew bolt -4- and detach pump for reducing agent - V437-
-item 6- from tank.
WARNING

safety goggles.
mediately.
Note

reducing agent.
– Disconnect return line -1-, metering line -2- and supply line
-3- ⇒ page 334 .
Installing
⇒ “3.5 Exploded view - pump for reducing agent V437 ”, page
324

Audi Q5 2008 ➤
3.12 Removing and installing control unit for

reducing agent metering system - J880-
Note
Fitting location: control unit for reducing agent metering system -

J880- is underneath reducing agent tank.
Removing
Caution

♦ Observe necessary waiting time before disconnecting the
battery ⇒ page 6 .
♦ Always switch off the ignition before disconnecting the
battery.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

Disconnecting and connecting battery .
– Remove aerodynamic fairing (left-side) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded view -
underbody trim .
– Release electrical connector -2- -arrow- and unplug.
Note
Depending on vehicle version, electrical connector may have two

parts.
– Remove nuts -1- and -3- and detach control unit for reducing
agent metering system - J880- .
Installing
⇒ “3.2 Exploded view - control unit for reducing agent metering
system”, page 321
– Connect battery and perform steps required after re-connect‐
ing battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Dis‐
connecting and connecting battery .
3.13 Checking control unit for reducing agent

metering system - J880-
♦ The control unit for reducing agent metering system - J880-
actuates the transfer pump for reducing agent - V436- and the
reducing agent heaters and processes the signals from the
tank sender for reducing agent - G684- .

Audi Q5 2008 ➤
♦ You can check the control unit for reducing agent metering
system -J880- via the “Guided Fault Finding” function ⇒ Vehi‐
cle diagnostic tester.

Audi Q5 2008 ➤
4 Exhaust gas temperature control

⇒ “4.1 Exploded view - exhaust gas temperature control”,
page 340
⇒ “4.2 Removing and installing exhaust gas temperature sender”,
page 341
4.1 Exploded view - exhaust gas temperature control
1 - Centre silencer
2 - Nut
⇒ page 299 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
3 - NOx sender 2 - G687- with respect to the correctness of information in this document. Copyright by AUDI AG.

⇒ page 288
sender 4 - G648-
⇒ page 346
❑ The thread of the ex‐
haust gas temperature
sender is coated; it must
not be be additionally
greased with high-tem‐
perature paste
❑ 60 Nm
5 - Pressure line
❑ For pressure differential
sender - G505-
❑ 45 Nm
6 - Nut
⇒ page 299
sender 1 - G235-
⇒ page 341
temperature paste; for
parts catalogue
❑ 45 Nm
8 - Turbocharger
9 - Pressure differential sender - G505-
10 - Pressure line
❑ For pressure differential sender - G505-
❑ 45 Nm
11 - Lambda probe - G39- with Lambda probe heater - Z19-

Audi Q5 2008 ➤

❑ The thread of the exhaust gas temperature sender is coated; it must not be be additionally greased with
❑ 60 Nm
4.2 Removing and installing exhaust gas

temperature sender
⇒ “4.2.1 Removing and installing exhaust gas temperature send‐
er 1 G235 ”, page 341
er 3 G495 ”, page 344
er 4 G648 ”, page 346
4.2.1 Removing and installing exhaust gas

temperature sender 1 - G235-
♦ Socket - T40055-
Removing
Note
– Remove rear noise insulationProtected

-2- ⇒ by General body repairs,
copyright. Copying for private orex‐
terior; Rep. gr. 66 ; Noise insulation; Exploded
permitted unless authorised view
by AUDI- AG.
noise
AUDI AG does not guarantee or accept any liability
insulation . with respect to the correctness of information in this document. Copyright by AUDI AG.
4. Exhaust gas temperature control 341

Audi Q5 2008 ➤


Note


Audi Q5 2008 ➤

- G505- .

3 - For Lambda probe - G39-
Note
Note
Disregard -item 1-.
– Remove nuts -arrows- and move particulate filter to rear.

Audi Q5 2008 ➤

sender 1 - G235- and unclip at bottom.
Note
– Unscrew exhaust gas temperature sender 1 - G235- -item 1-

and unclip electrical wiring -arrow-.
Installing
⇒ “4.1 Exploded view - exhaust gas temperature control”, page
340

♦ Socket - T40055-

Audi Q5 2008 ➤
Removing
Note
– Detach electrical connector -3- from bracket.

– Unplug electrical connector -4- and move clear.
– Remove exhaust gas temperature sender 3 - G495- -item 2-.
Note
Disregard -item 1-.
Installing
340
Caution
Risk of malfunctions caused by improperly secured exhaust

gas temperature senders.
♦ The threads of the exhaust gas temperature senders -
G495- and -G648- are coated. It is important that you do
NOT grease them additionally with high-temperature
paste and that you tighten them to the specified torque.

Audi Q5 2008 ➤

Removing
– Unclip electrical connector -C- from bracket -B- and unplug.
Note
– Remove exhaust gas temperature sender 4with- respect

G648-to the
-item 1-. of information in this document. Copyright by AUDI AG.
correctness
Installing
340
Caution
Risk of malfunctions caused by improperly secured exhaust

gas temperature senders.
♦ The threads of the exhaust gas temperature senders -
G495- and -G648- are coated. It is important that you do
NOT grease them additionally with high-temperature
paste and that you tighten them to the specified torque.

Audi Q5 2008 ➤
5 Exhaust gas recirculation

⇒ “5.1 Exploded view - exhaust gas recirculation system”,
page 347
⇒ “5.2 Removing and installing exhaust gas recirculation cooler”,
page 348
⇒ “5.3 Checking exhaust gas recirculation cooler change-over”,
page 350
5.1 Exploded view - exhaust gas recirculation system
1 - Gasket
❑ Renew
2 - Bolt
❑ 9 Nm
3 - Pipe for exhaust gas recir‐
culation
4 - Bolt
❑ 9 Nm
5 - Gasket
❑ Renew
6 - Bolt
❑ 9 Nm
7 - Coolant hose
cooler
❑ With integrated exhaust
gas recirculation control
motor - V338- with ex‐
haust gas recirculation
potentiometer - G212-
❑ Checking change-over
function ⇒ page 350
⇒ page 348
9 - Coolant hose
10 - Bolt
❑ 9 Nm
11 - Bolt
❑ 23 Nm
12 - Gaskets
❑ Renew
13 - Pipe for exhaust gas recirculation
14 - Bolt
❑ 23 Nm
5. Exhaust gas recirculation 347

Audi Q5 2008 ➤
5.2 Removing and installing exhaust gas re‐

circulation cooler
Removing

body brace .

Audi Q5 2008 ➤

-2-.

Note
– Remove bolts -2- for exhaust gas recirculation pipe.
Note
Disregard -item 1-.
– Remove bolts -1- for exhaust gas recirculation pipe.
Note
Disregard -item 2-.

Audi Q5 2008 ➤
– Unplug electrical connectors -2, 3, 4- and move electrical wir‐

ing clear.
Note
Disregard -item 1-.

– Remove bolts -1, 3- and detach exhaust gas recirculation
cooler.
Installing
⇒ “5.1 Exploded view - exhaust gas recirculation system”,
page 347
Note
♦ Renew gaskets and O-ring.

– Install coolant pipe (rear right) ⇒ page 198 .

body brace .
5.3 Checking exhaust gas recirculation

cooler change-over

Audi Q5 2008 ➤
Procedure
– Disconnect vacuum hose from vacuum unit and connect hand

vacuum pump - VAS 6213- in its place.
– Operate hand vacuum pump to produce a vacuum.
• The linkage of the exhaust gas recirculation
Protected cooler
by copyright. Copying for change-
private or commercial purposes, in part or in whole, is not
over should move -arrows-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
If the linkage does not move or only moves jerkily:

♦ The vacuum unit is defective.
♦ The change-over flap for exhaust gas recirculation is sticking.

Audi Q5 2008 ➤
6 Exhaust manifold
⇒ “6.1 Exploded view - exhaust manifold”, page 352
⇒ “6.2 Removing and installing exhaust manifold”, page 353
6.1 Exploded view - exhaust manifold
1 - Gasket
❑ Renew
2 - Exhaust manifold
⇒ page 353
3 - Nut
❑ 25 Nm
❑ Renew
temperature paste; for
parts catalogue
4 - Heat shield
5 - Nut
❑ 25 Nm

Audi Q5 2008 ➤
6.2 Removing and installing exhaust mani‐

fold
Removing
– Remove turbocharger ⇒ page 220 .
- G505- .

3 - For Lambda probe - G39- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Move particulate filter to rear.
Note
– Remove bolt -1- at retaining clamp for oil supply line.
Note
Disregard -item 2-.
– Remove nuts -arrows- and detach heat shield.
6. Exhaust manifold 353

Audi Q5 2008 ➤
Note
– Remove bolts -1- and -2-. Detach exhaust gas recirculation

pipe.
Caution
Risk of damage to oil supply line.

♦ Do not attempt to bend oil supply line to a different shape.
– Detach exhaust manifold.

Installing
Tightening torques:
• ⇒ “3.1 Exploded view - coolant pipes”, page 195 .
• ⇒ “6.1 Exploded view - exhaust manifold”, page 352 .
• ⇒ “5.1 Exploded view - exhaust gas recirculation system”,
page 347 .
Note
Renew gaskets and nuts.

– Install turbocharger ⇒ page 220 .

Audi Q5 2008 ➤
28 – Glow plug system

1 Glow plug system
⇒ “1.1 Exploded view - glow plug system”, page 355
⇒ “1.2 Removing and installing glow plug”, page 355
⇒ “1.3 Checking glow plug”, page 357
⇒ “1.5 Removing and installing Hall sender G40 ”, page 359
⇒ “1.4 Removing and installing engine speed sender G28 ”, page
357
1.1 Exploded view - glow plug system

⇒ page 359
2 - Bolt
❑ 9 Nm
3 - Glow plug
❑ Glow plug 1 - Q10- ,
glow plug 2 - Q11- , glow
plug 3 - Q12- , glow
plug 4 - Q13-
⇒ page 355
❑ 17 Nm
❑ For glow plug
5 - Bolt Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ 4.5 Nm with respect to the correctness of information in this document. Copyright by AUDI AG.
6 - Engine speed sender -

G28-
⇒ page 357
7 - Sealing flange (gearbox
end)
❑ With oil seal
8 - Sender wheel
❑ For engine speed send‐
er - G28-
⇒ page 68
1.2 Removing and installing glow plug

1. Glow plug system 355

Audi Q5 2008 ➤
♦ U/J extension and socket, 10 mm - 3220-
♦ Pliers - 3314-
Removing
– Clean glow plug openings in cylinder head; make sure no dirt
gets into cylinder.
Note
♦ Cleaning procedure:
♦ Use a vacuum cleaner to remove coarse dirt.
♦ Spray brake cleaner or suitable cleaning agent into glow plug
openings, let it work in briefly, and blow out with compressed
air.
♦ Then clean the glow plug openings using a cloth moistened
with oil.
– Release retaining clips at wiring harness and detach electrical

connectors from glow plugs.
356 Rep. gr.28 - Glow plug system

Audi Q5 2008 ➤
– Apply groove -arrow A- of pliers - 3314- to collar of support

sleeve -arrow B- and pull glow plug connectors off glow plugs.
Caution
Make sure that no wire connection is damaged when unplug‐

ging the glow plug connectors; otherwise the entire wiring
harness must be renewed. When unplugging the glow plug
connectors, do not compress the pliers - 3314- with too much
force so that the support sleeve is not damaged.
– To slacken the glow plugs use special tool U/J extension and
socket, 10 mm - 3220- .
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Fit glow plug connectors -1- back onto glow plugs -arrow-.
Note
Check that glow plug connectors are securely seated.
1.3 Checking glow plug

Automatic glow period control unit - J179- is located in relay and
fuse holder in electronics box in plenum chamber.
A - Automatic glow period control unit - J179-
The glow plug system is activated via the automatic glow period
control unit - J179- . The automatic glow period control unit - J179-
is capable of self-diagnosis.
A fault is stored in the engine control unit if a fault occurs in the
glow plug system.
The procedure for checking the glow plug system is described in
the “Guided Fault Finding”.
For faster starting, the vehicle is equipped with electronically con‐
trolled glow plugs and a separate glow period control unit.
Each glow plug is activated and diagnosed separately.
1.4 Removing and installing engine speed

sender - G28-

Audi Q5 2008 ➤
♦ Socket AF 4 mm - T10370-
Removing
– Remove pump for exhaust gas recirculation cooler - V400-
⇒ page 193 .
– Unplug electrical connector -1- at engine speed sender - G28-
using assembly tool - T10118- .
– Move wiring clear.
– Unscrew bolt using socket, AF 4 mm - T10370- .
Installing
– Install pump for exhaust gas recirculation cooler - V400-
⇒ page 193 .
358 Rep. gr.28 - Glow plug system

Audi Q5 2008 ➤
1.5 Removing and installing Hall sender -

G40-
Removing
– Detach toothed belt from idler roller and high-pressure pump
⇒ page 116 .
– Detach electrical connector -2- from bracket and unplug.
Note
Disregard -item 1-.
– Unbolt Hall sender - G40- -arrow-.
– Using a screwdriver, remove projections and take out cover

for repair opening -arrows-.
– Take Hall sender - G40- off cylinder head and guide its con‐
nector through repair opening in toothed belt cover.
Installing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Seal repair opening in toothed belt cover with rubber plug; for
rubber plug refer to ⇒ Electronic parts catalogue .
– Fit toothed belt and adjust valve timing ⇒ page 116 .

Service: Audi Q5 2008

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service: Audi Q5 2008

Uploaded by

Copyright:

Available Formats

Service

Service Department. Technical Information

All rights reserved.

Copyright © 2014 Audi AG, Ingolstadt D3E802B1D38

3.6 Resetting SCR learnt values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

2 Coolant pump/thermostat assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

4 Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

5.1 Exploded view - exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

1.1 Engine identification number/engine da‐

♦ The 4-character engine code can be found on the type plate

Code letters CGLA CGLB CJCD

Code letters CGLA CGLB CJCD

Code letters CJCA CJCB CMGA CGLC CGLD CMGB

2 Rep. gr.00 - Technical data

2.1 Safety precautions when working on the

Risk of injury - fuel system operates under pressure.

Observe the following points to prevent personal injuries and

To prevent irreparable damage to the electronic components

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

2.2 Safety precautions when working on ve‐

Risk of injury due to automatic engine start on vehicles with

2.3 Safety precautions when using testers

Accidents can be caused if the driver is distracted by test

4 Rep. gr.00 - Technical data

2.4 Safety precautions when working on the

Risk of damage to running gear components.

2.5 Safety precautions when working on the

Hot steam/hot coolant can escape - risk of scalding.

Overheating can occur if the filler cap is not fitted properly.

2.6 Safety precautions when working on the

Reducing agent can cause skin irritation.

When removing and installing components at the reducing agent

drawn back (i.e. 10 minutes after the ignition is switched off)

before disconnecting the battery ⇒ Electrical system; Rep. gr.

Safety risk due to escaping reducing agent.

6 Rep. gr.00 - Technical data

2.7 Safety precautions when working on the

Please note the following warnings when working on all parts

Avoid damage to flexible joint.

3.1 Rules for cleanliness

3.2 Contact corrosion

8 Rep. gr.00 - Technical data

3.3 Foreign particles in engine

3.4 Routing and attachment of pipes, hoses

3.5 Installing radiators and condensers

3.6 Resetting SCR learnt values

10 – Removing and installing engine

When installing a new base engine, it is essential that the

Special tools and workshop

10 Rep. gr.10 - Removing and installing engine

♦ Shackle - 10 - 222 A /12- for

♦ The engine is removedProtected

♦ Fit cable ties in the original

To prevent irreparable damage to the electronic components

– Switch off ignition and take out ignition key.

1. Removing and installing engine 11

– Disconnect earth wire -arrow- from battery terminal ⇒ Electri‐